P/N 1029717B ProBlue and DuraBlue Thermostat Service Kit - P/N 1028321 This instruction sheet provides separate instructions for replacing a thermostat on ProBlue and a DuraBlue adhesive melters. Tools: 3-mm hex wrench 4-mm hex wrench 6-mm hex wrench ProBlue Adhesive Melters Replacing the Manifold Thermostat DuraBlue instructions on back. Thermostat WARNING: Risk of electrocution! The manifold heater terminals carry high voltage. Before Removing the back panel of the melter, ensure that power to the melter is disconnected at the local power disconnect. Failure to properly disconnect power from the melter can result in personal injury, including death. M4 screws (spare) 1. Disconnect power to the melter at the local power disconnect switch. 4. Disconnect the thermostat leads, and then remove the two M4 screws. Discard the old thermostat. 2. Switch the melter off. 3. Remove the top and back panels. 5. Attach the thermostat to the manifold using the two M4 screws, and then connect the leads. 6. Reinstall the back and top panels. 7. Apply power to the melter, switch the melter on, and verify that the melter heats normally. If the melter does heat normally, refer to the Troubleshooting section of the melter manual. Continue
CPU Board Service Kit - P/N 1028325 P/N 1029721B Use this service kit to replace the CPU (central processor unit) in any ProBlue or DuraBlue adhesive melter. Phillips-head screwdriver 6-mm open-end wrench WARNING: Risk of electrocution! The control switch does not remove highvoltage power from the melter. Before opening the electrical compartment door, ensure that the local power disconnect switch is in the off position and locked. Failure to properly disconnect the power from the melter can result in personal injury, including death. 1. Switch the melter off. 2. Disconnect electrical power to the melter at the local power disconnect switch. 4. Disconnect the main board ribboncable (A) and the serial port ribbon cable (B) from the CPU board. CPU board 3. Open the electrical enclosure door. 5. Remove the six threaded spacers and lock washers that attach the CPU board to the enclosure door. 6. Disconnect the two ribbon cables (C) that connect the CPU board to the control panel. Threaded spacers and lock washers (Spare) 7. Remove and save the floating spacer and stand-off. They must be re-installed onto the new CPU board. Location of the ProBlue CPU board CAUTION: Before removing the new CPU board from its anti-static bag, ground yourself by touching any bare-metal part of the chassis or another grounded structure. Failure to properly ground yourself can cause electrostatic discharge resulting in damage to the board. 8. Install the new CPU board by reversing steps 3 through 7. 9. Restore electrical power to the melter, and then switch the melter on. Verify that the melter starts normally. Location of the DuraBlue CPU board
Replacing the Tank Thermostat 1. To replace the tank thermostat you must first remove the pump. If the temperature of the tank is below 120 C (250 F) it may not be possible to remove the pump until the melter is reheated. To reheat the melter: 2. Switch the melter off. 3. Relieve system hydraulic pressure. Refer to the melter manual for information on relieving hydraulic pressure. a. While pressing both the Setup and the Tank key, cycle the control switch off and then on again. The left display will flash to indicate that the melter is heating in the override mode. The melter will continue to reheat for 20 minutes and then automatically switch off. b. To continue reheating the melter, repeat step a. until the melter reaches 120 C (250 F). 4. Remove the pump as follows: a. Rotate the isolation valve handle upward until it is vertical. b. Remove the three pump-mounting bolts. c. While pulling the pump away from the manifold, tilt the top of the pump toward the front of the melter and then disconnect the air line from the back of the pump. d. Lift the pump clear of the melter. Note: To gain leverage when removing the pump, thread long M6 bolts into the two holes located on the face of the pump body. Continue
Note: The tank thermostat is located to the left of the tank RTD and behind the insulating blanket that surrounds the tank. 5. To expose the tank thermostat, carefully cut or peel the tape at the corner of the tank insulating blanket. 8. Replace or repair the tape. Use heat-resistant tape only. 9. Replace the top and bottom manifold O-rings (Top - P/N 1019515; Bottom - P/N 942111). 6. Disconnect the thermostat leads, and then remove the two M4 screws. Discard the old thermostat. 7. Attach the thermostat to the tank using the two M4 screws, and then attach the leads. CAUTION: When reinstalling the pump, ensure that the RTD is fully seated in its slot and that the RTD wires are not pinched between the pump and the manifold. 10. Reinstall the pump by reversing the sequence shown in step 4. 11. Apply power to the melter, switch the melter on, and verify that the melter heats normally. If the melter does heat normally, refer to the Troubleshooting section of the melter manual. DuraBlue instructions on back.
