AltaBlue TT Melter IP54 Upgrade Kit

Instruction Sheet P/N 1121211_02 AltaBlue TT Melter IP54 Upgrade Kit 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 provides the steps for using the AltaBlue TT IP54 upgrade kit (part 1120725) to upgrade melter part number 1107943. The resulting melter meets the standards for an IP54 designation. The upgrade kit includes manual part number 1107600, which applies to the upgraded melter. Use this instruction sheet as needed in conjunction with reference drawing 10011394. Refer to Parts at the end of this instruction sheet for a list of all parts contained in the upgrade kit. Figure 1 AltaBlue TT adhesive melter

2 AltaBlue TT Melter IP54 Upgrade Kit Prepare for Upgrade See Figure 2. 1. Following proper lockout/tagout and safety procedures, remove the melter from the production line and place it in a suitable rework location. 2. Remove the the following covers: rear (1) rear electrical (2) front (3) left and right (4) side (5) 3. Remove the tank lid assembly (6). 4. If present, remove the base plate (7) and discard it. 6 4 1 2 3 4 5 7 Figure 2 Removing the covers, the base plate, and the tank lid assembly

AltaBlue TT Melter IP54 Upgrade Kit 3 Install the Electrical Enclosure Gaskets 1. Remove the old gaskets from around the electrical enclosure. 2. See Figure 3. Apply RTV sealant (36) to the new bottom door gasket (35) and install the gasket. Item 35, P/N 1120283 Item 36, P/N 900411 INSERT ITEM 35 GASKET BETWEEN DOOR AND HINGE 35 36 Figure 3 Installing the bottom electrical enclosure gasket

4 AltaBlue TT Melter IP54 Upgrade Kit Install the Electrical Enclosure Gaskets (contd) 3. See Figure 4. Cut the supplied gasket (3) to the lengths shown in Figure 4 and install the gasket around the electrical enclosure frame. CUT TO 238 MM (9.375 IN.) 3 MINIMUM GAP BOTH SIDES Item 3, P/N 288221 (cut to install) 3 CUT TO 881 MM (34.7 IN.) DO NOT CUT ALL THE WAY THROUGH. MINIMUM GAP BOTH SIDES. 321 MM (12.625 IN.) TO 45 MITERS 3 321 MM (12.625 IN.) 881 MM (34.7 IN.) 321 MM (12.625 IN.) Figure 4 Installing the upper electrical enclosure gasket

AltaBlue TT Melter IP54 Upgrade Kit 5 4. See Figure 5. Cut the supplied gasket (3) to the lengths shown in Figure 5 and install the gasket around the rear frame. Item 3, P/N 288221 (cut pieces) CUT TO 235 MM (9.25 IN.) 2.54 MM (0.10 IN.) CUT TO 191 MM (7.25 IN.) 3 WRAP ITEM 3 AROUND CORNER Figure 5 Installing the electrical enclosure gasket around the frame

6 AltaBlue TT Melter IP54 Upgrade Kit Rework the Left Side Panel Item 31, P/N 1120248 See Figure 6. 1. Install the chimney tray (31) using the supplied screws, nuts, and washers (32, 33, 34). 2. Drill holes as shown in Figure 6 for the new baffle cover (21). 3. Install the new baffle cover (21) using the supplied screws, nuts, and washers (22, 23, 24). 4. Add an 11 x 2 O ring (29) to the spring latch. Item 21, P/N 1120245 Item 29, P/N 250252 Items 32, 33, 34, P/Ns 982503, 983127, 984751 Items 22, 23, 24, P/Ns 982201, 983127, 984706

AltaBlue TT Melter IP54 Upgrade Kit 7 43 MM (1.93 IN.) 22.3 MM (0.876 IN.) 44.6 MM (1.754 IN.) 9.4 MM (0.37 IN.) 104.7 MM (4.121 IN.) 3X REWORK PANEL FOR 3 X 6 MM (0.25 IN.) DIAMETER HOLES 21 3X 22 ITEMS 31 THRU 34 ARE USED ON BOTH SIDE PANELS. 23 24 31 34 33 32 Figure 6 Reworking the left side panel

8 AltaBlue TT Melter IP54 Upgrade Kit Rework the Right Side Panel Item 31, P/N 1120248 See Figure 7. 1. Install the chimney tray (31) using the supplied screws, nuts, and washers (32, 33, 34). 2. Install the supplied baffle cover (21) using the screws, nuts, and washers removed previously, positioning the fan components as shown in Figure 7. 3. Add an 11 x 2 O ring (29) to the spring latch. Item 21, P/N 1120245 Item 29, P/N 250252 Items 32, 33, 34, P/Ns 982503, 983127, 984751

