Nordson ProBlue P7 Adhesive Melter User Manual

Nordson ProBlue P7 Adhesive Melter

Melter Identification

See Figure 2‐2. 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.

Equipment identification plate

Key Components

Figure 2‐3 provides the name and the location of key Melter components.

Control panel

1. Fault LED
2. Ready LED
3. Component keys/LEDs
4. Right display and scroll keys
5. Function keys
6. Serial port
7. Keypad
8. Left display and scroll key
9. Service LED
10. Tank low‐level LED

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. Table 3‐1 describes each clearance.

Minimum installation clearances (Top and side views shown)

Table 3‐1 Installation Clearances

Table 3‐2 Melter Power Requirement

To connect a power cable to the Melter (Contd)

Table 3‐3 Electrical Service Information

To connect a voltage plug to the Melter

1. Refer to Table 3‐3 to determine the part number of the voltage plug that matches the required electrical service.
2. Insert the correct voltage plug into receptacle J1 on the main board. Ensure that the plug snaps into place. If the plug contains a neutral lead connect the neutral lead to receptacle J2 on the main board.
3. When the electrical service is completely installed and inspected in accordance with local electrical codes and standards, close the electrical enclosure door and switch the local power disconnect switch on. If the electrical service was configured correctly, the Melter control panel will display dashes.

Voltage plugs with and without the neutral lead

Connecting a Compressed Air Supply

To connect an air supply

1. Use a 5 mm hex wrench to turn the pressure adjustment screw counterclockwise until it stops (off).
2. Insert the male fitting located on the outlet side of the air filter (P/N 1023267) into the air inlet port on the back of the Melter . Pressure regulator and adjustment screw
3. Connect a regulated plant air supply to the inlet of the air filter. If required, use the 1/4 NPTF‐to‐G1/4 BSPP male adapter fitting (P/N 1034145) that is provided in the installation kit.
4. Open the plant air supply to the Melter.
5. Turn the pressure regulator adjustment clockwise to set the Melter’s operating air pressure (pressure supplied to the pump) to 1.4 Bar (20 psi). The operating air pressure should be adjusted later to meet the requirements of the manufacturing process.

Connecting the air filter and the plant air supply line

Connecting Hoses and Guns

Pro Blue Melter’s use standard Nordson hoses and guns. The P4 and P7 Melter’s support the connection of up to four hose/gun pairs. The P10 Melter supports the connection of up to six hose/gun pairs.

The hose/gun capacity of each Melter is determined by the number of hose/gun modules installed on the Melter. Each hose/gun module supports the connection of two hose/gun pairs. The hose/gun capacity of Melter’s that were ordered with less than their full hose/gun capacity can be increased by adding additional hose/gun modules. Unused hose/gun module positions are covered by blank modules.

To connect hoses

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.
• Always use hose port 1 first. The position of port 1 is stamped on the face of the manifold. The P4 and P7 Melter’s provide four hose ports on the face of the manifold and a fifth hose port at the bottom of the manifold. The P10 Melter provides nine ports, six of which can be used at any one  time.
• If you install an additional hose/gun module, you must restart the Melter and enter a set‐point temperature for each hose/gun that you connect to the new module in order for the new hoses/guns to be recognized.

Hose port 1 (P4/P7 Melter manifold shown)

• Use the 6‐hose manifold guard that is shipped with all P10 Melter’s. Instructions for installing the guard are provided with the guard.
• Coordinate the connection of each hose with the receptacles on each hose/gun module. For example, connect the coldest from the hose that is connected to port 1 (marked) to receptacle 1.
• 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.
• Use the 45‐ or 90‐degree hose fittings provided in the installation kit.

Connecting a hose

Table 3‐4 Common Operating Parameters

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 3‐5.

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 3‐6 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.

Reading or Editing Operating Parameters

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

To read or edit a parameter

1. Switch the Melter on.
   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 3‐6 for a complete list of parameters.
4. Do one of the following:
   • If the value is noneditable, refer to Section 4, Monitoring the Melter.
   • 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 for information about the numeric value or control option choices for each parameter.
7. Press the Enter key. The Melter checks that the new value or control option is acceptable.
   • If the numeric set‐point or control option is accepted, the left and right displays index to the next sequential parameter number and value.
   • 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.

Operating Parameters (contd)

Table 3‐6 Operating Parameters

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.

To restore saved settings

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.

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.

