AltaBlue A15,30,50,100

AltaBluet Adhesive Melters
Models 15, 30, 50, and 100

Customer Product Manual
Part 1072086A07
Issued 3/14
This document contains important safety information

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

www.nordson.com
Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General information
about Nordson can be found on the Internet using the following address: http://www.nordson.com.
Address all correspondence to:
Nordson Corporation
Attn: Customer Service
11475 Lakefield Drive
Duluth, GA 30097
Notice
This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2006.
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.
Trademarks
AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, Bowtie, CanWorks, Century, CF, CleanSleeve, CleanSpray, ColorMax,
Color-on-Demand, Control Coat, Coolwave, Cross-Cut, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber, DuraPail, Dura-Screen, Durasystem,
Easy Coat, Easymove Plus, Ecodry, Econo-Coat, e.dot, EFD, Encore, ESP, e stylized, ETI, Excel 2000, Fillmaster, FlexiCoat, Flex-O-Coat, Flow Sentry,
Fluidmove, FoamMelt, FoamMix, Fulfill, HDLV, Heli-flow, Horizon, Hot Shot, iControl, iDry, iFlow, Isocoil, Isocore, Iso-Flo, iTRAX, Kinetix, LEAN CELL,
Little Squirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, Microcoat, Micromark, MicroSet, Millennium, Mini Squirt, Mountaingate, MultiScan,
Nordson, OptiMix, Package of Values, Pattern View, PermaFlo, Plasmod, Porous Coat, PowderGrid, Powderware, Precisecoat, PRIMARC, Printplus, Prism,
ProBlue, Prodigy, Pro-Flo, ProLink, Pro-Meter, Pre-Stream, RBX, Rhino, Saturn, Scoreguard, Seal Sentry, Select Charge, Select Coat, Select Cure,
Signature, Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, SureBead, Sure Clean, Sure-Max, Sure Wrap, Tracking Plus, TRAK, Trends,
Tribomatic, TrueBlue, Ultra, Ultrasaver, UpTime, u−TAH, Vantage, VersaBlue, Versa-Coat, Versa-Screen, Versa-Spray, Watermark,
and When you expect more. are registered trademarks of Nordson Corporation.
Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AltaSlot, Alta Spray, AquaCure, ATS, Auto-Flo, AutoScan, Axiom, Best Choice,
Blue Series, Bravura, Champion, Check Mate, ClassicBlue, Classic IX, Clean Coat, Controlled Fiberization, Control Weave, ContourCoat, CPX, cScan+,
cSelect, Cyclo-Kinetic, DispensLink, Drop Cure, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, e.dot+, Emerald,
E-Nordson, EquiBead, FillEasy, Fill Sentry, FlowCoat, Fluxplus, Get Green With Blue, GreenUV, G-Net, G-Site, iON, Iso-Flex, iTrend, Lacquer Cure,
Maxima, Mesa, MicroFin, MicroMax, Mikros, MiniBlue, MiniEdge, Minimeter, MonoCure, Multifil, Myritex, Nano, OptiStroke, Partnership+Plus, PatternJet,
PatternPro, PCI, PicoDot, Pinnacle, Powder Pilot, Powder Port, Powercure, Process Sentry, Pulse Spray, Quad Cure, Ready Coat, RediCoat, Royal Blue,
Select Series, Sensomatic, Shaftshield, SheetAire, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit, Sure Coat, SureFoam,
Sure Mix, SureSeal, Swirl Coat, TAH, ThruWave, TinyCure, Trade Plus, Trilogy, TrueCoat, Ultra FoamMix, UltraMax, Ultrasmart, Universal, ValueMate,
VersaDrum, VersaPail, Vista, Web Cure, and 2 Rings (Design) are trademarks of Nordson Corporation.
Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes,
could lead to violation of the owners’ rights.
Buna-N is a registered trademark of Pittway Corps.

DeviceNet is a trademark of Open DeviceNet Vendor Association, Inc.
Never Seez is a registered trademark of Bostik Inc.
Parker Lubricant is a registered trademark of Parker Seal.
Profibus is a trademark of Profibus International.
Viton is a registered trademark of DuPont Dow Elastomers. L.L.C.
Windows is a registered trademark of Microsoft Corporation.
Part 1072086A07 E 2014 Nordson Corporation

All rights reserved
Table of Contents i
Table of Contents
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Alert Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Responsibilities of the Equipment Owner . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Instructions, Requirements, and Standards . . . . . . . . . . . . . . . . . . 1-2
User Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Applicable Industry Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Intended Use of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Instructions and Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Installation Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Operating Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Maintenance and Repair Practices . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Equipment Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Equipment Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Relieving System Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . 1-6
De-energizing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Disabling the Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
General Safety Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . 1-7
Other Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Safety Labels and Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Electromagnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Examples of Unintended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Residual Risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Key Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Tank Isolation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Pressure Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Automatic Scan (Normal Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Gear-to-Line Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Melter Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
E 2014 Nordson Corporation Part 1072086A07

ii Table of Contents
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Installation Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Experience of Installation Personnel . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Motor Drive Internal Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Other Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Unpacking the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Moving the Unpacked Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Contents of the Installation Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Customer-Supplied Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Configuring the Electrical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Residual Current Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Connecting the Electrical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Connecting Hoses and Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Setting Up the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Quick Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Selecting Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Reading or Editing Operating Parameters . . . . . . . . . . . . . . . . . 3-23
Set-point Temperature of the Tank, Hoses, and Guns . . . . . . . . . . 3-28
Save and Restore Melter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Review Parameter and Set-point Temperature Changes . . . . . . . 3-32
Setting Up Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Setting Up Gear-to-Line Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Setting Up Motor Run Status Monitoring . . . . . . . . . . . . . . . . . . . . . . . 3-41
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Installing Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Connecting a Gun Driver, Pattern Controller, or Timer . . . . . . . . . . . . 3-42
Flushing the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Disposing of Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Table of Contents iii
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Filling the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
About Heated Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Starting the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Manually Adjusting the Pump Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Adjusting Material Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Monitoring the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Confirm that the Melter is Operating Correctly . . . . . . . . . . . . . . . . 4-9
Monitor Component Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Monitor Melter Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Monitor the Service Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Adjusting Component Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Entering a Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Using Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Heater Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Master Pump Enable Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Setup Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Seven-Day Clock Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Standby Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Shutting Down the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Record of Melter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Relieving System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Through the Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Through the Melter Drain Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Locking Out the Motor Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
External Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Changing the Material Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Detaching the Exterior Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Fan and Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Motor and Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Changing the Motor Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Replacing a Motor or Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Tightening the Pump Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Tightening the Pump Gland Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Replacing a Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Filter Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Filter Service Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Pressure/Circulation Control Valve Service Kit . . . . . . . . . . . . . . . . . . 5-18
Cleaning the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Draining Material from the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Cleaning the Tank by Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Tightening the Fixing Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Main PCA Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Maintenance Record Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

iv Table of Contents
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Troubleshooting Quick-Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Returning the Melter Setup to Factory Settings . . . . . . . . . . . . . . . . . 6-2
Melter Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Motor Control Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Changing a Motor Control Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Motor Drive Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Changing a Motor Drive Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Calibrating the Pump Speed Display . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Melter Not Functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
One Channel (Heating Zone) Does Not Heat . . . . . . . . . . . . . . . . . 6-13
Control Panel Does Not Function . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
No Material (Motor Does not Rotate) . . . . . . . . . . . . . . . . . . . . . . . . 6-14
No Material (Motor Rotating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Too Little Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Material Pressure Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Material Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Material Residue in Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Material Hardens in Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Using the Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
AltaBlue Configuration Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
One/Two-Pump Melter Frame Parts . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Three/Four-Pump Melter Frame Parts . . . . . . . . . . . . . . . . . . . . . . . 7-6
Reservoir/Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
One/Two-Pump Melter Reservoir/Manifold Parts . . . . . . . . . . . . . . 7-8
Three/Four-Pump Melter Reservoir/Manifold Parts . . . . . . . . . . . . 7-10
100L Melter Reservoir/Manifold Parts . . . . . . . . . . . . . . . . . . . . . . . 7-12
Manifold Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Hopper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
One/Two-Pump Melter Hopper Parts . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Three/Four-Pump Melter Hopper Parts . . . . . . . . . . . . . . . . . . . . . . 7-20
100L Melter Hopper Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Pump Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Pump Module Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Single-Stream Pump Adapter Parts . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Dual-Stream Pump Adapter Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Single-Stream Gear Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Dual-Stream Gear Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Safety Valve Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Control Valve Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Control Valve Module Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Filter Cartridge Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Pressure Control Valve Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Pneumatic Pressure Control Valve Parts . . . . . . . . . . . . . . . . . . . . . 7-35
Circulation Control Valve Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

Table of Contents v
Parts (contd)
Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Electrical Enclosure Panel Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
One/Two-Pump Melter Left Panel Parts . . . . . . . . . . . . . . . . . . . . . 7-40
Three/Four-Pump and 100L Melter Left Panel Parts . . . . . . . . . . . 7-42
One/Two-Pump Melter Back Panel Parts . . . . . . . . . . . . . . . . . . . . 7-44
Three/Four-Pump and 100L Six Hose/Gun Melter
Back Panel Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
Three/Four-Pump and 100L Eight Hose/Gun Melter
Back Panel Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
One/Two-Pump Melter Right Panel Parts . . . . . . . . . . . . . . . . . . . . 7-56
Three/Four-Pump and 100L Six Hose/Gun Melter
Right Panel Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
Three/Four-Pump and 100L Eight Hose/Gun (400V) Melter
Three/Four-Pump and 100L Eight Hose/Gun (240V) Melter
One/Two-Pump Melter Bottom Panel Parts . . . . . . . . . . . . . . . . . . 7-64
Three/Four-Pump and 100L Melter Bottom Panel Parts . . . . . . . . 7-65
Control Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
Low Level Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
Expansion and Control Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
Pressure Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
Low Level Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
Pneumatic Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
Line-Speed Signal Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
Optional Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Mechanical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
One/Two and Three/Four Pump Melters . . . . . . . . . . . . . . . . . . . . . 8-3
100L Melters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

vi Table of Contents
Calculating Melter Power Requirements . . . . . . . . . . . . . . . . . . . . . A-1
Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Input Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Output Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-13
Seven-day Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-14
PID Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-20
Melter Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

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

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

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

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

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

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

hazardous situation that, if not avoided, can result in damage to equipment
or property.
E 2014 Nordson Corporation Issued 4-02 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 Issued 4-02 E 2014 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
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.

1-4 Safety
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 at the end of this section.
S If you are unsure of how to use the equipment, contact your Nordson
representative for assistance.
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.

Safety 1-5
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 factory-authorized refurbished or 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.
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

1-6 Safety
Equipment Shutdown
To safely complete many of the procedures described in this document, the
equipment must first be shut down. The level of shut down required varies
by the type of equipment in use and the procedure being completed.
If required, shut down instructions are specified at the start of the
procedure. The levels of shut down are:
Relieving System Hydraulic Pressure

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

Isolate the system (melter, hoses, 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.
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 1-7
General Safety Warnings and Cautions

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

1-8 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 1-9
Equipment
CAUTION: Hot surfaces! Avoid contact with the hot metal surfaces of
guns, hoses, and certain components of the melter. If contact can not
HM 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.

1-10 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
a 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.

Safety 1-11
Safety Labels and Tags

Figure1-1 illustrates the location of the product safety labels and tags affixed
to the equipment. Table 1-2 provides an illustration of the hazard
identification symbols that appear on each safety label and tag, the meaning
of the symbol, or the exact wording of any safety message.
1
2 3
Figure 1-1 Safety labels and tags
Table 1-2 Safety Labels and Tags

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

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

1-12 Safety

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

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

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

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

2-2 Introduction
Examples of Unintended Use

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

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

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

Introduction 2-3
Key Components
Figure 2-1 provides the name and the location of key melter components.
4
3
11
10
2
8
5
2
6
Figure 2-1 Key melter components
1 Control panel (see Figure 2-3) 5 Motors/pumps 9 Hose receptacles
2 Protective panel, removable 6 Filter cartridge 10 ID plate
3 Tank lid 7 Pressure control valve 11 Tank
4 Main power switch 8 Manifold

2-4 Introduction
Electrical Components
−7A21
8
9
6
−11A11 −3X11 −XM −X45
2
−1G21 −1K31
−1Q31 −1K71
−1Z71
−1N61 −9N51 −10N51 −4N21 −4N41
11 −9N21 −10N21
3 4
−1M51
−XL5 −XL6 −XL7 −XL8
10
1
7
2
38 −3X1 1 −X45 −1 G21
−11A11 −XM −1 K31 −1 N61

39
−XL911
−9N51 −1 0N51
−4N21
−4N41
−9N21
−1 0N21
−11A31 −12A31
Figure 2-2 Key electrical components

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

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

2-6 Introduction
Tank Isolation Valve

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

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

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

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

mode or key-to-line mode.

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

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

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

documentation provided with the optional equipment for installation and
operating instructions.
The illustrations accompanying the procedures in this section depict a

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

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

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

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

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

Installation 3-3
[109]
2770
OPERATION SPACE
[36] 37.09 [36]

914.4 942 914.4
914.4
[36]
OPERATION SPACE
[92.67]
10.63
20.67
2350
270
525
10.63
914.4
270 30/50L
[36]
[5.35] HOPPER VERSION
136 15L
90

HOPPER VERSION
1617.80
57.28
63.69
1455
50L
15/30L
49.53
1258
[38.29]
972.60
5.12
130
Figure 3-1 One/two-pump melter minimum installation clearances

3-4 Installation
Clearances (contd)
[109]
2780
OPERATION SPACE
37.09
942
914.4
[36]
OPERATION SPACE
10.63
37.40
2800
[110]
270
950
[36] [36]
914.4 914.4
10.63
914.4
270 50L
[36]
HOPPER VERSION
[5.35] 30L
136
90
5
57.87
1470
1347.80
53.06
38.90
988
5.71
145
Figure 3-2 Three/four-pump melter minimum installation clearances

Installation 3-5
[121.65]
3090
OPERATION SPACE
[36] 48.11 [36]
914.4 1222 914.4
914.4
[36]
OPERATION SPACE
[112.2]
25.00
37.40
2850
635
950
914.4
10.63 [36]
270
57.87
1470
1347.87
53.07
38.90
988
5.71
145
Figure 3-3 100L melter minimum installation clearances

3-6 Installation
Ventilation
AltaBlue melters are cooled by forced air. Air is drawn in through by the
ventilation fan and is exhausted out of the ventilation slots at the top of the
melter.
CAUTION! Do not block the fan air intake openings or the exhaust
ventilation slots.
Figure 3-4 Location of the ventilation openings
Electrical Power
Before installing the melter, ensure that the melter will not be overloaded
and that the plant’s electrical service is rated to handle the power required
by the melter and the hoses and guns that you plan to use.
Refer to Appendix A, Calculating Melter Power Requirements, for

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

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

Installation 3-7
Motor Drive Internal Filter

The AltaBlue melter is manufactured and shipped from the factory in
compliance with CE regulations. If the motor drive internal filter, located
inside each motor drive, is turned off, the melter will no longer be
CE-compliant.
Figure 3-5 Location of the motor drive internal filter inside a motor drive
Other Considerations
Consider the following additional factors when evaluating where to install
the melter.
S The maximum distance between the melter and each gun is dictated by
the power requirement of each hose. Refer to Appendix A, Calculating
Melter Power Requirements, for information about how to determine the
maximum allowable length.
S The operator must be able to safely reach the control panel and
accurately monitor the control panel indicators.
S The operator must be able to safely observe the level of hot melt inside
the tank.
S The melter must be installed away from areas with strong drafts or
where sudden temperature changes occur.
S The melter must be installed where it will be in conformance with the
ventilation requirements specified in the Material Safety Data Sheet for
the hot melt being used.
S The melter should not be exposed to excessive vibration.

3-8 Installation
Unpacking the Melter

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

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

The installation kit provided with the melter contains the components shown
in Figure 3-6.
The installation kit also contains a package of safety label overlays that are
printed in variety of languages. If required by local regulations, the
appropriate language overlay should be applied over the English version of
the same label. Refer to Safety Labels and Tags in Section 1, Safety, for the
location of each safety label.
Customer-Supplied Materials
The following additional materials are also required to install the melter.
S A power cable. Rigid or flexible electrical conduit will be required.

S (Optional) Gear-to-line input signal wiring
S (Optional) Input/output signal wiring
2 P/N 7400333
Figure 3-6 Installation kit components

1. Fuses 2. Straight hose connector (4)

Installation 3-9
This page intentionally left blank.

3-10 Installation
Configuring the Electrical Service

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

Local regulations in some geographic areas or industrial branches may
require residual current circuit breakers.
Then observe the following points:
S Permanent installation is required (fixed line voltage connection)

S The residual current circuit breaker is to be installed only between the
power supply and the melter.
S Only residual current circuit breakers sensitive to pulsating current or
universal current (> 30 mA) may be used.
Connecting the Electrical Service

NOTE: The melter must be installed securely (permanent power supply
connection).
WARNING! Operate only at the operating voltage shown on the ID plate.
NOTE: Permitted deviation from the rated line voltage is 10%.
NOTE: The power cable cross-section must comply with the maximum
power consumption (refer to Section 8, Technical Data).
WARNING! Ensure that cables do not touch rotating and/or hot melter
components. Do not pinch cables and check regularly for damage. Replace
damaged cables immediately!
1. See Figure 3-7. Route the power cable into the electrical cabinet
through the strain relief on the side of the base.
NOTE: Do not route any input/output wiring through this strain relief.
2. Connect the power cable to the service terminal block as indicated in

table Table 3-1 and illustrated in Figure 3-7.
3. Connect the service ground lead to the ground terminal located on the
DIN rail at XL0:PE.

Installation 3-11
Table 3-1 Electrical Service Wiring

Terminals
Line voltage
1 2 3 N PE
230 VAC 3-phase without neutral (Delta) D D D D
400 VAC 3-phase with neutral (star - WYE) D D D D D
N PE
N PE
Figure 3-7 Location of service wiring strain relief and terminal block

3-12 Installation
Connecting Hoses and Guns

WARNING! Risk of fire or equipment damage. Before connecting hoses and
guns to the melter, confirm that the power required by each hose/gun pair
and each hose/gun module, does not exceed the maximum wattages
specified in Appendix A, Table A-2, Maximum Allowable Wattages.
To connect hoses
See Figures 3-9 through 3-12 to properly connect the hose hydraulic fittings
based on the manifold configuration. If hoses are not connected properly,
the melter will not operate correctly.
If applicable, connect a return hose (see Figure 3-8). To do this, remove the
O-ring fitting from the return hose port and install the hose connector fitting
from the ship-with kit. The return hose port is located on the rear of the
melter at the top of the hopper.
See Figure 3-13 to connect hose cordsets.
Observe the following guidelines:
S For information about choosing the correct Nordson hot melt hose for
your manufacturing process, refer to the latest edition of Nordson’s hot
melt dispensing equipment Replacement Parts Catalog or contact your
Nordson representative.
S Refer to the user’s guide provided with each Nordson hose. The guide
contains important information about routing and installing the hose.
S Save all of the port plugs removed from the manifold. A port plug will
need to be reinstalled into the manifold if a hose is later removed.
Figure 3-8 Location of the optional return hose fitting

Installation 3-13
Pump 1: Output port 5
Pump 1: Output port 3 Pump 1: Output port 7
Figure 3-9 Connecting hoses—one/two-pump melter manifold with one single-stream (1 SS) pump
Note: Do not connect hoses to the top four manifold ports on any single-stream pump configuration.