DuraBlue Adhesive Melters WARNING: Risk of electrocution! The control switch does not remove high-voltage power from the melter. Before opening the electrical compartment door, ensure that the local power disconnect switch is in the off position and locked. Failure to properly disconnect the power from the melter can result in personal injury, including death. 1. Switch the melter off. 4. Disconnect the thermostat leads, and then remove the two M4 screws. Discard the old thermostat. 2. Disconnect power to the melter at the local power disconnect switch. 3. Remove the protective cover. Thermostat (D10/D16 tank shown) 5. Attach the new thermostat using the M4 screws, and then connect the leads. Thermostat protective cover 6. Reverse steps 1 3 to complete the thermostat replacement. 7. After switching the melter on, ensure that the melter operates correctly by monitoring the melter until it reaches ready status.
Handgun hanger Kit - P/N 1030530 P/N 1032567A This instruction sheet describes the installation of a hose hanger on any DuraBlue adhesive melter. M5 hex key 8 mm wrench WARNING: Risk of Burns! Do not hang the handgun from its trigger. When hanging up the handgun, ensure that the handgun s trigger is not in contact with the hanger. Hanging up the handgun incorrectly can result in the unintentional discharge of hot melt from the handgun. Handgun bracket M5 x 30 screw (2) M5 washer (4) M5 nut (Nylok ) (2)
Instruction Sheet P/N 1032566A Air Control Kit - P/N 1030533 41 DURABLUE IS 26 02/04 This kit contains the air control portion of the AD-41 handgun air-spray system. This kit can be installed on DuraBlue D4L, D10/10L, and D16/16L adhesive melters. Use of this kit also requires the air spray kit P/N 306983. 8 mm wrench WARNING: Risk of electrocution! The control switch does not remove highvoltage power from the melter. Before opening the electrical compartment door, ensure that the local power disconnect switch is in the off position and locked. Failure to properly disconnect the power from the melter can result in personal injury, including death. Air Control assembly M5 Nylok hex nut (2) 1. Switch the melter off. 2. Disconnect power to the melter at the local power disconnect switch. XP1 XP2 Connect the pneumatic fitting to the mating fitting on your AD-41 spray adapter. Refer to the instructions (P/N 1041223) provided with the air-spray kit. 3. Using the M5 washers and nuts provided, mount the air control assembly to the right-front leg of the melter. M5 flat washer (2) Note: The air control assembly can also be mounted to the left-front leg. 4. Route the solenoid cordset through the PG-16 penetration (plugged at factory), and then connect the cordset plug to receptacle XP1 or XP2 on the main board (24 VDC out). 5. Secure the solenoid cordset with the bulkhead fitting. 6. Restore power to the melter and confirm that the melter starts normally.
Instruction Sheet Analog Pressure Gage Kit - P/N 1030537 P/N 1032564B 41 DURABLUE IS 2410/03 This instruction sheet describes the installation of an analog pressure gage on all DuraBlue adhesive melters. Adjustable wrench (2) 1 / 4 -inch hex key Note: For new melters, skip steps 1 through step 3. 1. Allow the melter to heat up to ready status. Refer to Starting the Melter, in section 4 of the melter product manual, for information about ready status. Gage 2. For D10 and D16 melters, close the tank shut-off valve. 3. Switch the melter off. Valve Open Hose fitting (P/N 972628) Note: Adapter P/N 972879 is required to install the analog pressure gage on DuraBlue D25, D50, and D100 adhesiive melters. Valve Closed Swivel 4. Install the hose fitting (A) (P/N 972628) into any available hose port. Place a container under the manifold when removing the hose or port plug. 5. Apply PTFE tape to the swivel threads (B), and then screw the swivel into the gage (C). PTFE tape 6. Thread the swivel onto the hose fitting, adjusting the gage to the desired orientation, and then tighten the nut on the swivel to lock the gage into position. Note: The gage will accurately display the pressure in the manifold only when the melter is at ready status.
