Fulfill Retrofit for Mesa Meltersemanuals.nordson.com/adhesives/english_manuals/1121938.pdf · 2...

Fulfill Retrofit for Mesa� Melters

Customer Product ManualPart 1121938_02

Issued 5/13

NORDSON CORPORATION DULUTH, GEORGIA USAwww.nordson.com

This document contains important safety informationBe sure to read and follow all safety information in thisdocument and any other related documentation.

ATTENTION: Information on a new control box, PCA and level sensor is included in Appendix A.

Please refer to the Appendix if your unit was manufactured after May 2013. This information is found in theserial code of your unit; for example, SA13EXXXXX, where “E” represents the date code “May,” or any sequential letter after “E.”

Part 1121938_02 � 2013 Nordson CorporationAll rights reserved

For CE Declaration, refer to equipment documentation.

Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General informationabout Nordson can be found on the Internet using the following address: http://www.nordson.com.

Address all correspondence to:

Nordson CorporationAttn: Customer Service11475 Lakefield Drive

Duluth, GA 30097

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2010.No�part�of�this�document may be photocopied, reproduced, or translated to another language without the prior written

consent of Nordson�Corporation. The�information�contained in this publication is subject to change without notice.

Trademarks

AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, Bowtie, Build‐A‐Part, CanWorks, Century, CF, CleanSleeve,CleanSpray, ColorMax, Color‐on‐Demand, Control�Coat, Coolwave, Cross‐Cut, cScan+, Dage, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber,

DuraPail, Dura‐Screen, Durasystem, Easy�Coat, Easymove Plus, Ecodry, Econo‐Coat, e.DOT, EFD, Emerald, Encore, ESP, e stylized, ETI‐stylized,Excel 2000, Fibrijet, Fillmaster, FlexiCoat, Flex‐O‐Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Fulfill, GreenUV, HDLV, Heli‐flow, Horizon, Hot Shot,iControl, iDry, iFlow, Isocoil, Isocore, Iso‐Flo, iTRAX, Kinetix, LEAN�CELL, Little�Squirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, Microcoat,

Micromark, Micromedics, MicroSet, Millennium, MiniBlue, Mini Squirt, Mountaingate, NexJet, Nordson, Optimum, Package of Values, Pattern View,PermaFlo, PicoDot, Porous�Coat, PowderGrid, Powderware, Precisecoat, PRIMARC, Printplus, Prism, ProBlue, Prodigy, Pro‐Flo, ProLink, Pro‐Meter,

Pro‐Stream, RBX, Rhino, Saturn, Saturn with rings, Scoreguard, Seal Sentry, Select�Charge, Select�Coat, Select Cure, Signature, Slautterback, Smart‐Coat,Solder Plus, Spectrum, Speed‐Coat, SureBead, Sure Coat, Sure‐Max, Sure Wrap, Tracking�Plus, TRAK, Trends, Tribomatic, TrueBlue, TrueCoat,

Tubesetter, Ultra, UpTime, u‐TAH, Value Plastics, Vantage, VersaBlue, Versa‐Coat, VersaDrum, VersaPail, Versa‐Screen, Versa‐Spray, VP Quick Fit, Watermark, and When you expect more. are registered trademarks of Nordson Corporation.

Accubar, Active Nozzle, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AltaSlot, Alta Spray, Artiste, ATS, Auto‐Flo, AutoScan, Axiom, Best Choice, Blue Series, Bravura, CanPro, Champion, Check Mate, ClassicBlue, Classic IX, Clean�Coat, Cobalt, Controlled Fiberization, Control�Weave,

ContourCoat, CPX, cSelect, Cyclo‐Kinetic, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, e.dot+,E‐Nordson, Equalizer, EquiBead, 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,Partnership+Plus, PatternJet, PatternPro, PCI, PharmaLok, Pinnacle, Plasmod, Powder�Pilot, Powder Port, Powercure, Process Sentry, Pulse Spray,

PURBlue, PURJet, Ready Coat, RediCoat, RollVIA, Royal Blue, Select�Series, Sensomatic, Shaftshield, SheetAire, Smart, Smartfil, SolidBlue, Spectral,SpeedKing, Spray Works, StediFlo, StediTherm, Summit, SureFoam, Sure�Mix, SureSeal, Swirl�Coat, TAH, ThruWave, Trade�Plus, Trilogy, Ultra FoamMix,UltraMax, Ultrasaver, Ultrasmart, Universal, ValueMate, Versa, Vista, Web Cure, YESTECH, and 2�Rings (Design) are�trademarks of Nordson�Corporation.

Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes, could lead to violation of the owners' rights.

Table of Contents i

Part 1121938_02� 2013 Nordson Corporation

Fulfill� Retrofit for Mesa� Melters 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Alert Symbols 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Responsibilities of the Equipment Owner 2. . . . . . . . . . . . . . . . . . . . . . . . .

