Installation of Fillmaster DuraBlue Melters. System on. Introduction. Instruction Sheet P/N B

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1 Instruction Sheet P/N B Installation of Fillmaster DuraBlue Melters System on WARNING: Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others, and damage to the equipment. Introduction This instruction sheet includes the procedures for connecting the Fillmaster adhesive feed system to a standard DuraBlue D10 or D16 adhesive melter. Two kits are required: a sensor kit and a tank lid kit. These kits are purchased separately. After following these procedures, refer to the installation procedures in the Fillmaster product manual to complete the installation process. Also use the DuraBlue product manual as a reference when performing the procedures in this instruction sheet. NOTE: The Fillmaster adhesive feed system can only be used with standard DuraBlue D10 and D16 melters. It cannot be used with any DuraBlueLmelter A Figure 1 Fillmaster adhesive feed system connected to a DuraBlue melter

2 2 Installation of Fillmaster System on DuraBlue Melters Safety To safely perform the procedures in this document, first shut down the equipment. Relieving System Hydraulic Pressure Completely relieve system hydraulic pressure before breaking any hydraulic connection or seal. Refer to the DuraBlue product manual for the procedure for relieving system hydraulic pressure. De-energizing the System Isolate the system (melter, hoses and guns) 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). CAUTION: Power is still present inside the electrical cabinet even when the ON/OFF switch is in the OFF position. 2. 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. Kit Components Connecting the Fillmaster system to a DuraBlue melter requires two separately purchased kits: a sensor kit and a tank lid kit. The components of the sensor kit are shown in Figure 2.

3 Installation of Fillmaster System on DuraBlue Melters 3 Sensor Kit 6 5 Nordson R KFA I -- KL -- PG9 P/N U b full voll VDC 230VDC NC COM NO NC COM NO leer / low BE White Sensor bracket assembly 14 15, 16 8 Black Green/yellow Red Power supply cable Low-level signal cable A Figure 2 Sensor kit components 1. Probe 2. Sensor bracket 3. Connector, PG7 4. Nut, PG7 5. Sensor controller 6. Mounting plate 7. Screw, M4 x 8 (4) 8. Wire, black 9. Cable, 0.75 mm 10. Wire, green/yellow 11. Ring terminal 12. Plug, 5-pin 13. Plug, 3-pin 14. Screw, M4 x 6 (2) 15. Fuse, 250 V (2) 16. Fuse holder (2) Note: The sensor kit part number is Both the sensor kit AND the tank lid kit are required to connect the Fillmaster system to a melter.

4 4 Installation of Fillmaster System on DuraBlue Melters Sensor Kit Installation Install the Sensor 1. See Figure 3. Remove the DuraBlue melter lid by removing the four screws that secure the lid to the tank cover. 2. Secure the sensor bracket to the tank cover using the two inner lid-screw threads. Ensure that the sensor is inside the tank. 1 2 Figure 3 Mounting the sensor 1. Sensor mounting bracket 2. Outer lid screws (only the lower screw is used to secure the lid) 3. See Figure 4. Use a screw driver to bend back the sealing gasket on the inside of the tank and push the sensor plug through the opening. The sensor cable runs between the tank cover and the sealing gasket. Figure 4 Installed sensor cable

5 Installation of Fillmaster System on DuraBlue Melters 5 Install the Sensor Controller 1. Open the electrical enclosure door and remove the right-side panel. 2. See Figure 5. Using the two existing holes in the right-side panel, install the sensor controller and mounting plate assembly on the right-hand side inside the electrical enclosure. Figure 6 shows the installed controller and mounting plate assembly. NOTE: You may need to remove cable ties from the mounting holes and then rearrange and reaffix the wire routing. Opening the electrical enclosure door Figure 5 Location of mounting holes for sensor controller assembly (side panel of melter removed for clarity) Figure 6 Installed controller and mounting plate assembly

6 6 Installation of Fillmaster System on DuraBlue Melters Make the Electrical Connections 1. See Figure 7. Connect the 3-position connector (red wires) to terminal XT4 (low level input). XT4 Figure 7 Three-position connector (red wires) connected to XT4 2. See Figure 8. Connect the 5-position connector (black wires) to terminal XT2 (power supply). XT2 Figure 8 Five-position connector (black wires) connected to XT2 3. See Figure 9. Route the green/yellow tank ground wire toward the manifold and connect it as follows: a. Remove the cover to access the heater cartridges and the overtemperature thermostat. b. Remove the upper overtemperature thermostat screw. c. Secure the tank ground wire terminal ring and the overtemperature thermostat using the screw removed in step b.

7 Installation of Fillmaster System on DuraBlue Melters 7 Figure 9 Ground wire secured by the upper thermostat screw 4. Open the sensor controller cover and connect the gold plug of the sensor cable (coming from the tank) to the gold receptacle inside the sensor controller. 5. See Figure 10. Roll up any excess sensor cabling and secure with a cable tie. Figure 10 Rolled-up excess cable

8 8 Installation of Fillmaster System on DuraBlue Melters Communication Cable Connection For proper operation, the Fillmaster system must receive a READY signal and a LOW-LEVEL signal from the DuraBlue melter. 1. Connect the orange communication cable (located inside the Fillmaster hopper) to the communication cable connector located at the end of the transfer hose. 2. Connect the communication cable leads to the READY and LOW-LEVEL output terminal blocks on the I/O board inside the DuraBlue electrical enclosure. NOTE: Before connecting the communication cable to the output terminal blocks, you may need to make appropriate changes to the configuration of the output signals of the DuraBlue melter. Refer to the procedure for installing melter outputs in the Installation section of the DuraBlue product manual. Fillmaster System Setup and Operation Proceed to the Fillmaster product manual for the procedures for installing the cone, setting up the sensor, and operating the system. Parts See Figure 2 for an illustration of the kit components. Part Description Note Kit, sensor, Fillmaster, D10/D16 A S Fuse, fast-acting, 1 A, 240 VAC, 5 x 20 mm (two required) S Holder, fuse (two required) NOTE A: Both the sensor kit and the tank lid kit are required to connect the Fillmaster system to a DuraBlue melter. Issued 6/05 Original copyright date Nordson and the Nordson logo are registered trademarks of Nordson Corporation. DuraBlue and Fillmaster are registered trademarks of Nordson Corporation.

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