3-14 Installation
To connect hoses (contd)

Figure 3-10 Connecting hoses—one/two-pump melter manifold with two single-stream (2 SS) pumps
Note: Do not connect hoses to the top four manifold ports on any single-stream pump configuration.

Installation 3-15
Pump 2: Stream 2, Output port 1 Pump 1: Stream 1, Output port 1

Figure 3-11 Connecting hoses—one/two-pump melter manifold with two dual-stream (2 DS) pumps

3-16 Installation
To connect hoses (contd)



Figure 3-12 Connecting hoses—three/four-pump melter manifolds

Installation 3-17
Figure 3-13 Connecting a hose cordset

3-18 Installation
To connect guns
Observe the following guidelines:
S AltaBlue melters with 120-ohm nickel sensors support all Nordson

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

Installation 3-19

3-20 Installation
Setting Up the Melter

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

Installation 3-21
Table 3-2 Common Operating Parameters

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

pre-defined time period after the tank, hoses, and guns are at
the desired set-point temperature. The ready delay timer will
4 Ready Delay Time
only activate if the temperature of the tank, at the time the
0 minutes
melter is turned on, is below its assigned set-point
temperature by 27 C (50 F) or more.
A timer that turns on a service LED when the value set for the
timer equals the number of hours that the heaters have been
5 Service Interval Time
on. The service LED is used to signal the need for
500 hours
maintenance.
If the switch receptacle is used, this parameter determines the

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

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

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

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

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

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

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

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

3-22 Installation
Operating Parameters
The melter uses operating parameters to store noneditable and editable
values. Noneditable values are those that provide information about the
historical performance of the melter. Editable values are either a numeric
set-point or a control option setting. Control options settings affect the
display of information or the function of the melter.
Operating parameters are stored in the melter’s firmware in the form of a

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

Parameter
Group Group Description
Numbers
0 to 8 and Noneditable and other frequently used
Standard
10−14 parameters
Temperature Control 20 to 29 Control heaters
Input Setup 30 to 39 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 feature
In addition to the ability to read and edit parameter values, you can also
save and restore the current value of every operating parameter and review
a log of the last ten changes that were made to editable parameters.
Selecting Operating Parameters

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

are otherwise reserved in the firmware are excluded from Table 3-4 and
Appendix B.

Installation 3-23
Reading or Editing Operating Parameters

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

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

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

Setup key Clear/Reset key to return to parameter 1 and then re-enter the correct
parameter number.
When you have finished entering the one- or two-digit parameter

number, the right display indicates the parameter’s current value.
4. Do one of the following:

S If the value is noneditable, refer to Monitoring the Melter in
Section 4, Operation.
Clear/Reset key
S If the value is editable go to step 5.
5. Press the Enter key.

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

3-24 Installation
To read or edit a parameter (contd)

The melter checks that the new value or control option is acceptable.
S If the numeric set-point or control option is accepted, the left and
right displays index to the next sequential parameter number and
value.
S If the numeric set-point or control option is not accepted, the right
display will indicate dashes (----) for three seconds and then it will
change back to the original value.
8. Repeat step 5 through step 7 to read or change the next sequential

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

Parameter Name Range of Values Default Value
Standard
0 Enter Password 0 to 9999 4000
1 Total Hours with Heaters On (noneditable) 0 to 9999 0
2 Fault Log (noneditable) — _-F0 (empty)
3 Change History Log (noneditable) — P-_ (empty)
4 Ready Delay Time 0 to 60 minutes 0 minutes
5 Service Interval Time 0 to 8736 hours 500 hours
6 Service LED Heater Hours 0 to 9999 hours 0
81 Automatic Pump On 0 (disabled) or 1 (enabled) 1 (enabled)
10 Enable or Disable Password 0 (disabled) or 1 (enabled) 0 (disabled)
11 Create Password 0 to 9999 5000
Change Hose 1 Output to Electric Gun
121 0 (disabled) or 1 (enabled) 0 (disabled)
Activation
Change Hose 2 Output to Electric Gun
131 0 (disabled) or 1 (enabled) 0 (disabled)
Activation
14 External Communications Lock-out 0 or 1 0 (disabled)
Temperature Control
20 Temperature Units (degrees _C or _F) C (degrees Celsius) or F (degrees
C (degrees Celsius)
Fahrenheit)
21 Over Temperature Delta 5 _C (10 _F) to 60 _C (110 _F) 15 _C (25 _F)
22 Under Temperature 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 _F) 50 _C (100 _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)
27 Hose Standby Delta 1 _C (1 _F) to 190 _C (350 _F) 0 (disabled)
28 Gun Standby Delta 1 _C (1 _F) to 190 _C (350 _F) 0 (disabled)
29 Internal Zone Temperate Offset 0 _C (0 _F) to -15 _C (-30 _F) 0 (disabled)
1Not used with AltaBlue melters.

Installation 3-25
Parameter Name Range of Values Default Value

Input Setup
30 Standard Input 1 0–8 and 10−14 10 (Automatic Standby)
31 Standard Input 2 0–8 and 10−14 1 (Standby on/off)
32 Standard Input 3 0–8 and 10−14 2 (Heaters on/off)
33 Standard Input 4 4 (Hose/gun 1
0–8 and 10−14
enable/disable)
34 Optional Input 5 0–8 and 10−14 0 (disabled)
Output Setup
40 Standard Output 1 0–6 1 (Ready)
41 Standard Output 2 0–6 3 (Fault)
42 Standard Output 3 0–6 4 (Not used)
43 Optional Output 4 0–6 0 (disabled)
Seven-day Clock
50 Current Day 1 to 7 (1 = Monday) —
51 Current Hour 0000 to 2359 —
55 Schedule 1 Heaters On 0000 to 2359 06:00
56 Schedule 1 Heaters Off 0000 to 2359 17:00
57 Schedule 1 Enter Standby 0000 to 2359 —:—
58 Schedule 1 Exit Standby 0000 to 2359 —:—
60 Schedule 2 Heaters On 0000 to 2359 —:—
61 Schedule 2 Heaters Off 0000 to 2359 —:—
65 Schedule 3 Heaters On 0000 to 2359 —:—
66 Schedule 3 Heaters Off 0000 to 2359 —:—
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

3-26 Installation
To read or edit a parameter (contd)
You can exit the setup mode at any time by

pressing the Setup key.
Parameter numbers that are not applicable

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

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

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

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

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

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

Installation 3-27

3-28 Installation
Set-point Temperature of the Tank, Hoses, and Guns

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

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

Installation 3-29
To assign a global set-point temperature
1. Press and hold the Tank key for three seconds.

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

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

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

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

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

3-30 Installation
Save and Restore Melter Settings

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

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

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

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

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

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

Installation 3-31

3-32 Installation
Review Parameter and Set-point Temperature Changes

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

Operating parameter 1 flashes in the left display.
2. Press the left-display scroll key to change the display to parameter 3

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

Installation 3-33
Table 3-5 Change History Log

Second
First Digit Third and Fourth Digits
Digit
P (Parameter) Indicates the number of the parameter that was changed
Are used in conjunction with the LEDs on the component keys to indicate the
location and method of a set-point temperature change.
When this LED is And the Fourth The change was And the Method
on.. Digit Indicates.. to.. of Change was..
Tank Key 1 The tank Individual
− Hose Key 1– 6 A single hose Individual

S (Set-point)
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.
Unused log entries in the change history log are

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

since a specific change (displayed) was made,
simultaneously press both of the right-display
scroll keys.

3-34 Installation
Setting Up Inputs/Outputs
AltaBlue melters are equipped with four standard inputs. Each input is
customer-wired to the melter and then set up to provide one of the following
control options:
S Place the melter into the standby mode

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

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

provide one of the following outputs:
S The melter is ready

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

Installation 3-35
To wire inputs/outputs to the melter
See Figure 3-14.
1. Route a 2-, 4, 6, or 8-conductor signal cable from the control equipment

to the melter and through the PG-16 penetration on side of the base.
Use rigid or flexible conduit or a suitable strain relief to protect the cable
from the sharp edge of the conduit penetration.
NOTE: Use a signal cable suitable for NEC class1 remote control and
signaling circuits. To reduce the possibility of electrical shorting, route
the cable so that it does not touch nearby circuit boards.
2. Connect each pair of input and output wires to the appropriate terminals
on terminal block XI. Refer to Table 3-6 for the terminal numbers that
correspond to each input.
Figure 3-14 Location of the knockout hole and XI terminal block for connecting input/output wiring

3-36 Installation
Setting Up Inputs/Outputs (contd)
To set up inputs/outputs
Set up the parameter control option for each input and output that you
connected to the melter. Table 3-6 lists the available control options. Refer
to Setting Up the Melter earlier in this section for information about how to
select operating parameters and edit parameter control options.
With the exception of the motor Input Setup in Appendix B

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

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

increased from three outputs to seven outputs
by adding an optional I/O expansion card that
is available from Nordson Corporation.

Installation 3-37
Table 3-6 Input/Output Data

Operating
Item Description Control Options Terminals Notes
Parameter
1 Standard input 1 30 0 − Input Disabled XI:1, XI:2 A, B
1 − Standby On/Off
2 − Heaters On/Off
3 − Motor 1 Enable/Disable C
4 − Hose/Gun 1 Enable/Disable
10 – Automatic standby (Default) D
2 Standard input 2 31 0 − Input Disabled XI:3, XI:4
1 − Standby On/Off (Default)
2 − Heaters On/Off
3 Standard input 3 32 Same as parameter 31 XI:5, XI:6

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

3-38 Installation
Setting Up Inputs/Outputs (contd)
Table 3-6 Input/Output Data (contd)

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

Installation 3-39
Table 3-6 Input/Output Data (contd)

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

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

3-40 Installation
Setting Up Gear-to-Line Operation

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

Optional Accessories in Section 7, Parts, for the part number.
To use the gear-to-line capability, connect a 0−10 VDC signal from a

customer-supplied line-speed signal generator to the appropriate terminals
on terminal block XI inside the electrical enclosure. See Figure 3-14 for the
location of terminal block XI. Refer to Table 3-6 for the terminal numbers
that correspond to each input/output.

Installation 3-41
Setting Up Motor Run Status Monitoring

If desired, you can set up the melter to allow remote monitoring of the run
status (running or not running) of the pump motors.
Wiring
To use the motor run status monitoring capability, connect wiring from the
parent machine to the appropriate terminals on terminal block XI inside the
electrical enclosure. See Figure 3-14 for the location of terminal block XI.
Refer to Table 3-6 for the terminal numbers that correspond to each
input/output.
NOTE: The relay contact between terminals XI:25/XI:26 and XI:27/XI:28 is

normally open. When the motor is running, these contacts should close.
Programming
Use the keypad located on each motor drive inside the electrical enclosure
to set up the motor run status monitoring for each motor. Refer to Changing
a Motor Drive Parameter in Section 6, Troubleshooting, for a more detailed
procedure for changing a motor drive parameter.
1. Press ENT until I−O is displayed.

2. Press ENT again to access the I/O parameters.
3. Press the arrow keys until parameter r2 is displayed.
4. Press ENT to access this parameter.
5. Press the arrow keys until rUn is displayed.
6. Press ENT to save this value.
7. Press ESC twice to return to the monitoring mode.
Motor drive keypad (located on

each motor drive inside the
electrical enclosure)

3-42 Installation
Installing Optional Equipment

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

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

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

Operation 4-1
Section 4
Operation

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

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

4-2 Operation
Filling the Tank

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

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

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

The melter contains three groups of heated components. These are the
tank group, which contains tank, the grid, and the reservoir; the hose group;
and the 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 of the tank group is fixed at 1. Hose and gun position
numbers are automatically assigned based on the hose/gun receptacle they
are connected to.
Component keys
(tank, 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.

Operation 4-3
Starting the Melter

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

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

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

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

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

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

4. Melters equipped with the optional motion switch: Place the motion
switch in the ON position.
5. Press the pump mode key(s) to select the manual (LED on) or automatic
(LED off) mode.
Pump mode key and LED
6. Press the pump enable key(s) on the motor control panel(s) to enable
the motor(s). The LEDs turn on when a motor is enabled:
Manual Mode—If the system is at ready status (master pump enable
key LED is green) at the time a pump enable key is pressed, then the
motor(s) will start. If the system is not at ready status (master pump
enable key LED is yellow), wait until the LED is green, and then repress
the pump enable key(s).
Automatic Mode—If the system is at ready status (master pump enable
key LED is green) at the time a pump enable key is pressed, then the
Motor start/stop key and LED motor(s) will start. If the system is not at ready status (master pump
enable key LED is yellow), the motor(s) will start automatically when the
system reaches ready.
NOTE: If any one of standard inputs 1−4 (parameters 30−33) are being
used and if either control option 3 (Motor 1 Enable/Disable) or control
option 11 (Motor 2 Enable/Disable) is selected, the pump enable keys
have no effect. Refer to Setting Up Inputs/Outputs in Section 3,
Installation, for information on connecting and setting up inputs/outputs.

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

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

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

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

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

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

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

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

4-6 Operation
Manually Adjusting the Pump Speed

When the motor control is set to manual operation, the pump speed can be
adjusted from 0−94 rpm.
NOTE: When the motor control is set to automatic operation, pressing the
motor speed arrow keys will alter the ratio of the line speed reference signal
to allow for fine-tuning of the adhesive output rate.
To adjust the motor speed for manual operation
CAUTION! To ensure adequate motor control and cooling, the

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

Operation 4-7
Adjusting Material Pressure

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

4-8 Operation
Monitoring the Melter

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

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

Operation 4-9
Confirm that the Melter is Operating Correctly

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

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

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

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

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

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

4-10 Operation
Monitor Component Temperatures

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

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

Operation 4-11
To manually check a component’s temperature

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

to check, use the left-display scroll key to change to the correct
component number.
The right display indicates the actual temperature of the
selected component.
Component temperature display
3. Press the Setup key twice to return to the automatic scan mode.
When you scroll the left display past the

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

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

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

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

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

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

4-12 Operation
Monitor Melter Faults

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

Display
Name Affect on Melter Cause Corrective Action
Code/Sub-code
The RTD for the
Replace RTD
component indicated
has failed or the
F1/None RTD Heaters turn off Check hose/gun
component was
connections
disconnected from
the melter.
The actual temperature
of the component Check for conditions
indicated has dropped that may cause a drop
Under
F2/None Heaters turn off below the under in ambient temperature
temperature
temperature delta,
which was set using Replace RTD
parameter 22.

of the component
indicated has increased
F3/None Over temperature Heaters turn off beyond the over Replace RTD
temperature delta,
which was set using
parameter 21.
Melter stops
F4/1 RAM test Internal RAM failure Replace CPU
functioning
Heaters remain on,

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

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

Operation 4-13
Table 4-1 Melter Faults (contd)

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

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

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

4-14 Operation
F1, F2 and F3 Faults

When the melter detects an F1, F2, or an F3 fault:
1. The automatic scan stops and the melter begins to monitor the potential
fault for up to two minutes. The ready and heater LEDs remain on during
the two-minute time period. If, at any time during the two-minute period,
the melter detects that the fault condition no longer exists, the melter will
return to the automatic scan mode.
2. The LED on the affected component key (tank, hose, or gun) turns on to
indicate the type of component that has, or is, failing.
3. The right display indicates the type of fault (F1, F2, or F3).
4. The left display indicates, as follows, the component that has, or is,
failing.
S If the LED on the tank key is on, the left display will indicate either 1
for the tank or 2 for the pump.
S If the LED on the hose or gun key is on, the left display will indicate
the number of the affected hose or gun.
5. If the fault condition still exists at the end of the two-minute monitoring
period, the ready LED will turn off, the red fault LED will turn on, the
Fault LED (red) heaters turn off, and the melter records the fault in the fault log. Refer to
Monitor Melter Faults in this section.
To be able to put the melter back into operation, the fault must be remedied
and the melter reset (reset key). Refer to Section 6, Troubleshooting, for
information about diagnosing and correcting fault conditions. Also refer to
Returning the Melter to Factory Settings.

Operation 4-15
To view the temperature of a heated component

when an F2 or F3 fault exists, simultaneously
press and hold both of the right-display scroll
keys.
You can temporarily dismiss an F1 fault (RTD)

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

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

(458 _F), an immediate F3 fault will occur (no
two-minute monitoring period).
F4 Fault
When the melter detects an F4 fault:
1. The ready LED turns off and the red fault LED turns on.
2. All of the component key LEDs (tank, hose, and gun) turn off.
3. The right display indicates F4.
4. The left display indicates a sub-code. Sub-codes classify the fault as
being fatal or nonfatal. The affect on the melter of each of these two
classes of F4 faults is:
Fatal—The fault LED turns on and stays on and the melter stops
functioning completely.
Nonfatal—The fault LED turns on for five seconds, but the heaters and
pump continue to operate normally. Nonfatal faults affect the internal
clock.
5. The melter records the fault in the fault log. Refer to Monitor Melter
Faults in this section.

4-16 Operation
Resetting the melter

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

clock key, the internal clock function has failed.

Operation 4-17
Reviewing the Fault Log

1. Press and hold the Setup key.
The automatic scan stops and operating parameter 1 appears in the
left display.
2. Scroll the left display to parameter 2 (the fault log).
The right display indicates the last fault that occurred as follows:
Setup Key S If the last fault was an F1, F2, or F3 fault, then the LED on
the affected component key turns yellow.
S If the last fault to occur was an F4 fault, then the LEDs on all of
the component keys turn off.
S The right display indicates the log entry for the last fault to
occur. Table 4-2 provides the meaning of each digit in the log
entry. Following the table are two example fault log entries.
3. Press the right-display scroll key to review each of the remaining
nine log entries. Each press of the scroll key displays a progressively
Left display and scroll key older log entry.
NOTE: The fault log only stores the last ten faults. After ten faults
occur, the existing log entries are overwritten, beginning with the oldest
entry, by the eleventh and following log entries.
4. Press the Setup key to return to the automatic scan mode.
Scrolling through the fault log
Table 4-2 Fault Log

First Digit Second and Third Fourth Digit
Digits
Component: Type of fault:
1 = Tank or hose/gun 1 0 = Unused log entry
-F
2 = Pump or hose/gun 2 1 = RTD (open or short)
3 = Hose 3 or gun 3 2 = Component under temperature
4 = Hose 4 or gun 4 3 = Component over temperature
5 = Hose 5 or gun 5 4 = Processor or electrical failure
6 = Hose 6 or gun 6

4-18 Operation
Fault Log examples

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

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

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

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

Operation 4-19
Monitor the Service Interval

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

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

4-20 Operation
Adjusting Component Temperatures

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

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

parameters 20−29 in Appendix B, Operating Parameters.
To adjust the setpoint temperature using the global method

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

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

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

Operation 4-21
To adjust the setpoint temperature using the global-by-component

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

Tank, hose, and gun keys

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


4-22 Operation
To adjust the setpoint temperature of an individual component

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

component that you selected in the left display.

