Page 1 Model A4TP Customer Product Manual Part 1107600_03 Issued 3/14 This document contains important safety information Be sure to read and follow all safety information in this document and any other related documentation. NORDSON CORPORATION  DULUTH, GEORGIA  USA www.nordson.com...
Page 2 ContourCoat, CPX, cSelect, Cyclo‐Kinetic, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, e.dot+, E‐Nordson, Equalizer, EquiBead, FillEasy, Fill Sentry, Flow Coat, Fluxplus, Freedom, Get Green With Blue, G‐Net, Genius, G‐Site, IntelliJet, iON, Iso‐Flex, iTrend, Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros, MiniEdge, Minimeter, Multifill, MultiScan, Myritex, Nano, OmniScan, OptiMix, OptiStroke,...
Page 3: Table Of Contents
......... 2‐8 Part 1107600_03 E 2014 Nordson Corporation...
Page 4 ......... . 3‐45 E 2014 Nordson Corporation Part 1107600_03...
Page 5 ......6‐22 AltaBlue Troubleshooting Flowchart ......6‐27 Part 1107600_03 E 2014 Nordson Corporation...
Page 6 ..........8‐4 E 2014 Nordson Corporation Part 1107600_03...
Page 7 ......C‐5 Using Nordson Configuration Manager ......
Page 8 Table of Contents E 2014 Nordson Corporation Part 1107600_03...
Page 9: Safety
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. Issued 10-11 E 2014 Nordson Corporation...
Page 10: Responsibilities Of The Equipment Owner
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. Issued 10−11 E 2014 Nordson Corporation...
Page 11: User Qualifications
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. Issued 10-11 E 2014 Nordson Corporation...
Page 12: Instructions And Safety Messages
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.
Page 13: Maintenance And Repair Practices
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 www.nordson.com or by calling your Nordson representative. Confirm the correct operation of all safety devices before placing the equipment back into operation.
Page 14: Equipment Shutdown
2. Disconnect the input signal wiring to the applicator solenoid valve(s). 3. Reduce the air pressure to the applicator solenoid valve(s) to zero; then relieve the residual air pressure between the regulator and the applicator. Issued 10−11 E 2014 Nordson Corporation...
Page 15: General Safety Warnings And Cautions
General Safety Warnings and Cautions Table 1‐1 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.
Page 16 WARNING! Risk of fire or explosion! Nordson adhesive equipment is not rated for use in explosive environments and has not been certified for the ATEX directive or as nonincendive. In addition, this equipment HM, CA, PC should not be used with solvent‐based adhesives that can create an...
Page 17 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.
Page 18: Other Safety Precautions
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. Issued 10−11 E 2014 Nordson Corporation...
Page 19: Safety Labels And Tags
Burn hazard. Hot surfaces. Tag, hazardous voltage [located inside the electrical cabinet on the main board—refer to Section 7, Parts, for an illustration that shows the location of the main board] NS: Not Shown Issued 10-11 E 2014 Nordson Corporation...
Page 20 1-12 Safety Issued 10−11 E 2014 Nordson Corporation...
Page 21: Description
Description This manual describes the installation and use of the AltaBlue 4 (A4TP) adhesive melter. When necessary, the reader is referred to the documentation supplied with other Nordson products or products supplied by third parties. Part 1107600_03 E 2014 Nordson Corporation...
Page 22: Other Sources Of Information
The guide is appropriately sized and laminated so that it can be kept with the melter on the production floor. Online Support Visit www.enordson/support to download melter firmware updates and Blue Series software utilities. E 2014 Nordson Corporation Part 1107600_03...
Page 23: Product Description
Product Description See Figure 2‐1. Nordson AltaBlue adhesive melters are used in conjunction with Nordson hot melt hoses and guns to create a hot melt application system. The melter liquifies solid‐form hot melt and maintains the hot melt at the desired temperature.
Page 24: Intended Use
Melt and pump solid‐form hot melt materials that are engineered to be liquified and extruded at temperatures below 204 _C (400 _F) Be used with compatible hot melt hoses and guns that are manufactured by Nordson Corporation Be used in non‐explosive environments Limitations of Use Use AltaBlue melters only for the purpose for which they are designed.
Page 25: Melter Identification
The model and part number are indicated on the equipment identification plate that is located on the front of the melter. Figure 2‐2 Equipment identification plate Part 1107600_03 E 2014 Nordson Corporation...
Page 26: Key Components
4. Tank lid 7. Low‐level control box 2. Control panel (see Figure 2‐4) 5. Hose/gun receptacle 8. Electrical enclosure door 3. Motor and pump 6. Manifold (filter, drain valve, and pressure control valve visible) E 2014 Nordson Corporation Part 1107600_03...
Page 27 3. Pump mode key/LED 9. Setup key/LED 15. Right display and arrow keys 4. Pump enable key/LED 10. Fault light 16. Numeric keypad 5. Standby key/LED 11. Ready light 6. Master pump enable key/LED 12. Component keys/LEDs Part 1107600_03 E 2014 Nordson Corporation...
Page 28: Optional Equipment
Communications cards that allow the melter to communicate with other process equipment or a controller using standard network protocols. Pressure gauge that provides a manifold hydraulic pressure reading. Refer to Section 7, Parts, for a complete list of optional equipment. E 2014 Nordson Corporation Part 1107600_03...
Page 29: Installation
If optional equipment was ordered with the melter, refer to the documentation provided with the optional equipment for installation and operating instructions. Part 1107600_03 E 2014 Nordson Corporation...
Page 30: Additional Information
The instructions provided in this section are intended to be used by personnel who have experience in the following subjects: Hot melt application processes Industrial power and control wiring Industrial mechanical installation practices Basic process control and instrumentation E 2014 Nordson Corporation Part 1107600_03...
Page 31 Installation This page intentionally left blank. Part 1107600_03 E 2014 Nordson Corporation...
Page 32: Installation Requirements
Clearances Figure 3‐1 illustrates the minimum clearances that are required between the melter and surrounding objects. Table 3‐1 describes each clearance. Figure 3-1 Minimum installation clearances E 2014 Nordson Corporation Part 1107600_03...
Page 33 900 mm both the electrical enclosure door and tank lid are fully (35.42 in.) opened. Minimum vertical space required for the melter when 640 mm the tank lid is at its highest point. (25.18 in.) Part 1107600_03 E 2014 Nordson Corporation...
Page 34: Electrical Power
The melter must be installed away from areas with strong drafts or where sudden temperature changes occur. The melter must be installed where it will be in conformance with the ventilation requirements specified in the Material Safety Data Sheet for the hot melt being used. E 2014 Nordson Corporation Part 1107600_03...
Page 35: Unpacking The Melter
Before starting the installation, remove the melter from the pallet, locate the installation kit, and inspect the melter for damaged and missing parts. Report any problems to your Nordson representative. Customer‐Supplied Materials The following additional materials are required to install the melter Four 8 mm ( in.) machine bolts and locking hardware...
Page 36 2. Fuse, fast, 10 A, 250 VAC 6. Fuse, 6 A, 500 VAC (2) 3. Fuse, slow, 2 A, 250 VAC 7. 90‐degree hose fitting 4. Fuse, fast, 5 A, 250 VAC 8. Fan filter (2) E 2014 Nordson Corporation Part 1107600_03...
Page 37: Removing The Base Panels
Installation Removing the Base Panels See Figure 3‐3. To facilitate installation, remove the exterior base panels. Figure 3‐3 Removing the exterior base panels Part 1107600_03 E 2014 Nordson Corporation...