Double Hose Support Kit - P/N 1030539 P/N 1032568A This instruction sheet describes the installation of a double hose support on any DuraBlue adhesive melter. Flat-tip screwdriver 10 mm wrench 8 nm wrench Support plate 1. Use the M6 washers provided and the nuts that are already attached to the studs on the melter leg, to mount the support plate (A) onto the melter support leg. Support bracket (2) 2. Use two M4 screws to attach the hose cuff (B) to the support bracket (C). Slide bracket (2) 3. Hook the support bracket onto the support plate, and then slide it along the support plate until it is in position under the desired hose. 4. Use the slide bracket (D) and an M5 washer and nut to lock the support bracket into position on the support plate. Hose cuff and cap (2 each) 5. (Non-corrugated hoses only) Wrap the corrugated tube (E) around the hose. Corrugated tube (2) 6. Position the hose into the hose cuff, and then snap the cap onto the hose cuff. 7. (Optional) Repeat steps 2 through 6 to support a second hose. (Hose not shown for clarity) M4 screw (4) M5 washer (2) M5 nut (Nylok ) (2) M6 washer (2)
Front Panel Service Kit - P/Ns 1031176, 1031177, and 1031178 P/N 1032540A This instruction sheet describes the replacement of the front panel on any DuraBlue adhesive melter. 4 mm hex key 6 and 7 mm nutdrivers 5.5 mm nutdriver WARNING: Risk of electrocution! The control switch does not remove highvoltage power from the melter. Before opening the electrical compartment door, ensure that the local power disconnect switch is in the off position and locked. Failure to properly disconnect the power from the melter can result in personal injury, including death. B Note: The illustrations provided here depict a model D10/D16 melter. If you are working with a model D4, D10L, or D16L melter, disregard mention of components that do not apply to your melter. E Front panel (D10/D16 shown) 1. Switch the melter off. 2. Disconnect electrical power to the melter at the local power disconnect switch. 3. Open the electrical compartment door. A Front panel (D4L shown) 4. Disconnect the main board ribbon cable (A) from the CPU board and disconnect the control switch leads from the control switch (B). Remove the cable and leads from the cable clamp (C). 5. Disconnect the earth ground (D) from the front panel. C D 6. Disconnect the retention straps (E) from the front panel. Save all fasteners. (D10/D16 front panel shown) Continue
CAUTION: Before handling the CPU board, ground yourself by touching any bare-metal part of the chassis or another grounded structure. Failure to properly ground yourself can cause electrostatic discharge resulting in damage to the CPU board. 7. Disconnect the front panel assembly from the hinge (F) by removing the three nuts and matching washers. Save all fasteners. K Note: (Models D10/1D16 only) If a I/O expansion card is installed, disconnect all I/O wires from the card, and then remove the card before continuing. J G 8. Remove the six threaded spacers and lock washers (G) that secure the CPU board to the front panel. J 9. Disconnect the serial cable (H) from the CPU board, and then remove the serial port from the front panel. Save all fasteners. H 10. Disconnect the ribbon cables (I) that join the CPU board and the keypad membrane. Set the CPU board aside onto a clean surface. 11. Remove the spring latch(es) (J) and the control switch (K) from the front panel. Note the side from which each latch was removed. Save all fasteners. I 12. Reverse steps 8 through 11 to assemble all of the components that were removed from the old front panel onto the new front panel. F 13. Install the new panel assembly onto the melter by reversing steps 4 through 7. 14. Restore power to the melter, and then switch the melter on. Confirm that the melter starts correctly.
Main PCA Service Kit - P/N 1031200 P/N 1032542A Use this service kit to replace the main printed circuit assembly (PCA) in any DuraBlue adhesive melter. 7 mm nutdriver WARNING: Risk of electrocution! The control switch does not remove high-voltage power from the melter. Before opening the electrical enclosure door, ensure that the local power disconnect switch is in the off position and locked. Failure to properly disconnect power from the melter can result in personal injury, including death. 1. Disconnect power to the melter at the local power disconnect switch. 5. Remove and save the four M4 nuts that hold the PCA onto the mounting studs, and then remove the PCA. 2. Switch the melter off. Main PCA 3. Open the electrical enclosure door and locate the main PCA. CAUTION: Before removing the new PCA from its anti-static bag, ground yourself using the the disposable grounding strap provided. Instructions for proper use of the strap are printed on the ground strap packaging. Failure to properly ground yourself can cause electrostatic discharge resulting in damage to the PCA. Disposable grounding strap 6. Install the new PCA using the nuts that were removed in step 5. Location of the main PCA 4. Disconnect all of the power and control cables from the PCA. 7. Re-connect all of the power and control cables to the new PCA, and then close the electrical enclosure door. 8. Restore power to the melter and then switch the melter on. Verify that the melter starts normally.