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

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

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


Operation 4-23
If you enter a valid set-point temperature for a

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

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

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

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

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

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

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

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

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

4-24 Operation
Entering a Password
If the melter is password protected, a valid password must be
entered before any set-point temperature or melter parameter can be
changed.
To enter a melter password

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

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

enabled/disabled during system setup. Installation

Operation 4-25
Using Function Keys

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

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

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

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

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

4-26 Operation
Setup Key
Use the setup key to place the melter into and take the melter out of
the setup mode. When the melter is placed into the setup mode, the
automatic scan stops and the left and right displays are used to select and
read or edit operating parameters.
Setup key
Seven-Day Clock Key

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

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

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

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

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

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

the clock key, the internal clock function has
failed.

Operation 4-27
Standby Key
Use the standby key to manually place the melter into, and take it out of, the
standby mode. Using the standby mode during periods of time when the
melter is inactive helps conserve energy and allows heated components to
quickly return to their set-point temperatures when the melter is once again
needed.
Standby key
When the melter is placed into the standby mode, the temperatures of all
components are reduced down from their set-point temperature by a pre-set
standby delta. The melter will remain in the standby mode until the standby
key is pressed or the function of one of the operating parameters takes the
melter out of the standby mode.
If the melter was set up to use the manual standby timer (parameter 26),
pressing the standby key will place the melter in the standby mode for the
period of time specified by the timer. After the manual standby time has
elapsed, the melter will once again begin heating all of the components to
their assigned set-point temperature.
Using the standby key overrides the control of the melter (on or off) by the
seven-day clock or a remote input.
Refer to Section 3, Installation, Setting Up the Melter, and to Appendix B,

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

standby LED blinks.

4-28 Operation
Shutting Down the Melter

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

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

Operation 4-29
Record of Melter Settings

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

Flash point
Processing temperatures (Setpoint temperatures):

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

4-30 Operation

Service 5-1
Section 5
Service

documentation.
Maintenance is an important preventive measure for maintaining operating

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

WARNING! System and material pressurized. Relieve system of pressure
before disconnecting hoses, guns and hot melt handguns. Failure to
observe can result in serious burns.
Through the Guns

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

5-2 Service
Through the Melter Drain Valves

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

Service 5-3
Preventive Maintenance Schedule

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

Complete melter External cleaning Daily External Cleaning
Inspect for external Daily
damage
Purge with cleaning agent When material is changed Changing the
Material Type
Fan and air filter Check filter, clean or Depending on dust accumulation; Fan and Air Filter
replace if necessary daily if necessary
Clean fan screen
Power cable Inspect for damage Every time the melter is serviced
Air hoses Inspect for damage Every time the melter is serviced
Pump Tighten the gland bolt (if After initial startup Pump
present)
Check for leakage, tighten Dependent on hours of operation,
gland bolt (if present) if pump speed and pump
necessary temperature
Recommendation: Monthly
Tighten fixing screws Every 500 hours of operation
Motor / gear box / coupling Clean fan cover Depending on dust accumulation; Motor and Gear
daily if necessary Box
Change lubricant Every 15 000 hours of operation or
every 2 to 3 years
Pressure control valve Disassemble and clean Every six months Pressure Control
Valve
Filter cartridge Replace filter cartridge Depending on degree of material Filter Cartridge
Disassemble and clean pollution
filter cartridge Recommendation: Every 1000
hours of operation
Tank Clean tank by hand When there is material residue in Cleaning the Tank
tank
Tighten fixing screws Every 500 hours of operation

5-4 Service
Locking Out the Motor Drives

To perform some troubleshooting and repair activities, the main power to the
melter needs to be on and/or the melter needs to be at application
temperature. To prevent injury, the optional motion switch can be used to
lock out the motor drives while leaving the main power on.
To lock out the motor drives but leave the main power on, place the motion
switch in the OFF position. The main power to the melter will remain on and
the melter will stay at application temperature.
Location of the optional motion

switch
External Cleaning
CAUTION! Do not damage or remove safety labels. Damaged or removed
safety labels must be replaced by new ones.
S Remove material residue only with a cleaning agent recommended by

the material supplier. Heat with an air heater if necessary.
S Remove dust, flakes, etc. with a vacuum cleaner or a soft cloth.
S Nordson recommends the orange cleaning agent, P/N 771192 (12 spray
bottles, 0.5 l each).

Service 5-5
Changing the Material Type

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

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

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

5-6 Service
Motor and Gear Box

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

Operating temperature < 100 _C / 212 _F:
Every 15 000 hours of operation or at least every 4 years.
Lubricant Capacity
Ensure that the upper gears and rolling bearings are properly lubricated.
Lubricant Selection
Lubricant manufacturer Mineral oil CLP 220

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

Service 5-7
Replacing a Motor or Coupling

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

1 Motor coupling hub 3 Pump coupling hub
2 Coupling sleeve

5-8 Service
Replacing a Motor or Coupling (contd)

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

10. Tighten the screws that secure the motor to the base of the melter
11. To ensure proper motor and pump shaft alignment, ensure that you can
freely slide the coupling sleeve back and forth by about 4 mm (0.16 in.)
each way.
12. Reconnect the motor cable wires to the same terminals from which they
were disconnected.
13. Reinstall the melter covers and restore the system to normal operation.

Service 5-9
Pump
Tightening the Pump Screws
1. Ensure that the melter is turned off and that power has been
disconnected and locked out.
2. Ensure that the melter, tank, manifold, and pump are cold.
3. See Figure 5-4. Tighten the screws to 25 NSm (222 in.-lb).
Figure 5-4 Tightening the pump screws

4. Restore the system to normal operation.

5-10 Service
Tightening the Pump Gland Bolt

NOTE: This procedure applies only to pumps with a gland bolt.
On pumps with a gland bolt, adhesive may leak from the self-sealing pump
shaft packing at regular intervals. When leakage occurs, tighten the pump
gland bolt.
1. Heat the pump to application temperature using a heated air blower.

2. See Figure 5-5. Using a 24-mm short-handle, open-end wrench (with a
15-degree offset), tighten the pump gland bolt approximately 1/4 of a turn
Pump gland bolt
clockwise (in the direction of pump rotation). When the bolt can no
longer be tightened, replace the pump.
Figure 5-5 Tightening the pump gland bolt (clockwise)

Service 5-11
Replacing a Pump
Follow this procedure to replace a pump. You will need the following items:
S tool kit, including a torque wrench
S drain pan
S cleaning supplies
S replacement pump
S replacement pump O-rings
S O-ring lubricant
S anti-seize lubricant
NOTE: To rebuild a pump, contact your Nordson representative for
assistance.
1. Ensure the melter is at operating temperature.
2. Relieve system pressure. Refer to Section 1, Safety.
3. See Figure 5-6. Close the tank isolation valve.
Figure 5-6 Location of the tank isolation valve

5-12 Service
Replacing a Pump (contd)

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

1 Motor coupling hub 3 Pump coupling hub
2 Coupling sleeve

Service 5-13
8. See Figure 5-8. Remove the pump screws (3) and then remove the
pump (2) and O-rings (1).
1
3 2
1 2
440300046
Figure 5-8 Replacing a pump (single-stream and dual-stream pumps shown)

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

5-14 Service
Replacing a Pump (contd)

14. Slide motor assembly, including the motor coupling hub and sleeve,
toward the pump until the coupling sleeve engages with pump coupling
hub.
15. Ensure that the coupling sleeve cannot move, then slide the motor
assembly back 4 mm (0.16 in.), as indicated in Figure 5-9.
4 mm (0.16 in.)
Figure 5-9 Moving the motor assembly back 4 mm (0.16 in.)

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

Service 5-15
Filter Cartridge
To replace the filter cartridge

M10
SW 24
3. Apply high temperature grease to all threads and O-rings.

4. Insert the filter cartridge and tighten it to approximately 15 NSm
(133 in.-lb).
5. Feed material by allowing the pump to run until the material comes out
of the hose connection or gun free of bubbles.
6. Properly dispose of material according to local regulations.

5-16 Service
Filter Service Kit

Each kit contains three O-rings, filter sheath, filter screen and
high-temperature grease.
Service Kit, for P/N refer to Section 7, Parts.

Required tools:
Open-jawed wrench, size 24 and size 13
1. Disassemble the hot filter cartridge (material must be fluid).
Size 24
2
2 2. Replace filter sheath (1), O-rings (2) and filter screen (3).
1
3. Clean all other parts.
4. Apply grease to all threads and O-rings.

Size 13
2

Service 5-17
Pressure Control Valve

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

5-18 Service
Pressure/Circulation Control Valve Service Kit

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

Required tools:
Open-jawed wrench, size 24
Pliers
Torque wrench
1. Heat melter to operating temperature.
WARNING: Hot! Risk of burns. Wear appropriate protective

clothing/equipment.
2. Relieve melter pressure.

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

Service 5-19
Cleaning the Tank

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

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

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

Tank/reservoir M6 6−8 NSm / 53−71 in.-lb
Manifold/reservoir (high melt) M8 5−7 NSm / 44−62 in.-lb

5-20 Service
Main PCA Board

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

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

Service 5-21
+ C35
RV 13
RV 12
RV 10
RV 11
C10
RV 9
RV 7
C8
C3
C4
C9
C5
C56
C36
C23
C24
C25
C26
C27
C28
C29
R95
C30
R71
C44 R85 R81
R93 R5
R19 R17 RV 6 R20
C55
R80 R86
C50 C43 C1 R18
U16
R82
C54
R79
R26 R22 J1
R90
Q22
D17 R84 C60C53 XP5
1
RN4RN6 C31 Q20 C21 C2233 51
C20
L1 R63 R15 JP1
R121
R88
C74
HSNK1 RN3 R101 6 2
D16 C58 Q19
U2
RN2 RN1
RN9
+ U3
C75
D3 C7 RN10 R99
RN7
C45 C46 Q18
RN5
C37
C18
C42 C47 U7 R119
U4 Q17
C41
C6
U14 R120
T1
RN11
C19
DS4
R96
+
R72
L4
U1
L3
XP6 JP2
U17 C17
R87
RV 8 R134 R135
U5
R77
C12 C16 C15
C63
+
DS15R89
R124
C52 ++ D8
F4 R92 C66 D4
+
D18 Q26 R127 D6
2A R91 R133 DS17
C48 C49 C57 R129 C2
D1 D7 R4 RV 5
R33
F3 K1 L2 R128
2A
R122 R3 C11
D2 R1 R2 RV 4
+
XT1 DS16
R38 C76
D12 D10 D11 J2 1 D14
XP4
Q13 R130 C51
U22 C771
C40 R67
R45 R44 RV 3
C65
R75 U12 U23

R131 R132 C59 U25
+
C64 R46 R43 C78
XP1
XP2
R100
C84
C83
R68
R66
C61 R76U21
C32
R123
U26
R102 X6 R136 U9 R73
R69
D5 R74
+
C82
C80
R83 RV 1
R37 C62
F1 X7
F2 XP3
10A
10A
F6 F5 F11 F7
Q24 C39 1
6.3A 6.3A U24 R40 RV 2
R41
5A 5A F9 DS14 R42 R39 C67
F12 F8 F10
R114
R115
6.3A
6.3A 6.3A 6.3A R116
U15 Q14
DS10
R6
R8
R9
R59
R60
DS3 DS2
R57
R7
R16
R12
R13
R10
R11
R14 DS7 DS5 DS6

U18 Q16
12 12 DS11
R78
3 3 R94
X4 X5 U13 Q7
X1 DS9
R64
X2
R54
R53
X3 R51
1 1 U10 Q5
DS8
1
R35
1
U19 Q12
DS12
R48
R47
R113
R56
R62
R34
R97
R98
R50
R105
R112
R108
R117
R58
R65
R52
R36
R106
R110
C79 C70 C71

C69 C68 C72
C73 Q9
R109
R118
U20
R55
R49
R111
R70
R61
DS13
R107
R103
R104
Q25 Q15 Q23 Q8 Q6 Q10 Q11
Figure 5-12 Location of the JP1 terminal on the main PCA board

5-22 Service
Main PCA Board (contd)

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

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

Service 5-23
Maintenance Record Form

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

tank
Air filter
Tank
Pressure control valve
Filter cartridge

5-24 Service

Troubleshooting 6-1
Section 6
Troubleshooting

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

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

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

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

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

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

Display
Code/Sub-code
The RTD for the
Replace RTD
component indicated
has failed or the
F1/None RTD Heaters turn off Check hose/gun
component was
connections
disconnected from
the melter.
of the component Check for conditions
indicated has dropped that may cause a drop
Under
F2/None Heaters turn off below the under in ambient temperature
temperature
temperature delta,
which was set using Replace RTD
parameter 22.

of the component
indicated has increased
F3/None Over temperature Heaters turn off beyond the over Replace RTD
temperature delta,
which was set using
parameter 21.
Melter stops
F4/1 RAM test Internal RAM failure Replace CPU
functioning
Heaters remain on,

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

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

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

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

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

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

Troubleshooting 6-5
Motor Control Faults

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

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

6-6 Troubleshooting
Changing a Motor Control Parameter

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

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

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

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

6-8 Troubleshooting
Motor Drive Faults

The display on the motor drive located inside the electrical enclosure alerts
the operator to abnormal motor drive/motor operation. Motor drive faults
cause the pump to stop. Refer to Table 6-4 for the motor drive fault codes.
To clear a motor drive fault, correct the problem that caused the fault and
then remove power from the motor drive by turning the heaters off and wait
until the motor drive display is completely blank.
Figure 6-1 Motor drive power LED and display

1. Motor drive power LED (steady=OK,
flashing=fault, off=no power)
2. Display
Table 6-4 Motor Drive Faults

Fault Code Probable Cause Corrective Action
CrF Motor drive hardware failure Replace the motor drive.
Capacitor load circuit
EEF Internal memory fault S Check the environment
EEPROM fault (electromagnetic compatibility).
S Replace the motor drive.
InF Internal fault S Check the environment
Internal fault (electromagnetic compatibility).
S Replace the motor drive.
Continued...

Troubleshooting 6-9
Table 6-4 Motor Drive Faults (contd)

Fault Code Probable Cause Corrective Action
OCF S Adhesive too cold S Verify temperature setpoints and
Overcurrent S Pump or drive failure change as needed. The temperature
setpoints should be within the range
S Foreign object in pump recommended by the material
manufacturer.
S Replace the pump or the drive
assembly.
S Replace the pump.
SCF Short-circuit or earthing at the Check the cables between the motor
Motor short-circuit motor drive output drive and the motor; also check the
motor insulation.
OHF Motor drive temperature too high S Check the motor load, the motor
Motor drive overheated drive ventilation, and the
environment. Wait for the motor drive
to cool down before restarting.
S Ensure that the unit ambient
temperature does not exceed 50 _C
(120 _F), that the electrical enclosure
vents are not blocked, and that the
electrical enclosure fan is operating
properly.
OLF S Material exceeds the operating S Use a material that falls within the
Motor overload viscosity range allowable viscosity range. Refer to
S Excessive motor current Section 8, Technical Data, for
viscosity ranges.
S Overpressure condition caused
by pressure control valve
S Check the motor load. Wait for the
failure motor drive to cool down before
restarting.
S If the operating hydraulic pressure
exceeds the maximum allowable
pressure, replace the pressure
control valve. Refer to Section 8,
Technical Data, for pressure ranges.
OPF Loss of one or more phases at Check the connections between the
Motor phase loss motor drive output motor drive and the motor.
OSF S Line voltage too high Check the unit input line voltage. Refer
Overvoltage to Section 8, Technical Data, for
S Disturbed line supply allowable input voltage range.
CFF Motor drive parameter(s) changed Contact your Nordson representative.
Configuration fault
USF S Line supply too low Check the unit input line voltage. Refer
Undervoltage to Section 8, Technical Data, for
S Transient voltage dip allowable input voltage range.

6-10 Troubleshooting
Changing a Motor Drive Parameter

The motor drive parameters are factory set and do not need to be changed.
Use this procedure only if a motor drive parameter is inadvertently changed
and needs to be changed back to the factory setting shown in Table 6-5.
The motor drive parameters are changed through the keypad, shown in
Figure 6-3, present on each motor drive located inside the electrical
enclosure. Figure 6-2 shows how to change a motor drive parameter.
The following figure illustrates how to access parameters and assign their
values. To store the parameter value e, press the ENT key. The display
flashes when a value is stored.
Menu Parameter Value Assignment
ENT ENT The display

SEt− ACC 15.0 ESC
flashes when a
ESC ESC value is stored.
dEC 26.0 26.0
ENT
Next Parameter
All of the menus are drop-down type menus. Once you have reached the
last parameter in a list, press the key
y to return to the first parameter.
From the first parameter in the list, press the key to jump to the last
parameter.
ENT
Menu 1st
ESC
nth
last
If you have modified a parameter in a menu and you return to that menu
without accessing another menu in the meantime, you will be taken directly
to the parameter you last modified. See the illustration below. If you have
accessed another menu or have restarted the drive controller since the
modification, you will be taken to the first parameter in the menu. See the
illustration above.
1st
ENT
Menu nth
ESC
last
Figure 6-2 Changing a motor drive parameter

Troubleshooting 6-11
Figure 6-3 Motor drive keypad (located on each motor drive present inside the electrical enclosure)
1. Status LEDs 5. Run 9. Display
2. Exit/clear 6. Reference potentiometer 10. DC bus On
3. Enter 7. Advance display/decrease setting
4. Stop/Reset 8. Advance display/increase setting
Table 6-5 Motor Drive Parameter Factory Settings

Code Pr. Description Setting Note
L
drC UFt Type of voltage/frequency ratio
n SN1710 pump(s) only
SEt UFr lr Compensation/Voltage Boost 5
SEt SLP Slip compensation 35 SN1710 pump(s) only
SEt HSP High Speed 102
drC bFr Standard Motor Frequency 50
drC Uns Nominal Motor Voltage on Name Plate 230
drC FrS Nominal Motor Frequency on Name Plate 102
drC nCr Nominal Motor Current on Name Plate 2.7
drC nsP Nominal Motor Speed on Name Plate 1350
drC nrd Random Switching Frequency No
drC SFr Switching Frequency 4.0
drC tFr Maximum Output Frequency 102
1−0 tCC 2 Wire/3 Wire Control 2C
1−0 tCt Type of 2 Wire Control LEL
1−0 AOlt Configuration of Analog Output IOU
1−0 dO Analog/Logic Output OFR
CtL Fr1 Configuration Reference 1 AI1

Calibrating the Pump Speed Display

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

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

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

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

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

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

No Material (Motor Does not Rotate)

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

No Material (Motor Rotating)

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

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

Material Pressure Too High

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

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

Material Residue in Tank

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

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

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


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

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

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

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

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

7-2 Parts
AltaBlue Configuration Code

Use the following tables to determine the configuration of your melter.
Base Melter Options

Pump Pump Pump Pump Hose/ Flow Low Host Return Motion
Melter Capacity Voltage 1 2 3 4 Gun \ Control Spare Level I/O Spare Comm. Port Switch Sensor Spare Spare Spare
A B − \ X X X X X
Box Box Box Box Box Box Box Box Box Box Box Box Box Box Box Box Box Box Box Box Box Box Box Box Box
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Box Item Code Options Description

1−2 Melter AB — AltaBlue adhesive melter
3 Hyphen - — —
4−6 Tank capacity 015 15 l 15 l holding capacity
030 30 l 30 l holding capacity
7 Operating 3 240 VAC 3-phase Delta 240 VAC 3-phase Delta electrical service
voltage 4 380−415 VAC Wye 380−415 VAC Wye electrical service
5 400 VAC Delta 400 VAC Delta electrical service
6 480 VAC Delta 480 VAC Delta electrical service
8−11 Pump selection A SN0030, 1.4 kg/hr Single-stream gear pump
B SN0046, 2.2 kg/hr
C SN0062, 2.9 kg/hr
D SN0093, 4.5 kg/hr
E SN0186, 8.9 kg/hr
F SN0371, 17.8 kg/hr
G SN0773, 37.1 kg/hr
H SN1710, 82.1 kg/hr
9 SH0371, 17.8 kg/hr Stainless-steel gear pump
Z SH0773, 37.1 kg/hr
2 DN0030, 1.4 kg/hr/stream Dual-stream gear pump
3 DN0048, 2.2 kg/hr/stream
X None No pump at this location.
12 Hose/gun pairs 6 6 hose/gun pairs 6 hose/gun pairs (12 channels) for
external temperature control (standard)
8 8 hose/gun pairs 8 hose/gun pairs (16 channels) for
external temperature control
13 Slash \ — —
Continued...