Page 38: Mounting The Melter
318 mm (12.50 in.) 257 mm 249 mm (10.12 in.) (9.80 in.) 381 mm (15.00 in.) 10 mm (0.38 in.) 14 mm (0.56 in.) Figure 3-4 Bolt mounting pattern E 2014 Nordson Corporation Part 1107600_03...
Page 39 3-11 Installation This page intentionally left blank. Part 1107600_03 E 2014 Nordson Corporation...
Page 40: Configuring The Electrical Service
To configure the melter to function in your facility, you must connect a power cable to the melter and designate the service type by installing a Nordson‐supplied voltage plug into the melter. To connect a power cable to the melter WARNING! Risk of electrocution! Install a lockable power disconnect switch between the electrical service and the melter.
Page 41 3-13 Installation PE/G Figure 3‐5 Connecting the power cable and ground lead Part 1107600_03 E 2014 Nordson Corporation...
Page 42: Connecting Hoses And Guns
Use a 90‐degree fitting when connecting a hose to any of the bottom hose ports or to the end hose port. Refer to the user's guide provided with each Nordson hose. The guide Manifold hose ports contains important information about routing and installing the hose.
Page 43 Installation To connect guns Observe the following guidelines: For information about choosing the most appropriate Nordson hot melt gun for your manufacturing process, refer to the latest edition of Nordson's hot melt dispensing equipment Replacement Parts Catalog or contact your Nordson representative. Refer to Appendix A, Calculating Melter Power Requirements, for information about how to calculate the power required by Nordson hot melt guns.
Page 44: Setting Up The Melter
Temperature of the Tank, Hoses, and Guns later in this section to complete the installation process. If you need to make changes to the factory setup or if you want to learn about other operating parameters, go to the next part in this section, Operating Parameters. E 2014 Nordson Corporation Part 1107600_03...
Page 45 A group of parameters that control the melter's clock. 50 to 77 Seven‐day Clock The clock is used to automatically turn the heaters on Disabled and off and to place the melter into the standby mode. Part 1107600_03 E 2014 Nordson Corporation...
Page 46 3-18 Installation This page intentionally left blank. E 2014 Nordson Corporation Part 1107600_03...
Page 47: Operating Parameters
In addition to the ability to read and edit parameter values, you can also save and restore the current value of every operating parameter and review a log of the last ten changes that were made to editable parameters. Part 1107600_03 E 2014 Nordson Corporation...
Page 48: Selecting Operating Parameters
To read or edit a parameter 1. Switch the melter on. The melter performs a start‐up check. 2. Press the Setup key. The left display flashes parameter 1. Setup key E 2014 Nordson Corporation Part 1107600_03...
Page 49 (‐‐‐‐) for three seconds and then it will change back to the original value. 8. Repeat step 5 through step 7 to read or change the next sequential parameter number or press the Setup key to exit the setup mode. Part 1107600_03 E 2014 Nordson Corporation...
Page 50 0−9, 11, and 13−14 0 (disabled) Optional Input 8 0−9, 11, and 13−14 0 (disabled) Optional Input 9 0−9, 11, and 13−14 0 (disabled) Optional Input 10 0−9, 11, and 13−14 0 (disabled) Continued... E 2014 Nordson Corporation Part 1107600_03...
Page 51 NOTE: Motor control parameters are set differently from operating parameters. Refer to Setting Up the Motor Control later in this section. Some applications will require a change to one or more motor control parameters. Part 1107600_03 E 2014 Nordson Corporation...
Page 52 If password protection is enabled, the melter Appendix B, parameter 10 will return to the password protected mode whenever you exit the setup mode. E 2014 Nordson Corporation Part 1107600_03...
Page 53: Setpoint Temperature Of The Tank, Hoses, And Guns
Adjusting Component Temperatures in Section 4, Operation. As with operating parameters, you can also save and restore setpoint temperatures and review past changes that were made to setpoint temperatures. Part 1107600_03 E 2014 Nordson Corporation...
Page 54 Each component begins to heat or cool to the new global setpoint Enter key temperature and the melter returns to the automatic scan mode. When all of the components reach the global setpoint temperature, the ready LED turns on (green). Ready LED E 2014 Nordson Corporation Part 1107600_03...
Page 55: Save And Restore Melter Settings
If you use the restore feature before the save feature is used for the very first time, the factory default setpoint temperatures will be restored. This will cause the hoses and guns to stop heating. Part 1107600_03 E 2014 Nordson Corporation...
Page 56: Review Parameter And Setpoint Temperature Changes
Each press of a scroll key displays a progressively older log entry. LEDs on component keys 4. Press the Setup key to return to the automatic scan mode. Scrolling through the fault log E 2014 Nordson Corporation Part 1107600_03...
Page 57 Unused log entries in the change history log are indicated by “P-_” in the right display. To view how many heater hours have elapsed since a specific change (displayed) was made, simultaneously press both of the right-display scroll keys. Part 1107600_03 E 2014 Nordson Corporation...
Page 58: Setting Up The Motor Control
5. Repeat steps 3-4 for each parameter you want to change. 6. To exit the setup mode, press the Pump mode key one additional time after the last parameter has been displayed. Pump mode key and LED E 2014 Nordson Corporation Part 1107600_03...
Page 59 0. If the melter will operated in the gear‐to‐line mode, enter a minimum line speed. The motor speed will not fall below this valve even if the signal drops to 0 V. Part 1107600_03 E 2014 Nordson Corporation...
Page 60 3-32 Installation This page intentionally left blank. E 2014 Nordson Corporation Part 1107600_03...
Page 61: Installing Melter Inputs
NOTE: Use a signal cable suitable for NEC class1 remote control and signaling circuits. To reduce the possibility of electrical shorting, route the cable so that it does not touch nearby circuit boards. Opening the electrical enclosure door Part 1107600_03 E 2014 Nordson Corporation...
Page 62 20) on the I/O connectors. The connectors are preinstalled on terminal XT7 on the I/O expansion card. Table 3‐8 lists the terminal numbers that correspond to each input. I/O connectors (labeled 1-10 and 11-20) Inputs 1-10 11-20 Outputs Figure 3-6 Wiring inputs E 2014 Nordson Corporation Part 1107600_03...
Page 63 9 and 10 9 - Hose/Gun 6 Enable/Disable NOTE If control option 3 is selected, the motor will not turn on—even if you press the pump key—if voltage is not present on the input’s contacts. Part 1107600_03 E 2014 Nordson Corporation...
Page 64 3-36 Installation This page intentionally left blank. E 2014 Nordson Corporation Part 1107600_03...
Page 65: Installing Melter Outputs
NOTE: Use a signal cable suitable for NEC class1 remote control and signaling circuits. To reduce the possibility of electrical shorting, route the cable so that it does not touch nearby circuit boards. Opening the electrical enclosure door Part 1107600_03 E 2014 Nordson Corporation...
Page 66 8) on the 1-10 I/O connector. The connector is preinstalled on terminal XT7 on the I/O expansion card. Table 3‐8 lists the terminal numbers that correspond to each output. I/O connectors (labeled 1-10 and 11-20) Inputs 1-10 11-20 Outputs Figure 3-7 Wiring outputs E 2014 Nordson Corporation Part 1107600_03...
Page 67 Control option 6 provides an output signal when a potential fault is detected. If control option 3 and 6 are both used, then both a fault output and an alert output signal will be present when the fault LED turns on. Part 1107600_03 E 2014 Nordson Corporation...
Page 68: Setting Up Gear-To-Line Operation
