Nordson DuraBlue II Hot Melt Adhesive System
Installation Practices
- Install the equipment in accordance with the instructions provided in this document and in the documentation provided with auxiliary devices.
- Ensure that the equipment is rated for the environment in which it will be used. This equipment has not been certified for compliance with the ATEX directive nor as nonincendive and should not be installed in potentially explosive environments.
- Ensure that the processing characteristics of the material will not create a hazardous environment. Refer to the Safety Data Sheet (SDS) for the material.
- If the required installation configuration does not match the installation instructions, contact your Nordson representative for assistance.
- Position the equipment for safe operation. Observe the requirements for clearance between the equipment and other objects.
- Install lockable power disconnects to isolate the equipment and all independently powered auxiliary devices from their power sources.
- Properly ground all equipment. Contact your local building code enforcement agency for specific requirements.
- Ensure that fuses of the correct type and rating are installed in fused equipment.
- Contact the authority having jurisdiction to determine the requirement for installation permits or inspections.
Operating Practices
- Familiarize yourself with the location and operation of all safety devices and indicators.
- Confirm that the equipment, including all safety devices (guards, interlocks, etc.), is in good working order and that the required environmental conditions exist.
- Use the personal protective equipment (PPE) specified for each task. Refer to Equipment Safety Information or the material manufacturer’s instructions and SDS for PPE requirements.
- Do not use equipment that is malfunctioning or shows signs of a potential malfunction.
Maintenance and Repair Practices
- Allow only personnel with appropriate training and experience to operate or service the equipment.
- Perform scheduled maintenance activities at the intervals described in this document.
- Relieve system hydraulic and pneumatic pressure before servicing the equipment.
- De-energize the equipment and all auxiliary devices before servicing the equipment.
- Use only new Nordson-authorized refurbished or replacement parts.
- Read and comply with the manufacturer’s instructions and the SDS supplied with equipment cleaning compounds. NOTE: SDSs for cleaning compounds that are sold by Nordson are available at www.nordson.com or by calling your Nordson representative.
- Confirm the correct operation of all safety devices before placing the equipment back into operation.
- Dispose of waste the cleaning compounds, and residual process materials according to governing regulations. Refer to the applicable SDS or contact the authority having jurisdiction for information.
- Keep equipment safety warning labels clean. Replace worn or damaged labels.
Introduction
Intended Use
DuraBlue II adhesive melters may be used only to melt and convey suitable materials, e.g., thermoplastic hot melt adhesives. Any other use is considered to be unintended. Nordson will not be liable for personal injury or property damage resulting from unintended use. Intended use includes the observance of Nordson safety instructions. Nordson recommends obtaining detailed information on the materials to be used.
Electromagnetic Compatibility (EMC)
In regard to electromagnetic compatibility (EMC), the melter is intended for use in industrial applications. When operated in residential or commercial areas, the melter may cause interference in other electrical units, e.g., radios.
Examples of Unintended Use
The melter may not be used under the following conditions:
- In the defective condition
- Without an insulation blanket and protective panels
- With the electrical cabinet door open
- With the tank lid open
- In a potentially explosive atmosphere
- When the values stated under Technical Data are not complied with
The melter may not be used to process the following materials:
- Polyurethane hot melt adhesive (PUR)
- Explosive and flammable materials
- Erosive and corrosive materials
- Food products
Residual Risks
In the design of the unit, every measure was taken to protect personnel from potential danger. However, some residual risks cannot be avoided:
- Risk of burns from hot material.
- Risk of burns when filling the tank, from the tank lid, and from the tank lid supports.
- Risk of burns when conducting maintenance and repair work for which the melter must be heated up.
- Risk of burns when attaching and removing heated hoses.
- Material fumes can be hazardous. Avoid inhalation.
- Risk of damage to cables/lines belonging to the customer, if they were installed such that they come into contact with hot or rotating parts.
- The safety valve may malfunction due to hardened or charred material.
Key Components
Figure 2-1 provides the name and the location of key melter components.
Figure 2-1 Key melter components
- Control panel (see Figure 2-3)
- Protective panel, removable
- Tank lid
- Main power switch
- Motors/pumps
- Drain valve
- Pressure control valve
- Manifold
- Hose receptacles
- ID plate
- Tank
Electrical Components
Figure 2-2 Key electrical components
- Main board
- Circuit breakers
- Solid-state relay
- Fan
- Motor controller
- Signal conditioner
- Expansion board
- Power module
- Main switch
- Distribution block
- Contactor
Note: The central processing unit is not shown in this illustration. Refer to Section 7, Parts.