Parts 7-3
Box Item Code Options Description

14 Flow control A Pneumatic PCV Pneumatic PCVs are installed, allowing
the bypass pressure to be adjusted using
a customer-supplied air pressure
regulator.
V Circulation control valve Circulation control valves are installed,
allowing recirculated adhesive to be
controlled when a single adhesive stream
is split between multiple applications in
which the adhesive flow to each
application needs to be balanced because
of differing add-on rates.
X Manual PCV Standard manual PCVs are installed,
allowing the manual adjustment of
adhesive pressure.
15 Spare X — —
16 Low-level L Low-level indication present The low-level indication provides a signal
indication when the level of adhesive in the tank falls
below a specified value.
X None No low-level indication
17 I/O and Y I/O expansion card present The optional I/O expansion card (digital) is
indication installed.
X None No optional I/O expansion card
18 Spare X — —
19 Host E Ethernet card present The optional Ethernet card is installed.
communication D PROFIBUS card present The optional PROFIBUS card is installed.
V DeviceNet card present The optional DeviceNet card is installed.
X None No communication card
20 Return port R 1 hose return port One hose return port is installed.
X None No hose return port
21 Motion switch M Motion switch present The motion switch is a lockable motor
disconnect switch that removes power
from the motor drives, allowing the pump
and motor to be service without turning off
the melter heat.
X None No motion switch
22 Sensor type N 120-ohm nickel sensors Requires Nordson T-style hose/gun
connectors
P 100-ohm platinum sensors Requires Nordson M-style hose/gun
connectors
23−25 Spare X — —

7-4 Parts
Frame Assembly
The frame assembly parts vary depending on the size of the melter:
one/two-pump or three/four-pump. Refer to the correct parts list for your
melter.
One/Two-Pump Melter Frame Parts

See Figure 7-1.
Item Part Description Quantity Note

------- Panel assembly, tank side, 15L and 30L 2
901
------- Panel assembly, tank side, 50L 2
902 ------- Panel assembly, motor cover, side 2
903 ------- Panel assembly, motor cover front 1
904 ------- Panel assembly, electrical cover, front 1
905 224906 Tag, warning, electrical shock 2
906 ------- Rivet, pop, 1/8 x 0.187 8
907 ------- Plug, button, M16, plastic 1
908 ------- Nameplate, information 1
909 1025326 Tag, caution, hot surface, 1.19 x 6.544 1
910 1021983 Tag, warning, hot adh/hyd press, 1.6 x 6.5 1
911 1025795 Tag, warning, hazardous volts 1
914 7400868 Cable gland, clamp, M32, 15−22 mm 1
NS 7400342 Kit, ship with, one/two-pump 1
NS: Not Shown

Parts 7-5
905 906
908
906 916
909
910
901 907 917
911
902
904
914 903
Figure 7-1 One/two-pump melter frame assembly parts

7-6 Parts
Three/Four-Pump Melter Frame Parts

See Figure 7-2.

------- Panel assembly, tank side, 30L and 50L 2
901
------- Panel assembly, tank side, 100L 2
902 ------- Panel assembly, motor cover, side 2
903 ------- Panel assembly, motor cover, front 1
904 ------- Panel assembly, electrical cover, front 1
905 224906 Tag, warning, electrical shock 2
906 ------- Rivet, pop, 1/8 x 0.187 8
907 ------- Plug, button, M32, plastic 1
908 ------- Nameplate, information 1
909 1025326 Tag, caution, hot surface, 1.19 x 6.544 1
910 1021983 Tag, warning, hot adh/hyd pressure, 1.6 x 6.5 1
911 1025795 Tag, warning, hazardous volts 1
7400354 Cable gland, clamp, M32, 18−25 mm 1
914
7401255 Cable gland, clamp, M40, 24−30 mm 1
NS 7400821 Kit, ship-with, three/four-pump, 100L 1
NS: Not Shown

Parts 7-7
906 905
901
908
906 916
909
907
910
917
911
904
903
902
914
Figure 7-2 Three/four-pump melter frame assembly parts

7-8 Parts
Reservoir/Manifold Assembly
The reservoir/manifold assembly parts vary depending on the size of the
melter: one/two-pump, three/four-pump, or 100L. Refer to the correct parts
list for your melter.
One/Two-Pump Melter Reservoir/Manifold Parts

See Figure 7-3.

— ------- Assembly, manifold/reservoir, one/two pump —
101 ------- S Base 1
102 ------- S Manifold assembly 1 A
103 ------- S Spacer, manifold to base 4
104 ------- S Plate, insulator, manifold 1
105 ------- S Support, hydraulics 2
106 ------- S Washer, lock, split, M8 24
107 ------- S Washer, flat, narrow, M8 24
108 ------- S Screw, socket, M8 x 45 4
109 ------- S Screw, socket, M8 x 25 20
110 ------- S Nut, hex, M8 16
111 7400293 S Castor, swivel, 100 mm, 130 kg 2
112 7400294 S Castor, swivel, with lock, 100 mm, 130 kg 2
113 256800 S O-ring, 26 x 2 2
114 7400132 S O-ring, Viton, 45 x 2 2
115 ------- S Reservoir, machined 1
116 ------- S Screw, socket, M8 x 90 6
117 ------- S Spring washer, 16 mm OD 6
118 7400339 S Plug, M16, O-ring, Viton 4
119 7400297 S SERVICE KIT, HEATER, 240V, 800W, 1/2 X 3
13.75 (all melter manifolds)
13.75 (one/two pump melter reservoirs)
121 ------- S Washer, flat, oversize, M6, 22 OD 12
123 ------- S Screw, pan, recessed, M6 x 10 12
125 ------- S Lock washer, external, M3 2
126 7401366 S THERMOSWITCH, ALTABLUE 1
127 ------- S Deflector, adhesive 1
128 1058990 S Cordstock, 3 mm OD, Viton, 75 D 1
129 900298 S Compound, heat sink, 5 oz tube 1
130 900344 S Lubricant, Never Seez, 8 oz can 1
131 900223 S Lubricant, O-ring, Parker, 4 oz 1
132 900413 S Sealant, RTV, red, 2.8 oz. tube 1
NOTE A: Refer to Manifold Parts.

Parts 7-9
127
116, 117, 130
128, 132
120, 129
121
122 115
123, 130
126, 129
125 114, 131
124
113, 131
119, 129
121
122
123, 130
102
104
109, 106, 107, 130
103
105
108, 106, 107, 130
101
110
106
107
111
112
109
Figure 7-3 One/two-pump melter reservoir/manifold assembly parts (30L, 2 SS assembly shown)

7-10 Parts
Three/Four-Pump Melter Reservoir/Manifold Parts

See Figure 7-4.

— ------- Assembly, manifold/reservoir, three/four pump —
101 ------- S Base 1
103 ------- S Spacer, manifold/base 8
105 ------- S Support, manifold 1
108 ------- S Screw,socket, M8 x 45 8
109 ------- S Screw,socket, M8 x 25 4
110 ------- S Screw, socket, M10 x 25 16
113 256800 S O-ring, 26 x 2 4
114 7400132 S O-ring, Viton, 45 x 2 4
116 ------- S Screw, socket, M8 x 100 12
27.5 (three/four pump melter and 100L melter
reservoirs)
127 ------- S Plate deflector 2
128 1058990 S Cordstock, 3 mm OD, Viton, 75 D 2.4
134 ------- S Washer, flat, M10 16
136 ------- S Tag, pump number 2
137 ------- S Rivet, pop, 1/8 x 0.187 16

Parts 7-11
127
116, 117, 129

128, 132
120, 129
115
121
114, 131
123, 130
113, 131
126, 129
121
125
123, 130
124
102
119, 129
106, 107, 109, 130

121
105
123, 130
104 106, 107, 108, 130
103
136, 137
101
111
134
133
112
110
Figure 7-4 Three/four-pump melter reservoir/manifold assembly parts (50/100L, 2SS/2SS assembly shown)

7-12 Parts
100L Melter Reservoir/Manifold Parts

See Figure 7-5.

— ------- Assembly, manifold/reservoir, 100L —
101 ------- S Base 1
103 ------- S Spacer, manifold/base 8
105 ------- S Support, manifold 1
108 ------- S Screw,socket, M8 x 45 8
109 ------- S Screw,socket, M8 x 25 4
110 ------- S Screw, socket, M10 x 25 16
113 256800 S O-ring, 26 x 2 4−8
114 7400132 S O-ring, Viton, 45 x 2 4
116 ------- S Screw, socket, M8 x 100 12
27.5 (three/four pump melter and 100L melter
reservoirs)
127 ------- S Plate deflector 1
128 1058990 S Cordstock, 3 mm OD, Viton, 75 D 2.5
134 ------- S Washer, flat, M10 16
135 ------- S Manifold assembly, 2 SS 1 A
136 ------- S Tag, pump number 2
137 ------- S Rivet, pop, 1/8 x 0.187 16

Parts 7-13
139, 140, 141
127
144, 130
132, 128
129, 117, 116 116, 117, 129
129, 117, 138

115
142 118, 130
109, 107, 106

114, 131
120, 129
113, 131
130, 123, 121
129, 126
102
125, 124
143, 107, 106

104
103
135
106, 107, 109, 130
105
130, 123, 121
106, 107, 108, 130

119, 129
136, 137
101
111
112
133, 134, 110
Figure 7-5 100L melter reservoir/manifold assembly parts (2 DS/2 SS assembly shown)

7-14 Parts
Manifold Parts
See Figures 7-6 through 7-8.

— ------- Assembly, manifold/reservoir —
7400057 S MANIFOLD, 2 DUAL STREAM, DURA 1
1 7400058 S MANIFOLD, 1 SINGLE STREAM, DURA 1
7400059 S MANIFOLD, 2 SINGLE STREAM, DURA 1
2 313742 S O-RING 12X2 VITON B 1,2 or 4
7400408 S PLATE, DRAIN, 2DS 1
3 7400410 S PLATE, DRAIN, 1SS 1
7400409 S PLATE, DRAIN, 2SS 1
4 982031 S SCR,SKT,M6X25,BL 10
5 983409 S WASHER,LK,M,SPT,M6,STL,ZN 10
6 983410 S WASHER,FLT,M,NARROW,M6,STL,ZN 10
7 973480 S PLUG, O RING,STD THD,M14X1.5 8
8 7400339 S PLUG,M16 ,O-RING,VITON 6 or 8
9 7400340 S PLUG,M22,O-RING,VITON 3 or 6
10 7400341 S ADAPTER,M22 TO M16,O-RING PORT 2 or 4
11 7400355 S ORING,VITON,FOR M22 O-RING PLUG 2 or 4
12 900223 S LUBRICANT,O RING,PARKER,4 OZ,30122-5 0.02
13 900344 S LUBRICANT,NEVER SEEZ,8OZ CAN 0.01

Parts 7-15
01
APPLY 35−40 Nm TORQUE
08 12
08 12
08 12
07 12
02 12
03
06
05
04 13 APPLY 0.5−0.7 Nm TORQUE
Figure 7-6 Manifold assembly parts—one single-stream pump

7-16 Parts
Manifold Parts (contd)
09 12 APPLY 55−60 Nm TORQUE
01
10 11 12 08 12 APPLY 35−40 Nm TORQUE

08 12
02 12
03
06
05
04 13 APPLY 0.5−0.7 nm TORQUE
Figure 7-7 Manifold assembly parts—two single-stream pumps

Parts 7-17
09 12
01
10 11 12
08 12 APPLY 35−40 Nm TORQU
08 12
02 12
03
06
05
04 13 APPLY 0.5−0.7 Nm TORQ
Figure 7-8 Manifold assembly parts—one or two dual-stream pumps

7-18 Parts
Hopper Assembly
The hopper assembly parts vary depending on the size of the melter:
one/two-pump, three/four-pump, or 100L. Refer to the correct parts list for
your melter.
One/Two-Pump Melter Hopper Parts

See Figure 7-9.

— ------- Assembly, hopper, one/two pump —
201 ------- S Hopper/grid, machined 1
203 ------- S Washer, lock split, M6 40
204 ------- S Screw, socket, M6 x 25 20
7400135 S Gasket, hopper, 30L/50L, one/two pump 1
205
7400134 S Gasket, hopper, 15L, one/two pump 1
S SERVICE KIT, HEATER, 240V, 800W, 1/2 X 4 or 8
7400298
11.65 (one/two pump melter 30/50L hopper)
209
S SERVICE KIT, HEATER, 240V, 500W, 1/2 X
7400876 4
6.38 (two-pump hopper)
211 ------- S Screw, socket, M6 x 10 8
212 ------- S Frame, tank, paint 2
213 ------- S Washer, flat, regular, M6 12
214 ------- S Nut, hex, M6 12
217 ------- S Nut, hex, M8 4
218 ------- S Panel, rear, hydraulic 1
219 ------- S Panel, front, hydraulic 1
220 ------- S Bracket, heater terminal 1
221 ------- S Screw, flat, socket, M4 x 12 2
222 ------- S Heater, terminal block assembly 1
224 ------- S Washer, lock split, M5 6
225 ------- S Nut, hex, M5 2
226 ------- S Panel, top, hydraulic 1
227 ------- S Lid, outer 1
228 ------- S Lid, inner 1
229 ------- S Screw, pan, slotted, M3 x 6 8
232 7400047 S Hinge, lid 2
233 ------- S Screw, flat, recessed, M5 x 12 8
234 ------- S Screw, button, socket, M5 x 10 12
235 779664 S Handle, lid 1
Continued...

Parts 7-19

236 ------- S Screw, pan, M5 x 16 2
239 ------- S Rivet, pop, 1/8 x 0.187 2
240 224905 S Tag, warning, hot 1
241 ------- S Nut, hex, jam, M5 4
242 931074 S Tape, insulation 75
243 ------- S Insulation, foil backed, 600W x 1200L x 25 mm 1
244 ------- S Marker, SAKD 2.5 N 1
245 ------- S Sleeving, insulation, 0.500 ID 1
236 235
239, 240 228

229, 230, 231
227
223, 224, 241

234
233
226
232
213, 203, 214
218
212 223, 224, 225 220 222 SEE DETAIL ’A’

221
237, 209
203, 211, 210 206, 207 237, 208
202, 203, 204 201 219

205, 238
215, 216, 217
Figure 7-9 One/two-pump melter hopper assembly parts (30L hopper without hose return shown)

7-20 Parts
Three/Four-Pump Melter Hopper Parts

See Figure 7-10.

— ------- Assembly, hopper, three/four pump —
201 ------- S Hopper, machined 1
204 ------- S Screw, socket, M6 x 25 30
205 7400326 S Gasket, hopper, three/four pump, 50L 1
NS 7400327 S Gasket, hopper, three/four pump, 30L 1
209 7400875 S SERVICE KIT, HEATER, 240V, 750W, 1/2 x 9
11.85 (50L hopper)
NS 7400876 S SERVICE KIT, HEATER, 240V, 500W, 1/2 X 9
6.38 (30L hopper)
211 ------- S Screw, socket, M6 x 10 18
214 ------- S Nut, hex, M6 12
217 ------- S Screw, socket, M8 x 20 4
222 ------- S Heater, terminal block, left 1
225 ------- S Nut, hex, M5 4
227 ------- S Lid, outer 1
228 ------- S Lid, inner 1
229 ------- S Screw, pan, split, M3 x 6 8
232 7400047 S Hinge, lid 2
234 ------- S Screw, button,socket, M5 x 10 12
235 779664 S Handle, lid 1
236 ------- S Screw, pan, M5 x 16 2
237 900298 S Compound, heat sink,5 oz tube 1
238 900413 S Sealant, RTV, red, 2.8 oz tube 1
239 ------- S Rivet, pop, 1/8 x 0.187 2
241 ------- S Nut, hex, jam, M5 4
Continued...

Parts 7-21

243 ------- S Insulation, foil backed, 600W x 1200 L x 25 mm 1
246 7400540 S O-ring, Viton, 51.5 x 2.65 1
247 ------- S Plate, machined, hose return 1
248 ------- S Screw, socket, M6 x 20 6
249 7400337 S Fitting, hose,45deg, M16x9/16-18, O-ring, Viton 1
250 ------- S Heater, terminal block assembly, 400V, 1
three/four-pump, WYE
NS: Not Shown
236 235 227
229, 230, 231

240, 239
228
241, 224, 223
226
232 234
233
218 213, 203, 214
250
221 212 225, 224, 223 220 222
219
238, 205
249
201
204, 203, 202
209, 237 210, 203, 211 246 247
215, 216, 217 213, 203, 248
208, 237 206, 207
Figure 7-10 Three/four-pump melter hopper assembly parts (50L hopper with hose return shown)

7-22 Parts
100L Melter Hopper Parts

See Figure 7-11.

— ------- Assembly, hopper, 100L —
201 ------- S Hopper, machined 1
204 ------- S Screw, socket, M6 x 25 38
205 7400901 S Gasket, hopper, 100L 1
209 7401316 S Heater, 240V, 1000W, 0.50 D x 22.75 long 9
211 ------- S Screw, socket, M6 x 10 18
214 ------- S Nut, hex, M6 12
217 ------- S Screw, socket, M8 x 20 4
222 ------- S Heater, terminal block, left 1
225 ------- S Nut, hex, M5 4
227 ------- S Lid, outer 1
228 ------- S Lid, inner 1
229 ------- S Screw, pan, split, M3 x 6 8
232 7400047 S Hinge, lid 2
235 779664 S Handle, lid 1
236 ------- S Screw, pan, M5 x 16 2
237 900298 S Compound, heat sink,5 oz tube 1
238 900413 S Sealant, RTV, red, 2.8 oz tube 1
239 ------- S Rivet, pop, 1/8 x 0.187 2
241 ------- S Nut, hex, jam, M5 4
243 ------- S Insulation, foil backed, 600W x 1200 L x 25 mm 1
246 7400540 S O-ring, Viton, 51.5 x 2.65 1
247 ------- S Plate, machined, hose return 1
Continued...