Expansion PCA Service Kit - P/N 1031201 P/N 1032544A Use this service kit to replace the expansion printed circuit assembly (PCA) in a DuraBlue model D10 or D16 adhesive melter. Phillips-head screw driver WARNING: Risk of electrocution! The control switch does not remove high-voltage power from the melter. Before opening the electrical enclosure door, ensure that the local power disconnect switch is in the off position and locked. Failure to properly disconnect power from the melter can result in personal injury, including death. 5. Remove and save the voltage plug from the old PCA. It must be re-installed onto the new PCA. 1. Switch the melter off. Expansion PCA 2. Disconnect power to the melter at the local power disconnect switch. 6. Remove and save the seven Phillips-head screws and matching washers that are used to attach the expansion PCA to the chassis. Disposable grounding strap 3. Open the electrical enclosure door and locate the expansion PCA. CAUTION: Before removing the new PCA from its anti-static bag, ground yourself using the the disposable grounding strap provided. Instructions for proper use of the strap are printed on the ground strap packaging. Failure to properly ground yourself can cause electrostatic discharge resulting in damage to the PCA. 7. Install the new expansion PCA using the Phillips-head screws and washers that were removed in step 6. 8. Re-connect all of the power and control cables to the new PCA. Location of the expansion PCA 4. Disconnect all of the power and control cables from the PCA. 9. Re-install the voltage plug onto the new PCA, and then close the electrical enclosure door. 10. Restore power to the melter and then switch the melter on. Verify that the melter starts normally.
4-Channel Power Module PCA Service Kit - P/N 1031202 P/N 1032545A Use this service kit to replace the 4-channel power module printed circuit assembly (PCA) in a DuraBlue model D10 or D16 adhesive melter. 3 mm hex wrench 2.5 mm hex wrench WARNING: Risk of electrocution! The control switch does not remove high-voltage power from the melter. Before opening the electrical enclosure door, ensure that the local power disconnect switch is in the off position and locked. Failure to properly disconnect power from the melter can result in personal injury, including death. Power module PCA 1. Switch the melter off. 2. Disconnect power to the melter at the local power disconnect switch. 4. Disconnect the ground lead and all of the power and control cables from the PCA (J1 J5). 3. Open the electrical enclosure door and locate the power module PCA. 5. Remove and save the four screws that attach the power module PCA to the chassis. Disposable grounding strap CAUTION: Before removing the new PCA from its anti-static bag, ground yourself using the the disposable grounding strap provided. Instructions for proper use of the strap are printed on the ground strap packaging. Failure to properly ground yourself can cause electrostatic discharge resulting in damage to the PCA. 6. Install the new power module PCA using the screws that were removed in step 5. Location of the power module PCA 7. Re-connect all of the power and control cables to the new PCA, and then close the electrical enclosure door. 8. Restore power to the melter and then switch the melter on. Verify that the melter starts normally.
Main Board Fuses Service Kit - P/N 1031203 P/N 1032548A Use this service kit to replace one or more of the fuses on the main printed circuit board of any DuraBlue adhesive melter. 4 mm hex key Fuse-puller WARNING: Risk of electrocution! The control switch does not remove highvoltage power from the melter. Before opening the electrical compartment door, ensure that the local power disconnect switch is in the off position and locked. Failure to properly disconnect the power from the melter can result in personal injury, including death. F1 and F2 (Fast, 10 A, 250 VAC) F3 and F4 (Slow, 2 A, 250 VAC) 1. Switch the melter off. 2. Disconnect electrical power to the melter at the local power disconnect switch. 3. Open the electrical compartment door and locate the main board. Fuse Key F1/F2 Tank heaters F3/F4 5 and 24 VDC power supplies F5/F6 Pump heaters F7/F8 Hose/Gun 1 heaters F9/F10 Hose/Gun 2 heaters F11/F12 Motor F5 and F6 (Fast, 5 A, 250 VAC) Location of the main board F7 F12 (6.3 A, 250 VAC) 4. Remove the fuse cover, and then use a fuse-puller to remove and replace the desired fuse(s). Replace all fuse covers when finished.
