Nordson Mesa Fulfill Customer Product Manual
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Nordson Mesa Fulfill Customer Product Manual

Nordson Mesa Fulfill Customer Product Manual

Retrofit for mesa melters
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ATTENTION
Please refer to the Appendix if your unit was manufactured after May 2013. This information is found in the
serial code of your unit; for example, SA13EXXXXX, where "E" represents the date code "May," or any se­
quential letter after "E."
Fulfill
This document contains important safety information
Be sure to read and follow all safety information in this
document and any other related documentation.
: Information on a new control box, PCA and level sensor is included in Appendix A.
NORDSON CORPORATION  DULUTH, GEORGIA  USA
www.nordson.com
Retrofit for Mesat Melters
Customer Product Manual
Part 1121938_02
Issued 5/13

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Summary of Contents for Nordson Mesa Fulfill

  • Page 1 Please refer to the Appendix if your unit was manufactured after May 2013. This information is found in the serial code of your unit; for example, SA13EXXXXX, where “E” represents the date code “May,” or any se­ quential letter after “E.” 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, Get Green With Blue, G‐Net, G‐Site, IntelliJet, iON, Iso‐Flex, iTrend, Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros, MiniEdge, Minimeter, Multifill, MultiScan, Myritex, Nano, NexJet, OmniScan, OptiMix, OptiStroke,...

  • Page 3: Table Of Contents

    ........Part 1121938_02 E 2013 Nordson Corporation...
  • Page 4 ..........RetroFit Refill System with Nordson Level Sensor .

  • Page 5: Fulfill Retrofit For Mesat Melters

    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. Part 1121938_02 E 2013 Nordson Corporation...

  • Page 6: 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. E 2013 Nordson Corporation Part 1121938_02...

  • Page 7: 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. Part 1121938_02 E 2013 Nordson Corporation...

  • Page 8: 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 9: 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 10: 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. E 2013 Nordson Corporation Part 1121938_02...

  • Page 11: General Safety Warnings And Cautions

    General Safety Warnings and Cautions Table 1 contains the general safety warnings and cautions that apply to Nordson hot melt and cold adhesive equipment. Review the table and carefully read all of the warnings or cautions that apply to the type of equipment described in this manual.
  • Page 12 WARNING! Risk of fire or explosion! Nordson adhesive equipment is not rated for use in explosive environments and has not been cerfified for the ATEX directive or as nonincendive. In addition, this equipment should not be used with solvent‐based adhesives that can create an...
  • Page 13 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 14: 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. E 2013 Nordson Corporation Part 1121938_02...

  • Page 15: Safety Labels And Tags

    Figure 1 Safety labels and tags Table 2 Safety Labels and Tags Item Part Description 1021984 WARNING! Hazardous voltage. Disconnect all power supply connections before servicing. Part 1121938_02 E 2013 Nordson Corporation...

  • Page 16: Description

    Fulfill Retrofit for Mesat Melters Description The Mesa Fulfill Retrofit Kit converts a Mesa melter into an automatic fill system that maintains adhesive in the melter, improving productivity and reducing maintenance. The retrofit kit adds adhesive to the sealed tank, reducing the possibility of char, contaminants, thermal shock and incorrect adhesive temperatures that result in poor adhesive bonding.

  • Page 17: Theory Of Operation

     Fulfill Retrofit for Mesat Melters Theory of Operation NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated information. Overview The system adds small quantities of adhesive to the sealed tank at regular intervals, reducing the possibility of adhesive char, contaminants, thermal shock and incorrect adhesive temperatures that result in poor bonding.

  • Page 18: Adhesive Storage Bin

     Fulfill Retrofit for Mesat Melters Pneumatic & Mechanical Components Refer to Figure 3 as you learn about the components of the Mesa Fulfill retrofit assembly. Figure 3 Assembled Mesa Fulfill retrofit assembly. (1). Adhesive Storage Bin Place adhesive in the adhesive storage bin. The bin contains a gasket that prevents debris from entering the bin.