Parts 7-23

248 ------- S Screw, socket, M6 x 20 6
249 7400337 S Fitting, hose,45 degree, M16 x 9/16-18, O-ring, 1
Viton
250 ------- S Heater, terminal block, right 1
239 240 236 235 227 223, 224, 241 232 233 226 228 229, 230, 231
224
241
256
255
205, 238
252, 253, 254
212 218 220 222 214, 213, 209 201

221
250
246 249 203, 213, 248
209, 203, 251 252, 208, 206, 247 219

237 210. 253, 237 207
211 254
215, 216, 217 223, 224, 225 202, 203, 204
Figure 7-11 100L melter hopper assembly parts (100L hopper with hose return shown)

7-24 Parts
Pump Assemblies
The pump assembly parts vary depending on the type of pump:
single-stream or dual-stream. Refer to the correct parts lists for your melter.
Pump Module Parts

See Figure 7-12.

— ------ Assembly, pump module —
301 256800 S O-ring, 26 x 2 1
302 250269 S O-ring, 35 x 2 1
------ S Adapter assembly, single-stream, with shutoff 1 A
303
------ S Adapter assembly, dual-stream, with shutoff 1 B
304 ------ S Spring washer,16 mm OD 4
305 ------ S Screw, socket, M8 x 110 4
------ S Gear pump, single-stream 1 C
306
------ S Gear pump, dual-stream 1 D
NOTE A: Refer to Single-Stream Pump Adapter Parts.
B: Refer to Dual-Stream Pump Adapter Parts.
C: Refer to Single-Stream Gear Pumps for pump part numbers.
D: Refer to Dual-Stream Gear Pumps for pump part numbers.
NS: Not Shown

Parts 7-25
THIS V IEW SHOW S THE SINGLE STREAM PUMP
TIGHTEN SCREWS 309, 301

20 TO 25 N−M
306, 307, 308 305, 308 304 303 309, 302
THIS VIEW SHOWS THE BLANK
302, 309
309, 301 303 304 308, 305
THIS V IEW SHOW S THE DUAL STREAM PUMP
TIGHTEN SCREWS 309, 301

20 TO 25 N−M
306, 307, 308 305, 308 304 303 309, 302
Figure 7-12 Pump module parts

7-26 Parts
Single-Stream Pump Adapter Parts

See Figure 7-13.

— ------ Adapter assembly, single-stream, with shut off —
01 ------ S Adapter, pump, single-stream 1
02 ------ S Valve, rotary 1
03 ------ S Plate, stop 1
04 ------ S Screw, socket, M5 x 12 4
05 ------ S Washer, flat, narrow, M5 4
06 ------ S Washer, lock, split, M5 4
07 207932 S Valve, safety 1 A
08 973480 S Plug, O-ring, straight-thread, M14 x 1.5 4
10 900341 S Lubricant, Never-Seez, 16 oz can 1
12 250267 S O-ring, 32 x 2 1
13 985022 S Pin, dowel, M6 x 20 long, hose and gun 1
NOTE A: Refer to Safety Valve Parts.
05 06 04 10
03
09 12
13
02
08 10
01
08 10
07 10
Figure 7-13 Single-stream pump adapter parts

Parts 7-27
Dual-Stream Pump Adapter Parts

See Figure 7-14.

— ------- Adapter assembly, dual-stream, with shut off —
01 ------- S Adapter, pump, dual-stream 1
02 ------- S Valve, rotary 1
03 ------- S Plate, stop 1
04 ------- S Screw, socket, M5 x 12 4
07 207932 S Valve, safety 2 A
10 900341 S Lubricant, Never-Seez, 16 oz can 1
12 250267 S O-ring, 32 x 2 1
13 985022 S Pin, dowel, M6 x 20 long, hose and gun 1
NOTE A: Refer to Safety Valve Parts.
05 06 04 10
03
09 12
13
02
10 08
01
10 08
11 10
08 10
07 10
08 10
Figure 7-14 Dual-stream pump adapter parts

7-28 Parts
Single-Stream Gear Pumps

See Figure 7-15.
Item Gland Seal Variseal Description Quantity Note

Part Part
— 259598 7109715 Gear pump SN0030 (0.30 cc/rev) 1
— 253992 7131840 Gear pump SH0773, hardened (7.73 cc/rev) 1
— 259600 7130225 Gear pump SH0371, hardened (3.71 cc/rev) 1
— 394589 Refer to SERVICE KIT for gland seal pump sizes 1
Table 7-1 SN0030 to SN0773
— ----- — S O-ring 10 x 1.5, PTFE 1
— ----- — S Sealing paste, Stucarit 203, 100 ml 1
— ----- — S High-temp. grease, GLS 595/N2, 10 g 1
— 394596 Refer to SERVICE KIT for gland seal pump size 1
Table 7-2 SN1710
— ----- — S O-ring 15 x 1.5 1
Table 7-1 Variseal Pump Service Kits (Except SN1710)

NS 7136920 SEALING KIT,PUMP F.SHAFT D12,7 —
(pump seal service kit)
NS ------ S O-RING 22X3 VITON 70 SHORE A BLACK 2
NS ------ S RING ID 12,7 1
NS ------ S TURCON-ROTO-VARISEAL D12,7 INSIDE SEAL 1
NS ------ S ALLEN HEAD CAP SCREW M5X16 DIN912 A2-70 3
NS ------ S HIGH-TEMP.GREASE GLS 595/N2 CAN:10G 1
NS 7146229 S IN-ASSEMBLY TOOLS 7136915, 7136918,EN/GE 1 A
NS 7136915 ASSY TOOL F.SHAFT SEALING D12,7 —
(assembly tool service kit)
NS ------ S ASSY MANDREL F.SHAFT SEALING D12,7 1
NS ------ S ASSY BUSHING F.SHAFT SEALING D12,7 1
NOTE A: This is instruction may be obtained from http://emanuals.nordson.com, or contact your Nordson
representative.
NS: Not Shown

Parts 7-29
Table 7-2 Variseal Pump SN1710 Service Kit

— 7136921 SEALING KIT, PUMP F.SHAFT D16 —
(pump seal service kit)
NS ------ S O-RING 28X3 VITON 70 SHORE A SCHWARZ 2
NS ------ S BUFFER RING ID 16 1
NS ------ S TURCON-ROTO-VARISEAL D16 INSIDE SEAL 1
NS ------ S ALLEN HEAD CAP SCREW M6X20 DIN912 SST 4
NS ------ S HIGH-TEMP.GREASE GLS 595/N2 CAN:10G 1
— 7136918 ASSY TOOL F.SHAFT SEALING D16 — —
(assembly tool service kit)
NS ------ S ASSY MANDREL F.SHAFT SEALING D16 1
NS ------ S ASSY BUSHING F.SHAFT SEALING D16 1
NOTE A: This is instruction may be obtained from http://emanuals.nordson.com, or contact your Nordson
representative.
NS: Not Shown
Figure 7-15 Single-stream gland seal (left) and Variseal (right) gear pumps

7-30 Parts
Dual-Stream Gear Pumps

See Figure 7-16.
Item Gland Seal Variseal Description Quantity Note

Part Part
— 291995 7116580 Gear pump DN0030 (2 x 0.30 cc/rev) 1
— 7104645 Refer to SERVICE KIT for gland seal pump sizes 1
Table 7-1 DN0030 to DN0279
— ----- — S Seal, PU6/12, 94 x 80 x 0.8 2
Figure 7-16 Dual-stream gland seal gear pump

Parts 7-31
Safety Valve Parts

See Figure 7-17.

— 207932 Valve, safety, 85 bar 1
— 394592 SERVICE KIT 1
1 ----- S O-ring 11 x 2 1
2 ----- S O-ring 9 x 2 1
— ----- S High-temp. grease, GLS 595/N2, 10g 1
Figure 7-17 Safety valve parts

7-32 Parts
Control Valve Assemblies

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

See Figure 7-18.

— ------- Assembly, control valve module —
401 7104265 S Filter cartridge, MW0, complete 1 A
401 ------- S Plug, filter 1
203059 S Valve, pressure control, adjustable, 90 bar 1 B
207300 S Valve, pressure control, pneumatic 1 C
402
1070961 S Valve, circulation control 1 D
------- S Plug, pressure control valve (blank) 1
403 ------- S Ball, 8 mm, stainless-steel 1
404 ------- S Screw, drain valve 1
405 ------- S Retaining ring, internal, 51, basic 1
NOTE A: Refer to Filter Cartridge Parts.
B: Refer to Pressure Control Valve Parts.
C: Refer to Pneumatic Pressure Control Valve Parts.
D: Refer to Circulation Control Valve Parts.
402 401 402 401
403 404405
404
Figure 7-18 Pressure control module parts

Parts 7-33
Filter Cartridge Parts

See Figure 7-19.

— 7104265 Filter cartridge, mesh Size 0.2 mm, complete 1
— 394590 SERVICE KIT Filter 0.2 mm 1
— ----- S Filter sleeve Mesh Size 0,2 complete 1
— ----- S S Filter sheath D40 1
— ----- S S Filter sleeve MS 0,2 L104 1
— ----- S S O-ring 31x1 1
— ----- S S O-ring 44x3 1
— ----- S S O-ring 48x2 1
Figure 7-19 Filter cartridge parts

7-34 Parts
Pressure Control Valve Parts

See Figure 7-20.

— 203059 Valve, pressure control, adjustable, 90 bar 1
1 ----- Body, valve 1
2 ----- Piston, valve, supporting ring 1
3 ----- Set screw, black, 90 bar 1
4 ----- Compression spring, 2.2 x 7.4 x 34.4 1
5 ----- O-ring, 6 x 2 1
6 ----- O-ring, 11 x 2 1
7 ----- O-ring, 9 x 2 1
8 ----- Supporting ring, Da10, Di6.7, spiral 1
— 394600 SERVICE KIT Pressure control valve 1
6 ----- S O-ring 11 x 2 1
7 ----- S O-ring 9 x 2 1
— ----- S High-temp. grease, GLS 595/N2, 10 g 1
6 8
7 5
Figure 7-20 Pressure control valve parts

Parts 7-35
Pneumatic Pressure Control Valve Parts

See Figure 7-21.

— 207300 Valve, pressure control, pneumatic —
1 ----- S Piston, pressure control valve 1
2 ----- S Valve body, bypass 300 degree 1
3 ----- S Cylinder, bypass pneu., Di19.3 1
4 ----- S Valve body, bypass pneumatic, 6 bar (90 psi) 1
5 ----- S Piston, bypass pneu., Da19.3 1
6 ----- S Piston, bypass pneu., Da19.3 1
7 ----- S Seal, 19.7 x 0.6 1
8 ----- S O-ring, 11 x 2 1
9 ----- S O-ring, 9 x 2 1
10 ----- S Fitting, quick thread-in, -W-d04-G1/8-TURN 1
----- S Fitting, quick thread-in, -W-d08-R1/8-TURN 1
11 ----- S Inside seal, Turcon-Variseal-M2S 1
— 394600 SERVICE KIT Pressure control valve 1
8 ----- S O-ring, 11 x 2 1
9 ----- S O-ring, 9 x 2 1
— ----- S High-temp. grease, GLS 595/N2, 10 g 1
10
3
6
8 11
Figure 7-21 Pneumatic pressure control valve parts

7-36 Parts
See Figure 7-22.

1 207300 Valve, pressure control, pneumatic 1
2 ------- Hose, air-operated, D4, 0 D2, 5 PTFE 1.5
3 ------- Fitting, quick-thread, W-D04-G 1/8-turn 1
4 ------- Reducer 1
5 ------- Sealing ring, R1/4-type, PD 5
6 ------- T-piece 1
7 ------- Nipple, double 1
8 ------- Bulkhead connection, iG1/4 1
9 ------- Street el, G1/4 x RP1/4 1
10 279615 Bypass valve 1
11 — Item no. not used —
12 ------- Sign, max 6.0 1
13 — Item no. not used —
14 ------- Air coupling, male, AG1/4 L3 1
15 ------- Air coupling, female, D6 NE7.2 L60 1
16 ------- Hose, air-operated, D8.0, D6.0 PU blue 2
17 ------- Fitting, straight 1
18 ------- Grease, high-temperature, GLS 595/N2, can 1
THIS VALVE CONNECT TO MAINFOLD
1 2
ITEM 10 MUST BE VERTICAL
17 16 15 14 18 5 12 9 18 5 18 10 8 7 6 5 4 18 3 18
Figure 7-22 Pneumatic pressure control valve interface parts

Parts 7-37
Circulation Control Valve Parts

See Figure 7-23.

— 1070961 Valve, circulation control 1
1 ----- Body, circulation valve 1
2 ----- Spool, circulation valve 1
3 ----- Nut, hex, M12 1
4 ----- O-ring, 9 x 2 1
5 ----- O-ring, 11 x 2 1
6 ----- O-ring, Viton, 0.239 ID x 0.070 W 1
7 ----- Screw, set, cup, M4 x 4, stainless-steel 1
— 394600 SERVICE KIT Circulation control valve 1
4 ----- S O-ring 9 x 2 1
5 ----- S O-ring 11 x 2 1
1 2
Figure 7-23 Circulation control valve parts

7-38 Parts
Motor Assembly
See Figure 7-24.

— ------ Assembly, motor, standard —
501 7402299 S COUPLING, M24, DAN/NORMAL 1
7402293 S COUPLING, M24, DAN/SN1710 (SN1710 1
pumps only)
502 7402295 S SERVICE KIT,MOTOR,BG06-31/D06LA4TOF 1
503 ------ S Plate, mount, motor 1
504 ------ S Washer, flat, regular, M8 8
505 ------ S Washer, lock, split, M8 8
506 ------ S Screw, socket, M8 x 25 3
507 ------ S Nut, hex, M8 3
NS ------ S Cable assembly, motor 1
NS ------ S Harness, internal 1
NS: Not Shown
INSTALLATION GAP IS 4mm
506 505 504 504 505 507 508
503 502
Figure 7-24 Motor assembly parts (four-pump melter shown)

Parts 7-39

7-40 Parts
Electrical Enclosure Panel Assemblies

The electrical enclosure panel assembly parts vary depending on the size of
the melter: one/two-pump, three/four-pump, or 100L. Refer to the correct
parts lists for your melter.
One/Two-Pump Melter Left Panel Parts

See Figure 7-25.

— ------- Assembly, electrical, panel, left, one/two-pump —
1 ------- S PANEL,LEFT,INNER,ELECT CAB,4D 1
3 ------- S WIREWAY,45X65X330,ALTABLUE 1
6 ------- S WASHER,FLT,M,REG,M3,ZINC PLATE 11
7 ------- S WASHER,LK,M,SPT,M3,STL,ZN 11
8 ------- S NUT,ACORN,M3,STL,ZN 11
10 ------- S DIN RIAL, 280 LG 2
11 ------- S WASHER,FLT,M,REG,5,STL,ZN 8
13 ------- S NUT,HEX,M5,STL,ZN 8
14 202794 S MAIN SWITCH (400V MELTER) 1
7400378 S MAIN SWITCH (240V MELTER) 1
15 7401321 S SERVICE KIT,FILTER,FAN,ELECT.CAB 1
16 7400483 S MAIN CONTACTOR 40A 220V DIN MTG 1
7400762 S MAIN CONTACTOR 80A (240V MELTERS) 1
17 7400482 S R-C NOISE 240V SUPPRESS 1
18 254244 S CIRCUIT BREAKER 50A (400V MELTERS) 1
7104855 S CIRCUIT BREAKER 90A (240V MELTERS) 1
19 1032329 S BLOCK, DISTR, 250A, 600V 4
20 779662 S END STOP,TERMINAL BLOCK 9
21 7400369 S LOCKOUT SWITCH 63A 3POLE 600V 1 A
23 ------- S PANEL,LEFT,OUTSIDE,ELECT CAB,W/LK 1
24 ------- S SPACER SLEEVE, ALTABLUE 5
25 ------- S Lock Washer,External Tooth,, 6,Zi, 36M.3.1.A 5
27 ------- S MARKER, WIRE, PUSH ON, 16−22AWG 36
28 ------- S MARKER, WIRE, PUSH ON, 10−16AWG 35
33 ------- S PANEL,COVER,FILTER 1
NOTE A: Present only on melters with the optional lockout switch.

Parts 7-41
15
33
23
11 12 13
14 −1Q21
04
01
21 −1Q22
16
20
−1Q31 −1K71 17
−1Z71
18
20
03
05
10
−XL5−XL6−XL7−XL8
20
11 12 13
19
06 07 08
26 25 24
Figure 7-25 One/two-pump melter left panel assembly parts (400V melter shown)

7-42 Parts
Three/Four-Pump and 100L Melter Left Panel Parts

See Figure 7-26.

— ------- Assembly, electrical, panel, left, three/four-pump, —
100L, six hose/gun
01 ------- S Panel, left, inner, electrical cabinet 1
03 ------- S Wireway, 50 x 50 x 330 1
04 ------- S Wireway, 25 x 50 x 180 1
05 ------- S Wireway, 25 x 50 x 257 2
06 ------- S Washer, flat, M3 11
07 ------- S Washer, lock, M3 11
08 ------- S Nut, acorn, M3 11
10 ------- S DIN rail, 35 x 7.5 x 250 1
11 ------- S Washer, flat, M5 2
12 ------- S Washer, lock, M5 2
13 ------- S Nut, hex, M5 2
14 7400378 S Main switch, 100 A, 3-pole 1
15 7401321 S SERVICE KIT, FILTER, FAN, ELECT. CAB (2) 1
S Main contactor, 40 A (400V three/four pump six 1
7400483
hose/gun melters)
S Main contactor, 80 A (240V three/four pump six 1
16 7400762 hose/gun melters, 400V three/four pump eight
hose/gun melters, and 400V 100L melters)
S Main contactor, 95 A (240V three/four pump 1
7400319
eight hose/gun melters and 240V 100L melters)
17 7400482 S RC suppressor, 110−250 VAC 1
S Main breaker, 70 A (400V three/four pump six 1
7400380
hose/gun melters)
18
S Main breaker, 90 A (400V three/four pump 1
7104855
eight hose/gun melters and 100L melters)
19 ------- S Block, distribution, 250 A, 600V 4
20 ------- S End stop, terminal 5
21 7400369 S Switch, lockout (240V melters) 1 A
23 ------- S Panel, left, outer, electrical cabinet 1
26 ------- S Nut, hex, M6 5
27 ------- S Marker, wire, push on, 16−22 AWG 36
28 ------- S Maker, wire, push on, 10−16 AWG 29
NOTE A: Present only on melters with the optional lockout switch.

Parts 7-43
23
15
24 25 31
14
−1Q21
04
21
−1Q22
01
17 −1Q31
DETIAL ’B’
−1Z71
SEE DETAIL ’B’

18
16
−XL302
−XL300
−XL301
−XL302
03 1 1 1 3
SEE DETIAL ’A’ −1K71

05 2 24 2
10
−XL5 −XL6 −XL7
2 2 2 4
20 11 12 13
13 1 1
19
26 25 24 06 07 08 29 30
DETIAL ’A’
Figure 7-26 Three/four-pump and 100L melter left panel assembly parts (240V melter shown)

7-44 Parts
One/Two-Pump Melter Back Panel Parts

See Figure 7-27.