Pump Service Kit - P/N 1031204 (4.9 cc) or P/N 1031205 (7.8 cc) P/N 1032546A This instruction sheet describes the replacement of the pump assembly in a DuraBlue adhesive melter. Use service kit P/N 1031204 to replace a 4.9 cc pump assembly. Use service kit P/N 1031205 to replace a 7.8 cc pump assembly. Flat-tip screwdriver 13 mm open-end wrench 1 / 8- -inch hex wrench 1. Allow the melter to heat up to Ready status. Refer to Starting the Melter, in section 4 of the melter product manual, for information about ready status. 6. Remove the protective cover from the side of the pump. Pump 2. Close the tank shut-off valve (Position 2 is closed; position 1 is open.). 7. Remove the RTD and the heater from the pump body. Save the screws, washer, and the RTD retaining clip. Viton O-rings 1 Machine key 2 3. Switch the melter off. 8. Remove the four M8 pump screws and matching washers that attach the pump to the bottom of the tank. M8 x 90 mm screws w/washers (spare) 4. Disconnect power to the melter at the local power disconnect switch. 5. Disconnect all hoses from the manifold. Parker lubricant Note: When reassembling the drive assembly to the tank, tighten the M8 pump screws to 17.6 19 N m (13 14 ftlb.). Continue
9. Disconnect the motor pigtail from its connection point underneath the melter, and then slide the drive assembly out of the chassis. 10. Disassemble the manifold (A) and the motor assembly (B) from the pump (C), and then remove the coupling (D) from the pump shaft. 12. Slide the coupling onto the shaft of the new pump (Do not tighten the set screw), and then assemble the pump to the motor assembly. 13. Adjust the coupling on the pump shaft so that there is a 0.8 mm (0.031 in.) gap between the couplings, and then tighten the coupling set screw. 14. Lubricate the three new O-rings with Parker lubricant, and then insert them into their respective O-ring grooves on the new pump. 15. Remove any residual hot melt from the face of the manifold that mates with the pump. 16. Mount the manifold onto the pump. 17. Slide the drive assembly back into the chassis and reconnect the motor pigtail. 11. Insert the machine key into the groove at the end of the pump shaft. 18. Complete the pump replacement by reversing steps 2 8. 19. Restore power to the melter and then switch the melter on. Verify that the melter operates normally.
Motor Service Kit - P/N 1031211 ( 1 / 6 hp), P/N 1031212 ( 1 / 4 hp 89 RPM), P/N 1031213 ( 1 / 4 hp 131 RPM) P/N 1032584A This instruction sheet describes the replacement of the pump assembly in a DuraBlue adhesive melter. Phillips-head screwdriver 10 and 13 mm wrenches 3 and 4 mm hex keys Remove the Drive Assembly 1. Allow the melter to heat up to Ready status. Refer to Starting the Melter, in section 4 of the melter product manual, for information about ready status. 6. Remove the protective cover from the side of the pump. Motor 2. (D10/D16 melters only) Close the tank shut-off valve (Position 2 is closed; position 1 is open.). 7. Remove the RTD and the heater from the pump body. Save the screws, washer, and the RTD retaining clip. Capacitor 1 2 3. Switch the melter off. WARNING: Risk of electrocution! The control switch does not remove high-voltage power from the melter. Before opening the electrical compartment door, ensure that the local power disconnect switch is in the off position and locked. Failure to properly disconnect the power from the melter can result in personal injury, including death. 8. Remove the four M8 pump screws and matching washers that attach the pump to the bottom of the tank. Note: When reassembling the drive assembly to the tank, tighten the M8 pump screws to 16.3 17.6 N m (12 13 ft-lb.). 4. Disconnect power to the melter at the local power disconnect switch. 5. Disconnect all hoses from the manifold. Continue
9. Disconnect the motor electrical connector underneath the melter, and then slide the drive assembly out of the chassis. Replace the Motor 1. Remove the four bolts (A) that secure the pump/manifold group (B) to the motor bracket (E), and then pull the pump/manifold group (with one-half of the drive coupling attached) out of the bracket. Save the four spacers (G) that are located on the pump side of the bracket. 4. Using the four screws and removed in step 3, attach the new motor to the motor bracket. 5. Replace the machine key and portion of the drive coupling removed in step 2 onto the shaft of the new motor. DO NOT tighten the set screw. 6. Using the screws and spacers removed in step1, attach the pump/manifold group to the motor bracket. 7. While aligning both halves of the drive coupling, use the four bolts removed in step 1 to attach the pump/manifold group to the motor bracket. 8. Adjust the coupling on the motor shaft so that there is a 0.8 mm (0.031 in.) gap between both halves of the coupling, and then tighten the coupling set screw. 2. Remove the portion of the drive coupling (C) that remains on the motor shaft. Save the machine key. 3. Remove the four screws (D) that attach the motor to the motor bracket, and then separate the motor from the bracket. 9. Complete the motor replacement by reversing steps 6 through 9 Remove the Drive Assembly. Continue
Replace the Capacitor 1. Remove the right side-panel. Note: Before removing the capacitor leads, confirm that two of the leads are marked A and the third is marked B. 2. Remove the protective rubber boot, and then disconnect the leads from the capacitor. B A/A 4. Install the new capacitor, and then tighten the bracket. 5. Connect both of the leads marked A to one side of the capacitor and reconnect the lead marked B to the other side of the capacitor. 3. Loosen the bracket that holds the capacitor in place, and then remove and properly dispose of the capacitor. Note: The capacitor posts (with four terminal per post) are not polarity sensitive. 6. Complete the motor replacement by reversing steps 1 through 5 of Remove the Drive Assembly.