4. If you want to run the motor at a minimum speed other than rpm equals 0 at 0 VDC, change the value of motor control parameter LoS (minimum pump speed in gear‐to‐line mode). Refer to Setting Up the Motor Control earlier in this section. E 2014 Nordson Corporation Part 1107600_03...
Page 69 3-41 Installation TB2-1 (+) TB2−2 (−) Figure 3‐8 Connecting a line speed reference signal for gear‐to‐line operation Part 1107600_03 E 2014 Nordson Corporation...
Page 70 7. Rotate the jog dial until the display shows shows the value calculated in step 1. 8. Press the enter button to save the value. 9. Press ESC twice to exit the setup mode. E 2014 Nordson Corporation Part 1107600_03...
Page 71 (2) to clear an entry and revert to the value stored in memory. Motor drive buttons (located on the motor drive inside the electrical enclosure) Figure 3‐9 Part 1107600_03 E 2014 Nordson Corporation...
Page 72: Reinstalling The Base Panels
3-44 Installation Reinstalling the Base Panels When all installation procedures are complete, reinstall the exterior base panels. Figure 3‐10 Installing the melter base panels E 2014 Nordson Corporation Part 1107600_03...
Page 73: Installing Optional Equipment
Flushing the melter is accomplished by processing a minimum of one tank volume of hot melt through the melter, hoses, and guns. Refer to Section 4, Operation, for information about filling the tank and operating the melter. Part 1107600_03 E 2014 Nordson Corporation...
Page 74 3-46 Installation E 2014 Nordson Corporation Part 1107600_03...
Page 75: Operation
Procedural variations or special considerations are explained in the additional information table that follows most procedures. Where applicable, some table entries also contain cross‐reference information. Additional information tables are indicated by the symbol shown to the left. Part 1107600_03 E 2014 Nordson Corporation...
Page 76: More About Heated Components
(or otherwise identify) the auxiliary device as to the hose or gun position number that represents the device. The control panel will identify such devices as a hose or gun, regardless of what the device actually is. E 2014 Nordson Corporation Part 1107600_03...
Page 77: Filling The Tank
2. Use a scoop to fill the tank with hot melt. Table 4‐1 lists the tank capacity of each AltaBlue TT melter. NOTE: Nordson Corporation recommends that the tank be kept at least one‐half full while the melter is operating.
Page 78: Starting The Melter
2. Ensure that the pressure control valve screw is turned fully counterclockwise (at or near the valve's lowest pressure setting). Refer to Adjusting the Pressure Control Valve later in this section as needed. 3. Proceed to the next procedure, To start the melter. E 2014 Nordson Corporation Part 1107600_03...
Page 79 The current motor speed is indicated on the display. Heaters LED NOTE: Each press of an arrow key increases/decreases the motor speed by 1 rpm (factory default). Automatic scan sequence Ready LED Pump speed arrow keys Part 1107600_03 E 2014 Nordson Corporation...
Page 80 Operation To start the melter (contd) CAUTION! Do not operate Nordson pumps without material. Before enabling the motor(s), ensure that the tank is filled. 3. Press the master pump enable key to enable the pump. The LED on the key turns yellow to indicate that the pump is enabled, but not running.
Page 81 If the seven-day clock was on prior to the power failure, the melter will restart in the mode dictated by the clock schedule at the time the melter restarts. Part 1107600_03 E 2014 Nordson Corporation...
Page 82: Manually Adjusting The Pump Speed
2. Press the pump speed arrow keys to adjust the motor(s) to the desired speed (rpm). The current motor speed is indicated on the display. NOTE: Each press of an arrow key increases/decreases the motor speed by 1 rpm (factory default). Pump speed arrow keys E 2014 Nordson Corporation Part 1107600_03...
Page 83: Adjusting The Pressure Control Valve
Figure 4‐1 Adjusting the pressure control valve Part 1107600_03 E 2014 Nordson Corporation...
Page 84: Monitoring The Melter
Refer to Monitor Melter Faults and Using Melter Function Keys later in this section for information about melter faults and using the seven‐day clock and standby functions. Refer to Appendix B, parameter 4, for information about the ready delay. E 2014 Nordson Corporation Part 1107600_03...
Page 85 If the clock has placed the melter into the standby mode, pressing the standby key will return the heated components to their assigned setpoint temperature. Part 1107600_03 E 2014 Nordson Corporation...
Page 86: Monitor Component Temperatures
3. When the position number of the desired component appears in the left display, observe the right display to determine the component's actual temperature. LEDs on component keys E 2014 Nordson Corporation Part 1107600_03...
Page 87 UP scroll key. Holding down the scroll key while the melter is in the automatic scan mode reveals the setpoint of each component that is scanned. Part 1107600_03 E 2014 Nordson Corporation...
Page 88: Monitor Melter Faults
RAM backup Clock does not Insufficient voltage from F4/3 Replace CPU battery function RAM backup battery Internal clock Heaters remain on, Battery‐backed RAM F4/4 battery backed but fault condition Replace CPU failure persists Continued... E 2014 Nordson Corporation Part 1107600_03...
Page 89 The gun RTD type selected in one or more Change parameters Mismatched gun of parameters 92-97 92-97 to match the Heaters turn off does not match the RTD connected guns. type of the corresponding gun Part 1107600_03 E 2014 Nordson Corporation...
Page 90: How F1, F2, And F3 Faults Are Handled
LED will turn off, the red fault LED will turn on, the heaters turn off, and the melter records the fault in the fault log. Refer to To review the fault log later in this section. Fault LED E 2014 Nordson Corporation Part 1107600_03...
Page 91: How F4 Faults Are Handled
I/Os. Refer to Section 6, Troubleshooting, for information about diagnosing F4 faults. 5. The melter records the fault in the fault log. Refer to To review the fault log later in this section. Part 1107600_03 E 2014 Nordson Corporation...
Page 92 2. Return the melter to the automatic scan mode by pressing the Setup key twice. 3. Press the Clear/Reset key. 4. Press the Heaters key to turn on the heaters. Clear/reset key Heaters key E 2014 Nordson Corporation Part 1107600_03...
Page 93 235 _C (458 _F), an immediate F3 fault will occur (no two‐minute monitoring period). If F4 appears in the right display when you press the clock key, the internal clock function has failed. Part 1107600_03 E 2014 Nordson Corporation...
Page 94 4. Press the Setup key to return to the automatic scan mode. Scrolling through the fault log E 2014 Nordson Corporation Part 1107600_03...
Page 95 When an F1 fault is the result of a hose/gun pair being disconnected from the melter, two fault log entries are created. The first entry is for the gun and the second entry is for the hose. Part 1107600_03 E 2014 Nordson Corporation...
Page 96: Monitor Motor Control Or Motor Drive Faults
With the melter in the scan mode, press the Clear/Reset key to turn off the service LED and reset the service interval time. Service LED (yellow) Clear/reset key The default setting for the service interval time Appendix B, parameter 5 is 500 hours. E 2014 Nordson Corporation Part 1107600_03...
Page 97: Adjusting Component Temperatures
For example, hose/gun pair 1 should be connected to the receptacle 1. Refer to More About Heated Components earlier in this section for information about hose/gun positions. Part 1107600_03 E 2014 Nordson Corporation...
Page 98 5. Press the Tank key. Enter key All components begin to heat or cool to the new global setpoint temperature. When all of the components reach their setpoint temperature, the ready LED turns on (green). Ready LED E 2014 Nordson Corporation Part 1107600_03...
