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Nordson AltaBlue User Manual
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AltaBlue™ Touch Adhesive Melters
Customer Product Manual
Part 1120130A03
Issued 3/12
NORDSON CORPORATION
DULUTH, GEORGIA
USA
www.nordson.com
This document contains important safety information
Be sure to read and follow all safety information in this
document and any other related documentation.
2
Table of Contents
Default Chapter
3
Table of Contents
3
Safety
10
Safety Alert Symbols
10
Responsibilities of the Equipment Owner
11
Safety Information
11
Instructions, Requirements, and Standards
11
User Qualifications
12
Applicable Industry Safety Practices
12
Intended Use of the Equipment
12
Instructions and Safety Messages
13
Installation Practices
13
Operating Practices
13
Maintenance and Repair Practices
14
Equipment Safety Information
14
Equipment Shutdown
15
Relieving System Hydraulic Pressure
15
De-Energizing the System
15
Disabling the Applicators
15
General Safety Warnings and Cautions
16
Other Safety Precautions
19
First Aid
19
Safety Labels and Tags
20
Introduction
23
Intended Use
23
Electromagnetic Compatibility (EMC)
23
Examples of Unintended Use
24
Residual Risks
24
Key Components
25
Electrical Components
26
Pump Shut-Off Valve
27
Pressure Control Valves
27
Modes of Operation
28
Heating and Heaters off (Normal Mode)
28
Standby
28
Fault
28
Gear-To-Line Capability
28
Melter Identification
29
Hardware Installation and Setup
32
Overview
32
Additional Information
32
Installation Tasks
33
Experience of Installation Personnel
33
Installation Requirements
33
Clearances
33
Ventilation
37
Electrical Power
37
Pump Drive Internal Filter
38
Other Considerations
38
Unpacking the Melter
39
Moving the Unpacked Melter
39
Contents of the Installation Kit
39
Customer-Supplied Materials
39
Configuring the Electrical Service
41
Residual Current Circuit Breakers
41
Connecting the Electrical Service
41
Connecting Hoses and Applicators
43
To Connect Hoses
43
To Connect Applicators
49
Connecting and Programing the Pump for Remote Control
55
Wiring
55
Programming
55
Installing Optional Equipment
57
Connecting a Applicator Driver, Pattern Controller, or Timer
57
Flushing the Melter
57
Disposing of Melter
57
About the Touch Screen Display and User Interface
59
Overview
59
Starting the Melter for the First Time
59
What's Next
59
Navigating the Touch Screen Displays
60
About the Main Display
60
Accessing the Main Display
60
About the Monitor Display
61
Accessing the Monitor Display
61
What the Monitor Display Status Colors Indicate
62
About the Operator Display
63
State and Status Indicators from the Operator Display
64
Zone and Pump State Color Indicators
64
Zone and Pump Status Color Indicators
64
Master Control Color Indicators
65
About the Settings Display
65
Accessing the Settings Display
65
About the System Primary Display
67
Accessing the System Display
67
Operating the Melter
70
Introduction
70
Starting the Melter
70
Filling the Reservoir
71
Operating Zones
71
Operating Pumps
73
Adjusting Pump RPM in Manual Mode
74
Adjusting Pump RPM in Geartoline Mode
75
Using the Master Controls
75
Performing Advanced System Operations
77
Running a System Diagnostic
77
Reverting Back to Factory Settings
77
Resetting the Password
77
6-1
79
Configuring and Modifying Temperature, Pump and Melter Settings
79
Overview
79
Manage Temperature Settings
81
Manage Pump Settings
82
Managing System Settings
83
Service
88
Relieving System Pressure
88
Through the Applicators
88
Through the Melter Drain Valves
89
Preventive Maintenance Schedule
90
Locking out the Motor Drives
91
External Cleaning
91
Changing the Material Type
92
Detaching the Exterior Panels
92
Fan and Air Filter
92
Motor and Gear Box
93
Changing the Motor Lubricant
93
Lubricant Changing Interval
93
Lubricant Capacity
93
Lubricant Selection
93
Replacing a Motor or Coupling
94
Pump
96
Tightening the Pump Screws
96
Tightening the Pump Gland Bolt
