Fulfill Retrofit Kit ProBlue 4/7/10 Melters

Transcription

1 Fulfill Retrofit Kit ProBlue 4/7/10 Melters Customer Product Manual Issued 5/13 This document contains important safety information Be sure to read and follow all safety information in this document and any other related documentation. ATTENTION: Information on a new control box, PCA and level sensor is included in Appendix A. Please refer to the Appendix if your unit was manufactured after May This information is found in the serial code of your unit; for example, SA13EXXXXX, where E represents the date code May, or any sequential letter after E. NORDSON CORPORATION DULUTH, GEORGIA USA

2 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: Address all correspondence to: Nordson Corporation Attn: Customer Service Lakefield Drive Duluth, GA Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date Nopartofthisdocument may be photocopied, reproduced, or translated to another language without the prior written consent of NordsonCorporation. Theinformationcontained in this publication is subject to change without notice. Trademarks AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, Bowtie, Build A Part, CanWorks, Century, CF, CleanSleeve, CleanSpray, ColorMax, Color on Demand, ControlCoat, Coolwave, Cross Cut, cscan+, Dage, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber, DuraPail, Dura Screen, Durasystem, EasyCoat, Easymove Plus, Ecodry, Econo Coat, e.dot, EFD, Emerald, Encore, ESP, e stylized, ETI stylized, Excel 2000, Fibrijet, Fillmaster, FlexiCoat, Flex O Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Fulfill, GreenUV, HDLV, Heli flow, Horizon, Hot Shot, icontrol, idry, iflow, Isocoil, Isocore, Iso Flo, itrax, Kinetix, LEANCELL, LittleSquirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, Microcoat, Micromark, Micromedics, MicroSet, Millennium, MiniBlue, Mini Squirt, Mountaingate, NexJet, Nordson, Optimum, Package of Values, Pattern View, PermaFlo, PicoDot, PorousCoat, PowderGrid, Powderware, Precisecoat, PRIMARC, Printplus, Prism, ProBlue, Prodigy, Pro Flo, ProLink, Pro Meter, Pro Stream, RBX, Rhino, Saturn, Saturn with rings, Scoreguard, Seal Sentry, SelectCharge, SelectCoat, Select Cure, Signature, Slautterback, Smart Coat, Solder Plus, Spectrum, Speed Coat, SureBead, Sure Coat, Sure Max, Sure Wrap, TrackingPlus, TRAK, Trends, Tribomatic, TrueBlue, TrueCoat, Tubesetter, Ultra, UpTime, u TAH, Value Plastics, Vantage, VersaBlue, Versa Coat, VersaDrum, VersaPail, Versa Screen, Versa Spray, VP Quick Fit, Watermark, and When you expect more. are registered trademarks of Nordson Corporation. Accubar, Active Nozzle, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AltaSlot, Alta Spray, Artiste, ATS, Auto Flo, AutoScan, Axiom, Best Choice, Blue Series, Bravura, CanPro, Champion, Check Mate, ClassicBlue, Classic IX, CleanCoat, Cobalt, Controlled Fiberization, ControlWeave, ContourCoat, CPX, cselect, Cyclo Kinetic, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, e.dot+, E Nordson, Equalizer, EquiBead, FillEasy, FillSentry, Flow Coat, Fluxplus, Get Green With Blue, G Net, G Site, IntelliJet, ion, Iso Flex, itrend, Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros, MiniEdge, Minimeter, Multifill, MultiScan, Myritex, Nano, NexJet, OmniScan, OptiMix, OptiStroke, Partnership+Plus, PatternJet, PatternPro, PCI, PharmaLok, Pinnacle, Plasmod, PowderPilot, Powder Port, Powercure, Process Sentry, Pulse Spray, PURBlue, PURJet, Ready Coat, RediCoat, RollVIA, Royal Blue, SelectSeries, Sensomatic, Shaftshield, SheetAire, Smart, Smartfil, SolidBlue, Spectral, SpeedKing, Spray Works, StediFlo, StediTherm, Summit, SureFoam, SureMix, SureSeal, SwirlCoat, TAH, ThruWave, TradePlus, Trilogy, Ultra FoamMix, UltraMax, Ultrasaver, Ultrasmart, Universal, ValueMate, Versa, Vista, Web Cure, YESTECH, and 2Rings (Design) aretrademarks of NordsonCorporation. 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. All rights reserved

3 Table of Contents i Fulfill Retrofit Kit - ProBlue 4/7/10 Melters... 1 Safety... 1 Safety Alert Symbols... 1 Responsibilities of the Equipment Owner... 2 Safety Information... 2 Instructions, Requirements, and Standards... 2 User Qualifications... 3 Applicable Industry Safety Practices... 3 Intended Use of the Equipment... 3 Instructions and Safety Messages... 4 Installation Practices... 4 Operating Practices... 4 Maintenance and Repair Practices... 5 Equipment Safety Information... 5 Equipment Shutdown... 6 Relieving System Hydraulic Pressure... 6 De energizing the System... 6 Disabling the Guns... 6 General Safety Warnings and Cautions... 7 Other Safety Precautions First Aid Safety Labels and Tags Description Theory of Operation Overview Pneumatic & Mechanical Components (1). Adhesive Storage Bin (2). Air Pressure Regulator/Solenoid Assembly (3). Suction Lance (4). Adhesive Transfer Hose (5). Lid Assembly (6). Pump Inlet Screen (Not Shown) Electrical Components (7). Control Box Membrane Panel PCA (8). Sensor Installation Remove the Existing Lid, Screen and Level Sensor Install the Control Box Install the Tank and Lid Components Assemble the Transfer Hose, Air Line, and Suction Lance Level Sensor Adjustment and Calibration Baseline Setting Final Setting Operation Time Settings Monitoring Refill Operation... 28

4 ii Table of Contents Maintenance Troubleshooting Refill PCA Troubleshooting Diagnostic Instructions Parts Using the Illustrated Parts Lists ProBlue Retrofit Kit Assemblies Lid Assembly Parts Control Assembly with Bracket Control Box Assembly Regulator/Solenoid Assembly Service Kits Accessories Service Parts Specifications Dimensions P10 Fulfill Retrofit P7 Fulfill Retrofit P4 Fulfill Retrofit Wiring Diagram RetroFit Refill System with Nordson Level Sensor... A 1 Sensor Features... A 1 Wide Sensing Area... A 1 Simplified Mechanical Mounting... A 1 Push Button Calibration... A 2 RTD Temperature Compensation... A 2 Sensor Diagnostics... A 2 Low Tank Output... A 2 Unit Features... A 3 Delay Timer... A 4 Overfill Fault Timer... A 4 Status Relay Contact Output... A 5 Configuration Switch... A 6 Sensor Calibration... A 8 Calibration Summary... A 8 Basic (Empty Level) Calibration... A 9 Precision (Full Level) Calibration... A 9 Troubleshooting... A 10 Fault LED/Red Status LED... A 10 Fill Enable LED/Yellow Status LED/Yellow Light Tower... A 11 Installation... A 12 Installing the Power Harness... A 12 Common Chassis Connection... A 14 Service Parts... A 14 Retrofit Wiring Diagram... A 15

5 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 1 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 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.