Page 99 Refer to Entering the Melter Password later in this section. 5. Press the Enter key. The hoses or the guns begin to heat or cool to their new setpoint temperature. Part 1107600_03 E 2014 Nordson Corporation...
Page 100 To register the new setpoint temperature and return to the automatic scan mode, go to step 6. 6. Press any component key (tank, hose, or gun). The selected component begins to heat or cool to its new setpoint temperature. E 2014 Nordson Corporation Part 1107600_03...
Page 101 Temperature Changes You can save setpoint temperature changes by Refer to Section 3, Installation, Save simultaneously pressing the 1 key and the Setup and Restore Melter Settings key. Part 1107600_03 E 2014 Nordson Corporation...
Page 102: Entering The Melter Password
Setup key twice. The melter password is created and Setting Up the Melter in Section 3, enabled/disabled during system setup. Installation E 2014 Nordson Corporation Part 1107600_03...
Page 103: Using Melter Function Keys
When a fault occurs (refer to Monitor Melter Faults earlier in this section) the heaters automatically turn off. The heaters key is used to turn the heaters back on after correcting a fault condition. Part 1107600_03 E 2014 Nordson Corporation...
Page 104: Master Pump Enable Key
When the melter is placed into the setup mode, the automatic scan stops and the left and right displays are used to select and read or edit operating parameters. Setup key E 2014 Nordson Corporation Part 1107600_03...
Page 105: Seven-Day Clock Key
The clock will still operate when the melter is faulting or is in the setup mode. If F4 appears in the right display when you press Section 7, Troubleshooting the clock key, the internal clock function has failed. Part 1107600_03 E 2014 Nordson Corporation...
Page 106: Standby Key
The melter may also be set up to automatically Appendix B, Parameters 25, 26, 57, enter the standby mode using a variety of 30–33, 62, and 67 operating parameters. Whenever manual standby is enabled, the Appendix B, Parameter 26 standby LED blinks. E 2014 Nordson Corporation Part 1107600_03...
Page 107: Shutting Down The Melter
Section 5, Maintenance, as needed. 3. Disable the guns as follows: Air‐operated guns: Turn off the air supply to the guns. Electric guns: Turn off the gun driver, pattern controller, or timer. Melter control switch (A4) Part 1107600_03 E 2014 Nordson Corporation...
Page 108 4-34 Operation E 2014 Nordson Corporation Part 1107600_03...
Page 109: Maintenance
AltaBlue TT melters operating within their specified limits and to prevent equipment malfunctions. For information about maintaining optional equipment that was supplied by Nordson, refer to the instructions provided with the equipment. If the melter stops operating or is operating incorrectly, refer to Section 6, Troubleshooting, for information about diagnosing common problems and performing corrective maintenance.
Page 110 Tightening the pump screws Tightening the Pump Screws When leakage occurs When the pump screws become loose At scheduled service intervals Calibrating the level sensor As needed throughout the life of the melter E 2014 Nordson Corporation Part 1107600_03...
Page 111: Relieving System Pressure
2. Set the control option for parameter 14 to 1 (enabled). 3. When the service activity is complete, return parameter 14 to 0 (disabled). Pump mode key Refer to Setting Up the Melter in Section 3, Installation, for information about changing operating parameters. Part 1107600_03 E 2014 Nordson Corporation...
Page 112: Cleaning The Melter
4. Reverse steps 2-3 to reinstall panels. To clean the electrical enclosure After panels are removed, inspect the fan area and ensure that the air flow path for both side panels is clear. Remove excessive dust from inside the cabinet. E 2014 Nordson Corporation Part 1107600_03...
Page 113 Maintenance Figure 5‐2 Removing the exterior panels Part 1107600_03 E 2014 Nordson Corporation...
Page 114: Replacing The Adhesive Filter
LED that turns on at the end of a customer‐defined time period. Refer to Setting Up the Melter in Section 3, Hot melt flow path Installation, for information about the service interval time. E 2014 Nordson Corporation Part 1107600_03...
Page 115 6. Screw the filter into the pump body and then tighten the filter to 4.5 Nm (40 in.‐lb). 7. Reinstall the side base panel and resume normal operation. Figure 5‐3 Replacing the adhesive filter Part 1107600_03 E 2014 Nordson Corporation...
Page 116: Cleaning The Tank
7. Pump all of the flushing material from the tank and through the hoses and guns. 8. Return the melter to normal operation and pump a minimum of one tank volume of fresh hot melt through the tank, hoses, and guns. E 2014 Nordson Corporation Part 1107600_03...
Page 117 10. Replace the adhesive filter. Refer to Replacing the Adhesive Filter earlier in this section. 11. Fill the tank with fresh hot melt and then purge all of the hoses and guns with the fresh hot melt. 12. Restore the system to normal operation. Part 1107600_03 E 2014 Nordson Corporation...
Page 118: Tightening The Pump Screws
4. Relieve system pressure. Refer to Relieving System Pressure earlier in this section as needed. To access the pump and tighten the screws 1. See Figure 5‐4. Using a 4‐mm hex key, remove the base panels. Figure 5‐4 Removing the exterior base panels E 2014 Nordson Corporation Part 1107600_03...
Page 119 3. See Figure 5‐5. Tighten the screws to 25 NSm (222 in.‐lb). Figure 5‐5 Tightening the pump screws 4. Reinstall the exterior base panels and restore the system to normal operation. Part 1107600_03 E 2014 Nordson Corporation...
Page 120: Calibrating The Level Sensor
LED turns green and then adding an additional one‐half ( ) counterclockwise turn calibrates the sensor. 7. Reinstall the base side panel and restore the system to normal operation. E 2014 Nordson Corporation Part 1107600_03...
Page 121 Green = Amber = adhesive adhesive present present Green Amber Figure 5‐6 Location of the level sensor adjustment screws and LEDs 1. Level sensor 2. Level sensor LED 3. Level sensor adjustment screw (behind plug) Part 1107600_03 E 2014 Nordson Corporation...
Page 122 5-14 Maintenance E 2014 Nordson Corporation Part 1107600_03...
Page 123: Troubleshooting
If you cannot resolve the problem using the troubleshooting flowchart, contact your Nordson representative for technical assistance. Safety Never disconnect cables from, or reconnect cables to, any circuit board while the melter is energized.
Page 124: Melter Faults
RAM backup Clock does not Insufficient voltage from F4/3 Replace CPU battery function RAM backup battery Internal clock Heaters remain on, Battery‐backed RAM F4/4 battery backed but fault condition Replace CPU failure persists Continued... E 2014 Nordson Corporation Part 1107600_03...
Page 125 The gun RTD type selected in one or more Change parameters Mismatched gun of parameters 92-97 Heaters turn off 92-97 to match the does not match the RTD connected guns. type of the corresponding gun Part 1107600_03 E 2014 Nordson Corporation...
Page 126: Motor Control Faults
Calibrating the Pump Speed Display later in this section. Motor control not Improper motor control Check motor control operating as expected parameter settings parameter settings. Refer to Setting Up the Motor Control in Section 3, Installation. E 2014 Nordson Corporation Part 1107600_03...
Page 127: Motor Drive Faults
Wait until the motor drive display is completely blank before restoring power. Figure 6-1 Location of the motor drive display Part 1107600_03 E 2014 Nordson Corporation...
Page 128 Check the cables connecting the drive CIRCUIT] drive output or significant ground to the motor. leakage current at drive output if several motors are connected in parallel [OVERSPEED] Instability or driving load too high Check the motor. Continued... E 2014 Nordson Corporation Part 1107600_03...
Page 129 Line voltage too high or line supply Check the line voltage. OVERVOLTAGE] disturbed [UNDERVOLTAGE] Insufficient line supply or low Check the supply voltage to the motor voltage condition drive. Motor drive failed Replace the motor drive. Part 1107600_03 E 2014 Nordson Corporation...