Control Panel
Figure 2-3 Control panel (melter control panel and two motor control panels shown)
- Pump speed arrow keys
- Pump speed display (rpm)
- Pump mode key/LED
- Pump enable key/LED
- Standby key/LED
- Master pump enable key/LED
- Heaters key/LED
- Clock key/LED
- Set up key/LED
- Fault light
- Ready light
- Component keys/LEDs
- Control switch
- Left display and arrow key
- Right display and arrow keys
- Numeric keypad
- Serial port
Tank Isolation Valve
The tank isolation valve allows replacement of the pump without first emptying the tank.
Pressure Control Valves
The manual pressure control valves can be adjusted from 0-90 bar.
Modes of Operation
DuraBlue II adhesive melters operate in the following modes.
Automatic Scan (Normal Mode)
The melter automatically checks and displays the current temperature of the tank, hoses, and guns to confirm that they are within their pre-defined temperature range. By default, the melter is always in the automatic scan mode unless it is placed into another operating mode.
Standby
The temperatures of the tank, hoses, and guns are reduced 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.
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.
Installation
Overview
DuraBlue-II adhesive melters are factory-configured for each order and require only the assembly and setup 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 operation 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.
Installation Tasks
The installation sequence is as follows:
- Verify that the required environmental conditions and utilities exist.
- Unpack and inspect the melter.
- Configure the electrical service.
- Connect hot melt hoses and applicators.
- (Optional) Configure key-to-line.
- (Optional) Connect to the pressure control transducer.
- Set up the melter to work with the manufacturing process.
- (Optional) Install inputs and outputs.
- Install optional equipment.
- Connect an applicator driver, pattern controller, or timer.
- Flush the melter.
Experience of Installation Personnel
The instructions provided in this section are intended to be used by personnel who have experience in the following subjects:
- Hot melt application processes
- Industrial power and control wiring
- Industrial mechanical installation practices
- Basic process control and instrumentation
Installation Requirements
Before installing the melter, ensure that the desired installation location provides the required clearances, environmental conditions, and utilities.
Clearances
Figure 3-1 illustrates the minimum clearances that are required between the melter and surrounding objects.
Ventilation
DuraBlue II melters are cooled by forced air. Air is drawn in through 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.
Electrical Power
Before installing the melter, ensure that the melter will not be overloaded and that the plant’s electrical service is rated to handle the power required by the melter and the hoses and applicators that you plan to use. Refer to Appendix A, Calculating Melter Power Requirements, for information about how to calculate the maximum allowable hose lengths and applicator wattages that can be used in your manufacturing application.
WARNING! Risk of electrocution! Install a lockable power disconnect switch between the electrical service and the melter. Failure to install or properly use the disconnect switch when servicing the melter can result in personal injury, including death.
Other Considerations
Consider the following additional factors when evaluating where to install the melter.
- The maximum distance between the melter and each applicator is dictated by the power requirement of each hose. Refer to Appendix A, Calculating Melter Power Requirements, for information about how to determine the maximum allowable length.
- The operator must be able to safely reach the control panel and accurately monitor the control panel indicators.
- The operator must be able to safely observe the level of hot melt inside the tank.
- The melter must be installed away from areas with strong drafts or where sudden temperature changes occur.
- The melter must be installed where it will be in conformance with the ventilation requirements specified in the Safety Data Sheet for the hot melt being used.
- The melter should not be exposed to excessive vibration.
Unpacking the Melter
Before starting the installation, remove the melter from the pallet, locate the installation kit, and inspect the melter for damaged and missing parts. Report any problems to your Nordson representative.
Moving the Unpacked Melter
When moving the melter, always support the melter by placing any lifting device under the chassis.
Contents of the Installation Kit
The installation kit contains a package of safety label overlays that are printed in a variety of languages. If required by local regulations, the appropriate language overlay should be applied over the English version of the same label. Refer to Safety Labels and Tags in Section 1, Safety, for the location of each safety label.
Customer-Supplied Materials
The following additional materials are also required to install the melter.
- A power cable. Rigid or flexible electrical conduit will be required.