6 2 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 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 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. Make safety information available to equipment users in accordance with governing regulations. Contact the authority having jurisdiction for information. Maintain safety information, including the safety labels affixed to the equipment, in readable condition. Instructions, Requirements, and Standards Ensure that the equipment is used in accordance with the information provided in this document, governing codes and regulations, and best industry practices. 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. Provide appropriate emergency and first aid equipment. Conduct safety inspections to ensure required practices are being followed. Re evaluate safety practices and procedures whenever changes are made to the process or equipment.

7 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 3 User Qualifications Equipment owners are responsible for ensuring that users: receive safety training appropriate to their job function as directed by governing regulations and best industry practices are familiar with the equipment owner's safety and accident prevention policies and procedures 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 possess industry and trade specific skills and a level of experience appropriate to their job function 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 Use the equipment only for the purposes described and within the limits specified in this document. Do not modify the equipment. 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.

8 4 Fulfill Retrofit Kit ProBlue 4/7/10 Melters Instructions and Safety Messages Read and follow the instructions provided in this document and other referenced documents. 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. If you are unsure of how to use the equipment, contact your Nordson representative for assistance. 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 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. 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 MSDS for PPE requirements. Do not use equipment that is malfunctioning or shows signs of a potential malfunction.

9 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 5 Maintenance and Repair Practices 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 MSDS supplied with equipment cleaning compounds. NOTE: MSDSs for cleaning compounds that are sold by Nordson are available at or by calling your Nordson representative. Confirm the correct operation of all safety devices before placing the equipment back into operation. 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. 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: hot melt and cold adhesive application equipment and all related accessories pattern controllers, timers, detection and verification systems, and all other optional process control devices

10 6 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 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 NOTE: Adhesive dispensing guns are referred to as applicators in some industries. 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.

11 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 7 General Safety Warnings and Cautions Table 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 as follows: HM = Hot melt (melters, hoses, guns, etc.) PC = Process control CA = Cold adhesive (dispensing pumps, pressurized container, and guns) Equipment Type Table 1 General Safety Warnings and Cautions Warning or Caution HM 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 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. HM 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 react violently with halogenated hydrocarbons. The use of halogenated hydrocarbon compounds in Nordson equipment can cause personal injury, including death. HM, CA WARNING! System pressurized! Relieve system hydraulic pressure before breaking any hydraulic connection or seal. Failure to relieve the system hydraulic pressure can result in the uncontrolled release of hot melt or cold adhesive, causing personal injury. Continued...

12 8 Fulfill Retrofit Kit ProBlue 4/7/10 Melters Equipment Type General Safety Warnings and Cautions (contd) Table 1 General Safety Warnings and Cautions (contd) Warning or Caution HM WARNING! Molten material! Wear eye or face protection, clothing that protects exposed skin, and heat protective gloves when servicing 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. HM, PC 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 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. HM, CA, PC 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. 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. HM, CA, PC 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 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. HM, CA, PC 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 can damage to the equipment.

13 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 9 Equipment Type Warning or Caution HM CAUTION! Hot surfaces! Avoid contact with the hot metal surfaces of guns, hoses, and certain components of the melter. If contact can not be avoided, wear heat protective gloves and clothing when working around heated equipment. Failure to avoid contact with hot metal surfaces can result in personal injury. HM 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 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. HM, CA CAUTION! Before using any cleaning or flushing compound on or in the equipment, read and comply with the manufacturer's instructions 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. HM CAUTION! Nordson hot melt equipment is factory tested with Nordson Type R fluid that contains polyester adipate plasticizer. 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.

14 10 Fulfill Retrofit Kit ProBlue 4/7/10 Melters Other Safety Precautions Do not use an open flame to heat hot melt system components. Check high pressure hoses daily for signs of excessive wear, damage, or leaks. Never point a dispensing handgun at yourself or others. Suspend dispensing handguns by their proper suspension point. First Aid If molten hot melt comes in contact with your skin: 1. Do NOT attempt to remove the molten hot melt from your skin. 2. Immediately soak the affected area in clean, cold water until the hot melt has cooled. 3. Do NOT attempt to remove the solidified hot melt from your skin. 4. In case of severe burns, treat for shock. 5. Seek expert medical attention immediately. Give the MSDS for the hot melt to the medical personnel providing treatment.

15 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 11 Safety Labels and Tags Figure 1 illustrates the location of the product safety labels and tags affixed to the equipment. Table 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 Figure 1 Safety labels and tags Table 2 Safety Labels and Tags Item Part Description WARNING! Hazardous voltage. Disconnect all power supply connections before servicing.

16 12 Fulfill Retrofit Kit ProBlue 4/7/10 Melters Description The ProBlue Fulfill Retrofit Kit converts a ProBlue 4, 7 or 10 melter into an automatic fill system that maintains adhesive in the melter, improving productivity and reducing maintenance. The retrofit kit adds adhesive to the sealed tank, reducing the possibility of char, contaminants, thermal shock and incorrect adhesive temperatures that result in poor adhesive bonding. The Fulfill system is shipped with the components illustrated in Figure Figure 2 Fulfill system components 1. Adhesive storage bin 2. Transfer hose 3. Suction lance 4. Control box and mounting bracket with level sensor, filter-regulator w/ gauge, and solenoid 5. Hose clamp (2) 6. Air line (4m) 7. Wire tie (5) 8. Lid assy Optional accessories available for the Fulfill Retrofit include: a vibrator kit for the adhesive storage bin a remote power harness kit a light tower kit for audio/visual fill/fault indication of the Fulfill processes a powered cable kit. Contact your Nordson representative for more information on these kits.