Page 130: Motor Drive Parameters
(2) to clear an entry and revert to the value stored in memory. Figure 6-2 Motor drive buttons (located on the motor drive inside the electrical enclosure) E 2014 Nordson Corporation Part 1107600_03...
Page 131 10. Press ESC to exit the menu. 11. Repeat steps 2.-10. as needed until all parameters are set to the factory default values shown in Tables 6‐4 to 6‐12. 12. Press ESC to until the display shows rdy. Part 1107600_03 E 2014 Nordson Corporation...
Page 132: Motor Drive Parameter Settings
Table 6-4 Motor Drive rEF Menu Parameter Settings Settings Menu Parameter Factory Setting Customer Setting rEF 1500 Hz AIUI 1100% LSP to HSP NOTE: Shaded parameters do not appear in on the display because of values set in corresponding functions. E 2014 Nordson Corporation Part 1107600_03...
Page 133 SdC1 0.7 In tdC2 UFr2 SdC2 0.5 In FLG2 StA2 SLP2 100% 10Hz 50Hz 100% 1.6A 4kHz NOTE: Shaded parameters do not appear in on the display because of values set in corresponding functions. Part 1107600_03 E 2014 Nordson Corporation...
Page 134 Setting IO — I‐O- CrL3 CrH3 20mA AOIt Table 6-8 Motor Drive CtL Menu Parameter Settings Settings Factory Customer Settings Factory Customer Parameter Parameter Menu Setting Setting Menu Setting Setting CtL — Ctl- CHCF E 2014 Nordson Corporation Part 1107600_03...
Page 135 JOG rPC — 10Hz Upd P1 StC 0.7 In 0.5s bLC AdC tdC1 0.5s 0.5s SdC1 0.7 In 1.1A 0 LSP tdC2 SdC2 0.5 In 0.8A 0.5s SA1 LC2 1.5 in Continued... Part 1107600_03 E 2014 Nordson Corporation...
Page 136 Settings Factory Customer Settings Factory Customer Parameter Parameter Menu Setting Setting Menu Setting Setting FLt FLt- 10Hz NOTE: Shaded parameters do not appear in on the display because of values set in corresponding functions. E 2014 Nordson Corporation Part 1107600_03...
Page 137 L14A L15A L16A AIA A11A A12A A13A NOTE: Shaded parameters do not appear in on the display because of values set in corresponding functions. Part 1107600_03 E 2014 Nordson Corporation...
Page 138: Calibrating The Pump Speed Display
If using a tachometer, enter the rpm value indicated by the tachometer. If not using a tachometer, enter a pump rpm value of 80. 5. Press the Pump mode key. Pump speed arrow keys Pump mode key and LED E 2014 Nordson Corporation Part 1107600_03...
Page 139: Pump Operational Status
Activation of a switched input (handgun or footswitch) Activation of the pump key Tables 6‐13 and 6‐14 provide the status of the pump LED for each combination of the pump operating variables. Pump speed arrow keys and display Part 1107600_03 E 2014 Nordson Corporation...
Page 140 “Off” means that the key was not pressed. B: If any of Parameters 30-39 are set to 3 or 11, then the remote motor input is assigned. E 2014 Nordson Corporation Part 1107600_03...
Page 141 Manual or Auto Enabled Present On/Off Manual or Auto Enabled Present Manual Enabled Present Manual or Auto NOTE A: If a remote motor input is assigned, then its status is described in this column. Part 1107600_03 E 2014 Nordson Corporation...
Page 142: Using The Troubleshooting Flowchart
Use of the chart assumes that the melter is installed correctly and that it is set up to support the current manufacturing process. Refer to Section 3, Installation, for information about installing and setting up the melter. Troubleshooting question and action blocks a) Question b) Action E 2014 Nordson Corporation Part 1107600_03...
Page 143: Troubleshooting Quick-Checks
Setup key and the right‐display scroll DOWN key, and then, while holding down these keys, cycle the melter control switch off and on. When the melter restarts, release the two keys. Restoring factory settings Part 1107600_03 E 2014 Nordson Corporation...
Page 144: Identifying Electrical Components
Hose/gun 1 heaters (6.3 A, 250 V, 5 x 20 mm) F9/F10 −− Hose/gun 2 heaters (6.3 A, 250 V, 5 x 20 mm) F11/F12 −− Motor start (6.3 A, 250 V, 5 x 20 mm) Continued... E 2014 Nordson Corporation Part 1107600_03...
Page 145 Optional outputs on I/O expansion card (refer to Installing Melter Outputs in Section 3, Installation) XT7-9 to XT7-20 Input Optional inputs on I/O expansion card (refer to Installing Melter Inputs in Section 3, Installation) Part 1107600_03 E 2014 Nordson Corporation...
Page 146 TRIG INPUT) on main back panel board Ribbon cable J1 on CPU board J1 on main board 1026662 NOTE A: Refer to Thermostat, Heaters, and RTDs in Section 7, Parts, for heater kit part numbers. E 2014 Nordson Corporation Part 1107600_03...
Page 147 Tank Heater (Left and Right) Thermostat (Center) Tank RTD (Bottom Right) Back Panel (Not Used) Pump RTD (Top) Pump Heater (Bottom) CPU Power CPU Failure (green) (red) Motor Contol (relay board or motor control terminal block assembly) Control Switch TP2 (+) TP4 (−) 4.75−5.25 VDC Motor...
Page 148 This page intentionally left blank.
Page 149: Altablue Troubleshooting Flowchart
AltaBlue Troubleshooting Flowchart No adhesive output from one or more guns Is the control panel illuminated? − Go to Start (melter in manual mode; motor speed dial not on 0) Do dashes appear in both Do the words UP LOAD Is the fault LED Is the ready LED the left and right display?
Page 151 Is there power on the plant Check/repair the plant side of the disconnect wiring. − switch that is serving the Control panel is not illuminated melter? Is the power disconnect Turn the disconnect switch switch that is serving the − melter turned on? Replace the main board.
Page 153 P/N 1031179 − board between 4.75 and P/N 1026662 5.25 VDC? See Figure 6‐4. Is the green power LED on Does changing the main Contact Nordson for the CPU board board correct the problem? technical assistance. − − illuminated? P/N 1078624 See Figure 6‐4.
Page 155 Record the fault codes Go to Go to indicated in both the left T.2.1 T.2.2 and right displays and then contact Nordson for technical assistance. Is the tank key LED Are all of the gun‐to‐hose Secure the electrical illuminated? and hose‐to‐melter connectors and then press −...
Page 157 T.2.1 Reset the melter and turn the heaters back on Fault LED is illuminated > F2 fault exists Is the tank key LED Is the affected gun or hose Are the hose or gun Does the fault reoccur if illuminated? cordset loose? (The tank or cordset pins bent, loose, or you move the faulting...
Page 159 T.2.2 Reset the melter and turn the heaters back on Fault LED is illuminated > Is more than one Is the tank LED Was the setpoint F3 fault exists component overheating? illuminated? temperature of the faulting − − − Go to (Check the actual hose/gun just reduced? T.2.4...
Page 161 Are the tank and pump Replace the main board. tank TRIACS functioning P/N 1078624 − properly? Are the tank and manifold Replace the malfunctioning Contact Nordson for RTDs functioning properly? RTD. technical assistance. − Tank ‐ P/N 1031234 Pump ‐ P/N 1031233...
Page 163 T.2.4 Does the fault clear if you Does the fault clear if you Have LEDs DS8/DS9 or switch the faulting replace just the hose or just DS12/DS13 on the main Fault LED is illuminated > − − − hose/gun pair to a known the gun RTD and then board stopped flashing? An F3 fault exists on a hose or gun >...
Page 165 Heater Specifications in Section 8 for resistance values. ? W ait for all components to Wait for the ready delay to The melter is in the Contact Nordson for reach setpoint count down. standby mode. technical assistance. temperature. Refer to Appendix B, Refer to Standby Key in parameter 4.
Page 167 Is the motor running? Is the pump key LED Is the pump key LED Is the pump key LED flashing yellow? illuminated yellow, but not illuminated green? Go to − − − flashing? T.4.3 − Press the pump key to Go to enable the pump.
Page 169 − box connected to the motor controller? Stop. Is the motor excessively Does swapping the main Contact Nordson for hot? board with a known good technical assistance. − − board correct the problem? Replace the pump.