AltaBlue TT Melter IP54 Upgrade Kit 9 31 34 33 32 ITEMS 31 THRU 34 ARE USED ON BOTH SIDE PANELS. 21 (USE THE 3 EXISTING SCREWS ) 21 REINSTALL THE 3 EXISTING SCREWS. DIRECTION OF AIR FLOW 31 29 POSITION SCREEN SO THAT THE FAN BLADES MOVE FREELY(YOU MAY HAVE TO FLIP THE SCREEN OVER) Figure 7 Reworking the right side panel

10 AltaBlue TT Melter IP54 Upgrade Kit Rework the Side Cover See Figure 8. 1. Assemble the 11 x 2 O rings (29) and spring latches (44) on the new side cover (52) using the supplied nuts (45). 2. Install the ground tag (4) and lug (5) using the supplied washer (33) and nut (34). Item 52, P/N 1120724 SIDE COVER 52 Item 44, P/N 208498 Item 4, P/N 240674 M Item 5, P/N 933618 29 44 4 5 33 Item 45, P/N 249675 34 Item 29, P/N 250252 DETAIL M 7 4X Items 33 and 34, P/Ns 983127 and 984751 Figure 8 Reworking the side cover

AltaBlue TT Melter IP54 Upgrade Kit 11 Rework the Rear Cover See Figure 9. 1. Assemble the 11 x 2 O rings (29) and spring latches (44) on the new rear cover (2) using the supplied nuts (45). 2. Install a ground tag (4) and lug (5) using the supplied nut (34) and washer (33). Item 2, P/N 1120593 K Item 44, P/N 208498 Item 4, P/N 240674 2 REAR COVER Item 5, P/N 933618 34 33 5 ATTACH GROUND WIRE, ITEM 56, TO LUG 4 29 44 45 4X Item 45, P/N 249675 DETAIL K Item 29, P/N 250252 Figure 9 Reworking the rear cover Items 33 and 34, P/Ns 983127 and 984751

12 AltaBlue TT Melter IP54 Upgrade Kit Connect Ground Wires See Figure 10. Item 51, P/N 271221 1. Install the double lugs (51) on the top ground stack inside the electrical enclosure using the supplied washers (23) and nuts (24). 2. Connect the supplied ground wires (56) to the new lugs and route them through the unit, one towards the side cover and the the other towards the rear cover. Items 23 and 24, P/Ns 983127 and 984706 Item 56, P/N 1120735 3X 56 51 24 23 Figure 10 Installing the double lug and connecting ground wires

AltaBlue TT Melter IP54 Upgrade Kit 13 Install the ID Tag on the Front Cover Item 57, P/N 985109 See Figure 11. Use the new tag as a template to drill two 3.2 mm (⅛ in.) holes in the front cover and then install the new ID plate (58) and tag (59) using the supplied rivets (57). Item 58, P/N 1026451 Item 59, P/N 1086140 Figure 11 Installing the ID tag on the front cover

14 AltaBlue TT Melter IP54 Upgrade Kit Rework the Tank and Lid Assemblies 1. See Figure 12. Remove the tank tray. 2. Install the new tank flange (14) and tank gasket (15). Item 14, P/N 1120338 Item 15, P/N 1120339 ( TANK LID ASSEMBLY) Item 3, P/N 288221 (typical) Item 36, P/N 900411 ( TANK TRAY ) 15 Item 13, P/N 1120337 14 Item 55, P/N 983408 RE-ADJUST GASKET SO THAT IT SITS NO MORE THAN 1.6 MM (1/16 IN.) ABOVE TANK Figure 12 Installing the tank flange and gasket

AltaBlue TT Melter IP54 Upgrade Kit 15 3. See Figure 13. Cut the supplied tank tray gasket (3) to the lengths shown in Figure 13, apply RTV sealant (36) to the gasket, and install the gasket around the tank tray as shown. 4. Reinstall the tank tray. BEFORE RE-ASSEMBLING TRAY, APPLY ITEM 36 (RTV) TO BOTH OUTSIDE SEAMS ( TANK TRAY ) ALIGN GASKET TANGENT TO EDGE AND RADII ON TRAY (ONE TIME EACH SIDE) 3 CUT TO 0.37 MM (8.7 IN.) LONG (PLACE GASKET ON BOTH SIDES OF THE THE TANK TRAY) Figure 13 Installing the tank tray gasket