Drive Assembly Service Kit - P/Ns 1031216, 1031217, 1031218, and 1031219 P/N 1032600A This instruction sheet describes the replacement of the drive assembly (motor, coupling, pump, and manifold) and capacitor in a DuraBlue adhesive melter. 13 mm open-end wrench 3 mm hex key 4 mm hex key Replace the Drive Assembly 1. Allow the melter to heat up to Ready status. Refer to Starting the Melter, in section 4 of the melter product manual, for information about ready status. 6. Remove the protective cover from the side of the pump. 2. (D10/D16 melters only) Close the tank shut-off valve (Position 2 is closed; position 1 is open.). Drive assembly ( 1 / 6 hp shown) 7. Remove the RTD and the heater from the pump body. Save the screws, washer, and the RTD retaining clip. 1 Capacitor 2 Pump O-ring WARNING: Risk of electrocution! The control switch does not remove high-voltage power from the melter. Before opening the electrical compartment door, ensure that the local power disconnect switch is in the off position and locked. Failure to properly disconnect the power from the melter 3. Switch the melter off. 8. Remove the four M8 pump screws and matching washers that attach the pump to the bottom of the tank. Note: When reassembling the drive assembly to the tank, tighten the M8 pump screws to 16.3 17.6 N m (12 13 ft-lb.). Parker lubricant 4. Disconnect power to the melter at the local power disconnect switch. 5. Disconnect all hoses from the manifold. Continue
9. Disconnect the motor electrical connector from underneath the melter, and then slide the drive assembly out of the chassis. 10. Remove and discard the old drive assembly. 11. Lubricate the O-ring provided with Parker lubricant, and then install the O-ring in the O-ring groove on the top of the pump. 12. Complete the drive assembly replacement by reversing steps 6 through 9. Replace the Capacitor 1. Remove the right side-panel. 2. Remove the protective rubber boot, and then disconnect the leads from the capacitor. Take note that two of the leads are marked A and the third lead is marked B. B 4. Install the new capacitor, and then tighten the bracket. A/A 3. Loosen the bracket that holds the capacitor in place, and then remove and properly dispose of the capacitor. 5. Connect both of the leads marked A to one side of the capacitor and reconnect the lead marked B to the other side of the capacitor. Note: The capacitor posts (with four terminal per post) are not polarity sensitive. 6. Complete the motor replacement by reversing steps 1 through 5 of Replace the Drive Assembly.
Heater Assembly Service Kit - P/N 1031223 through 1031233 P/N 1032553A This instruction sheet describes the procedure for replacing either the pump heater assembly or the tank heater assembly in a DuraBlue adhesive melter. 3 mm hex key 4 mm hex key End cutters WARNING: Risk of electrocution! The control switch does not remove high-voltage power from the melter. Before opening the electrical compartment door, ensure that the local power disconnect switch is in the off position and locked. Failure to properly disconnect the power from the melter can result in personal injury, including death. 1. Switch the melter off. 4. Remove the left side-panel. 120 or 240 VAC pump heater 2. Disconnect power to the melter at the local power disconnect switch. 3. Remove the protective cover from over the heater. 120 or 240 VAC tank heater Tank heater cover Pump heater cover Thermal compound Continue
5. Disconnect the heater from main board terminal X1 (pump heater) or main board terminal X2 (tank heater), and then remove the heater leads from the cable bundle by cutting the appropriate wire ties. Tank heaters (Right side-panel shown removed) 6. Remove the screw and washer that hold the heater in place, and then remove and discard the heater assembly. 7. Apply thermal compound to the new heater(s), and then reverse steps 1 6 to complete the RTD replacement. Pump heater 8. After switching the melter on, ensure that the melter operates correctly by monitoring the melter until it reaches ready status.