Page 171 T.4.2 No faults > Is the tank empty? Is the pump input shaft Replace the turning? motor‐to‐pump coupling or Ready LED is illuminated > − − replace the shaft key. No hot melt output from all guns > Motor is turning Fill the tank.
Page 172 This page intentionally left blank.
Page 173 T.4.3 No faults > Is the motor (pump) speed Is the manual/gear‐to‐line Is the motor controller dial set to 0%? switch set to the power LED on or flashing? Ready LED is illuminated > − − − gear‐to‐line mode? No hot melt output from all guns > Motor is turning Place the manual/ Increase the motor (pump)
Page 174 This page intentionally left blank.
Page 175 T.4.4 No faults > Is the motor controller Is motor start relay ‐K6 Replace relay ‐K6. power LED flashing? energized? Ready LED is illuminated > Refer to Section 7, Parts. − − No hot melt output from all guns > Motor is turning Refer to Motor Control Replace the motor.
Page 176 This page intentionally left blank.
Page 177 Is the setpoint temperature Adjust the setpoint of the affected hose/gun temperature. No faults > − within the temperature Ready LED is illuminated > range recommended by No hot melt output from some guns the hot melt manufacturer? ? The heaters in the affected Is the melter set up for a Is the affected hose/gun at hose/gun may be turned off...
Page 178 This page intentionally left blank.
Page 179: Parts
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 part.
Page 180: Melter Assembly Part Number
G: Refer to Right Panel Assembly Parts. H: Refer to Control Module Parts. Refer to Voltage Module Parts. J: Refer to Section 3, Installation, for the contents of the ship‐with kit. Figure 7-1 Melter assemblies E 2014 Nordson Corporation Part 1107600_03...
Page 181: Unit Assembly Parts
‐ ‐ ‐ ‐ ‐ ‐ S CONDUIT,1.0", 1200"L, POLYAMIDE ‐ ‐ ‐ ‐ ‐ ‐ 1 ft S AMPLIFIER, CAPACITIVE PROBE, RECHNER ‐ ‐ ‐ ‐ ‐ ‐ (low‐level control box) Continued... Continued... Part 1107600_03 E 2014 Nordson Corporation...
Page 182 ‐ ‐ ‐ ‐ ‐ ‐ 6 in. S WASHER,LK,INT,M5,ZN 983127 S WIRE,GROUND,A4TP-IP54 ‐ ‐ ‐ ‐ ‐ ‐ S NUT,HEX,M6,STL,ZN 984703 S WASHER,FLT,M,REG,M6,STL,ZN 983029 S WASHER,LK,M,SPT,M6,STL,ZN 983409 S O-RING 11x2 VITON 250252 Continued... E 2014 Nordson Corporation Part 1107600_03...
Page 183 B: Refer to Low‐Level Control Box later in this section for the part number of this item. C: Used as needed to secure conduit (item 46). D: This cable is shipped separately. AR: As Required NS: Not Shown Part 1107600_03 E 2014 Nordson Corporation...
Page 184 Parts Unit Assembly Parts (contd) TORQUE 48-60 IN LBS TORQUE 48-54 IN LBS Figure 7-2 Unit assembly parts (1 of 9) E 2014 Nordson Corporation Part 1107600_03...
Page 185 Parts SEE DETAIL G DETAIL G DETAIL A DETAIL B Figure 7-3 Unit assembly parts (2 of 9) Part 1107600_03 E 2014 Nordson Corporation...
Page 186 Parts Unit Assembly Parts (contd) DETAIL F Figure 7-4 Unit assembly parts (3 of 9) E 2014 Nordson Corporation Part 1107600_03...
Page 187 Parts DETAIL E Figure 7-5 Unit assembly parts (4 of 9) Part 1107600_03 E 2014 Nordson Corporation...
Page 188 (ITEMS 54, 2, 77, 78, 79) WHITE WIRE BLUE WIRE BROWN WIRE RECHNER LEVEL CONTROL (ITEM 48) ( ITEM 20) CONDUIT (ITEM 46) SEE DETAIL D Figure 7-6 Unit assembly parts (5 of 9) E 2014 Nordson Corporation Part 1107600_03...
Page 189 7-11 Parts DETAIL J ( HEATER WIRES ) ( ITEM 105) (TANK RTD AND THERMOSTAT WIRES) DETAIL H Figure 7-7 Unit assembly parts (6 of 9) Part 1107600_03 E 2014 Nordson Corporation...
Page 190 7-12 Parts Unit Assembly Parts (contd) 55 77 78 79 Figure 7-8 Unit assembly parts (7 of 9) E 2014 Nordson Corporation Part 1107600_03...
Page 191 7-13 Parts WIRE TO BE INSTALLED FROM THE MAIN GROUND TOWER TO RIGHT SIDE DOOR PANEL BROWN WIRE BLUE WIRE (ITEM 48) Figure 7-9 Unit assembly parts (8 of 9) Part 1107600_03 E 2014 Nordson Corporation...
Page 192 7-14 Parts Unit Assembly Parts (contd) DETAIL M SIDE PANEL DETAIL K REAR PANEL Figure 7-10 Unit assembly parts (9 of 9) E 2014 Nordson Corporation Part 1107600_03...
Page 193: Base Assembly Parts
NOTE A: Refer to Left Panel Assembly Parts later in this section. B: Refer to Right Panel Assembly Parts later in this section. GASKET NOT SHOWN IN THIS VIEW Figure 7‐11 Base assembly parts Part 1107600_03 E 2014 Nordson Corporation...
Page 194: Pump, Manifold, And Drive Assembly Parts Lists
NOTE A: Refer to Drive Assembly Parts later in this section. B: This item is also included in service kit part 1063803. Refer to Recommended Spare Parts and Supplies later in this section for the kit contents. AR: As Required E 2014 Nordson Corporation Part 1107600_03...
Page 195 7-17 Parts TORQUE TO 12-13 FT/LBS Figure 7-12 Pump/manifold/drive module parts Part 1107600_03 E 2014 Nordson Corporation...
Page 196 D: This item is also included in service kit part 1063803. Refer to Recommended Spare Parts and Supplies later in this section for the kit contents. E: Refer to Manifold Parts later in this section. NS: Not Shown E 2014 Nordson Corporation Part 1107600_03...
Page 197 7-19 Parts .060 SPACE BETWEEN COUPLING JAWS .030 Figure 7-13 Drive assembly parts Part 1107600_03 E 2014 Nordson Corporation...
Page 198: Pump Parts
NOTE A: This item is also included in service kit part 1063803. Refer to Recommended Spare Parts and Supplies later in this section for the kit contents. NS: Not Shown 25 NSm (222 in.‐lb) Figure 7-14 Pump service kit parts E 2014 Nordson Corporation Part 1107600_03...
Page 199 7-21 Parts This page intentionally left blank. Part 1107600_03 E 2014 Nordson Corporation...
Page 200: Manifold Parts
S KEY,SWIVEL,LOCKING,H/F,1.250 IN HEX ‐ ‐ ‐ ‐ ‐ ‐ S ELL,PIPE,HYD,90,1/8,STL,ZN* 973126 S ADAPTER,PIPE,SAE,1/8,BRASS* 973565 NOTE A: To replace this item, order service kit part 1028305. B: To replace this item, order service kit part 1031221. E 2014 Nordson Corporation Part 1107600_03...
Page 201 7-23 Parts Figure 7-15 Manifold parts Part 1107600_03 E 2014 Nordson Corporation...
Page 202: Voltage Module Parts
‐ ‐ ‐ ‐ ‐ ‐ NOTE A: Refer to Thermostat, Heaters, and RTDs later in this section for part numbers. B: These caps are installed on the hose connector plugs. NS: Not Shown E 2014 Nordson Corporation Part 1107600_03...
Page 203 7-25 Parts ( NOT SHOWN ) Figure 7-16 Voltage module parts Part 1107600_03 E 2014 Nordson Corporation...
Page 204 ‐ ‐ ‐ ‐ ‐ ‐ NOTE A: Refer to Front Panel Assembly Parts later in this section. B: To replace this item, order service kit part 1104490. C: To replace this item, order service kit part 1081271. E 2014 Nordson Corporation Part 1107600_03...
Page 205 7-27 Parts Figure 7-17 Control module parts Part 1107600_03 E 2014 Nordson Corporation...
Page 206 S SCR,BTN,SKT,M4X8,ZN 982446 S NUT,HEX,M3,STL,ZN ‐ ‐ ‐ ‐ ‐ ‐ NOTE A: To replace this item, order service kit part 1028325. B: To replace this item, order service kit part 1099532. NS: Not Shown E 2014 Nordson Corporation Part 1107600_03...
Page 207 7-29 Parts Figure 7-18 Front panel assembly parts Part 1107600_03 E 2014 Nordson Corporation...
Page 208 3 yd S GUARD,WIRE MESH,FAN,80 MM X 80 MM 1080447 S COVER,BAFFLE,A4TP 1120245 S TRAY,CHIMNEY,A4TP 1120248 S SCREW,M5 X .08 X 10,BUTTON SOCKET 1068280 HD,SS S WASHER,LK,INT,M5,ZN 983127 S NUT,HEX,M5,SSTL 984751 NS: Not Shown E 2014 Nordson Corporation Part 1107600_03...
Page 209 7-31 Parts DIRECTION OF AIR FLOW ( PART OF ITEM 3 ) ( PART OF ITEM 3 ) Figure 7-19 Left panel assembly parts Part 1107600_03 E 2014 Nordson Corporation...
Page 210 S GASKET,SILICONE,STRIP‐N‐STICK .062X.50 1107456 0.85 YD S COVER,BAFFLE,A4TP 1120245 S SCR,SKT,M5X8,BL 982201 S WASHER,LK,INT,M5,ZN 983127 S NUT,HEX,M5,STL,ZN 984706 S TRAY,CHIMNEY,A4TP 1120248 S SCREW,M5 X .08 X 10,BUTTON SOCKET 1068280 HD,SS S WASHER,LK,INT,M5,ZN 983127 S NUT,HEX,M5,SSTL 984751 E 2014 Nordson Corporation Part 1107600_03...
Page 211 7-33 Parts ITEM NUMBER 7 ( GASKET ) NOT SHOWN IN THIS VIEW. Figure 7‐20 Right panel assembly parts Part 1107600_03 E 2014 Nordson Corporation...