97
Replacing a Pump
98
Filter Cartridge
102
To Replace the Filter Cartridge
102
Filter Service Kit
103
Pressure Control Valve
104
To Replace the Pressure Control Valve
104
Pressure/Circulation Control Valve Service Kit
105
Cleaning the Tank
106
Draining Material from the Tank
106
Cleaning the Tank by Hand
106
Tightening the Fixing Screws
106
Main PCA Board
107
To Replace the Main PCA Board
107
Maintenance Record Form
110
Troubleshooting
113
Safety
113
Troubleshooting Quick-Checks
114
Returning the Melter Setup to Factory Settings
114
Running and Saving Melter Diagnostics
114
Returning the Customer SD Card Back into the Melter
115
Touch Screen Alerts and Faults
116
About Touch Screen Messages
116
Pump and Zone Alerts/Faults
116
System Alerts
117
System Faults
118
Motor Drive Faults
119
Troubleshooting Tables
124
Melter Not Functioning
124
One Channel (Heating Zone) Does Not Heat
124
Troubleshooting Pump
125
No Material (Pump Does Not Rotate)
125
No Material (Motor Rotating)
126
Too Little Material
126
Material Pressure too High
127
Material Pressure too Low
127
Material Residue in Tank
128
Material Hardens in Tank
128
Others
128
Parts
130
Using the Illustrated Parts List
130
Altablue Configuration Code
131
Frame Assembly
133
One/Two-Pump Melter Frame Parts
133
Three/Four-Pump Melter Frame Parts
135
Reservoir/Manifold Assembly
137
One/Two-Pump Melter Reservoir/Manifold Parts
137
Three/Four-Pump Melter Reservoir/Manifold Parts
139
Manifold Parts
141
Hopper Assembly
145
One/Two-Pump Melter Hopper Parts
145
Three/Four-Pump Melter Hopper Parts
148
Pump Assemblies
151
Pump Module Parts
152
Single-Stream Pump Adapter Parts
153
Dual-Stream Pump Adapter Parts
154
Single-Stream Gear Pumps
155
Dual-Stream Gear Pumps
158
Safety Valve Parts
159
Control Valve Assemblies
160
Control Valve Module Parts
160
Filter Cartridge Parts
162
Pressure Control Valve Parts
163
Pneumatic Pressure Control Valve Parts
164
Pneumatic Pressure Control Valve Interface Parts
166
Manual Pneumatic Pressure Control Valve Parts
167
Flow Control Bypass Control Valve Parts
169
Manual Pneumatic Pressure Control Valve Cabinet
171
Flow Control Bypass Control Valve Cabinet
172
Manual Pneumatic Pressure & Flow Control Bypass Control Valve Interface Parts
174
Flow Control Bypass Control Valve Solenoid Parts
175
Manual Pneumatic Pressure & Flow Control Bypass Control Valve Multi Connector Parts
176
Circulation Control Valve Parts
177
Schematics
178
Motor Assembly
180
Electrical Enclosure Panel Assemblies
181
400V Melter Left Panel
181
One/Two-Pump Melter 2 Hose/Gun (400V) Back Panel Parts (15, 30L)
183
One/Two-Pump Melter 2 Back Panel Parts
187
One/Two-Pump Melter 4/6 Hose/Gun (400V) Back Panel Parts (15L, 30L)
189
One/Two-Pump Melter 4/6 Hose/Gun (400V) Back Panel Parts (15L, 30L
190
Three/Fourpump 4/6 Hose/Gun (400V) Melter Back Panel Parts(30,50L)
193
Three/Four-Pump Eight Hose/Gun (400V) Melter Back Panel Parts (30,50L)
195
Two Hose/Gun (400V) Melter Right Panel Parts
197
Four Hose/Gun(400V) Melter Right Panel Parts
199
Six Hose/Gun (400V) Melter Right Panel Parts
201
Eight Hose/Gun (400V) Melter Right Panel Parts
203
One/Two-Pump Melter Bottom Panel Parts
205
Three/Four-Pump Melter Bottom Panel Parts
206
Control Panel Assembly
207
Sensor Assembly
209
Low Level Assembly
211
Optional Accessories
212
Pressure Indication
212
Low Level Indication
212
Pneumatic Pressure Control Valve
212
Line-Speed Signal Generator
213
Optional Fittings
213
Recommended Spare Parts
215
Technical Data
221
General Data
221
Temperatures
221
Electrical Data
222
Mechanical Data
223
One/Two and Three/Four Pump Melters
223
Electrical Schematics
223
Hydraulic Schematic
224
Calculating Melter Power Requirements (Including Heater Specifications
226
4
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Nordson AltaBlue Specifications
General
Brand
Nordson
Model
AltaBlue
Category
Industrial Equipment
Language
English
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