Safety Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instructions, Requirements, and Standards 2. . . . . . . . . . . . . . . . . . . .User Qualifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applicable Industry Safety Practices 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use of the Equipment 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instructions and Safety Messages 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation Practices 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Practices 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance and Repair Practices 5. . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Safety Information 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Equipment Shutdown 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving System Hydraulic Pressure 6. . . . . . . . . . . . . . . . . . . . . . .De‐energizing the System 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disabling the Applicators 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Safety Warnings and Cautions 7. . . . . . . . . . . . . . . . . . . . . . . .Other Safety Precautions 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .First Aid 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Labels and Tags 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Theory of Operation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overview 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(1). Adhesive Storage Bin 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2). Air Pressure Regulator/Solenoid Assembly 14. . . . . . . . . . . . . . . .(3). Suction Lance 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(4). Adhesive Transfer Hose 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(5). Lid Assembly 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Membrane Panel 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Components 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(6). Control Box 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PCA 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(7). Sensor (Not Shown) 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Prepare the Melter 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Install the Control Box 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Install the Tank Lid Components 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assemble the Transfer Hose, Air Line, and Suction Lance 25. . . . . . . . . .Level Sensor Adjustment and Calibration 26. . . . . . . . . . . . . . . . . . . . . . . .

Baseline Setting 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Final Setting 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Time Settings 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monitoring Refill Operation 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsii

Part 1121938_02 � 2013 Nordson Corporation

Maintenance 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Refill PCA Troubleshooting Diagnostic Instructions 31. . . . . . . . . . . . . . . .

Parts 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using the Illustrated Parts Lists 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mesa Retrofit Kit Assemblies 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ship With Fastener Kit 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lid Assembly Parts 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Assembly with Bracket 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Box Assembly 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Container/Wand Kit 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Kits 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Accessories 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Service Parts 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Diagram 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RetroFit Refill System with Nordson Level Sensor A‐1. . . . . . . . . . . .

Sensor Features A‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wide Sensing Area A‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Simplified Mechanical Mounting A‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Push Button Calibration A‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .RTD Temperature Compensation A‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sensor Diagnostics A‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Features A‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Delay Timer A‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overfill Fault Timer A‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Status Relay Contact Output A‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Configuration Switch A‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sensor Calibration A‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Calibration Summary A‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Basic (Empty Level) Calibration A‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Precision (Full Level) Calibration A‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting A‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fault LED/Red Status LED A‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fill Enable LED/Yellow Status LED/Yellow Light Tower A‐11. . . . . . . . . . . . .

Installation A‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Common Chassis Connection A‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Parts A‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Retrofit Wiring Diagram A‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fulfill Retrofit for Mesa� Melters 1


Fulfill Retrofit for Mesa� Melters

Safety Read this section before using the equipment. This section containsrecommendations and practices applicable to the safe installation, operation,and maintenance (hereafter referred to as “use”) of the product described inthis document (hereafter referred to as “equipment”). Additional safetyinformation, in the form of task‐specific safety alert messages, appears asappropriate throughout this document.

WARNING! Failure to follow the safety messages, recommendations, andhazard avoidance procedures provided in this document can result inpersonal injury, including death, or damage to equipment or property.

Safety Alert Symbols

The following safety alert symbol and signal words are used throughout thisdocument to alert the reader to personal safety hazards or to identifyconditions that may result in damage to equipment or property. Comply withall safety information that follows the signal word.

WARNING! Indicates a potentially hazardous situation that, if not avoided,can result in serious personal injury, including death.

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 potentiallyhazardous situation that, if not avoided, can result in damage to equipment orproperty.

Fulfill Retrofit for Mesa� Melters2


Responsibilities of the Equipment Owner

Equipment owners are responsible for managing safety information, ensuringthat all instructions and regulatory requirements for use of the equipment aremet, and for qualifying all potential users.

Safety Information � Research and evaluate safety information from all applicable sources,

including the owner‐specific safety policy, best industry practices,governing regulations, material manufacturer's product information, andthis document.

� Make safety information available to equipment users in accordance with

governing regulations. Contact the authority having jurisdiction forinformation.

� Maintain safety information, including the safety labels affixed to the

equipment, in readable condition.

Instructions, Requirements, and Standards � Ensure that the equipment is used in accordance with the information

provided in this document, governing codes and regulations, and bestindustry practices.

� If applicable, receive approval from your facility's engineering or safety

department, or other similar function within your organization, beforeinstalling or operating the equipment for the first time.

� 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.



User Qualifications

Equipment owners are responsible for ensuring that users:

� receive safety training appropriate to their job function as directed by

governing regulations and best industry practices

� are familiar with the equipment owner's safety and accident

prevention policies and procedures

� receive equipment and task‐specific training from another qualified

individual

NOTE: Nordson can provide equipment‐specific installation,operation, and maintenance training. Contact your Nordsonrepresentative for information

� possess industry‐ and trade‐specific skills and a level of experience

appropriate to their job function

� are physically capable of performing their job function and are not

under the influence of any substance that degrades their mentalcapacity or physical capabilities

Applicable Industry Safety Practices

The following safety practices apply to the use of the equipment in themanner described in this document. The information provided here is notmeant to include all possible safety practices, but represents the best safetypractices for equipment of similar hazard potential used in similar industries.