Page 212: Circuit Boards And Motor Drive
‐ ‐ ‐ ‐ ‐ ‐ Service kit, RTD, tank — 1031234 — S Sensor assembly, RTD and thermostat ‐ ‐ ‐ ‐ ‐ ‐ NOTE All heater and RTD service kits include thermal compound. NS: Not Shown E 2014 Nordson Corporation Part 1107600_03...
Page 213: Cables And Harnesses
1091209 SENSOR, CAPACITIVE, M8/25, RECHNER, 1.1M (low-level probe) 1087922 AMPLIFIER, CAPACITIVE PROBE, RECHNER (low‐level control box) NOTE For the location of the control box, see Figure 7-4 earlier in this section. NS: Not Shown Part 1107600_03 E 2014 Nordson Corporation...
Page 214: Fuses
S Fuse, slow, 2 A, 250 VAC, 5 x 20 mm, F3−F4 939955 S Fuse, fast, 5 A, 250 VAC, 5 x 20 mm, F5−F6 1027144 S Fuse, 6.3 A, 250 VAC, 5 x 20 mm, F7−F12 939683 Figure 7-21 Fuse service kit parts E 2014 Nordson Corporation Part 1107600_03...
Page 215: Recommend Spare Parts And Supplies
All items in this parts list are recommended spare parts. 221696 RELAY,24VDC 1085183 MEMBRANE PANEL MOTOR CONTROL,STD ALTA 1078085 MEMBRANE PANEL,ALTABLUE,4,10,16 FAN W/TERMINALS,3.15 X 3.15 X 1.00, 230V 1079543 FILTER ASSY,FAN,80MM X 80MM 1080365 Part 1107600_03 E 2014 Nordson Corporation...
Page 216 7-38 Parts E 2014 Nordson Corporation Part 1107600_03...
Page 217: Technical Data
180-264 VAC Frequency 50/60 Hz Hose/gun heating capacity 2 hose/gun pairs 40 to 230 C (100 to 450 F) Control temperature range .5 C ( 1 F) Control temperature accuracy IP rating IP 54 Part 1107600_03 E 2014 Nordson Corporation...
Page 218: Heater Specifications
Melter with filter Up to 35 kg/hr: 75 bar (1100 psi) Single-stream: Displacement 7.73 cc/rev (35 kg/hr) Pump speed Up to 35 kg: 80 rpm NOTE A: Displacement per hour shown at 80 rpm motor speed. E 2014 Nordson Corporation Part 1107600_03...
Page 219: Dimensions
Technical Data Dimensions A4 Melter 899.67 mm (35.42 in.) 280.67 mm (11.05 in.) 639.57 mm (25.18 in.) 30.23 mm 31.24 mm (1.19 in.) (1.23 in.) 362.97 mm (14.29 in.) A4 melter dimensions Figure 8‐1 Part 1107600_03 E 2014 Nordson Corporation...
Page 220: Conduit Penetration Sizes
Technical Data Conduit Penetration Sizes PG-16 1/2 NPT PG16 PG-21 Conduit penetration sizes (melter bottom panel shown) Figure 8‐2 Wiring Diagram A wiring diagram is provided on the following pages for your reference as needed. E 2014 Nordson Corporation Part 1107600_03...
Page 221 Technical Data Figure 8‐3 Wiring diagram (1 of 12) Part 1107600_03 E 2014 Nordson Corporation...
Page 222 Technical Data Figure 8‐4 Wiring diagram (2 of 12) E 2014 Nordson Corporation Part 1107600_03...
Page 223 Technical Data Figure 8‐5 Wiring diagram (3 of 12) Part 1107600_03 E 2014 Nordson Corporation...
Page 224 Technical Data Figure 8‐6 Wiring diagram (4 of 12) E 2014 Nordson Corporation Part 1107600_03...
Page 225 Technical Data Figure 8‐7 Wiring diagram (5 of 12) Part 1107600_03 E 2014 Nordson Corporation...
Page 226 8-10 Technical Data Figure 8‐8 Wiring diagram (6 of 12) E 2014 Nordson Corporation Part 1107600_03...
Page 227 8-11 Technical Data Figure 8‐9 Wiring diagram (7 of 12) Part 1107600_03 E 2014 Nordson Corporation...
Page 228 8-12 Technical Data Figure 8‐10 Wiring diagram (8 of 12) E 2014 Nordson Corporation Part 1107600_03...
Page 229 8-13 Technical Data Figure 8‐11 Wiring diagram (9 of 12) Part 1107600_03 E 2014 Nordson Corporation...
Page 230 8-14 Technical Data Figure 8‐12 Wiring diagram (10 of 12) E 2014 Nordson Corporation Part 1107600_03...
Page 231 8-15 Technical Data Figure 8‐13 Wiring diagram (11 of 12) Part 1107600_03 E 2014 Nordson Corporation...
Page 232 8-16 Technical Data Figure 8‐14 Wiring diagram (12 of 12) E 2014 Nordson Corporation Part 1107600_03...
Page 233: Calculating Melter Power Requirements
Two hose/gun pair maximum—The combined wattage of hose/gun pairs 1 and 2 If your Nordson representative has already calculated the hose/gun power requirements and confirmed that the maximum allowable wattages will not be exceeded, then no further calculation is necessary. However, you should re‐evaluate the hose and gun power requirements before you:...
Page 234 Table A‐2, then the configuration or position of the hose/gun pairs must be rearranged, shorter hoses must be used, or lower power guns must be used in order to reduce the power requirement. E 2014 Nordson Corporation Part 1107600_03...
Page 235 Table A‐2 Maximum Allowable Hose/Gun Wattages Column in Component Maximum Wattage Table A-1 Any single hose or gun 1000 W Any hose/gun pair 1200 W Sum of hose/gun pairs 1 and 2 2000 W Part 1107600_03 E 2014 Nordson Corporation...
Page 236 Calculating Melter Power Requirements E 2014 Nordson Corporation Part 1107600_03...
Page 237 42 to 46 Configure the standard and optional outputs Seven-day Clock 50 to 77 Configure the clock feature Automatic Fill Timer Configure the external motor control switch PID Selection 80 to 91 Configure the PID settings Part 1107600_03 E 2014 Nordson Corporation...
Page 238: Operating Parameters
F1, F2, F3, and F4 Use: Use the right-display scroll keys to review the log entries for the last ten faults. Empty log entries are indicated by “_-F0.” Refer to Monitoring the Melter in Section 4, Operation. E 2014 Nordson Corporation Part 1107600_03...
Page 239 The service LED will turn on after the pre-set time elapses. With the melter in the scan mode, press the Clear/Reset key to turn off the service LED and reset the time. Part 1107600_03 E 2014 Nordson Corporation...
Page 240 If Automatic Pump On is enabled and the pump is enabled, the pump will turn on automatically when the melter is ready. NOTE: If Automatic Pump On is disabled (0) while the pump is running, the pump will remain on until the pump key is pressed. E 2014 Nordson Corporation Part 1107600_03...
Page 241 Format: — Use: Use only when a Nordson manifold-mounted electric gun is installed and a switching device is connected to the melter’s switch receptacle. Refer to the electric gun manual for information on mounting and using the gun. Part 1107600_03...
Page 242 Format: — Use: Use only when a Nordson manifold-mounted electric gun is installed and a switching device is connected to the melter’s switch receptacle. Refer to the electric gun manual for information on mounting and using the gun. External Communications Lock-out Description: Used as a safety feature when performing maintenance on the melter.
Page 243: Pressure Control
— Default Value: Format: — Use: This parameter is available only when the optional analog I/O board is installed on the melter. Refer to Section 7, Parts, for the I/O board kit part number. Part 1107600_03 E 2014 Nordson Corporation...
Page 244: Temperature Control
The number of degrees that the temperature of any component can decrease from its setpoint temperature before an under temperature fault (F2) occurs. Value: 5 _C (10 _F) to 60 _C (110 _F) Resolution: Default Value: 25 _C (50 _F) Format: — Use: — E 2014 Nordson Corporation Part 1107600_03...
Page 245 (parameter 24) before the heaters turn off. Value: 0 to 1440 minutes (24 hours) Resolution: 1 minute Default Value: 0 (disabled) Format: — Use: Set parameter 24 (automatic standby timeout) to the desired value before setting parameter 25. Part 1107600_03 E 2014 Nordson Corporation...
Page 246 This parameter functions like parameter 23 except when it is set to 0, in which case it reverts to the setting for parameter 23. NOTE: The standby delta does not affect the under temperature delta (parameter 22). E 2014 Nordson Corporation Part 1107600_03...
Page 247 Default Value: Format: — Use: Melter internal zones are designated as follows: DuraBlue D10/D16: primary=tank; secondary=pump DuraBlue D4L/D10L/D16L: primary=tank; secondary=pump AltaBlue TT: primary=tank; secondary=pump DuraBlue 25/50/100: primary=grid; secondary=reservoir AltaBlue 15/30/50/100: primary=grid; secondary=reservoir DuraDrum: primary=platen; secondary=pump Part 1107600_03 E 2014 Nordson Corporation...
Page 248: Input Setup