16 AltaBlue TT Melter IP54 Upgrade Kit Rework the Tank and Lid Assemblies (contd) 5. See Figure 14. Replace the tank lid assembly spacers with the supplied spacers (13). 13 Figure 14 Replacing the tank lid spacers 6. See Figure 15. Reinstall the tank lid assembly using the three supplied washers (55) between the tank lid hinge and the tank tray. 15 ( TANK TRAY ) Figure 15 Installing the tank lid assembly and supplied washers

AltaBlue TT Melter IP54 Upgrade Kit 17 Replace the Control Panel Cover Hinges See Figure 16. Replace the control panel cover hinges (9, 48, 49, 50). Refer to the Hinge Replacement Notes in Figure 16. Item 49, P/N 1120729 50 4X 48 4X 9 49 EXISTING DOOR FRAME Item 48, P/N 1120730 EXISTING DOOR Items 9 and 50, P/Ns 984700 and 982343 NOTE: MAGNETS NOT SHOWN FOR CLARITY. DO NOT REMOVE MAGNETS. FINISHED HINGE/DOOR ASSEMBLY HINGE REPLACEMENT NOTES 1. DISASSEMBLE DOOR FROM EXISTING HINGE COMPONENTS 2. INSERT DOOR INTO HINGE, ITEM 49, AS SHOWN. 3, SECURE SCREWS, ITEM 50, THROUGH DOOR AND THREAD INTO NUTS, ITEM 9, INTO CAVITIES OF HINGE. 4. INSERT HIINGE, ITEM 48, INTO FRAME AS SHOWN. 5. SECURE DOOR TO HINGE SIMILAR TO PREVIOUS SEQUENCE Figure 16 Replacing the control panel cover hinges

18 AltaBlue TT Melter IP54 Upgrade Kit Insulate the Heater Wiring See Figure 17. Item 17, P/N 1120332 1. Loosen the retaining screw that secures the manifold heater, remove the heater, and remove and discard the heater cover. 2. Slide the 0.375 ID insulation sleeving (16) onto the heater wire. 3. Reinstall the heater and secure it using the new heater cover (17). Use cable ties (19) as needed to secure the wiring. INSTALL AS SHOWN.; ROUTE HEATER AND RTD WIRES FOR THE PUMP BRACKET THRU SLEEVING ITEM 16. MAKE SURE THAT THE END OF THE SLEEVING IS SECURE BEHIND THE TANK INSULATION. Item 18, P/N 931134 (0.750 ID) Item 16, P/N 931200 (0.375 ID) J 17 INSTALL ITEM 17 UNDER EXISTING PLATE. 16 Item 19, P/N 182105 WHEN ASSEMBLED THE END OF THE SLEEVING NEEDS TO TERMINATE INSIDE OF COVER WHEN ASSEMBLING THE SLEEVING. MAKE SURE THE LOOP IN THE SLEEVING IS LOWER THAN THE HEATERS IN THE PUMP BRACKET. DETAIL J Figure 17 Installing the manifold heater wire insulation sleeving

AltaBlue TT Melter IP54 Upgrade Kit 19 See Figure 18. 4. Loosen the retaining screw that secures the two tank heaters and remove the heaters. 5. Cut the 0.750 ID insulation sleeving (18) into two 46 cm (18 in.) pieces and slide the sleeves onto the heater wires. 6. Reinstall the tank heaters and tighten the heater cover screws. Use cable ties (19) as needed to secure the heater wiring. ITEM 19 USED TO SECURE HEATER WIRES. INSTALL SLEEVING SO THAT THE LOWEST POINT ON THE RADIUS IS BELOW THE HEATERS ) DETAIL H SEE DETAILS "G " & "H" 18 CUT TO FIT ( HEATER WIRES ) ( ITEM 19 ) USE ITEM 19 TO SECURE THERMOSTAT AND RTD WIRES AS NEEDED ) ( TANK RTD AND THERMOSTAT WIRES ) Figure 18 BOTH ENDS OF THE SLEEVING TO TERMINATE AS CLOSE TO THE HEATER CARTRIDGE AS POSSIBLE. Installing the tank heater wire insulation sleeving DETAIL G SERVICE LOOP TO BE BELOW HEATERS

20 AltaBlue TT Melter IP54 Upgrade Kit Rework the PCV See Figure 19. Remove the pressure control valve, rework the valve (using items 6, 40, 41, and 47) as shown below, and reinstall the valve. Item 41, P/N 1120640 REMOVE PRESSURE CONTROL VALVE AND REWORK AS SHOWN. Items 47, 40, and 6, P/Ns 983402, 983403, and 982446 6 40 47 Figure 19 41 Reworking the pressure control valve REMOVE ONE OF THE EXISTING SET SCREWS AND REPLACE WITH ITEMS 6,40,41 AND 47 AS SHOWN