— — ASSEMBLY, ELECTRICAL ENCLOSURE, BACK —
PANEL, ONE/TWO PUMP
1 ------ S PANEL,BACK,INNER,ELECT CAB, 2D 1
01A 171856 S S SHUNT,0.1 IN.,2-POSITION 2 A
2 ------ S WIREWAY,50 X 50 X 500,ALTA 2
3 ------ S WIREWAY,25 X 50 X 290,ALTA 3
4 ------ S WASHER,FLT,M,REG,M3,ZINC PLATE 17
5 ------ S WASHER,LK,M,SPT,M3,STL,ZN 17
6 ------ S NUT,ACORN,M3,STL,ZN 17
7 ------ S RAIL,DIN,290 LG 2
8 ------ S WASHER,FLT,M,REG,5,STL,ZN 6
10 ------ S NUT,HEX,M5,STL,ZN 6
11 1078624 S SVCE KIT,DURABLUE,MAIN,PCA 1
12 ------ S SCR,PAN,REC,M4X10,ZN 4
13 ------ S WASHER,LK,M,EXT,M4,STL,ZN 4
14 1031201 S SVCE KIT, DURABLUE, EXPANSION PCA 1
16 ------ S LOCKWSHRM,EXT,M3,STL,ZN 7
17 227569 S JUMPER,3/N/PE AC,400−230V 1
227568 S JUMPER,3/PE AC,200−240V 1
18 ------ S TBCONN, 7POS, MCVR, LBL1−7, KEYED 1
19 ------ S TBCONN, ASSY, 7POS, MCVR, LBL8−14, 1
KEYED
20 7400071 S CIRCUIT BREAKER, 32A (400V melters) 2
7400320 S CIRCUIT BREAKER, 32A (240V melters) 2
21 7400072 S CIRCUIT BREAKER,13A,1 POLE 4
(400V melters)
7400321 S CIRCUIT BREAKER,13A,2-POLE 4
(240V melters)
22 251364 S CIRCUIT BREAKER 16A 1-POLE 1
(400V melters)
7400322 S CIRCUIT BREAKER 16A 2-POLE 1
(240V melters)
23 256141 S CIRCUIT BREAKER, 16A 3-POLE 1
24 256227 S CIRCUIT BREAKER 2A,1-POLE 1
(400V melters)
7400323 S CIRCUIT BREAKER 2A,2-POLE 1
(240V melters)
25 ------ S TERMINAL BLOCK ZTR 2.5-2 19
26 ------ S TERMINAL BLOCK, END PLATE ZAP/TW7 6
27 ------ S TERMINAL CONNECTOR ZQV 2, 5/2 3
35 ------ S END STOP,TERMINAL BLOCK 4
36 7400318 S SERVICE KIT,MOTOR CONTROL,ALTA BLUE 1 or 2
38 7140101 S INTERFERENCE FILTER 230VAC/2X6A B 1
39 ------ S WASHER,FLT,M,NARROW,M4,STL,ZN 2
Continued...

Parts 7-45

44 ------ S MARKER, WIRE, PUSH ON, 16−22AWG 150
45 ------ S MARKER, WIRE, PUSH ON, 10−16AWG 50
46 ------ S SCR,PAN,SLT,M4X12MM LG 2
47 ------ S SPACER SLEEVE, ALTABLUE 4
48 ------ S Lock Washer,External Tooth,, 6,Zi, 36M.3.1.A 4
50 ------ S PANEL,BACK,OUTER,ELECT CAB, 2D 1
51 933320 S CONNECTOR,PLUG,3 CIRCUIT 1 or 2
52 939327 S SOCKET,ELECT.CONN,GND 1 or 2
53 939697 S CONNECTOR,SOCKET,16−18AWG,GOLD 2 or 4
54 933321 S CONNECTOR, RECEPTACLE 1 or 2
55 939326 S PIN,ELECT.CONN,GND 1 or 2
56 939696 S CONNECTOR,PIN,16−18AWG,GOLD 2 or 4
NOTE A: See Figure 7-28 for the location of this part on the main board.

7-46 Parts
One/Two-Pump Melter Back Panel Parts (contd)
47 48 49 15 16 18 19 11 12 13
50
01
14
17
04 05 06
SEE DETAIL ”B” −4Q41 −9Q51 −10Q51 −1Q32

07
−4Q11 −9Q21 −10Q21 −11Q31 −1Q31
SEE DETAIL ”C” 08 09 10

−XL13
−XL14
−XL15
07
−XL911
−XL11 −XL12
−11V31
03
02
08 09 10
02
36
−11A31 −12A31
39 40 41
38
35 20 22 35
35 25 27 27
12345 1 2345
12 12 12321
16A
16A
16A
32A
32A
13A
13A
13A
13A
16A
2A
W X
%
.1
9
1
_
8
p
7
5
2
.2
O
L
F
D
A
B
C ,J4
.Y
IS
W
M
E
R
G
P
T
N0
.0H
−
K
U7
5
3
1
0
Z
V
H
B
M
R
E
O
W
CJ−Y
3
K
IT
N
U
S
G
F
Y
A
L
_
D
P
X HT
C
S
Z
A
T
P
X 1H
D
R
N
5
C
L
0
Y
R
W
T
%
,0
1
P
D
T
L
C
B
IP
F
W
29 29 28 26 35 21 23 35
DETAIL ”B”
DETAIL ””C
Figure 7-27 One/two-pump melter back panel assembly parts (400V melter shown)

Parts 7-47
1A
+ C35
RV 13
RV 12
RV 10
RV 11
C10
RV 9
RV 7
C8
C3
C4
C9
C5
C56
C36
C23
C24
C25
C26
C27
C28
C29
R95
C30
R71
C44 R85 R81
R93 R5
R19 R17 RV 6 R20
C55
R80 R86
C50 C43 C1 R18
U16
R82
C54
R79
R26 R22 J1
R90
Q22
D17 R84 C60C53 XP5
1
RN4RN6 C31 Q20 C21 C2233 51
C20
L1 R63 R15 JP1
R121
R88
C74
HSNK1 RN3 R101 6 2
D16 C58 Q19
U2
RN2 RN1
RN9
+ U3
C75
D3 C7 RN10 R99
RN7
C45 C46 Q18
RN5
C37
C18
C42 C47 U7 R119
U4 Q17
C41
C6
U14 R120
T1
RN11
C19
DS4
R96
+
R72
L4
U1
L3
XP6 JP2
U17 C17
R87
RV 8 R134 R135
U5
R77
C12 C16 C15
C63
+
DS15R89
R124
C52 ++ D8
F4 R92 C66 D4
+
D18 Q26 R127 D6
2A R91 R133 DS17
C48 C49 C57 R129 C2
D1 D7 R4 RV 5
R33
F3 K1 L2 R128
2A
R122 R3 C11
D2 R1 R2 RV 4
+
XT1 DS16
R38 C76
D12 D10 D11 J2 1 D14
XP4
Q13 R130 C51
U22 C771
C40 R67
R45 R44 RV 3
C65
R75 U12 U23

R131 R132 C59 U25
+
C64 R46 R43 C78
XP1
XP2
R100
C84
C83
R68
R66
U21
C61 R76
C32
R123
U26
X6 R136 U9 R73
R102
R69
D5 R74
+
C82
C80
R83 RV 1
R37 C62
F1 X7
F2 XP3
10A
10A
F6 F5 F11 F7
Q24 C39 1
6.3A 6.3A U24 R40 RV 2
R41
5A 5A F9 DS14 R42 R39 C67
F12 F8 F10
R114
R115
6.3A
6.3A 6.3A 6.3A R116
U15 Q14
DS10
R6
R8
R9
R59
R60
DS3 DS2
R57
R7
R16
R12
R13
R10
R11
R14 DS7 DS5 DS6

U18 Q16
12 12 DS11
R78
3 3 R94
X4 X5 U13 Q7
X1 DS9
R64
X2
R54
R53
X3 R51
1 1 U10 Q5
DS8
1
R35
1
U19 Q12
DS12
R48
R47
R113
R56
R62
R34
R97
R98
R50
R105
R112
R108
R117
R58
R65
R52
R36
R106
R110
C79 C70 C71

C69 C68 C72
C73 Q9
R109
R118
U20
R55
R49
R111
R70
R61
DS13
R107
R103
R104
Q25 Q15 Q23 Q8 Q6 Q10 Q11
Figure 7-28 Location of the shunt on the main board

7-48 Parts
Three/Four-Pump and 100L Six Hose/Gun Melter Back Panel Parts

See Figure 7-29.

— — ASSEMBLY, ELECTRICAL ENCLOSURE, BACK —
PANEL, THREE/FOUR PUMP, 100L, SIX
HOSE/GUN
1 ------ S PANEL,BACK,INNER,ELECT CAB,4D 1
2 ------ S WIREWAY,45X65X590,ALTABLUE 2
3 ------ S WIREWAY,25X65X690,ALTABLUE 4
4 ------ S WASHER,FLT,M,REG,M3,ZINC PLATE 24 4
5 ------ S WASHER,LK,M,SPT,M3,STL,ZN 24 4
6 ------ S NUT,ACORN,M3,STL,ZN 24 4
7 ------ S RAIL,DIN,35X7.5X690,ALTABLUE 2
8 ------ S WASHER,FLT,M,REG,5,STL,ZN 4
13 ------ S WASHER,LK,M,EXT,M4,STL,ZN 4
16 ------ S LOCKWSHRM,EXT,M3,STL,ZN 7
17 227569 S JUMPER,3/N/PE AC,400−230V 1
227568 S JUMPER,3/PE AC,200−240V 1
18 ------ S TBCONN, 7POS, MCVR, LBL1−7, KEYED 1
19 ------ S TBCONN, ASSY, 7POS, MCVR, LBL8−14, 1
KEYED
20 7400071 S CIRCUIT BREAKER, 32A (400V melters) 2
7400320 S CIRCUIT BREAKER, 32A (240V melters) 2
(400V melters)
(240V melters)
(400V melters)
(240V melters)
(400V melters)
(240V melters)
25 ------ S TERMINAL BLOCK ZTR 2.5-2 62 or 68
26 ------ S TERMINAL BLOCK, END PLATE ZAP/TW7 8
27 ------ S TERMINAL CONNECTOR ZQV 2, 5/2 10 or 11
29 ------ S TERMINAL CONNECTOR ZQV2,5/10 2
34 ------ S CLIP,RELAY 1
35 ------ S END STOP,TERMINAL BLOCK 10
Continued...

Parts 7-49

38 7140101 INTERFERENCE FILTER 230VAC/2X6A B
S 2
39 ------ WASHER,FLT,M,NARROW,M4,STL,ZN
S 2
40 ------ WASHER,LK,M,SPT,M4,STL,ZN
S 2
41 ------ NUT,HEX,M4,STL,ZN
S 2
44 ------ MARKER, WIRE, PUSH ON, 16−22AWG
S 200
45 ------ MARKER, WIRE, PUSH ON, 10−16AWG
S 80
46 ------ TERMINAL BLOCK,GRAY,IEC,22−10 AWG,J4
S 10
47 ------ End barrier, AB, 1492-EBJ3
S 1
48 1053122 MODULE, CONDITIONER, SIGNAL, 0−10V,
S 1
1K OHM
49 1049720 S BOARD, BREAKOUT, DURABLUE, EXPAND, 1
TB, 20POS
50 171234 S RELAY,OMRON,24VDC,4PDT 1
51 172857 S SOCKET,OMRON,4PDT,DIN,TOUCHPRF 1
53 ------ S PANEL,BACK,OUTER,ELECT CAB,4D 1
54 ------ S SPACER SLEEVE, ALTABLUE 4
55 ------ S Lock Washer,External Tooth,, 6,Zi, 36M.3.1.A 4
57 ------ S SCR,PAN,SLT,M4X12MM LG 2
58 ------ S MARKER, SAKD 2.5 N, 4 PUMP 1

7-50 Parts
Three/Four-Pump and 100L Six Hose/Gun Melter Back Panel Parts (contd)
01 15 16 14 18 19 17 11 12 13
53
03
10 09 08
SEE DETAIL ’B’
07
SEE DETAIL ’C’
−12A31 −13A31 −14A31

−11A31
02
39 40 41
−11V31
−13V31
06 05 04
SEE DETAIL ’A’ 38 36 08 09 10 54 55 56 DETAIL ”A”
35 21 22 23 20 21 49
47 27 29 28
−4Q41 −9Q51 −10Q51 −16Q41 −1Q11

−XL163
−XL165
−XL161
−11A11
−XL3
−XL1
−X45 −XM −XL11 −XL13 −XL15
0 0 0 0 0 0 0 0 0 0 8 7 6 5
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 1 2 1 2 3 1 2
4 1
13A
13A
13A
13A
13A
13A
16A
32A
32A
2A
16A
16A
13A
16A
11
4 3
X45X45X45X45X45X45X45 XMXMXMXMXMXMXMXMXMXM XL11
XL11
XL11
XL11
XL11
XL11
XL11
XL11
XL11
XL11XL12
XL12
XL12
XL12
XL12
XL12
XL12
XL12
XL12
XL12XL13
XL13XL14
XL14XL15
XL15
XL15XL911
XL911 1
2 1 1
1 0 9
XL1XL2XL3XL4XL1XL162
61 XL1XL1
63 XL165
64 X166
−XL162
−XL164
−XL166
−XL2
−XL4
−XL12
−XL911
−XL14
−4Q11 −9Q21 −10Q21 −11Q31 −1Q32 −16Q21 −16Q61 −3X11

−1K31
35 46 25 26 25 26 29 25 26 27 50 51 34 48 24
DETAIL ”B”
DETAIL ”C”
Figure 7-29 Three/four-pump and 100L six hose/gun melter back panel assembly parts (400V melter shown)

Parts 7-51

7-52 Parts
Three/Four-Pump and 100L Eight Hose/Gun Melter Back Panel Parts

See Figure 7-30.

— ------- ASSEMBLY, ELECTRICAL ENCLOSURE, BACK —
PANEL,THREE/FOUR PUMP, 100L, EIGHT
HOSE/GUN
1 ------- S PANEL,BACK,INNER,ELECT CAB,4D 1
6 ------- S NUT,ACORN,M3,STL,ZN 24
7 ------- S RAIL,DIN,35X7.5X690,ALTABLUE 2
8 ------- S WASHER,FLT,M,REG,5,STL,ZN 10
10 ------- S NUT,HEX,M5,STL,ZN 10
12 ------- S SCR,PAN,REC,M4X10,ZN 4
13 ------- S WASHER,LK,M,EXT,M4,STL,ZN 4
15 ------- S SCR,PAN,REC,M3X8,ZN 7
16 ------- S LOCKWSHRM,EXT,M3,STL,ZN 7
17 227569 S JUMPER,3/N/PE AC,400−230V 1
227568 S JUMPER,3/PE AC,200−240V 1
18 ------- S TBCONN, 7POS, MCVR, LBL1−7, KEYED 1
19 ------- S TBCONN, ASSY, 7POS, MCVR, LBL8-14, 1
KEYED
(400V melters)
(240V melters)
(400V melters)
(240V melters)
(400V melters)
(240V melters)
25 ------- S TERMINAL BLOCK ZTR 2.5-2 62 or 68
26 ------- S TERMINAL BLOCK, END PLATE ZAP/TW7 8
27 ------- S TERMINAL CONNECTOR ZQV 2, 5/2 10 or 11
28 ------- S TERMINAL CONNECTOR ZQV 2, 5/3 1
29 ------- S TERMINAL CONNECTOR ZQV2,5/10 2
30 ------- S BOARD,ASSY,8 H/G EXP. BASE,PB II 1
34 ------- S CLIP,RELAY 1
35 ------- S END STOP,TERMINAL BLOCK 12
38 7140101 S INTERFERENCE FILTER 230VAC/2X6A B 2
Continued...

Parts 7-53

39 ------- WASHER,FLT,M,NARROW,M4,STL,ZN
S 2
40 ------- WASHER,LK,M,SPT,M4,STL,ZN
S 2
41 ------- NUT,HEX,M4,STL,ZN
S 2
44 ------- MARKER, WIRE, PUSH ON, 16−22AWG
S 200
45 ------- MARKER, WIRE, PUSH ON, 10−16AWG
S 80
46 ------- TERMINAL BLOCK,GRAY,IEC,22−10 AWG,J4
S 10
47 ------- End barrier, AB, 1492-EBJ3
S 1
48 1053122 MODULE, CONDITIONER, SIGNAL, 0−10V,
S 1
1K OHM
49 1049720 S BOARD, BREAKOUT, DURABLUE, EXPAND, 2
TB, 20POS
50 171234 S RELAY,OMRON,24VDC,4PDT 1
51 172857 S SOCKET,OMRON,4PDT,DIN,TOUCHPRF 1
53 ------- S PANEL,BACK,OUTER,ELECT CAB,4D 1
54 ------- S SPACER SLEEVE, ALTABLUE 4
55 ------- S Lock Washer,External Tooth,, 6,Zi, 36M.3.1.A 4
57 ------- S SCR,PAN,SLT,M4X12MM LG 2
58 ------- S MARKER, SAKD 2.5 N, 4 PUMP 1
59 ------- S RAIL,DIN 35mm, 7.5mm 0.1

7-54 Parts
Three/Four-Pump and 100L Eight Hose/Gun Melter Back Panel Parts

(contd)
49 30 10 09 08 15 16 14 18 19 17 11 12 13
01
53 −7A21
35
59
−3X11 −3X51
03
−3A21
SEE DETAIL ’B’ −2A21
10 09 08
07
SEE DETAIL ’C’
02
−11A31 −12A31
SEE DETAIL ’A’
−13A31 −14A31
39 40 41
−11V31
−13V31
06 05 04
38 36 08 09 10 54 55 56
DETAIL ’A’
35 21 21 21 21 20 21 21 22 23 24 47 27 29 28
−XL163
−XL165
−XL161
−11A11
−XL3
−XL1
−4Q41 −9Q51 −10Q51 −16Q41 −17Q51 −18Q51 −1Q11 −X45 −XL13 −XL15
−4Q21 −XM −XL11
0 0 0 0 0 0 0 0 0 0 8 7 6 5
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 1 2 1 2 3 1 2
4 1
13A
13A
13A
13A
13A
13A
13A
32A
32A
13A
13A
13A
13A
16A
16A
16A
16A
2A
11
4 3
X45X45
X45
X45
X45X45
X45 XMXMXMXMXMXMXMXMXMXM XL11
XL11
XL11
XL11
XL11
XL11
XL11
XL11
XL11
XL11XL12
XL12
XL12
XL12
XL12
XL12
XL12
XL12
XL12
XL12XL13
XL13XL14
XL14XL15
XL15
XL15XL911
XL911 1
2 1 1
1 0 9
XL1XL2XL3XL4XL1XL162
61XL1XL1
63 XL165
64X166
−XL162
−XL164
−XL166
−XL2
−XL4
−XL911
−XL12
−XL14
−4Q31 −9Q21 −10Q51 −16Q21 −17Q21 −18Q21 −11Q31 −1Q32

−1K31
DETAIL ’B’ 35 46 25 26 25 26 29 25 26 27 50 51 34 48
DETAIL ”C”
Figure 7-30 Three/four-pump and 100L eight hose/gun melter back panel assembly parts (400V melter shown)

Parts 7-55

7-56 Parts
One/Two-Pump Melter Right Panel Parts

See Figure 7-31.