NOTE: Parameter 78, Automatic Fill Timer, must be set to a value of 1 or greater in order to use option 13 or 14. Output option 6, Alert, can be used to signal when the Automatic Fill Timer expires. E 2014 Nordson Corporation Part 1107600_03...
Page 249 NOTE: Parameter 78, Automatic Fill Timer, must be set to a value of 1 or greater in order to use option 13 or 14. Output option 6, Alert, can be used to signal when the Automatic Fill Timer expires. Part 1107600_03 E 2014 Nordson Corporation...
Page 250: Output Setup
If the potential fault condition clears before the end of the two minute period, the output signal ends. Refer to Section 4, Operation, Monitor Melter Faults, for information about fault monitoring. E 2014 Nordson Corporation Part 1107600_03...
Page 251 B-15 Operating Parameters This page intentionally left blank. Part 1107600_03 E 2014 Nordson Corporation...
Page 252: Seven-Day Clock
71 through 77 is schedule 0, which has no time values assigned to it. With the default set to sched- ule 0, unintentionally pressing the clock key will have no affect on the melter. E 2014 Nordson Corporation Part 1107600_03...
Page 253: Example 1
1600 at the end of the day, every day of the week: Par 55 = 0600 Par 56 = 1600 Par 57 = 1130 Par 58 = 1230 Par 71 through 75 = 1 Par 71 and 77 = 1 Part 1107600_03 E 2014 Nordson Corporation...
Page 254 Resolution: 1 minute Default Value: 1700 Format: Hours, Hour: Minute, Minute Use: To disable this parameter, set the parameter’s value to “- - - -” by simultaneously pressing both of the right-display scroll keys. E 2014 Nordson Corporation Part 1107600_03...
Page 255 Hours, Hour: Minute, Minute Use: Set the desired time for the heaters to turn on. To disable this parameter, set the parameter’s value to “- - - -” by simultaneously pressing both of the right-display scroll keys. Part 1107600_03 E 2014 Nordson Corporation...
Page 256 Note: Do not set an exit standby time that is outside of the time period defined by the schedule’s heater on and off time. The melter cannot enter the standby mode when the heaters are off. E 2014 Nordson Corporation Part 1107600_03...
Page 257 Note: Do not set an enter standby time that is outside of the time period defined by the schedule’s heater on and off time. The melter cannot enter the standby mode when the heaters are off. Part 1107600_03 E 2014 Nordson Corporation...
Page 258 Default Value: Format: — Use: Selects the active schedule(s) for the day. NOTES: If the 0 schedule option is used, the heaters will not turn on again until the next scheduled heaters on time arrives. E 2014 Nordson Corporation Part 1107600_03...
Page 259 Default Value: Format: — Use: Selects the active schedule(s) for the day. NOTES: If the 0 schedule option is used, the heaters will not turn on again until the next scheduled heaters on time arrives. Part 1107600_03 E 2014 Nordson Corporation...
Page 260 Default Value: Format: — Use: Selects the active schedule(s) for the day. NOTES: If the 0 schedule option is used, the heaters will not turn on again until the next scheduled heaters on time arrives. E 2014 Nordson Corporation Part 1107600_03...
Page 261 Default Value: Format: — Use: Selects the active schedule(s) for the day. NOTES: If the 0 schedule option is used, the heaters will not turn on again until the next scheduled heaters on time arrives. Part 1107600_03 E 2014 Nordson Corporation...
Page 262: Automatic Fill Timer
0 or 1 depending on the channel type (hose or gun) Format: — Use: Consult your Nordson representative before changing PID settings. PID Selection for Hose/Gun Receptacles 5, 6, 7, 88 - 91 and 8 (DuraBlue D25, D50, and D100 melters only) Description: Used to change the preset PID selections.
Page 263: Melter Communications
Melter Communications Appendix Melter Communications This appendix describes the installation and use of the Nordson Configuration Manager (NCM) communications utility. With this utility you can: transfer operating parameters and temperature setpoints between melters upgrade or reload your melter's firmware Software Availability If you do not already have the NCM utility, you can download it from the internet by navigating to www.enordson.com/support.
Page 264: Installing The Software
When the installation file is executed, an installation wizard will detect your operating system and start the installation routine. NOTE: Installing the NCM for the first time also installs the latest version of the melter's firmware. E 2014 Nordson Corporation Part 1107600_03...
Page 265 (2 through 5) as required by your operating system. NOTE: When prompted to select an installation location, Nordson Corporation recommends that you select the default location offered.
Page 266: Removing The Software From Your Pc
1. From the Windows Start menu, select Settings > Control Panel, and then double‐click Add/Remove Programs. The Add/Remove Programs dialog box appears. 2. Select Blue Series Software from the list, and then click Remove. E 2014 Nordson Corporation Part 1107600_03...
Page 267: Connecting The Pc And The Melter
CPU Power CPU Failure (green) (red) TP2 (+) TP4 (−) 4.75−5.25 VDC CPU Board (B22) Figure C‐1 Location of J3 on the CPU/display board (I/O expansion card not shown for clarity) Part 1107600_03 E 2014 Nordson Corporation...
Page 268: Using Nordson Configuration Manager
Melter Communications Using Nordson Configuration Manager Configuration Manager is launched from your Windows desktop using the icon shown to the left. Use Configuration Manager when you want to... Configuration Manager copy melter settings from one melter to another melter desktop icon...
Page 269 6. Click Save Settings. The Save As dialog box appears. NOTE: The default location for saving settings files is Windows My Documents folder. To avoid loosing saved settings files, Nordson Corporation recommends that you do not change the default save location.
Page 270: Upgrading Or Restoring Melter Firmware
3. Double‐click the NCM icon on the Windows desktop. The NCM dialog box appears. 4. Click Select. The device dialog box appears. 5. Select your melter from the list, and then click Ok. The Select COM Port dialog box appears. E 2014 Nordson Corporation Part 1107600_03...
Page 271 To close the NCM, click Exit. To restore melter settings other than the settings that were in use by the melter before the upgrade, go to Saving and Restoring Melter Settings earlier in this guide. Part 1107600_03 E 2014 Nordson Corporation...
Page 272 The right side of the status area indicates “CONNECTED”. 4. Click Restore Pre‐Upgrade Settings. The pre‐upgrade settings are restored and the melter returns to the scan mode. 5. Click Exit to close the NCM. E 2014 Nordson Corporation Part 1107600_03...
Page 273: Troubleshooting
C-11 Melter Communications Troubleshooting Using Nordson Configuration Manager Symptom/Message Action After selecting a device and the COM port, an Access Denied PC-to-Blue communications may be running or another message appears. application may be using the COM port. Close Internet Explorer and end the communications connection (if prompted).
Page 274 C-12 Melter Communications E 2014 Nordson Corporation Part 1107600_03...
Page 275 The product specified conforms to the directives and standards described above. Technical File Contact: Dieter Ziesmer Nordson Engineering GmbH Gregory P. Merk, Senior Vice President Lilienthalstrasse 6 Adhesives Dispensing Systems 21337 Lueneburg GERMANY Date: 20 March 2014 Nordson Corporation S 28601 Clemens Road S Westlake, Ohio 1105311A05 DOC074R6...

Nordson AltaBlueA4TP Customer Product Manual

Safety

Description

Installation

Operation

Maintenance

Troubleshooting

Parts

Technical Data

Calculating Melter Power Requirements

Operating Parameters

Melter Communications

Quick Links

Troubleshooting

Need help?

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Summary of Contents for Nordson AltaBlueA4TP

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