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22 AltaBlue TT Melter IP54 Upgrade Kit Rework the Rear Electrical Cover See Figure 20. Item 43, P/N 1025632 1. Remove the gasket from the new rear cover (43), cut a new gasket (3) as shown in Figure 20, and install the new gasket. 2. Cut the gasket tape (20) to the lengths shown in Figure 20 and install them on the cover. 3. Add an 11 x 2 O ring (29) to the spring latch. Item 3, P/N 288221 (typical) Item 29, P/N 250252 REMOVE PANEL AND INSTALL O-RING Item 20, P/N 1120364 REMOVE AND REPLACE GASKET WITH ITEM 3 CUT 150 MM (5 7/8 IN.) LG; ENSURE GASKET RUNS THE ENTIRE LENGTH OF COVER AS SHOWN 3 29 43 CUT LENGTH 68 MM (2 11/16 IN.) LG.; INSTALL AS SHOWN (CURVE AROUND BRACKET) 20 Figure 20 Reworking the rear electrical cover

AltaBlue TT Melter IP54 Upgrade Kit 23 WHEN RE-INSTALLING THE NEW COVER TUCK GASKET (ITEM 20) INTO GAPS ( AS SHOWN ) Figure 21 Reworking the rear electrical cover

24 AltaBlue TT Melter IP54 Upgrade Kit Replace the Frame Bolts See Figure 22. Replace the six frame bolts with the supplied bolts (30). Item 30, P/N 1120585 6X REMOVE OLD BOLTS REPLACE WITH ITEM 30 30 6X Figure 22 Replacing the frame bolts

AltaBlue TT Melter IP54 Upgrade Kit 25 Install the New Base Plate See Figure 23. Install the new base plate (25) using the supplied nuts (26) and washers (27, 28). Item 25, P/N 1120246 Items 26, 27, and 28, P/Ns 984703 983029, and 983409 TYP 4 PLCS 26 27 28 25 Figure 23 Installing the base plate Note: Covers are not yet installed, even though they are shown here.

26 AltaBlue TT Melter IP54 Upgrade Kit Reinstall Panels and Covers See Figure 24 1. Connect the two ground wires (56) installed previously to the side cover (4)and the rear cover (3). 2. Reinstall the left and right panels (1), the front cover (2), the rear cover (3), and the side panel (4). 1 3 1 2 4 Figure 24 Reinstalling the panels and covers

AltaBlue TT Melter IP54 Upgrade Kit 27 Replace the Motor Control Board Set Up the Motor Control Verify the Firmware Versions Go to instruction sheet 1099219 to replace the motor control board with the new board from the upgrade kit ship with kit. Return here to continue. Refer to the motor control setup instructions in the installation section of the AltaBlue TT adhesive melter manual, P/N 1107600. The manual is included in the upgrade kit ship with kit. Return here to continue. Upon initial power on, confirm that the melter firmware version is 2.078 or later and that the motor control board firmware version is 2.0 or later.