RTD Sensor Assembly Service Kit - P/N 1031233 and P/N 1031234 P/N 1032559A This instruction sheet provides the procedure for replacing either the pump or the tank RTD on a DuraBlue adhesive melter. Use service kit P/N 1031233 to replace the pump RTD. Use service kit P/N 1031234 to replace the tank RTD assembly. Phillips-head screwdriver 3 mm hex key 4 mm hex key WARNING: Risk of electrocution! The control switch does not remove high-voltage power from the melter. Before opening the electrical compartment door, ensure that the local power disconnect switch is in the off position and locked. Failure to properly disconnect the power from the melter can result in personal injury, including death. 1. Switch the melter off. 4. Remove the right side-panel. Pump RTD assembly 2. Disconnect power to the melter at the local power disconnect switch. 3. Remove the protective cover from over the RTD. Tank RTD assembly (includes thermostat leads) Thermal compound Tank RTD cover Pump RTD cover Continue
5. Disconnect the RTD from main board terminal XP5 (pump RTD) or main board terminal XP6 (tank RTD), and then remove the RTD leads from the cable bundle by cutting the appropriate wire ties. Tank RTD and thermostat leads (D10/D16 tank shown) 6. Remove the RTD retaining clip, disconnect the RTD assembly leads from the thermostat (tank RTD assembly only), and then remove and discard the old RTD assembly. 7. Apply thermal compound to the new RTD(s), and then reverse steps 1 6 to complete the RTD replacement. Pump RTD 8. After switching the melter on, ensure that the melter operates correctly by monitoring the melter until it reaches ready status.
Manifold Service Kit - P/N 1031207 or P/N 1031208 P/N 1032578A Use this service kit to replace the manifold in a DuraBlue adhesive melter. Use service kit P/N 1031207 to replace a nonfiltered manifold and use service kit P/N 1031208 to replace a filtered manifold. 13 mm open-end wrench Flat-tip screwdriver 1. Allow the melter to heat up to ready status. Refer to Starting the Melter, in section 4 of the melter product manual, for information about ready status. 2. For D10 and D16 melters, close the tank shut-off valve (Position 2 is closed; position 1 is open.). For D4 melters, drain the tank through one of the manifold ports. 6. Remove the two existing O-rings that are located between the pump and the manifold and replace them with the two new O-rings, which have been lubricated with Parker lubricant. Manifold (4-port manifold shown) Viton O-rings 1 2 7. Clean off any residual hot melt from the face of the pump, and then use the M8 screws and matching flat washers to install the new manifold onto the pump. Tighten the M8 screws to 6.44 N m (54 60 ft-lb). M8 x 90 mm screws w/washers (spare) 3. Switch the melter off. 4. Disconnect all of the hoses from the manifold. 8. Install hose fittings, as required, into the manifold. Use 90-degree hose fittings, if provided, when connecting a hose to any bottom hose port or to the end hose port. Hose fittings (Type and quantity varies by kit) 5. Remove the two M8 pump screws and matching washers that attach the manifold to the pump. 8. Reverse the steps 2 4 to complete the manifold replacement. Parker lubricant
Instruction Sheet P/N 1041418B Drain Valve Kit - P/N 103749 and P/N 1056531 Issued 10/04 This instruction sheet describes the installation of the drain valve on any DuraBlue or VersaBlue adhesive melter. Use kit PN 103749 for all Dura- Blue 4, 10, and 16 adhesive melters. Use kit PN 1056531 for all other DuraBlue and VersaBlue adhesive melters. Adjustable wrench (2) 1 / 4 -inch hex key Note: For new melters, skip steps 1 through step 3. Adapter 1. Allow the melter to heat up to ready status. Refer to the melter product manual, for information about ready status. Closed Open Closed 0 1 2. Close the tank shut-off (isolation) valve. Open O-ring, high-temperature PN 259850 (Kit PN 1056531 ONLY) 3. Switch the melter off. CAUTION: Risk of Burns! Install the drain valve with the drain hole facing down. Shut-off valve on DuraBlue 4, 10, and 16 Shut-off valve on VersaBlue and DuraBlue 25, 50, and 100 Drain valve 4. (DuraBlue 25, 50, 100, and VersaBlue only) For or applications where the tank setpoint temperature is greater than 204 C (400 F), replace the O-ring on the adapter with hightemperature O-ring PN 259850. 5. Install the adapter (B) into the manifold using any available hose port (A). Place a container under the manifold when removing the hose or port plug. 6. Apply PTFE tape to the threads of the drain valve (C), and then screw the valve into the adapter. 7. Open the tank shut-off valve, and then restore the melter to normal operation. Manifold on DuraBlue 4, 10, and 16 Manifold on VersaBlue and DuraBlue 25, 50, and 100