17 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 13 Theory of Operation NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated information. Overview The system adds small quantities of adhesive to the sealed tank at regular intervals, reducing the possibility of adhesive char, contaminants, thermal shock and incorrect adhesive temperatures that result in poor bonding. A capacitance sensor located in the melter detects low adhesive level, and then sends a signal to the system control. A delay timer prevents the fill system from frequently cycling on and off. At the end of the delay the control activates the vacuum via a solenoid valve. Air pressure flows to a suction lance that is placed in the supplied bulk adhesive container. Using vacuum, the system conveys adhesive from the bulk container to the adhesive melter tank. The controller activates the suction lance for a limited amount of time to prevent over fill conditions. If the maximum fill time is exceeded, the controller activates a fault that stops the system from filling.

18 14 Fulfill Retrofit Kit ProBlue 4/7/10 Melters Pneumatic & Mechanical Components Refer to Figure 3 as you learn about the components of the ProBlue Fulfill retrofit assembly Figure 3 Assembled ProBlue Fulfill retrofit assembly. (1). Adhesive Storage Bin Place adhesive in the adhesive storage bin. The bin contains a gasket that prevents debris from entering the bin. For best results, break up the adhesive as much as possible when emptying into the bin. Do not get the adhesive wet. (2). Air Pressure Regulator/Solenoid Assembly The supplied air pressure regulator is permanently set at 65 psig, the optimal setting for most adhesives. The solenoid valve turns on after the sensor indicates level state and the time delay has been reached. The solenoid directs compressed air to flow to the suction lance.

19 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 15 (3). Suction Lance The suction lance draws adhesive from the adhesive storage bin. The suction lance includes: A venturi pump to draw in and transport the adhesive. A vibrator to keep the adhesive in loose condition. The vibrator is active as long as compressed air is supplied to the suction lance. Air line tubing and the adhesive transfer hose are connected to the suction lance. The lance is placed in the PVC pipe located in the adhesive storage bin. (4). Adhesive Transfer Hose The adhesive transfer hose connects the suction lance to the lid assembly. The transfer hose conveys adhesive from the adhesive storage bin to the melter tank. (5). Lid Assembly The lid assembly includes the filter stack, lid, fill tube, baffle and deflector: The filter stack contains a replaceable filter sock to prevent adhesive fines and talc/powder in the adhesive from being emitted into the ambient air. The fill tube attaches to the adhesive transfer hose. The baffle prevents adhesive from entering the filter sock. The deflector distributes adhesive evenly in the tank. Two thumb screws mount the lid to the melter. The thumbscrews can be replaced by Allen head screws supplied in the ship with kit. Do not remove the lid during operation, unless the system is disabled by turning power off at the control box. (6). Pump Inlet Screen (Not Shown) The pump inlet screen is specifically designed for use with the fill system. It easily snaps in place, and blocks any adhesive from flowing on to the sensor from the return port in the ProBlue tank.

20 16 Fulfill Retrofit Kit ProBlue 4/7/10 Melters Electrical Components NOTE: Refer to Appendix A,Retrofit Refill System With Nordson Level Sensor, for updated information. (7). Control Box The control box contains the membrane panel and PCA. It connects to the melter via the supplied bracket. An optional remote mount kit is available to mount the control box away from the melter. Membrane Panel The front panel of the electrical control box shown in Figure 4 contains three LEDs that have different colored lights to indicate the unit condition: Enable LED (green light) - Indicates that the system is enabled. Pressing the Enable button will toggle the indicator. Enable button - Press the enable button to turn the fill system on or off. Adhesive transfer LED (blue light) - Indicates adhesive delivery is active. When a low level is detected, the indicator notes that adhesive is being transferred from the adhesive storage bin into the melter tank through the transfer hose. Fault LED (red light) - activates if the system exceeds the user defined fill time limit. The system will not resume operation until the fault is cleared with the clear fault button. Clear fault button - Press the clear fault button to reset fault and resume normal activity Figure 4 Fill system controls and indicators 1. Enable On/Off 2. Filling activated symbol and blue LED 3. Fault symbol and red LED 4. Clear fault

21 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 17 PCA NOTE: Refer to Appendix A,Retrofit Refill System With Nordson Level Sensor, for updated information. See Figure 5. The PCA is inside the control box: Figure 5 PCA board (located inside the control box) Connect line voltage to the control box at the supplied terminal block and ground. Power can be supplied from the plant service to the control box or directly from the ProBlue melter using the optional power harness kit. A potentiometer labeled Delay is for a fill time delay. This delay is the time duration between the level sensor calling for more adhesive and when the fill system activates. The delay time prevents the system from frequently turning on and off. The delay time is preset from the factory at 60 seconds, but can be adjusted from 0 to 119 seconds. The factory sets the potentiometer at the 12 o'clock position, sufficient for the majority of applications. For reference, 9 o'clock is 20 seconds and 3 o'clock is 100 seconds.

22 18 Fulfill Retrofit Kit ProBlue 4/7/10 Melters PCA (contd) A potentiometer labeled fault limits the amount of filling time in case of level sensor failure. t is only for overflow protection. The factory setting is at the 12 o'clock position, sufficient in most applications. The time can be adjusted from 5 to 115 seconds. For reference, the 9 o'clock position is 22 seconds and the 3 o'clock position is 98 seconds. A potentiometer labeled AIR is a pre vibrate timer for the optional storage bin vibrator kit. The range for this potentiometer is 0 to 20 seconds. When installed, this vibrator will activate up to 20 seconds before the fill system activates and stay on until the level sensor is satisfied. This kit is well suited for adhesives and plant conditions that are prone to bridging. A dip switch labeled SW1 is preset at the factory. Position M1 should always be OFF and position M2 should always be ON. A terminal block labeled XT2. An optional light tower may be attached here. The functions of the light tower are Fill (Blue) - visual Fault (Red) - visual Fault (Alarm) - audible. NOTE: The fault outputs will engage simultaneously. (8). Sensor NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated information. NOTE: The Theory of Operation has been revised to reflect the new control box, PCA and level sensor. Refer to Appendix A for the current Theory of Operation as it pertains to the new control box and PCA. The level sensor detects the level of adhesive in the melter tank. When the adhesive falls below the set point, the level sensor sends a signal to the Fulfill control box. The sensor comes preset from the factory for an average application whereby the tank is typically molten. For optimal performance based on specific applications, see the Level Sensor Adjustment and Calibration detailed later in the manual.