— ------- Assembly, electrical enclosure, right panel, —
one/two pump
01 ------- S Panel, right, electrical cabinet 1
02 ------- S Wireway, 50 x 50 x 500 2
03 ------- S Wireway, 25 x 50 x 250 4
06 ------- S Nut, acorn, M3 20
07 ------- S Rail, DIN, 250 long 3
10 ------- S Nut, hex, M5 6
11 1031175 S SVCE KIT, DURABLUE, 2H TO 4H 1
CONVERSION
12 ------- S Screw, pan, slotted, M4 x 10 4
13 ------- S Washer, lock, external, M4 4
14 1053122 S Module, conditioner, signal, 0−10 V, 1k ohm 1
15 1049720 S Board, breakout, expand, terminal block, 1
20-position
16 ------- S Terminal block, ZTR 2.5-2 21
17 ------- S Terminal connector, ZQV 2 5/2 4
18 ------- S Terminal block, end plate 2
19 779392 S Socket,relay mount 1
20 777604 S Relay, 24 VDC, DPDT 1
21 ------- S Clip, relay 1
22 159684 S Power supply, 24 VDC, 0.6 A, 15 W 1
23 207396 S Solid-state relay, 100−260 VAC, 15 A, 5
DC trigger
24 7400070 S Solid state relay, 100−260 VAC, 35 A, 2
DC trigger
25 ------- S End stop,terminal block 9
26 7401320 S SERVICE KIT, FAN, 240VAC, 170 CFM 1
28 ------- S Screw, socket, cap, M4 x 45 2
29 ------- S Terminal, block, jumper, 10-position 4
31 ------- S Label, wiring 1
32 ------- S Marker, SAKD 2.5N 1
34 ------- S Maker, wire, push on, 10−16 AWG 16

Parts 7-57
25 14 15 16
11 01
12 13
03
−7A21
DETAIL ”A” 4X 17 18
SEE DETAIL ’A’

−XM
25 16 17 19 20 21 22
4 56
02 −11A11
−3X11 −X45
13 14
9 12
12345 12 2 3 4 5 1121212 3 −V V+
DC ON
OMRON
S82K−01524
POW ER SUPPLY
DVE
V. ADJ
−1G21
−1K31 IN P U T
MADE IN JAPAN
−XL15
−XL11−XL13 SEE DETAIL ’B’ 85 L N
41
123
07 30 29 18
−XL12
−XL14
−XL911
24
DETAIL ”B”
−1N61−9N51 −10N51
−4N21−4N41 25
04 05 06 SEE DETAIL ’C’
OMRON OMRON OMRON OMRON OMRON OMRON OMRON
08 09 10 −9N21−10N21 0
H
N
%
1
8
p
7
5
2
D
G
A
Y
S
P
F
K
._
0
X
B
C
O
E
R.9
IO
IW
T
L
U
MW
T
X
C
M
R
E 10
D
S
,J4
L
−7
5
2
3
1
G3PB−215−VDG3PB−215−VDG3PB−215−VDG3PB−215−VDG3PB−215−VD G3PB−235−VD G3PB−235−VD
27
−1M51
26 DETAIL ”C”
23
28
Figure 7-31 One/two-pump melter right panel assembly parts

7-58 Parts
Three/Four-Pump and 100L Six Hose/Gun Melter Right Panel Parts

See Figure 7-32.

three/four pump, 100L, six hose/gun
01 ------- S Panel, right, inner, electrical cabinet 1
02 ------- S Wireway, 25 x 50 x 337 1
03 ------- S Wireway, 25 x 50 x 291 3
04 ------- S Washer, flat, M3 12
05 ------- S Washer, lock, M3 12
06 ------- S Nut, acorn, M3 12
07 ------- S Rail, DIN, 35 x 7.5 x 220 2
08 ------- S Washer, flat, M5 4
09 ------- S Washer, lock, M5 4
10 ------- S Nut, hex, M5 4
11 1031175 S SVCE KIT, DURABLUE, 2H TO 4H 1
CONVERSION
12 ------- S Screw, M4 x 10 4
13 ------- S Washer, lock, external, M4 4
14 159684 S Power supply, 24 VDC, 0.6 A, 15 W, TP 1
DC trigger
16 207396 S Solid state relay, 100−260 VAC,15 A, 8 or 9
DC trigger
20 ------- S Screw, M4 x 45 long 2
22 ------- S Panel, right, outer, electrical cabinet 1
23 ------- S Nut, hex, M6 4
24 ------- S Washer, flat, M6 4
29 ------- S Cover, fuse, 5 x 20 mm 4

Parts 7-59
29 22
25 24 23 01 16 14
−7A21 100. . . 240V A C
NL
21 13 12
OMRON OMRON OMRON
Te le me c anique
A B L 7C E M 24006
V.Out
G3PB−215−VD G3PB−235−VD G3PB−235−VD −−−
02
OUT P UT
+ NC −
24V D C − 0. 6A − 15W
11
SEE DETAIL ’A’
−1N61 −16N21 −16N41 −1G21
03 17 15
07
DETAIL ’A’
SEE DETAIL ’B’
17 16
−9N51 −10N51 −4N41 −4N16
08 09 10
OMRON OMRON OMRON OMRON OMRON OMRON OMRON OMRON
04 05 06
G3PB−215−VD
G3PB−215−VD
G3PB−215−VD G 3P DB −215−V
G 3P B −215−V G 3P DB −215−V G3PB−215−VD
G 3P DB −215−V D
−9N21 −10N21 −4N21 −16N61
20
DETAIL ’B’
−1M51
18
19
Figure 7-32 Three/four-pump and 100L six hose/gun melter right panel assembly parts

7-60 Parts
Three/Four-Pump and 100L Eight Hose/Gun (400V) Melter Right Panel

Parts
See Figure 7-33.

three/four pump, 100L, eight hose/gun
02 ------- S Wireway, 25 x 50 x 337 1
03 ------- S Wireway, 25 x 50 x 291 3
04 ------- S Washer, flat, M3 12
05 ------- S Washer, lock, M3 12
06 ------- S Nut, acorn, M3 12
07 ------- S Rail, DIN, 35 x 7.5 x 220 2
08 ------- S Washer, flat, M5 4
09 ------- S Washer, lock, M5 4
10 ------- S Nut, hex, M5 4
DC trigger
DC trigger
20 ------- S Screw, M4 x 45 long 2
23 ------- S Nut, hex, M6 4
24 ------- S Washer, flat, M6 4

Parts 7-61
22
25 24 23 01
02
SEE DETAIL ’B’
−4N21 −1N61 −16N21 −16N41 −1G21 17 16 15 14

03
07 2X 100. . . 240V A C
NL
OMRON OMRON OMRON OMRON OMRON
Te le me c anique
A B L 7C E M 24006
V.Out
G3PB−215−VD G 3P B −215−VG D3P B −235−V D G3PB−235−VD
G3PB−215−VD −−−
OUT P UT
−4N31
SEE DETAIL ’C’ + NC −
24V D C − 0. 6A − 15W
−17N21 −18N21 −9N21 −10N21 −4N51
08 09 10
DETAIL ’B’
04 05 06 17 16
−17N51 −18N51 −9N51 −10N51 −4N71
OMRON OMRON OMRON OMRON OMRON OMRON OMRON OMRON OMRON OMRON
20 2X G 3P B −215−V
G3PB−215−VD G 3P BD −215−V
G 3P BD −215−V
G3PB−215−VD
D G3PB−215−VD
G 3P B −215−V
G 3P BD −215−V G3PB−215−VD
G 3P BD −215−V D
−1M51 DETAIL ’C’
18
19
Figure 7-33 Three/four-pump eight hose/gun (400V) melter right panel assembly parts

7-62 Parts
Three/Four-Pump and 100L Eight Hose/Gun (240V) Melter Right Panel

Parts
See Figure 7-34.

three/four pump, 100L, eight hose/gun, 240V
02 ------- S Wireway, 25 x 50 x 337 1
03 ------- S Wireway, 25 x 50 x 291 3
04 ------- S Washer, flat, M3 12
05 ------- S Washer, lock, M3 12
06 ------- S Nut, acorn, M3 12
07 ------- S Rail, DIN, 35 x 7.5 x 220 2
08 ------- S Washer, flat, M5 4
09 ------- S Washer, lock, M5 4
10 ------- S Nut, hex, M5 4
11 ------- S Rail, DIN, 35 mm x 7.5 mm 0.11
12 7400320 S Circuit breaker, 32 A, 3-pole 2
13 7400321 S Circuit breaker, 13 A, 2-pole 1
DC trigger
DC trigger
20 ------- S Screw, M4 x 45 long 2
23 ------- S Nut, hex, M6 4
24 ------- S Washer, flat, M6 4

Parts 7-63
22 17 13 12 12
SEE DETAIL ’A’

25 24 23 01
13 A
13 A
−16Q21
32A
32A
32A
32A
11
02
−4Q41 −16Q41
DETAIL ’A’
SEE DETAIL ’B’
−4N21 −1N61 −16N21 −16N41 −1G21 17 16 15 14

03
07
NL
OMRON OMRON OMRON OMRON OMRON
Te le me c anique
A B L 7C E M 24006
V.Out
G3PB−215−VD G 3P B −215−VGD3P B −235−V D
G3PB−215−VD G3PB−235−VD −−−
OUT P UT
−4N31
SEE DETAIL ’C’ + NC −
−17N21 −18N21 −9N21 −10N21 −4N51
08 09 10
DETAIL ’B’
04 05 06 17 16
−17N51 −18N51 −9N51 −10N51 −4N71
OMRON OMRON OMRON OMRON OMRON OMRON OMRON OMRON OMRON OMRON
20 G3PB−215−VD G 3P B
G 3P B −215−V D −215−V
G 3P BD −215−V
G3PB−215−VD
D G3PB−215−VD
G 3P B −215−V G 3P B
G 3P BD −215−V D −215−V D
G3PB−215−VD
−1M51 DETAIL ’C’
18
19
Figure 7-34 Three/four-pump eight hose/gun (240V) melter right panel assembly parts

7-64 Parts
One/Two-Pump Melter Bottom Panel Parts

See Figure 7-35.

— ------- Assembly, electrical enclosure, bottom panel, —
one/two pump
01 ------- S Panel, bottom electrical cabinet 1
02 ------- S Rail, DIN, 210 long 1
05 ------- S Nut, hex, M5 4
07 ------- S Terminal block, ZDU 16 3 or 4
08 ------- S Grommet, rubber, 0.812 ID x 1.25 OD 2
09 ------- S Tag, ground 1
10 ------- S Terminal block, end plate, ZAP/TW ZDU16 1
11 ------- S Terminal block, ZPE 16 1
14 ------- S Terminal, 28 position, I/O 1
18 ------- S Wire, vinyl, 22 AWG, dark blue,105C, 600V 110
19 ------- S Ferrule, wire, 22 AWG, insulated, white 56
07
22
09
23
L1 L2 L3 PE
09
−XL0 −XI −XE
03
04
01
05
08 10 11 14
Figure 7-35 One/two-pump melter bottom panel assembly parts

Parts 7-65
Three/Four-Pump and 100L Melter Bottom Panel Parts

See Figure 7-36.

— ------- Assembly, electrical enclosure, bottom panel, —
three/four pump, 100L
01 ------- S Panel, bottom electrical cabinet 1
02 ------- S Grommet, rubber, ID32 5
06 ------- S Nut, hex, M5 6
08 ------- S Terminal block, ZDU 16 3 or 4
10 ------- S Terminal block, ZPE 16 1
11 ------- S Terminal block, ZDK2,5/1.5 PE 4
12 ------- S Terminal block, end plate, ZAP/TWZDK2.5 1
13 ------- S Terminal block, 40-position, I/O 1
−XE
15 2 3 4
01
1 2 3 4 5
145~150 15 ~20
−XL −XE
L1 L2 L3 N PE
06 05 04
−XLO 02 11 12
DETAIL C
14 08 10 09 THIS PART ONLY 13 SEE DETAIL ”C”

USED IN 30L/50L
Figure 7-36 Three/four-pump and 100L melter bottom panel assembly parts (400V melter shown)

7-66 Parts
Control Panel Assembly

See Figure 7-37.

— ------- Assembly, control panel —
01 S PANEL,CONTROL,2 MOTORS, 2D 1
02 1085183 S MEMBRANE PANEL MOTOR CONTROL,STD 2
ALTA
03 1085104 S PCA, MOTOR,ALTABLUE 2
06 1025743 S MEMBRANE PANEL, W/KEYPAD, FINAL, 1
DURABLUE
07 1017947 S SWITCH,ROCKER,SPST,250V,16A,GOLD 1
09 1029938 S CABLE ASSY, RIBBON, SERIAL PORT, 1
9-POS, DURA
10 1028325 S KIT,SERVICE,CPU BOARD 1
11 ------- S THRDSPCRMM,MALE/FEM,SS,HEX,M3,8MM 14
LG
12 ------- S WASHER,LK,M,INT,M3,STL,ZN 14
13 ------- S CONNHDWE,SCREWLOCK,#4-40,D-SUB 2
CONNECTOR
14 ------- S CAP,D-SHELL CONNECTOR,9 PIN,FEM 1
16 ------- S LATCH, QUARTER TURN, DURA PANEL 2
20 ------- S CLAMP,RIBBON CABLE 3
NS ------- S MARKER, WIRE, PUSH ON, 16−22AWG 60
NS: Not Shown

Parts 7-67
20
01
07
11 12
10
14
02
11 12
13
03
06
12A61 11A61
16
FRONT VIEW 19 18 17 09
REAR VIEW
Figure 7-37 Control panel assembly parts (four-pump melter shown)

7-68 Parts
Sensor Assembly
See Figure 7-38. The sensors on your melter may be one of two types:
120-ohm nickel or 100-ohm platinum.

— ------- Assembly, sensors, with hose/gun channels —
801 ------- S 6 hose connector assembly, NI120, 1
one/two-pump
NS ------- S 6 hose connector assembly, PT100, 1
one/two-pump
NS ------- S 6 hose connector assembly, NI120, 1
three/four-pump/100L
three/four-pump/100L
NS ------- S 8 hose connector assembly, NI120, 1
three/four-pump, 100L
three/four-pump, 100L
802 7401367 S RTD assembly, reservoir, NI120 1
NS 7400281 S RTD assembly, reservoir, PT100 1
803 7401368 S RTD assembly, grid, NI120 1
NS 7400280 S RTD assembly, grid, PT100 1
806 ------- S Nut, hex, M6 4
807 ------- S Screw, button, socket, M6 x 12 1
808 171856 S Shunt, 1 in., 2 position 2 A
809 ------- S Panel, cover, manifold, three/four-pump 2
NS ------- S Panel, cover, manifold, one/two-pump 2
NOTE A: This part is present only on PT100 melters. See Figure 7-28 for the location of this part on the main board.
NS: Not Shown

Parts 7-69
ITEM 808 SHUNT REQUIRED

WITH PT100 SENSORS
JP1
REF MAIN PCB BOARD
803 801 807
802 804, 805, 806 804, 805, 806 809
Figure 7-38 Sensor assembly parts (four-pump 100-ohm platinum melter shown)

7-70 Parts
Low Level Assembly

See Figure 7-39.

— 7400563 Low level indication, 15/30L, one/two pump —
— 7401273 Low level indication, 50L, one/two pump —
— 7401274 Low level indication, 30/50L, three/four pump —
— 7401275 Low level indication, 100L —
1201 ------- S Wire harness, low level 1
1202 ------- S Low level assembly, 169 mm 1
NS ------- S Cable tie, 4 in., 302 degrees F 5
NS: Not Shown
1202
1201
ROUTE WIRE FROM SWITCH

ASSEMBLY BETWEEN THE GASCKET
HOPPER GASKET AND TOP COVER.
Figure 7-39 Low level assembly parts

Parts 7-71
Optional Accessories
To optimize the use of your system, Nordson Corporation recommends
these optional accessories.
Expansion and Control Kits

Part Description Quantity
1036607 Kit, I/O expansion card (digital)
1063740 Kit, analog I/O board
1053288 Kit, DeviceNet card
1053289 Kit, Ethernet card
1053300 Kit, PROFIBUS card
Pressure Indication
Part Description Note
1030537 Kit, gauge, analog pressure, 1500 psi
Low Level Indication

7400563 Low level indication, 15/30L, one/two pump
7401273 Low level indication, 50L, one/two pump
7401274 Low level indication, 30/50L, three/four pump
7401275 Low level indication, 100L
NOTE: Refer to Low Level Assembly earlier in this section for a parts list and illustration.
Pneumatic Pressure Control Valve

1079939 Kit, pressure control valve, pneumatic
NOTE: Refer to Pneumatic Pressure Control Valve Parts earlier in this section for a parts list and illustration.

7-72 Parts
Line-Speed Signal Generator

To use the gear-to-line capability of the melter, you must install a device that
measures the speed of the production line. The default type of line-speed
signal input is 0−10 VDC, although other inputs can be accepted. Nordson
Corporation offers the following 0−10 VDC generator.

119560 Generator, 0−10 VDC, with bracket and cable
Optional Fittings
See Figure 7-40. These fittings can be used at the melter end of a hose.
Fitting Fitting Size, Fitting Size,

Hose Size Fitting Type
Part Number Melter Side Hose Side
7400333 Straight M16 x 1.5 9/ -18 JIC
16
8-mm 7400337 45-degree M16 x 1.5 9/ -18 JIC
16
7400335 90-degree M16 x 1.5 9/ -18 JIC
16
7401279 Straight M16 x 1.5 3/ -16 JIC
4
7401278 45-degree M16 x 1.5 3/ -16 JIC
12-mm 4
7401277 90-degree M16 x 1.5 3/ -16 JIC
4
7400334 Straight M22 x 1.5 11/16 JIC
16-mm (see Note) 7400338 45-degree M22 x 1.5 11/16 JIC
7400336 90-degree M22 x 1.5 11/16 JIC
1 2 3
Figure 7-40 Typical non-swivel fittings
1. Straight fitting 2. 45-degree fitting 3. 90-degree fitting

Parts 7-73
Recommended Spare Parts

Table 7-3 Recommended Spare Parts
P/N Description
All Melters
7402299 COUPLING, M24, DAN/NORMAL (except for melters with pump SN1710)
7402293 COUPLING, M24, DAN/SN1710 (melters with pump SN1710 only)
7400298 SERVICE KIT, HEATER, 240V, 800W, 1/2 X 11.65 (one/two pump melter 30/50L
hopper)
7400876 SERVICE KIT, HEATER, 240V, 500W, 1/2 X6.38 (one/two pump melter 15L hoppers
and three/four pump melter 30L hoppers)
7400875 SERVICE KIT, HEATER, 240V, 750W, 1/2 x11.85 (three/four pump melter 50L hoppers)
7401316 SERVICE KIT HEATER, 240V, 1000W, 1/2X22.75 (100L melter hoppers)
7400297 SERVICE KIT, HEATER, 240V, 800W, 1/2 X 13.75 (all melter manifolds)
7400569 SERVICE KIT, HEATER, 240V, 400W, 1/2 X 13.75 (one/two pump melter reservoirs)
7400874 SERVICE KIT, HEATER, 240V, 800W, 1/2 X 27.5 (three/four pump melter and 100L
melter reservoirs)
7401366 THERMOSWITCH ASSY, ALTABLUE
777604 RELAY, 24VDC, DPDT
779392 SOCKET, RELAY MOUNT
7401321 SERVICE KIT, FILTER, FAN, ELECT.CAB
7401320 SERVICE KIT, FAN, 240VAC, 170 CFM
7400318 SERVICE KIT, MOTOR CONTROL, ALTABLUE
7140101 INTERFERENCE FILTER 230VAC/2X6A B
1078624 SVCE KIT, DURABLUE, MAIN, PCA
1031201 SVCE KIT, DURABLUE, EXPANSION PCA
1031175 SVCE KIT, DURABLUE, 2H TO 4H CONVERSION
1028325 KIT, SERVICE, CPU BOARD
207396 SOLID-STATE RELAY, 100−260VAC, 15A, DC TRIGGER
7400070 SOLID STATE RELAY, 100−260VAC, 35A, DC TRIGGER
203059 SAFETY VALVE 100 BAR TKZU ADJUSTABLE
207300 SAFETY VALVE 90 BAR PNEU.
1070961 VALVE, CIRCULATION CONTROL, ALTABLUE
207932 Safety valve, 85 bar, VB/DB
7400299 SERVICE KIT, O-RING, VITON, 45 X 2
7400300 SERVICE KIT, O-RING, VITON, 26 X 2
1058990 CORDSTOCK, 3 MM OD, VITON, 75D
7400134 GASKET, HOPPER, 15L (one/two pump melters)
7400135 GASKET, HOPPER, 30/50L, ALTA
7400326 GASKET, 50L, HOPPER, 4D
7400327 GASKET, 30L, HOPPER, 4D
7400901 GASKET, HOPPER, 100L
7402295 SERVICE KIT, MOTOR, BG06-31/D06LA4TOF
Pumps
394589 SERVICE KIT, PUMP O-RING, SINGLE-STREAM, PUMP SIZE SN0030−SN0773
394596 SERVICE KIT, PUMP O-RING, SINGLE-STREAM, PUMP SIZE SN1710
7104645 SERVICE KIT, PUMP O-RING, DUAL-STREAM
Continued...