- (Optional) Gear-to-line input signal wiring
- (Optional) Input/output signal wiring
Configuring the Electrical Service
DuraBlue II melters are shipped from the factory without an attached power cable. To configure the melter to function in your facility, you must connect a properly rated power cable. The maximum power draw of the melter for any supported service code is 86 A.
Residual Current Circuit Breakers
Local regulations in some geographic areas or industrial branches may require residual current circuit breakers. Then observe the following points:
- Permanent installation is required (fixed line voltage connection)
- The residual current circuit breaker is to be installed only between the power supply and the melter.
- Only residual current circuit breakers sensitive to pulsating current or universal current (> 30 mA) may be used.
Connecting the Electrical Service
NOTE: The melter must be installed securely (permanent power supply connection).
WARNING! Operate only at the operating voltage shown on the ID plate.
NOTE: Permitted deviation from the rated line voltage is 10%.
NOTE: The power cable cross-section must comply with the maximum power consumption (refer to Section 8, Technical Data).
WARNING! Ensure that cables do not touch rotating and/or hot melter components. Do not pinch cables and check regularly for damage. Replace damaged cables immediately!
- See Figure 3-3. Route the power cable into the electrical cabinet through the strain relief on the side of the base.
NOTE: Do not route any input/output wiring through this strain relief. - Connect the power cable to the service terminal block as indicated in Table 3-1 and illustrated in Figure 3-3.
- Connect the service ground lead to the ground terminal located on the DIN rail at XL0\:PE.
Connecting Hoses and Applicators
WARNING! Risk of fire or equipment damage. Before connecting hoses and applicators to the melter, confirm that the power required by each hose/applicator pair and each hose/applicator module does not exceed the maximum wattages specified in Appendix A, Table A-2, Maximum Allowable Wattages.
Connect Hoses
See Figure 3-4 to properly connect the hose hydraulic fittings based on the manifold configuration. If hoses are not connected properly, the melter will not operate correctly. See Figure 3-5 to connect hose cordsets. Observe the following guidelines:
- For information about choosing the correct Nordson hot melt hose for your manufacturing process, refer to the latest edition of Nordson’s hot melt dispensing equipment Replacement Parts Catalog or contact your Nordson representative.
- Refer to the user’s guide provided with each Nordson hose. The guide contains important information about routing and installing the hose.
- Save all of the port plugs removed from the manifold. A port plug will need to be reinstalled into the manifold if a hose is later removed.
Connect Applicators
Observe the following guidelines:
- DuraBlue II melters with 120-ohm nickel sensors support all Nordson T-style applicators. DuraBlue-II melters with 100-ohm platinum sensors support all Nordson M-style applicators.
- For information about choosing the most appropriate Nordson hot melt applicator for your manufacturing process, refer to the latest edition of Nordson’s hot melt dispensing equipment Replacement Parts Catalog or contact your Nordson representative. Refer to Appendix A, Calculating Melter Power Requirements, for information about how to calculate the power required by Nordson hot melt applicators.
- Refer to the user’s guide that is shipped with each applicator for information about installing the applicator and connecting a hose to the applicator.
NOTE: DuraBlue II adhesive melters are shipped with a 0.2 mm hot melt filter installed in the manifold. Order the appropriate applicator nozzle based on this filter mesh size.
Setting Up the Melter
After physically installing the melter, it must be set up to support your manufacturing process. Melter setup consists of enabling or making changes to factory-set operating parameters that affect the use and function of the melter. The operating temperature (set-point) of the tank and each hose and applicator is also established during melter setup. The melter is shipped from the factory with the most commonly used operating parameters already set up. The factory setup can be modified at any time to suit your manufacturing process.
Quick Setup
Table 3-2 describes the most commonly used operating parameters and their factory settings. Review the table to determine if the factory settings for each parameter will support your manufacturing process. If the default values for each of these operating parameters are appropriate for your manufacturing process, then no melter setup is required.
Go directly to Set-point Temperature of the Tank, Hoses, and Applicators later in this section to complete the installation process. If you need to make changes to the factory setup or if you want to learn about other operating parameters, go to the next part in this section, Operating Parameters.
Operating Parameters
The melter uses operating parameters to store non-editable and editable values. Non-editable values are those that provide information about the historical performance of the melter. Editable values are either a numeric set-point or a control option setting. Control options settings affect the display of information or the function of the melter.
Operating parameters are stored in the melter’s firmware in the form of a sequentially numbered list. The list is organized into the logical groups described in Table 3-3. 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 effect 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.
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