23 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 19 Installation 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. Remove the Existing Lid, Screen and Level Sensor 1. Operate the melter until the tank is empty. 2. De energize the system as directed in the Maintenance section of the ProBlue manual. 3. See Figure 6. Remove the rear panel and the pump cover of the melter. Unplug the level sensor connector from the melter. Replace the rear panel and the pump cover. 2 1 Figure 6 Unplug the level sensor 1. Rear panel 2. Pump cover

24 20 Fulfill Retrofit Kit ProBlue 4/7/10 Melters Remove the Existing Lid, Screen and Level Sensor (contd) CAUTION! Remove dirt and debris from the melter before proceeding with these procedures. 4. See Figure 7. Remove the tank lid by inserting a flat head screw driver into the slot on the spring loaded hinge pin then pull the hinge pin out from its seat. Figure 7 Removing the tank lid 5. See Figure 8. Remove the two hex nuts then remove the level switch assembly from the tank cover. Figure 8 Removing the level sensor and screen 6. Remove the existing screen by pulling the screen horizontally out from the track in the tank. Discard the screen.

25 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 21 Install the Control Box 1. Attach the control box to the mounting bracket with the two threaded knobs provided. 2. See Figure 9. Place the bracket and control box onto the rear of the melter. 3. Secure the bracket with the two flat washers and nuts on the melter. Figure 9 Install the Fulfill control box onto the melter

26 22 Fulfill Retrofit Kit ProBlue 4/7/10 Melters Install the Control Box (contd) 4. Thread a customer supplied, AWG power cord into the control box. 5. See Figure 10. Connect the wiring to the terminal blocks in the control box Figure 10 Connect the customer-supplied power cord to the control box 1. L1/L2 wire power cord connection (interchangeable) 2. Ground wire power cord connection 3. Power cord strain relief 6. Tighten the strain relief.

27 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 23 Install the Tank and Lid Components 1. See Figure 11. Install the lid clip (2) and lid retainer (4) onto the melter tank Figure 11 Installing the tank components 2. Snap in the new filter screen (1). NOTE: The level sensor comes pre calibrated from the factory with the fill line 2 inches from the bottom of the probe holder. The level can be reduced by loosening the holder's hex nut, and then sliding the probe lower. Tighten the nut to keep the probe from moving. 3. Place the level sensor and holder (3) onto the top of the melter tank. The level sensor has been positioned at the factory for optimal performance range. Secure with two nuts. 4. Place the Fulfill lid assembly onto the top of the melter. Fit the lid clip (2) through the opening in the rear of the tank lid. 5. Secure the lid by screwing the two knobs on top of the lid into the threaded holes in the lid retainer.

28 24 Fulfill Retrofit Kit ProBlue 4/7/10 Melters Assemble the Transfer Hose, Air Line, and Suction Lance CAUTION! Allow for 10 in. bend radius for installation/use of the adhesive transfer hose. 1. Using one hose clamp, attach the transfer hose (A) to the end of the suction lance (B). 2. Insert the suction lance into the PVC pipe inside the adhesive storage bin. 3. Use the remaining hose clamp to attach the transfer hose to the feed system inlet tube (C). The hose should be routed without sharp bends or kinks. NOTE: If necessary, loosen the inlet tube retaining screws and then reposition the inlet tube. 4. Connect the air line (D) to the suction lance air inlet (E). 5. Route the air line along the transfer hose, securing it with wire ties as you go. The hose should be routed without sharp bends or kinks. 6. Leaving enough air line to reach the outlet (G) of the air solenoid, cut the air line to length and then insert the end of the air line into the outlet. 7. Connect plant air to the regulator. For best results, run the air piping from the main header. A B E C F G D Figure 12 Assembling the transfer hose, air line, and suction lance

29 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 25 Level Sensor Adjustment and Calibration NOTE: Refer to Appendix A,Retrofit Refill System With Nordson Level Sensor, for updated information. The level sensor consists of a level probe and a control box. The level probe permanently connects to the control box by a wire. The level probe has a black line around its diameter near the tip to note the maintained adhesive level. CAUTION! Do not raise the fill line of the probe above 2 inches from bottom of the probe holder. Doing so will degrade the level sensor's performance. Figure 13 Adjustment potentiometer See Figure 13. The LED indicator next to the adjustment potentiometer on the control box changes color from green to amber, depending on the adhesive level that the probe detects. When adhesive drops below the desired level, the LED will turn green. When adhesive reaches or exceeds the desired level, the LED will turn amber. The adjustment potentiometer sets the sensitivity of the level sensor. Different adhesives require different calibration settings. Adhesives that build up on the level probe require less sensitivity, while adhesives that do not build up on the level probe require more sensitivity. The level sensor should be recalibrated any time the level probe's height is changed or the type of adhesive being used changes.

30 26 Fulfill Retrofit Kit ProBlue 4/7/10 Melters Baseline Setting NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated information. Upon setting the probe's height, calibrate the level sensor. 1. Remove the threaded plug on the front face of the level sensor control box to reveal the adjustment potentiometer. 2. Fill the tank with adhesive and allow it to melt completely. 3. Adjust the liquid level to coincide with the black line on the level probe. 4. If the LED on the control box is amber, turn the adjustment potentiometer counter clockwise until it turns green. If the LED on the control box is green, turn the adjustment potentiometer clockwise until it just turns amber. The point at which the LED transitions from green to amber is the switching point. 5. Once the switching point is found, rotate the adjustment potentiometer 1 / 2 turn clockwise and leave it at that position. Final Setting NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated information. 1. Begin normal operation. Check the adhesive level in the tank after 30 minutes of operation. 2. If the adhesive level is satisfactory, the calibration procedure is complete. Re install the plug over the calibration pot to discourage tampering. 3. If unmelted adhesive is piled up to the top of the tank or the system has already faulted due to overfilling, rotate the adjustment pot 1 / 2 turn clockwise to increase the level sensor's sensitivity. Wait 10 minutes and check the adhesive level again. If the adhesive level is still too high, repeat this process until the adhesive level is satisfactory. When finished, reinstall the plug over the calibration potentiometer. 4. If unmelted adhesive has built up on the probe and the adhesive level in the tank has dropped below the black line on the probe, rotate the adjustment potentiometer 1 / 2 turn counter clockwise to decrease the level sensor's sensitivity. If the adhesive level is still too low, repeat this process until the adhesive level is satisfactory.