7-74 Parts
Recommended Spare Parts (contd)
Table 7-3 Recommended Spare Parts (contd)

P/N Description
Select Based on Specific Melter Configuration
One/Two-Pump Melters, 240 VAC
7400762 Main contactor, 600V/50hz/60hz, 3-pole, 80 A
7104855 Circuit breaker, 90 A, 3-pole
7400322 Circuit breaker, 16 A, 2-pole, inductive load
One/Two-Pump Melters, 400 and 480 VAC
7400483 Contactor, 40 A, 440V, 3-phase, 240 VAC coil
256227 Circuit breaker, 2 A
Three/Four-Pump and 100L Melters, 240 VAC
7400319 Main contactor, 95 A
Three/Four-Pump and 100L Melters, 400 and 480 VAC
7400483 Contactor, 40 A, 440V, 3-phase, 240 VAC coil
7400380 Main breaker, 70 A, 3-pole
256227 Circuit breaker, 2 A
PT100 Melters
7400281 RTD assembly, reservoir, PT100
7400280 RTD assembly, tank, PT100
Ni120 Melters
7401367 RTD assembly, reservoir, Ni120
7401368 RTD assembly, tank, Ni120

Technical Data 8-1
Section 8
Technical Data
General Data
Storage temperature − 45° C to + 75 ° C
− 49 ° F to + 167 ° F
Type of heating Cartridge-type resistance heating elements
Temperature sensor Ni120 and PT100 " 1 ° C
— Measuring precision
Material pressure 5 to 85 bar 0.5 to 8.5 MPa 72.5 to 1 233 psi
Melting capacity 1 tank-full per hour
Degree of protection IP 33
Noise emission 1 motor: 60 dBA
2 motors: 62 dBA
Motor type 3 ph AC motor
Gear box type Helical gear
Motor/pump speeds 94 rpm
Heatup time <45 min
Temperatures
Min. ambient temperature - 5 °C 23 °F
Max. ambient temperature 40 ° C 104 °F
Humidity 10 to 95 %, not condensing
Min. operating temperature 40 ° C 100 °F
(setpoint)
Max. operating 230 ° C 450 °F
temperatures
Overtemperature shutdown 260 ° C 500 °F
by thermostat

8-2 Technical Data
Electrical Data
WARNING! The unit is designed for only one operating voltage. Operate
only at the operating voltage shown on the ID plate.
Available operating 230 VAC 3-phase without neutral (Delta)

voltages 400 VAC 3-phase with neutral (star — WYE)
400 VAC 3-phase without neutral (Delta)
480 VAC 3-phase without neutral (Delta)
Maximum melter power One/two-pump melter 15 L: 15,037 W

requirements 30 L: 16,237 W
50 L: 19,437 W
Three/four-pump melter, six 30 L: 22,257 W
hose/gun 50 L: 24,507 W
Three/four-pump melter, eight 30 L: 26,257 W
hose/gun 50 L: 28,507 W
100L melter, six hose/gun 29,157 W
100L melter, eight hose/gun 33,157 W
Operating voltage 50/60 Hz
frequency
Fuse protection Refer to ID plate
Max. load per hose 1 000 W, any single hose or gun
receptacle (2 channels), 1 200 W, any hose/gun pair
six hose/gun melters
2 000 W, sum of hose/gun pairs 1 and 2
2000 W, any single hose, or gun 5 or 6
2000 W, hose/gun pair 5 or 6
NOTE: Total external wattage must not exceed 8,000 W.
Max. load per hose 1 000 W, any single hose or gun
receptacle (2 channels), 1 200 W, any hose/gun pair
eight hose/gun melters

Technical Data 8-3
Mechanical Data
One/Two and Three/Four Pump Melters
Item 15L 30L 50L
Weight 200 kg (441 lb) One/two pump: One/two pump:
225 kg (496 lb) 250 kg (551 lb)
Three/four pump: Three/four pump:
440 kg (970 lb) 472 kg (1,041 lb)
Tank opening (length and 145 x 270 mm 270 x 270 mm 270 x 270 mm
width)
Approximate tank volume 15 L 30 L 50 L
Number of pumps 1−2 single-stream 1−2 single-stream 1−2 single-stream
(one/two-pump melter) 1−2 dual-stream 1−2 dual-stream 1−2 dual-stream
Number of pumps Not applicable 3−4 single-stream 3−4 single-stream
(three/four-pump melter)
Number of hose connections One single-stream manifold: 7 connections
Two single-stream manifolds: 3 connections per pump stream
Dual-stream manifold: 2 connections per pump stream
100L Melters
Item Specification
Weight 590 kg (1,301 lb)
Tank opening (length and 270 x 635 mm
width)
Approximate tank volume 100 L
Number of pumps Up to four single-stream or dual-stream pumps
Number of hose connections One single-stream manifold: 7 connections
Two single-stream manifolds: 3 connections per pump stream
Dual-stream manifold: 2 connections per pump stream
Electrical Schematics
Refer to the electrical schematics provided with the melter.

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

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

calculating melter power requirements.
S Single-component maximum—The wattage of any single hose or

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

A-2 Calculating Melter Power Requirements
To evaluate the hose/gun power requirements
1. Identify all hose/gun pairs based on the hose/gun receptacle to which

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

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

A B C
Component
Type/Size Component Hose/Gun Pair Two Hose/Gun
Number
Wattage Wattage Pair Wattage
Hose 1
Gun 1
Hose 2
Gun 2
Hose 3
Gun 3
Hose 4
Gun 4
Hose 5
Gun 5
Hose 6
Gun 6
Hose 7
Gun 7
Hose 8
Gun 8
Table A-2 Maximum Allowable Hose/Gun Wattages

(Six Hose/Gun Melters)
Column in
Component Maximum Wattage
Table A-1
A Any single hose or gun 1000 W
B Any hose/gun pair 1200 W
Sum of hose/gun pairs 1 and 2 2000 W
C
D Any single hose, or gun 5 or 6 2000 W
E Hose/gun pair 5 or 6 2000 W
F Sum of hose/gun pairs 5 and 6 4000 W

A-4 Calculating Melter Power Requirements
To evaluate the hose/gun power requirements (contd)
Table A-3 Maximum Allowable Hose/Gun Wattages

(Eight Hose/Gun Melters)
Column in
Component Maximum Wattage
Table A-1
A Any single hose or gun 1000 W
B Any hose/gun pair 1200 W
C
Any single hose, or gun 3 or 4
D 2000 W
Any single hose, or gun 5 or 6
Hose/gun pair 3 or 4
E 2000 W
Hose/gun pair 5 or 6
Sum of hose/gun pairs 3 and 4
F 4000 W
Sum of hose/gun pairs 5 and 6

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

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

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

Resolution: 1 hour
Default Value: 0
Format: —
Use: The display registers up to 9999 hours and then rolls over to 0000.
2 Fault Log (Noneditable)
Description: Stores a record of the last ten faults.

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

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

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

Description: The number of heater-on hours that must elapse before the service LED turns
on.
Value: 0 hours (disabled) to 8736 (one year)

Resolution: 1 hour
Default Value: 500 hours
Format: —
Use: Set the service interval time to signal a user-defined service check or
maintenance event, such as changing the filter. The service LED will turn on
after the pre-set time elapses. With the melter in the scan mode, press the
Clear/Reset key to turn off the service LED and reset the time.

Standard (contd)
6 Service LED Heater Hours

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

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

Description: Not being used, only displayed.
8 Automatic Pump On
(Not used with AltaBlue melters)
Description: Determines if the pump can be enabled before the melter is ready.
Value: 0 = disabled or 1 = enabled
Resolution: —
Default Value: 1 (enabled)
Format: —
Use: If enabled, the pump can be enabled before the melter is ready. Once enabled,
the pump will start automatically when the melter is ready.
If disabled, the pump must be started by pressing the pump key(s) after the
melter is ready.
NOTE: If automatic pump on is disabled (0) while the pump is running, the
pump will remain on until the pump key is pressed.

10 Enable or Disable the Melter Password

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

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

Standard (contd)
13 Change Hose 2 Output to Electric Gun Activation

Description: Changes the proportioned 240 VAC current that is provided to the hose 1
heater to a switched 240 VAC current that is used to activate a
manifold−mounted electric gun.
Value: 0 (disabled)
1 (enabled)
Resolution: —
Format: —
Use: Use only when a Nordson manifold-mounted electric gun is installed and a
switching device is connected to the melter’s switch receptacle. Refer to the
electric gun manual for information on mounting and using the gun.
20 Temperature Units
Description: Sets the units for temperature display.
Value: C (degrees Celsius) or F (degrees Fahrenheit)
Resolution: 0 = Celsius
1 = Fahrenheit
Default Value: 0
Format: —
Use: —
21 Over Temperature Delta

Description: The number of degrees that the temperature of any component can increase
over its assigned set-point temperature before an over temperature fault (F3)
will occur.
Value: 5 _C (10 _F) to 60 _C (110 _F)
Resolution: 1_C
1_F
Default Value: 15 _C (25 _F)

Format: —
Use: —

22 Under Temperature Delta

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

Resolution: 1_C
1_F
Format: —
Use: —
23 Standby Delta
Description: The number of degrees by which all heated components will be decreased
when the melter is placed into the standby mode.
Value: 25_C to 190_C (50_F to 350_F)

Resolution: 1_C
1_F
Format: —
Use: A standby delta should be selected that results in a balance between melter
energy savings during periods of inactivity, the amount of time and energy
required to bring the melter back up to set-point temperature, and a
temperature at which the hot melt can be held in the tank for extended periods
of time without charring. Refer to Section 4, Operation, Function Keys.
NOTE: The standby delta does not affect the under temperature delta
(parameter 22).

Standard (contd)
24 Automatic Standby Timeout

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

Description: The amount of time that must elapse after the automatic standby time elapses
(parameter 24) before the heaters turn off.
Value: 0 to 1440 minutes (24 hours)

Format: —
Use: Set parameter 24 (automatic standby timeout) to the desired value before
setting parameter 25.
26 Manual Standby Time

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

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

27 Hose Standby Delta

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

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

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

Resolution: 1 _C
1 _F
Default Value: 0
Format: —
Use: This parameter functions like parameter 23 except when it is set to 0, in
which case it reverts to the setting for parameter 23.
(parameter 22).
29 Internal Zone Temperature Offset

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

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

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

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

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

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

2 – Motor 1 On/Off
3 – Motor Enable/Disable
Resolution: 1
Default Value: 0 (Disable)
Format: —
setting up inputs.
NOTE: When more than one input is set to the same value, the controller
follows the state of the active input.

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

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

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

Seven-day Clock
Before setting up the clock, refer to Function Keys in Section 4, Operation,
to familiarize yourself with the function and use of the clock feature.
If you are unfamiliar with the procedure for accessing and editing operating
parameters, refer to Section 3, Installation, Setting Up the Melter.
To Set the Clock
1. Use parameter 50 to select the current day of the week.

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

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

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

50 Current Day
Description: Used to set the current day of the week.
Value: 1 to 7 (1 = Monday, 2 = Tuesday, etc.)
Resolution: 1
Default Value: —
Format: —
Use: Refer to Section 4, Operation, Function Keys, for information about the use and
affects of the seven-day clock feature.
51 Current Time
Description: Used to set the local time of the day.
Value: 0000 to 2359 (European time format)
Default Value: (Time set at factory)
Format: Hours, Hour: Minute, Minute
Use: This setting only needs to be made once for all daily schedules
55 Schedule 1 Heaters On
Description: Used to set the time that the clock will turn on the heaters during schedule 1.
Value: 0000 to 2359, - - - -
Default Value: 0600
Use: Set the desired time for the heaters to turn on.
To disable this parameter, set the parameter’s value to “- - - -” by
simultaneously 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 Value: 1700
Use: To disable this parameter, set the parameter’s value to “- - - -” by

Seven-day Clock (contd)
57 Schedule 1 Enter Standby

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

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

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

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


Value: 0000 to 2359, - - - -

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


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


Seven-day Clock (contd)
Value: 0000 to 2359, - - - -

Value: 0000 to 2359, - - - -

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



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

71 Schedules for the Days of the Week

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

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

PID Selection
80−91 PID Selection for Receptacles, Hose/Gun 1, 2, 3 and 4

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

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

melters
S upgrade or reload your melter’s firmware
Software Availability
If you do not already have the NCM utility, you can download it from the
internet by navigating to www.enordson.com/support.
If you do not have a connection to the internet, you can request a software
CD from your Nordson representative.
System Requirements
The following hardware and software requirements are necessary to install
and run Blue Series software:
S Any AltaBlue, ProBlue, or DuraBlue 10/16 adhesive melter

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

C-2 Melter Communications
Installing the Software

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

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

To install Blue Series software

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

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

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

Removing the Software from Your PC

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

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

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

Using Nordson Configuration Manager

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

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

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

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

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

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

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

Use the NCM to upgrade your melter to a newer version of firmware or
reload the current version of the firmware. The version of Blue Series
adhesive melter firmware that is currently available is posted on the internet
at www.enordson.com/support.
NOTE: The version of firmware that is loaded on your melter appears on

the control panel when the melter is first switched on.
During the upgrade process, all current melter settings are downloaded and
saved on your PC. After upgrading or restoring a melter’s firmware, you can
use the NCM to restore the pre-upgrade settings.
CAUTION! The upgrade process returns the melter’s settings to factory

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

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

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

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

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

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

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

EC Declaration of Conformity
for Adhesive and Sealant Application Equipment
conforming to European Council Directives
PRODUCTS:
AltaBlue Melters, Models 15, 30, 50, 100 Mesa Melters
AltaBlue TT Melters, Models A4, A10, A16 MiniPUR Melters
AltaPail Melters ProBlue Melters, Models P4, P7, P10, P15, P30 and P50
Cobalt GR Series Bulk Material Unloaders ProBlue Fulfill, Models P4F, P7F, P10F
DuraBlueMelters PURBlue Melters
FoamMelt FM‐200 Melter Series 3000V Melters
Freedom Hot Melt Adhesive System SureFoam Foam Dispensing System
Fulfill Retrofit Kit
Model Number_________________________
Serial Number______________________________________
APPLICABLE DIRECTIVES: STANDARDS USED TO VERIFY COMPLIANCE:

Machinery Directive: 2006/42/EC EN ISO 12100 EN 60204‐1 EN 61000-6-4
Electromagnetic Compatibility Directive: 2004/108/EC EN ISO 13732‐1 EN 61000‐6‐2
EN 55011 (Class A, Group 1 for industrial environments. Use in
other environments may pose potential difficulty ensuring
electromagnetic compatibility due to conducted as well as
radiated disturbances.)
PRINCIPLES:
This product has been manufactured according to good engineering practice.
The product specified conforms to the directives and standards described above.
Technical File Contact:

Dieter Ziesmer
Nordson Engineering GmbH
Gregory P. Merk, Senior Vice President Lilienthalstrasse 6
Adhesives Dispensing Systems 21337 Lueneburg
GERMANY
Date: 20 March 2014
Nordson Corporation 28601 Clemens Road Westlake, Ohio 1105311A05

DOC074R6

AltaBlue A15,30,50,100

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

AltaBlue A15,30,50,100

Uploaded by

Copyright:

Available Formats

AltaBluet Adhesive Melters

Models 15, 30, 50, and 100

This document contains important safety information

NORDSON CORPORATION  DULUTH, GEORGIA  USA

Address all correspondence to:

Buna-N is a registered trademark of Pittway Corps.

Part 1072086A07 E 2014 Nordson Corporation

E 2014 Nordson Corporation Part 1072086A07

Part 1072086A07 E 2014 Nordson Corporation

E 2014 Nordson Corporation Part 1072086A07

Part 1072086A07 E 2014 Nordson Corporation

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

E 2014 Nordson Corporation Part 1072086A07

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

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

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

Part 1072086A07 E 2014 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 2014 Nordson Corporation Issued 4-02 A1EN−01−[XX−SAFE]−10

Responsibilities of the Equipment Owner

Instructions, Requirements, and Standards

A1EN−01−[XX−SAFE]−10 Issued 4-02 E 2014 Nordson Corporation

S receive safety training appropriate to their job function as directed by

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

Applicable Industry Safety Practices

Intended Use of the Equipment

E 2014 Nordson Corporation Issued 4-02 A1EN−01−[XX−SAFE]−10

Instructions and Safety Messages

A1EN−01−[XX−SAFE]−10 Issued 4-02 E 2014 Nordson Corporation

Maintenance and Repair Practices

Equipment Safety Information

E 2014 Nordson Corporation Issued 4-02 A1EN−01−[XX−SAFE]−10

Relieving System Hydraulic Pressure

De-energizing the System

Disabling the Guns

A1EN−01−[XX−SAFE]−10 Issued 4-02 E 2014 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 that

E 2014 Nordson Corporation Issued 4-02 A1EN−01−[XX−SAFE]−10

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

WARNING: Allow only personnel with appropriate training and

A1EN−01−[XX−SAFE]−10 Issued 4-02 E 2014 Nordson Corporation

CAUTION: Some Nordson melters are specifically designed to

CAUTION: Before using any cleaning or flushing compound on or in

CAUTION: Nordson hot melt equipment is factory tested with

E 2014 Nordson Corporation Issued 4-02 A1EN−01−[XX−SAFE]−10

Other Safety Precautions

A1EN−01−[XX−SAFE]−10 Issued 4-02 E 2014 Nordson Corporation

Safety Labels and Tags

Figure 1-1 Safety labels and tags

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