  • Page 19: Suction Lance

    The thumb screws mount the lid to the melter. The thumbscrews can be replaced by Allen head screws supplied in the ship with kit. Do not remove the lid during operation, unless the system is disabled by turning power off at the control box. Part 1121938_02 E 2013 Nordson Corporation...

  • Page 20: Membrane Panel

     Fulfill Retrofit for Mesat Melters Electrical Components NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated information. (6). Control Box The control box contains the membrane panel and PCA. It connects to the melter via the supplied bracket. An optional remote mount kit is available to mount the control box away from the melter.

  • Page 21: Pca

     Fulfill Retrofit for Mesat Melters NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated information. See Figure 5. The PCA is inside the control box: Figure 5 PCA board (located inside the control box) Connect line voltage to the control box at the supplied terminal block and ground.

  • Page 22: Sensor (Not Shown)

    NOTE: The fault outputs will engage simultaneously. (7). Sensor (Not Shown) NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated information. The level sensor detects the level of adhesive in the melter tank. When the adhesive falls below the set point, the level sensor sends a signal to the Fulfill control box.

  • Page 23: Installation

    CAUTION! Remove dirt and debris from the melter before proceeding with these procedures. 6. See Figure 7. Remove the five screws that secure the pump/lid support bracket, and then remove the bracket. Set the screws aside for reassembly. Part 1121938_02 E 2013 Nordson Corporation...

  • Page 24: Install The Control Box

    M5 x 25 screws provided in the ship with kit. 4. Anchor the solenoid cable to the left side of the melter with the wire tie and anchor provided. Figure 8 Install the Fulfill control box onto the melter E 2013 Nordson Corporation Part 1121938_02...
  • Page 25 6. Secure the provided anchor to the rear of the Mesa melter above the manifold. 7. Route the ground wire through the anchor. 8. See Figure 10. Route the ground wire around the manifold and into the interior of the Mesa melter. Part 1121938_02 E 2013 Nordson Corporation...
  • Page 26 10. Attach the right side panel with the five screws previously removed. 11. See Figure 11. Thread a customer supplied, 14-18 AWG power cord into the control box. 12. Connect the power wiring to the terminal blocks in the control box. E 2013 Nordson Corporation Part 1121938_02...
  • Page 27 Figure 11 Connect the customer‐supplied power cord to the control box 1. L1-L2/N wire power cord connection 3. Power cord strain relief (interchangeable) 2. Ground wire power cord connection 13. Tighten the strain relief. Part 1121938_02 E 2013 Nordson Corporation...

  • Page 28: Install The Tank Lid Components

    4. Place the Fulfill lid assembly (6) onto the top of the melter. 5. Secure the lid by screwing the thumb screws on top of the lid into the threaded holes in the lid support (2). E 2013 Nordson Corporation Part 1121938_02...

  • Page 29: Assemble The Transfer Hose, Air Line, And Suction Lance

    Connect plant air to the regulator. For best results, run the air piping from the main header. Figure 13 Assembling the transfer hose, air line, and suction lance Part 1121938_02 E 2013 Nordson Corporation...

  • Page 30: Level Sensor Adjustment And Calibration

    Fulfill Retrofit for Mesat Melters Level Sensor Adjustment and Calibration NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated information. The level sensor consists of a level probe and a control box. The level probe permanently connects to the control box by a wire.

  • Page 31: Baseline Setting

    Fulfill Retrofit for Mesat Melters Baseline Setting NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated information. Upon setting the probe's height, calibrate the level sensor. 1. Remove the threaded plug on the front face of the level sensor control box to reveal the adjustment potentiometer.

  • Page 32: Operation

    Fulfill Retrofit for Mesat Melters Operation NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated information. Once enabled, the fill system immediately begins operation. Maintain adhesive level in the storage bin to maintain automatic operation.

  • Page 33: Monitoring Refill Operation

    Inspect the system daily to ensure that hose fittings are secure and that the unit is free from dirt and debris. Inspect the filter sock weekly to ensure that it's not clogged; replace as needed. Part 1121938_02 E 2013 Nordson Corporation...

  • Page 34: Troubleshooting

     Fulfill Retrofit for Mesat Melters Troubleshooting NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated information. Problem Possible Cause Corrective Action Solenoid stuck open Clean or replace. System overfilled Sensor ground wire not connected Connect.