31 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 27 Operation NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated information. Once enabled, the fill system immediately begins operation. Maintain adhesive level in the storage bin to maintain automatic operation. NOTE: During warm up, the melter's ready-delay time may need to be increased for the Fulfill to operate properly. The proper ready-delay time depends on the tank size and shape, adhesive type, and application temperature. Time Settings See Figure 14. There are three timers found on the PCA board in the control box: Fault - The overfill timer. A fault is generated if the Fulfill unit dispenses longer than the time allotted. Time range is 5 to 115 seconds. Delay - The time duration the Fulfill unit waits to transfer adhesive from the storage bin to the melter once a signal from the level sensor has been transmitted to the control box. Time range is 1 to 119 seconds. Air - Used only with the optional vibrator kit. The air timer signals the amount of time the vibrator actuates once the filling process begins. Time range is 0 to 20 seconds. Figure 14 PCA timer settings (located inside the control box) Use a flat head screwdriver to turn the timers clockwise to increase the time settings, counterclockwise to decrease the timer settings.

32 28 Fulfill Retrofit Kit ProBlue 4/7/10 Melters Monitoring Refill Operation NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated information. See Figure 15. Under normal conditions, the operator need not monitor or intervene in the operation of the fill system. However, if the fill system is unable to satisfy the tank sensor in the time limit set for the Fill Time, the refill alarm LED will illuminate. Refer to Troubleshooting for a list of possible fault causes and solutions Figure 15 Fill system controls and indicators 1. Enable On/Off 2. Filling activated symbol and blue LED 3. Fault symbol and red LED 4. Clear fault Maintenance Inspect the system daily to ensure that hose fittings are secure and that the unit is free from dirt and debris. Inspect the filter sock weekly to ensure that it's not clogged; replace as needed.

33 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 29 Troubleshooting NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated information. Problem Possible Cause Corrective Action 1. System overfilled Solenoid stuck open Clean or replace. Sensor ground wire not connected Refill board not working Connect. Replace if defective. See Refill PCA Troubleshooting Instructions shown later in the Troubleshooting section. Sensor not calibrated properly Calibrate the sensor. Refer to Level Sensor Adjustment and Calibration provided earlier. 2. System underfilled No adhesive Add adhesive. No power Ensure that power is available to the system. Adhesive bridging Dislodge adhesive. Add optional vibrator kit if problem persists. Clogged wand/hose/lid Inspect the parts for improper connections, clogs or kinks. Replace as needed. Clogged filter sock Replace if needed. No/low air pressure Verify that sufficient air pressure and flowrate is supplied to the Fulfill unit from your factory. Static pressure should be 65 psi min.; operating pressure should be 45 psi min. Replace the regulator if defective. No power to the level sensor Verify that power is being supplied to the level sensor (LED not lit = no power) and that the power cord is installed properly. Deflector bent Repair or replace. No power to fill board Verify power to the control box and at the board. Replace if needed. Solenoid failure Verify the connections to the solenoid. Replace if defective. Bad fill board Replace. See Refill PCA Troubleshooting Instructions shown later in the Troubleshooting section. Overfill timer too short Adjust timer. Sensor not calibrated properly Calibrate the sensor. Refer to Level Sensor Adjustment and Calibration provided earlier. 3. Frequent overfill alarms with no cause Timers not properly set Adjust the timer settings. See Time Settings provided earlier.

34 30 Fulfill Retrofit Kit ProBlue 4/7/10 Melters Refill PCA Troubleshooting Diagnostic Instructions Perform the following steps, in order, to either isolate the problem within the PCA board or to eliminate the PCA board as a cause. These tests should only be performed by personnel qualified to work on high voltage circuits. 1. Verify input power is reaching the PCA. Measure line voltage across the input side (side of the fuse closest to the input connectors J1 and J2) of fuses F1 and F2. The input voltage should be between VAC. If input voltage not present, correct input power. 2. Verify that the 24 VDC power supply on the Refill PCA board is working by measuring the voltage between XT1 pin 24V and XT1 pin COM. It should be 24 VDC ( + / - 5%). If not 24 VDC, verify fuses are not blown. If fuses have been blown, replace fuses. If fuses blow again, replace Refill PCA. If fuses OK but 24 VDC not present, replace Refill PCA. 3. Check to make sure the DIP switch settings have not been changed. SW1 DIP switch settings: M1 should be OFF; M2 should be ON. 4. Make sure the timer potentiometers are set as expected: FAULT potentiometer adjustment range: 5 to 115 seconds (60 seconds at 12:00 position), DELAY potentiometer adjustment range: 1 to 119 seconds (60 seconds at 12:00 position), AIR (optional pre vibrator) potentiometer adjustment range: 0 to 20 seconds (10 seconds at 12:00 position). 5. Make sure the Refill PCA is enabled by verifying that the ENA LED close to the membrane panel connector (X1) is illuminated. If not, press the ENABLE button on the membrane panel to enable the Refill PCA. If the ENA LED does not turn on with the membrane panel, the membrane panel or PCA may be bad. With a piece of wire, briefly touch X1 pin 1 to X1 pin 2 (the membrane tail will need to be unplugged to perform this test). If the ENA LED illuminates after this test, replace the membrane panel. If not, then replace the Refill PCA. 6. To ensure that the level sensor signal is getting to the Refill PCA with the level sensor calling for adhesive, verify that there is 24 VDC ( + / - 5%) between XT1 pin SIG and XT1 pin COM. If not, repair the level sensor cable, recalibrate level sensor, or replace level sensor. 7. To ensure that the Refill PCA fill output is working correctly with the level sensor calling for adhesive and after waiting the DELAY time duration, verify that 24 VDC ( + / - 5%) is applied to the fill control output (XT2 pin FILL measured to any COM pin). Verify with the level sensor is NOT calling for adhesive that the fill control output is 0 to 0.5V. If the problem has not be isolated to this point, replace the Refill PCA and/or membrane panel.