Installing Melter Inputs

Pro Blue Melter’s are equipped with four standard inputs. Each input is customer‐wired to the Melter and then set up to provide one of the following control options:

• Place the Melter into the standby mode
• Turn the heaters on and off
• Enable or disable a specific hose or gun
• Turn the pump on and off

Inputs are activated using a constant 10 to 30 VDC signal voltage, which is supplied by the customer’s control equipment. The inputs are not polarity sensitive.

To wire inputs to the Melter

1. Route a 2‐, 4, 6, or 8‐conductor signal cable from the control equipment to the Melter, and through the PG‐16 penetration in the sub‐base. Use rigid or flexible conduit or a suitable strain relief to protect the cable from the sharp edge of the conduit penetration.
2. Connect each pair of input wires to the appropriate terminals (8 through 14) on connector P/N 277909. If input number four is used, terminal 7 on connector P/N 277908 must also be used. Both connectors are provided in the installation kit. Table 3‐8 lists the terminal numbers that correspond to each input.
3. Plug the connector (P/N 277909) into the bottom receptacle of terminal TB2, which is located on the right side  of the main board. If input number four is used, plug connector P/N 277908 into the top receptacle on terminal TB2.Wiring inputs

Table 3‐8 Input Data

Pump Key

Use the pump key to start or stop the pump. The LED on the pump key turns on (green) when the pump is running. If the automatic pump on feature (parameter 8) is disabled, then the pump key must be used to start the pump when the Melter is ready.

If any of the inputs are set up to use the pump enable/disable control option (option 3), the pump will not start until the pump key is pressed (LED on) and the correct voltage is applied to the input contacts. If the pump is enabled, but the input voltage is not present, the pump LED will flash green.

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.

Shutting Down the Melter

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

To shut the Melter down

1. Switch the Melter off.
   The automatic pressure discharge (APD) valve relieves the hydraulic pressure in the manifold back to the tank.
2. Disable the guns as follows:
   • Air‐operated guns: Turn off the air supply to the guns.
   • Electric guns: Turn off the gun driver, pattern controller, or timer.

Table 5‐1 Preventive Maintenance Tasks

Replacing the Filter

Pro Blue Melter’s are equipped with a 100‐mesh (.15 mm) disposable hot melt filter. The filter removes debris and char from the hot melt as it flows from the tank. Hot melt flows from the inside to the outside of the filter, trapping contaminants inside the filter. There is no need to back‐flush or clean the filter.

When the filter reaches the end of its service life, it should be replaced. The factors that determine the service life of the filter are:

• the type, grade, and purity of the solid‐form hot melt
• the set point temperature of the tank
• the period of time that the hot melt remains in the tank The filter should also be replaced when making the change to a different type or grade of hot melt.

To determine the optimal service life for the filter, monitor and compare the total number of hours that the heaters are on with observations of:

• the purity of the dispensed hot melt
• increases in operating pressure
• the frequency of gun nozzle replacement or cleaning

Troubleshooting

Melter Faults

Table 6‐1 lists the four types of Melter faults, potential causes, and expected corrective actions.

Table 6‐1 Melter Faults

Identifying Electrical Components (contd)

Table 6‐4 Hose/Gun Power Module

Table 6‐5 6‐Hose Expansion Board (optional)

DP.5 Check the Resistance of the Tank and Manifold Heaters

1. De‐energize the Melter. Refer to Section 1, Safety. See Figure 6‐1.
2. Disconnect the power harness plug (P/N 1024529) from receptacle J6 on the main board.
3. Measure the resistance across pins 1 and 2 (tank) or pins 3 and 4 (manifold) on the power harness plug, and then do one of the following:
   • If the resistance is within the range shown in Table 6‐6, go to step 4.
   • If the resistance is not within the range shown in Table 6‐6, go to step 8.Table 6‐6 Heater Resistance

   	Resistance
   Model	Tank	Manifold
   P4	46–58 ohms	46–58 ohms
   P7	40–50 ohms
   P10

    

4. Individually check the resistance between the chassis and pins 1 and 2 (tank) or pins 3 and 4 (manifold) on the power harness plug, and then do one of the following:• If the resistance is greater than 1 Meg ohm, return to the troubleshooting chart.
   • If the resistance is less than 1 Meg ohm, go to step 5.
5. Remove the front and rear panels from the Melter. Refer to Section 5, Cleaning the Melter, for the procedure to remove the panels.

RESISTANCE IN OHMS

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Nordson ProBlue P7 Adhesive Melter-FAQs