  • Page 35: Refill Pca Troubleshooting Diagnostic Instructions

    Fulfill Retrofit for Mesat Melters Refill PCA Troubleshooting Diagnostic Instructions NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated information. Perform the following steps, in order, to either isolate the problem within the PCA board or to eliminate the PCA board as a cause. These tests should only be performed by personnel qualified to work on high voltage circuits.

  • Page 36: 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.

  • Page 37: Mesa Retrofit Kit Assemblies

    1101882 Kit, Fulfill retrofit, Mesa 9 ------- 1101883 Kit, Fulfill retrofit, Mesa 14 1101838 S Control box / reg.assy,Mesa Fulfill 1101214 S Lid assy, Mesa 4, Fulfill retrofit 1101215 S Lid assy, Mesa 6, Fulfill retrofit 1101216 S Lid assy, Mesa 9, Fulfill retrofit...

  • Page 38: Lid Assembly Parts

    S Scr, skt, M4X14, bl 1098021 S Knob, black plastic with M5 X 30 lg stud 983408 S Washer, flt, M, narrow, M5, stl, zn 940073 S O ring, Viton, .145ID X .070W .BR, 10407 NS: Not Shown E 2013 Nordson Corporation Part 1121938_02...
  • Page 39  Fulfill Retrofit for Mesat Melters Figure 17 Lid assembly parts Part 1121938_02 E 2013 Nordson Corporation...

  • Page 40: Control Assembly With Bracket

    306005 S Wire mount, cable strap, 4 way 939110 S Cabletie, 3.9 in., nylon 1101099 S Harness assy, solenoid, 3.5 ft NOTE A: Parts for the control box are provided later in this section. E 2013 Nordson Corporation Part 1121938_02...
  • Page 41  Fulfill Retrofit for Mesat Melters Figure 18 Control assy. with bracket parts Part 1121938_02 E 2013 Nordson Corporation...

  • Page 42: Control Box Assembly

    S Scr, skt, hd, M3x20 mm, steel, zn 1096221 S PCA, refill controller 1098484 S Domeplug, .750 in.D, .250 in. pnl thk 1046998 S Connector, strain relief, PG7, nylon 933607 S Connector, strain relief ,PG11 1098475 S Harness, AC power E 2013 Nordson Corporation Part 1121938_02...
  • Page 43  Fulfill Retrofit for Mesat Melters Figure 19 Control box assembly Part 1121938_02 E 2013 Nordson Corporation...

  • Page 44: Container/Wand Kit

    1095965 Tubing, 10mm X 8mm, nylon, 15 ft 1095983 Cable tie, 14.5 ,nylon 6.6, 4.0 bundle 231362 Clamp, hose, worm dr, 1.06−2 in., ss 939955 Fuse, time−lag, 2A, 5X20 mm, ceramic 1099544 Gasket, container E 2013 Nordson Corporation Part 1121938_02...

  • Page 45: Specifications

    Pump Type Venturi Noise Emission 76 dBA Suction Lance Dimensions (L) 615 mm x max (W) 105 mm (24.21 in. x max 4.14 in.) Storage Bin Capacity 60 Kg (132 lb) Enclosure rating IP54 Part 1121938_02 E 2013 Nordson Corporation...

  • Page 46: Wiring Diagram

     Fulfill Retrofit for Mesat Melters Wiring Diagram E 2013 Nordson Corporation Part 1121938_02...

  • Page 47: Dimensions

     Fulfill Retrofit for Mesat Melters Dimensions Part 1121938_02 E 2013 Nordson Corporation...
  • Page 48  Fulfill Retrofit for Mesat Melters E 2013 Nordson Corporation Part 1121938_02...

  • Page 49: Retrofit Refill System With Nordson Level Sensor

    Wide Sensing Area The Nordson level sensor has a wide sensing range that is the nearly equal to the length of the sensor rod. The fill control point can be adjusted electronically without the need to mechanically move the sensor.