35 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 31 Parts NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated information. This section provides information about parts that are associated with the fill system. Refer to the melter manual for information about all other melter components. Using the Illustrated Parts Lists To order parts, call the Nordson Customer Service Center or your local Nordson representative. Use these five column parts lists, and the accompanying illustrations, to describe and locate parts correctly. The following chart provides guidance for reading the parts lists. The number in the Item column corresponds to the circled item number in the parts list illustration. A dash in this column indicates that the item is an assembly. The number in the Part column is the Nordson part number you can use to order the part. A series of dashes indicates that the part is not saleable. In this case, you must order either the assembly in which the part is used or a service kit that includes the The part. Description column describes the part and sometimes includes dimensions or specifications. The Note column contains letters that refer to notes at the bottom of the parts list. These notes provide important information about the part. The Quantity column tells you how many of the part is used to manufacture the assembly shown in the parts list illustration. A dash or AR in this column indicates that the amount of the item required in the assembly is not quantifiable. Item Part Description Quantity Note Assembly A Part of assembly A 2 A 2 Part of item Part of item 2 AR NS Part of item 3 2 NOTE A: Important information about item 1 AR: As Required NS: Not Shown

36 32 Fulfill Retrofit Kit ProBlue 4/7/10 Melters ProBlue Retrofit Kit Assemblies Item Part Description Quantity Note Kit, Fulfill retrofit, ProBlue Kit, Fulfill retrofit, ProBlue Kit, Fulfill retrofit, ProBlue Lid assembly, P4 1 A Lid assembly, P7/P10 1 A 2 Ctl. assy. w//brkt, P4/P7 1 B 2 Ctl. assy. w//brkt, P10 1 B Screen, inlet, pump, P4, push-on Screen, inlet, pump, P7, push-on Screen, inlet, pump, P10, push-on Retainer,lid Clip,lid Kit,container,wand and hose assy Adapter, 1 / 4 BSPP female X 1 / 4 NPT male Fuse, time-lag, 2A, 5X20 mm, ceramic Filter, sock, 200 micron Kit, lid fasteners 1 NOTE A: Components for lid assemblies are shown later in this section. B: Components for control assemblies are shown later in this section.

37 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 33 Lid Assembly Parts See Figure 16. Item Part Description Quantity Lid assembly, P7/10, Fulfill retrofit Lid assembly, P4, Fulfill retrofit Enclosure assy,filter, lid, Easy Pac Tube, inlet Scr, skt, M4X14, bl Washer, flt, M, oversized, M4, zn Filter, sock, 200 micron Scr, skt, M5X40, bl Collar, lid Retainer, filter housing Tube, exhaust Lid, outer, P7/P Lid, outer, P Spacer, lid Insulation, lid, P7/P Insulation, lid, P Lid, inner, P7/P Lid, inner, P Baffle, exhaust Scr, skt, M5X10, zn Deflector Knob, black plastic with M5X30 lg stud Washer, flt, M, narrow, M5, stl, zn O ring,viton,.145id X.070W.BR,

38 34 Fulfill Retrofit Kit ProBlue 4/7/10 Melters Figure 16 Lid assembly parts

39 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 35 Control Assembly with Bracket See Figure 17. Item Part Description Quantity Note Ctl. assy. w/ brkt, P4/P Ctl. assy. w/ brkt, P Control box assy. 1 A Bracket, ctl. assy, P4/P Bracket, ctl. assy, P Level sensor, capacitive, w/ 150 mm probe Plastic knob, M5 x Skt scr, M5 x Lug, 45, single,.250, Regulator/sol. assy Scr, skt, M4X25, zn Nut, hex, M4, stl, zn Washer, flt, M, oversized, M4, zn Harness, solenoid Bracket, ctl. box, P4/P Bracket, ctl. box, P Scr, hex, washhd, tf, M5 x 12, blk Holder assy, level probe, 16 mm 1 NS Strap, cable, , natural 3 NOTE A: Parts for the control box are provided later in this section. NS: Not Shown

40 36 Fulfill Retrofit Kit ProBlue 4/7/10 Melters Figure 17 Control assy. with bracket parts (P4/P7 unit shown)

41 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 37 Control Box Assembly See Figure 18. Item Part Description Quantity Control box assy, Fulfill retrofit Enclosure, poly, machined Scr, skt, M3X10, zn Washer, lk, M, int, M3, stl, zn Scr, panhd, thd form, M4X12, bl Scr, skt, M5X10, zn Washer, lk, M, spt, M5, stl, zn Termlug, ground, 6-14 AWG Scr, skt, M3X14, B Block, terminal, 2 station Domeplug,.500 in. D,.250 in. pnl thk Membrane panel Panel, mtg, ckt. bd Block, heat sink, Easy-Pac Scr, skt, hd, M3x20 mm, steel, zn PCA, refill controller Domeplug,.750 in.d,.250 in. pnl thk Connector, strain relief, PG7, nylon Connector, strain relief,pg Harness, AC power 1

42 38 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 17 Figure 18 Control box assembly

43 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 39 Regulator/Solenoid Assembly See Figure 19. Item Part Description Quantity Regulator/sol. assy..,fulfill Valve, solenoid, 3 way, 24V, 1 / 4 in. NPT Muffler, polyethylene, 1 / 4 in. NPT, Saturn Elbow, male, 1 / 4 in. NPT Regulator/filter, 40 mic, 1 / 4 in. NPT, 65 PSIG Conn, male, elbow, 10mm tube X 1 / 4 in. NPT union Figure 19 Regulator/solenoid assembly

44 40 Fulfill Retrofit Kit ProBlue 4/7/10 Melters Service Kits Part Description Kit, membrane panel Kit, service, level sensor Kit, service, PCA Kit, service, sock filter, 5 pc Accessories Part Description Kit, cable, ProBlue, powered Kit, vibrator, adhesive container Kit, light tower Kit, remote mount Service Parts Part Description Regulator/solenoid assy Regulator/filter, 40 mic, 1 / 4 NPT, 65 psig Regulator/filter, 40 mic, 1 / 4 NPT, psig Valve, solenoid, 3 way, 24V, 1 / 4 NPT Screen, inlet, pump, P4, push-on Screen, inlet, pump, P7, push-on Screen, inlet, pump, P10, push-on Container assembly, 120L Suction wand Vibrator, Suction Wand Hose, transfer, 15 ft Tubing, 10mm X 8mm, nylon, 15 ft Cable tie, 14.5,nylon 6.6, 4.0 bundle Clamp, hose, worm dr, in., ss Lid assembly, P7/ Lid assembly, P Fuse, time-lag, 2A, 5X20 mm, ceramic Gasket, container