28 AltaBlue TT Melter IP54 Upgrade Kit Upgrade Kit Parts See Figures 25-34. NOTE: Unused item numbers are not included. Item Part Description Quantity Note 1120725 KIT,UPGRADE,A4TP,IP-54 2 1120593 COVER,REAR,A4TP 1 3 288221 GASKET,.354X.216,MPL,3000V 12.0 FT 4 240674 TAG,GROUND 2 5 933618 LUG,45,SINGLE,.250X.032 2 6 982446 SCR,BTN,SKT,M4X8,ZN 3 9 984700 NUT,HEX,M3,STL,ZN 7 13 1120337 SPACER,8MM HEX,M5 X.56 LG. 4 14 1120338 TANK,FLANGE,A4TP 1 15 1120339 TANK,FLANGE,GASKET,A4TP 1 16 931200 SLEEVING,INSULATION,.375ID 1.5 FT 17 1120332 COVER,HEATER,A4TP 1 18 931134 SLEEVING,INSULATION,.750ID 4 FT 19 182105 CABLETIE,4 IN,338F/170C,PTFE,BLUE 15 20 1120364 TAPE,GASKET,STRIP-N-STICK,177 DEG C 0.5 FT 21 1120245 COVER,BAFFLE,A4TP 2 22 982201 SCR,SKT,M5X8,BL 6 23 983127 WASHER,LK,INT,M5,ZN 7 24 984706 NUT,HEX,M5,STL,ZN 7 25 1120246 BASE,PLATE,A4TP 1 26 984703 NUT,HEX,M6,STL,ZN 4 27 983029 WASHER,FLT,M,REG,M6,STL,ZN 4 28 983409 WASHER,LK,M,SPT,M6,STL,ZN 4 29 250252 O-RING 11x2 VITON 6 30 1120585 SCREW,ALLEN HEAD,M10 X 30,DIN912,SS 6 31 1120248 TRAY,CHIMNEY,A4TP 2 32 982503 SCR,BTN,SKT,M5X10,ZN 4 33 983127 WASHER,LK,INT,M5,ZN 4 34 984751 NUT,HEX,M5,SSTL 4 35 1120283 GASKET,DOOR,A4TP 1 36 900411 SEALANT,RTV,CLEAR,2.8 OZ. TUBE 1 40 983403 WASHER,LK,M,SPT,M4,STL,ZN 1 41 1120640 BRACKET,SCREW,CAPTURE 1 43 1025632 COVER,ASSY,ELECTRICAL,4L 1 44 208498 LATCH,SPRING,MED,4MM HEXHD 4 45 249675 NUT,HEX,M3,W/EXT TOOTH,WSHR 8 NS 1120726 KIT,SHIP WITH,UPGRADE,A4TP-IP54 1 NS 1029938 CABLE ASSY,RIBBON,SERIAL PORT,9 1 POS, DURA NS 1085104 PCA, MOTOR, ALTABLUE 1 NS 1099219 INSTR, MOTOR BOARD SERVICE KIT 1 NS 1107600 MAN, ALTABLUE TT ADHESIVE MELTER, A4TP 1 47 983402 WASHER,FLT,M,NARROW,M4,STL,ZN 1 Continued...

AltaBlue TT Melter IP54 Upgrade Kit 29 Item Part Description Quantity 48 1120730 HINGE,CLAMPED,LEFT,CONTROLS,D4 1 49 1120729 HINGE,CLAMPED,RIGHT,CONTROLS,D4 1 50 982343 SCR,PAN,REC,M3X10,BL 4 51 271221 LUG,45,DOUBLE,.250,.438 2 52 1120724 COVER,SIDE,A4TP-IP54 1 55 983408 WASHER,FLT,M,NARROW,M5,STL,ZN 3 56 1120735 WIRE,GROUND,A4TP-IP54 2 57 985109 RIVET,POP, 1/8X.125,CARBON STL 2 58 1026451 PLATE,STAMPING,6.812 X 1.3 1 59 1086140 TAG,STAMPING,BLANK,DURABLUE 1 NS: Not Shown Note TYP 4 PLCS 26 27 28 25 Figure 25 Upgrade kit parts, base plate

30 AltaBlue TT Melter IP54 Upgrade Kit Upgrade Kit Parts (contd) 15 6 14 40 47 41 13 Figure 26 Upgrade kit parts, tank and pressure control valve assemblies

AltaBlue TT Melter IP54 Upgrade Kit 31 43 3 29 20 35 Figure 27 Upgrade kit parts, rear cover and gasket

32 AltaBlue TT Melter IP54 Upgrade Kit Upgrade Kit Parts (contd) 3 55 3 30 6X Figure 28 Upgrade kit parts, tank and electrical enclosure gaskets

AltaBlue TT Melter IP54 Upgrade Kit 33 3X 56 51 24 23 Figure 29 Upgrade kit parts, double lugs and associated hardware

34 AltaBlue TT Melter IP54 Upgrade Kit Upgrade Kit Parts (contd) 50 4X 48 4X 9 49 Figure 30 Upgrade kit parts, control panel cover 57 58 59 Figure 31 Upgrade kit parts, ID tag and hardware

AltaBlue TT Melter IP54 Upgrade Kit 35 G J 37 17 16 18 Figure 32 Upgrade kit parts, heater wiring insulation DETAIL G

36 AltaBlue TT Melter IP54 Upgrade Kit Upgrade Kit Parts (contd) 21 31 31 21 33 34 32 57 66 57 22.00.25 21 3X 22 23 24 Figure 33 Upgrade kit parts, left and right covers

AltaBlue TT Melter IP54 Upgrade Kit 37 44 29 45 4X M 52 44 K 29 4X 45 2 Figure 34 Upgrade kit parts, side and rear covers Issued 3/14 Original copyright date 2013. Nordson and the Nordson logo are registered trademarks of Nordson Corporation.

38 AltaBlue TT Melter IP54 Upgrade Kit