  • Page 50: Push Button Calibration

    RetroFit Refill System with Nordson Level Sensor Push Button Calibration The Nordson level sensor uses two push buttons to set levels as opposed to the previous level sensor’s potentiometer. Two buttons on the Refill board provide two types of calibration. Information on calibration can be found later in this section.

  • Page 51: Unit Features

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

  • Page 52: Delay Timer

    RetroFit Refill System with Nordson Level Sensor Unit Features(contd) The picture shows the major components of the RetroFit control box. 24VDC power supply Siren Refill PCA Figure A‐2 Control box Delay Timer The delay timer determines how long the Refill board waits when the sensor calls for adhesive before the vacuum system is activated.

  • Page 53: Status Relay Contact Output

    RetroFit Refill System with Nordson Level Sensor Status Relay Contact Output A form­C electromechanical relay contact output is available for to monitor the fill system status. This relay provides a common (COM), normally closed (NC), and normally open (NO) potential free contact. These contacts are labeled COM, NC, and NO on the PCB and are located at terminal block TB3.

  • Page 54: Configuration Switch

    RetroFit Refill System with Nordson Level Sensor Configuration Switch The configuration switches are used to set various system modes. Refer to the following table for the configuration switch settings on your unit. Melter Configuration Switch Settings Switch 1 Switch 2...
  • Page 55 RetroFit Refill System with Nordson Level Sensor Figure A‐4 shows the features of the Refill PCA. Fill low Status LED Power LED Configuration switches Full calibration button Empty calibration button Overfill fault Delay timer potentiometer potentiometer Unit Low LED Vibrator LED...

  • Page 56: Sensor Calibration

    RetroFit Refill System with Nordson Level Sensor Sensor Calibration The following sections will describe the various methods available to calibrate the level sensor. For all calibrations, the button(s) must be held for 5 seconds in order to be recognized. For best results, the unit should be at application temperature when calibration is performed.

  • Page 57: Basic (Empty Level) Calibration

    RetroFit Refill System with Nordson Level Sensor Basic (Empty Level) Calibration CAUTION! Do not attempt empty calibration with a full melter. Doing so will result in an overfill condition. 1. Allow tank to reach application temperature. 2. Adhesive level should be at or below the bottom of the probe.

  • Page 58: Troubleshooting

    A-10 RetroFit Refill System with Nordson Level Sensor Troubleshooting Fault LED/Red Status LED The diagnostic fault messages (red flashes) for the STATUS LED (DS3, located on Refill PCA) are listed below. These flash codes are also performed on the FAULT LED located on the membrane panel.

  • Page 59: Fill Enable Led/Yellow Status Led/Yellow Light Tower

    A-11 RetroFit Refill System with Nordson Level Sensor Fill Enable LED/Yellow Status LED/Yellow Light Tower The table below lists the diagnostic warning (yellow flashes) messages for the STATUS LED (DS3, located on Refill PCA). These flash codes are also shown on the FILL ENABLE LED located on the membrane panel.

  • Page 60: Installation

    Description 1121799 Kit, service, power cable, MKIII PB FF Retrofit 1121800 Kit, service, power supply, Fulfill 1121802 Kit, service, Nordson sensor, 150 mm, Fulfill retrofit 1121804 Kit, service, PCA, MKIII Fulfill 1121406 Harness, Line in, Retrofit 1121491 Harness, 24 VDC, Retrofit...

  • Page 61: Retrofit Wiring Diagram

    A-13 RetroFit Refill System with Nordson Level Sensor Retrofit Wiring Diagram Part 1121938_02 E 2013 Nordson Corporation...
  • Page 62 A-14 RetroFit Refill System with Nordson Level Sensor This page intentionally left blank. E 2013 Nordson Corporation Part 1121938_02...
  • Page 63 The product specified conforms to the directives and standards described above. Technical File Contact: Dieter Ziesmer Nordson Engineering GmbH Peter Lambert, Senior Vice President Lilienthalstrasse 6 Adhesives Dispensing Systems 21337 Lueneburg GERMANY Date: 14 December 2012 Nordson Corporation S 28601 Clemens Road S Westlake, Ohio 1105311A03 DOC074R4...

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