45 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 41 Specifications Parameter Adhesive Forms Maximum size Input voltage Power cord Adhesive Transfer Maximum Rate Transfer Hose Length Operating Air Total Air Consumption Conditioning Inlet Air Connection Pump Type Noise Emission Suction Lance Dimensions Storage Bin Capacity Enclosure rating Specification Pellets, pastilles, mini slats Pastilles: 12 mm (0.472 in.) diameter Mini slats: 12 mm X 12 mm (0.472 in. X in.) in length /1 VAC, 1 A Customer supplied, AWG 227 kg (500 lb)/hour (dependent on adhesive type) 4 m (13 ft) Minimum 4.5 bar (0.45 MPa or 65 psi) Maximum 8.6 bar (0.86 MPa or 125 psi) 679 Liters/min (24 SCFM) when feeding Dry, non-lubricated 1/4 in. NPT female Venturi 76 dba (L) 615 mm x max (W) 105 mm (24.21 in. x max 4.14 in.) 60 Kg (132 lb) IP54

46 42 Fulfill Retrofit Kit ProBlue 4/7/10 Melters Dimensions P10 Fulfill Retrofit MM (24.08 IN.) MM (1.46 IN.) POWER CONNECTION Allow for 10 in. bend radius for installation/use of the adhesive transfer hose MM (.40 IN.) MM (13.92 IN.) MM (25.60 IN.) LID CLOSED 720 MM (28.35 IN.) CLEARANCE REQUIRE TO REMOVE LID

47 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 43 P7 Fulfill Retrofit Allow for 10 in. bend radius for installation/use of the adhesive transfer hose

48 44 Fulfill Retrofit Kit ProBlue 4/7/10 Melters P4 Fulfill Retrofit Allow for 10 in. bend radius for installation/use of the adhesive transfer hose

49 Fulfill Retrofit Kit ProBlue 4/7/10 Melters 45 Wiring Diagram NOTE: Refer to Appendix A, RetroFit Refill System with Nordson Level Sensor, for updated information. 2 1

50 46 Fulfill Retrofit Kit ProBlue 4/7/10 Melters

51 RetroFit Refill System with Nordson Level Sensor A-1 Appendix A RetroFit Refill System with Nordson Level Sensor 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. Sensor Features The Nordson level sensor features include a wide sensing area, simplified mechanical mounting, push button calibration, RTD temperature compensation, new diagnostics to help identify sensor problems and a separate low level output. Wide Sensing Area The Nordson level sensor has a wide sensing range that is the nearly equal to the length of the sensor rod. The fill control point can be adjusted electronically without the need to mechanically move the sensor. Simplified Mechanical Mounting The Nordson level sensor simply drops into the tank with no height adjustments required.

52 A-2 RetroFit Refill System with Nordson Level Sensor Push Button Calibration The Nordson level sensor uses two push buttons to set levels as opposed to the previous level sensor s potentiometer. Two buttons on the Refill board provide two types of calibration. Information on calibration can be found later in this section. The level sensor uses the calibration points to control the level of adhesive in the tank. The system determines the appropriate fill level based on the calibration information. When the tank is less than this point, the fill system turns on. When the tank level is higher than this point, the fill system turns off. RTD Temperature Compensation Most capacitive sensor readings will vary with temperature. To minimize sensor reading inaccuracies due to temperature effects, the Nordson level sensor incorporates a RTD to accurately measure the probe temperature and to compensate for changes in probe temperature. Sensor Diagnostics The Nordson level sensor offers several diagnostic functions not present in the previous Fulfill level sensor. These new diagnostic functions are reported with LED flash codes. The flash codes are displayed on the membrane panel. Low Tank Output A low level output is generated when the adhesive level gets near the bottom of the probe. It provides a warning to the user if the tank level becomes abnormally low. For example, if the fill system is disabled while the pump is running, the low level output would warn the user that the tank level is low before the unit runs out of adhesive.

53 RetroFit Refill System with Nordson Level Sensor A-3 Unit Features Figure A 1 shows the Retrofit system and its components. Siren Fill Enabled LED Fault LED Reset Fault Button Fill Enable Button Fill Active LED Air filter/regulator Fill Control Solenoid Level sensor Figure A 1 Control box assembly and bracket

54 A-4 RetroFit Refill System with Nordson Level Sensor Unit Features(contd) The picture shows the major components of the RetroFit control box. 24VDC power supply Siren Refill PCA Figure A 2 Control box Delay Timer The delay timer determines how long the Refill board waits when the sensor calls for adhesive before the vacuum system is activated. The delay timer potentiometer is adjustable from 1 to 60 seconds. Overfill Fault Timer The overfill fault timer determines how long the vacuum system is operated while trying to fill the unit. If the level sensor is not satisfied before the overfill fault timer expires, an overfill fault is generated. The overfill fault timer potentiometer is adjustable from 5 to 300 seconds.

55 RetroFit Refill System with Nordson Level Sensor A-5 Status Relay Contact Output A form C electromechanical relay contact output is available for to monitor the fill system status. This relay provides a common (COM), normally closed (NC), and normally open (NO) potential free contact. These contacts are labeled COM, NC, and NO on the PCB and are located at terminal block TB3. If the fill system is working properly (powered, fill enabled, and no alarms present) the COM contact will be connected to the NC contact and disconnected from the NO contact. Any other system state will de energize the relay and change the output state. The relay contacts are rated for 30 VDC maximum at 1 Amp maximum. If a 24 VDC signal is desired instead of a potential free contact, connect 24 VDC to the COM contact and then use the NC and NO contacts. Use the NC contact for a signal that supplies 24 VDC when the fill system is working normally and the NO contact for a signal that supplies 24 VDC when a problem with the fill system exists. See Figure A 3. TB3 Figure A 3 Photo of TB3:

56 A-6 RetroFit Refill System with Nordson Level Sensor Configuration Switch The configuration switches are used to set various system modes. Refer to the following table for the configuration switch settings on your unit. Melter Configuration Switch Settings Switch 1 Switch 2 Switch 3 Switch 4 ProBlue 4 Integrated INTEGR INT TcA 150 ProBlue 7 Integrated INTEGR INT TcA 150 ProBlue 10 Integrated INTEGR INT TcB 150 ProBlue 4 Retrofit RETRO INT TcA 150 ProBlue 7 Retrofit RETRO INT TcA 150 ProBlue 10 Retrofit RETRO INT TcB 150 ProBlue 15, 30/50 RETRO INT TcB 150 Mesa 4 RETRO INT TcA 150 Mesa 6 RETRO INT TcA 150 Mesa 9 RETRO INT TcB 150 Mesa 14 RETRO INT TcB 150 Series 3100 RETRO INT TcA 150 Series 3400 RETRO INT TcA 150 Series 3500 RETRO INT TcB 150 Series 3700 RETRO INT TcB 150 Series 3860/3960 RETRO INT TcB 300 DuraBlue 10 RETRO INT TcB 150 DuraBlue 16 RETRO INT TcB 150 DuraBlue/VersaBlue 25 RETRO INT TcB 300 DuraBlue/VersaBlue 50 RETRO INT TcB 300 DuraBlue/VersaBlue 100 RETRO INT TcB 300 NOTE: Each board setting is configured to the specific melter at the factory. NOTE: Switch 2 is used to select an external (EXT) external amplifier sensor such as the level sensor used on previous Fulfill units.