Instruction Sheet P/N 1032554A Pump Seal Kit - P/N 1037756 (4.9 cc pump) and P/N 1037757 (7.8 cc pump) 41 DURABLUE IS 15 02/04 This instruction sheet describes the procedure for replacing the pump seal on DuraBlue 4.9 and 7.8 cc gerotor pumps. Use service kit P/N 1037756 for the 4.9 cc pump and use service kit P/N 1037757 for the 7.8 cc pump. Flat-tip screwdriver 13 mm open-end wrench 6 mm hex key Retaining ring pliers Viton O-rings P/N 941470 (1) P/N 940024 (1) P/N 941161 (1) P/N 941230 (1) Remove the Drive Assembly 1. Allow the melter to heat up to Ready status. Refer to Starting the Melter, in section 4 of the melter product manual for information about ready status. 6. Remove the protective cover from the side of the pump. 2. For D4 melter, operate the melter until the tank is empty. For all other melters, close the tank shut-off valve (Position 2 is closed; position 1 is open). Retaining Ring (Internal) Washer 7. Remove the RTD and the heater from the pump body. Save the screws, washer, and the RTD retaining clip. Seal Key Pin 1 Retaining Rings (Crescent) Shaft 3. Switch the melter off. WARNING: Risk of electrocution! The control switch does not remove high-voltage power from the melter. Before opening the electrical compartment door, ensure that the local power disconnect switch is in the off position and locked. Failure to properly disconnect the power from the melter can result in personal injury, including death. 2 8. Remove the four M8 pump screws and matching washers that attach the pump to the bottom of the tank. Note: When reassembling the drive assembly to the tank, tighten the M8 pump screws to 16.3 17.6 N m (12 13 ft-lb.). Parker lubricant Insertion Tool 4. Disconnect power to the melter at the local power disconnect switch. 5. Disconnect all hoses from the manifold. Continue
9. Disconnect the motor pigtail from its connection point underneath the melter, and then slide the drive assembly out of the chassis. Remove the Pump 1. Disassemble the manifold (A) and the motor assembly (B) from the pump (C). Save the four spacers that are between the mounting bracket and the pump. Reassemble the Drive 1. Insert the new machine key into the slot on the end of the pump shaft, and then slide the coupling onto the shaft. (Do not tighten the set screw). 2. Assemble the pump to the motor assembly. Ensure that the four spacers are replaced. 3. Adjust the coupling on the pump shaft so that there is a 0.8 mm (0.031 in.) gap between the couplings, and then tighten the coupling s set screw. 4. Lubricate the three new O-rings with Parker lubricant, and then insert them into their respective O-ring grooves on the pump. 2. Remove the coupling (D) from the end of the pump shaft and discard the machine key (E). 5. Remove any residual hot melt from the face of the manifold that mates with the pump. 6. Mount the manifold onto the pump. 3. Remove and discard the three pump O-rings. Continue
Disassemble the Pump 1. Remove the assembly screws (A). 2. Insert a flat-tip screwdriver into the notch (B) on each side of the pump plate, and then pry the pump plates (C) apart. 3. Remove and discard the internal retaining ring (D), the washer (E) and the pump seal. 4. Pull the shaft-gerotor assembly (G) out of the large pump plate. Remove the external gerotor (H) if it does not come out with the assembly. 5. Remove and discard the O-ring (I). G J H I C 6. Note which side of the internal gerotor (K) is facing the tapered end of the shaft. The internal gerotor must be installed onto the new shaft facing in the same direction. K L 7. Remove one of the crescent retaining rings (J) from the shaft, and then remove the internal gerotor (K) and the pin (L). Discard the retaining ring, pin, and shaft. A B 8. Clean the pump plates and gerotors using the appropriate cleaning fluid. E F A C D 19.6 21.0 Nm (14.5 15.5 ft.-lb) Continue
Rebuild the Pump 1. Rebuild the shaft-gerotor assembly using the new shaft, crescent retaining rings, and pin. Ensure that the internal gerotor is installed onto the new shaft facing in the same direction as it was on the old shaft. 2. Using the seal insertion tool, insert the new pump seal (F) with the spring side of the seal facing the pump plate. C 3. Insert the new washer (E), and then insert the new retaining ring (D). G J H I 4. Lubricate the new O-ring (I) (P/N 941470) with Parker lubricant, and then insert the O-ring into the O-ring groove on the pump plate. 5. Lubricate the gerotors (H and K) with high-temperature oil (Mobile Therm 603 or equivalent). A K L 6. Insert the shaft-gerotor assembly into the large pump plate. B 7. Reassemble the pump plates using the two assembly screws. Tighten the screws to 19.6 21.0 Nm (14.5 15.5 ft.-lb). D E 19.6 21.0 Nm (14.5 15.5 ft.-lb) F A C Complete the Installation 1. Reassemble the drive assembly. Refer to Reassemble the Drive on page 2. 2. Slide the drive assembly back into the chassis and reconnect the motor pigtail. 3. Complete the installation by reversing steps 2 through 8. 4. Restore power to the melter, and then switch the melter on. Verify that the melter operates normally.