57 RetroFit Refill System with Nordson Level Sensor A-7 Figure A 4 shows the features of the Refill PCA. Power LED Fill low LED Status LED Configuration switches Full calibration button Unit Low LED Delay timer potentiometer Overfill fault potentiometer Empty calibration button Fault LED Siren LED Vibrator LED Fill enabled LED Fill active LED Figure A 4 PCA board (ProBlue 4 Fulfill integrated settings shown)

58 A-8 RetroFit Refill System with Nordson Level Sensor Sensor Calibration The following sections will describe the various methods available to calibrate the level sensor. For all calibrations, the button(s) must be held for 5 seconds in order to be recognized. For best results, the unit should be at application temperature when calibration is performed. The sensor also detects if the calibration is done out of sequence. For example, if a full calibration is attempted before an empty calibration was performed, then the calibration is ignored and the STATUS and LOW LEDs on the circuit board will turn red for 5 seconds after attempting the calibration indicating a bad calibration attempt. The unit can also report the last calibration successfully performed. If the ENABLE and RESET buttons on the front panel are held simultaneously, the panel LEDs will illuminate to indicate the last calibration. An illuminated green Enable LED indicates that a basic (empty level) calibration was performed and an illuminated blue FILLING LED indicates that a precision (full level) calibration was performed. Two levels are stored in non volatile memory, the calibrated empty point and the calibrated full point. The level at which the unit fills to is computed based on the empty and full calibration points Order to Perform Type Calibration 1 Basic Calibration (Empty 2 (optional) Level) Precision Calibration (Full Level) Calibration Summary The table below summarizes the different types of calibration available. The different calibrations should be performed in the specific order shown below. Buttons Used Blue Button (SW3) White Button (SW2) Data Points Affected Empty and Full Full only Notes Full point is set to a predetermined level above empty that is suitable for a wide range of adhesives. This is the only calibration that most units will require. The empty calibration point is not changed, only the full. Use this calibration (after an empty calibration) to provide more precise level control than an empty calibration alone

59 RetroFit Refill System with Nordson Level Sensor A-9 Basic (Empty Level) Calibration CAUTION! Do not attempt empty calibration with a full melter. Doing so will result in an overfill condition. 1. Allow tank to reach application temperature. 2. Adhesive level should be at or below the bottom of the probe. 3. Close lid. 4. Press SW3 (blue button) until all LEDs stop changing color (approximately 5 seconds). Precision (Full Level) Calibration 1. Allow tank to reach application temperature. 2. Hand fill the adhesive level so that the pellets are at the top of the probe. 3. Close lid. 4. Within 30 seconds, press SW2 (white button) until all LEDs stop changing color (approximately 5 seconds).

60 A-10 RetroFit Refill System with Nordson Level Sensor Troubleshooting Fault LED/Red Status LED The diagnostic fault messages (red flashes) for the STATUS LED (DS3, located on Refill PCA) are listed below. These flash codes are also performed on the FAULT LED located on the membrane panel. Number of Red Flashes (DS3) and Panel Fault LED Diagnostic 1 Over fill fault. Unit did not fill in the allowed time. 2 Blown Fuse. The fuse supplying 24V to the outputs is blown. 3 Shorted Cable. There is a problem with the sensor cable. 4 Communications failure. There is a problem with the communications to the CPU board (integrated unit only) 5 RTD shorted. The temperature compensation RTD is electrically shorted. 6 Internal memory failure. Unit was not able to store calibration settings. Action Required Check adhesive level in bin. Check hose lines for blockage. Increase overfill timer value. Find and fix the source of the excessive current draw and replace the fuse (2 Amp max.) If sensor was calibrated, replace sensor. If sensor needed calibration, calibrate sensor. If persists, replace sensor. Check cable between the Refill board and the CPU board. If this is a RetroFit unit, check DIP switch settings on Refill board. Replace sensor Replace Refill board if fault persists

61 RetroFit Refill System with Nordson Level Sensor A-11 Fill Enable LED/Yellow Status LED/Yellow Light Tower The table below lists the diagnostic warning (yellow flashes) messages for the STATUS LED (DS3, located on Refill PCA). These flash codes are also shown on the FILL ENABLE LED located on the membrane panel. Number of Yellow Flashes (DS3) and Panel Enable LED Diagnostic Action Required 1 Pressure switch open (if used). Check air supply to pressure switch. If air supply good, replace pressure switch. Check jumper if pressure switch not used. 2 Lid switch open (if used). Replace or re align lid switch, if used. Check jumper if not used. 3 RTD open. Unit will still function, but probe Replace sensor temperature compensation will be disabled. 4 Sensor is disconnected. Reconnect or tighten sensor connector. If persists, recalibrate the sensor. If still persists, replace sensor. 5 Melter ready input open (if used) This is normal during melter warm up. If occurs while melter is ready, check connections to input. If melter ready signal not used, check jumper. 6 Unstable sensor readings Check the sensor cable connections. If the problem persists, replace the sensor and/or refill PCA. 7 Probe temperature is under 175 F (80 C) and filling is prevented. Allow probe to heat above 175 F (80 C)

62 A-12 RetroFit Refill System with Nordson Level Sensor Installation Installing the Power Harness Refer to Figure A Figure A 5 1. Connector (splitter used on P10 melters) 2. Power Accessing the melter 3. Chassis ground 4. Knockout 1. Disconnect and lock out power to the melter.

63 RetroFit Refill System with Nordson Level Sensor A Open the front access panel. 3. Plug the supplied power harness into the connector on the main board, and attach the ground wire (3) to the chassis. 4. Punch out the knockout (4), install the strain relief, and then run the power harness through the knockout. 5. Close the front access panel. Figure A 6 Access the control box