Intended Use of the Equipment � Use the equipment only for the purposes described and within the limits

specified in this document.

� Do not modify the equipment.

� Do not use incompatible materials or unapproved auxiliary devices.

Contact your Nordson representative if you have any questions onmaterial compatibility or the use of non‐standard auxiliary devices.



Instructions and Safety Messages � Read and follow the instructions provided in this document and other

referenced documents.

� Familiarize yourself with the location and meaning of the safety warning

labels and tags affixed to the equipment. Refer to Safety Labels and Tagsat 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.

� Ensure that the equipment is rated for the environment in which it will be

used. This equipment has not been certified for compliance with theATEX directive nor as nonincendive and should not be installed inpotentially explosive environments.

� Ensure that the processing characteristics of the material will not create a

hazardous environment. Refer to the Material Safety Data Sheet (MSDS)for the material.

� If the required installation configuration does not match the installation

instructions, contact your Nordson representative for assistance.

� Position the equipment for safe operation. Observe the requirements for

clearance between the equipment and other objects.

� Install lockable power disconnects to isolate the equipment and all

independently powered auxiliary devices from their power sources.

� Properly ground all equipment. Contact your local building code

enforcement agency for specific requirements.

� Ensure that fuses of the correct type and rating are installed in fused

equipment.

� Contact the authority having jurisdiction to determine the requirement for

installation permits or inspections.

Operating Practices � Familiarize yourself with the location and operation of all safety devices

and indicators.

� Confirm that the equipment, including all safety devices (guards,

interlocks, etc.), is in good working order and that the requiredenvironmental conditions exist.

� Use the personal protective equipment (PPE) specified for each task.

Refer to Equipment Safety Information or the material manufacturer'sinstructions and MSDS for PPE requirements.

� Do not use equipment that is malfunctioning or shows signs of a potential

malfunction.



Maintenance and Repair Practices � Allow only personnel with appropriate training and experience to operate

or service the equipment.

� Perform scheduled maintenance activities at the intervals described in

this document.

� Relieve system hydraulic and pneumatic pressure before servicing the

equipment.

� De‐energize the equipment and all auxiliary devices before servicing the

equipment.

� Use only new Nordson‐authorized refurbished or replacement parts.

� 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 areavailable 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.

� Dispose of waste cleaning compounds and residual process materials

according to governing regulations. Refer to the applicable MSDS orcontact the authority having jurisdiction for information.

� Keep equipment safety warning labels clean. Replace worn or damaged

labels.

Equipment Safety Information

This equipment safety information is applicable to the following types ofNordson equipment:

� hot melt and cold adhesive application equipment and all related

accessories

� pattern controllers, timers, detection and verification systems, and all

other optional process control devices



Equipment Shutdown

To safely complete many of the procedures described in this document, theequipment must first be shut down. The level of shut down required varies bythe type of equipment in use and the procedure being completed. If required, shut down instructions are specified at the start of the procedure.The levels of shut down are:

Relieving System Hydraulic Pressure

Completely relieve system hydraulic pressure before breaking any hydraulicconnection or seal. Refer to the melter‐specific product manual forinstructions on relieving system hydraulic pressure.

De‐energizing the System

Isolate the system (melter, hoses, applicators, and optional devices) from allpower sources before accessing any unprotected high‐voltage wiring orconnection point.

1. Turn off the equipment and all auxiliary devices connected to theequipment (system).

2. To prevent the equipment from being accidentally energized, lock andtag the disconnect switch(es) or circuit breaker(s) that provide inputelectrical power to the equipment and optional devices.

NOTE: Government regulations and industry standards dictate specificrequirements for the isolation of hazardous energy sources. Refer to theappropriate regulation or standard.

Disabling the Applicators

NOTE: Adhesive dispensing applicators are referred to as “guns” in someprevious publications.

All electrical or mechanical devices that provide an activation signal to theapplicators, applicator solenoid valve(s), or the melter pump must bedisabled before work can be performed on or around an applicator that isconnected to a pressurized system.

1. Turn off or disconnect the applicator triggering device (pattern controller,timer, PLC, etc.).

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; thenrelieve the residual air pressure between the regulator and the applicator.



General Safety Warnings and Cautions

Table 1 contains the general safety warnings and cautions that apply toNordson hot melt and cold adhesive equipment. Review the table andcarefully read all of the warnings or cautions that apply to the type ofequipment described in this manual.

Equipment types are designated in Table 1 as follows:

HM = Hot melt (melters, hoses, applicators, etc.)

PC = Process control

CA = Cold adhesive (dispensing pumps, pressurized container, andapplicators)

Table 1 General Safety Warnings and Cautions

EquipmentType Warning or Caution

HM

WARNING! Hazardous vapors! Before processing any polyurethanereactive (PUR) hot melt or solvent‐based material through a compatibleNordson melter, read and comply with the material's MSDS. Ensurethat the material's processing temperature and flashpoints will not beexceeded and that all requirements for safe handling, ventilation, firstaid, and personal protective equipment are met. Failure to comply withMSDS requirements can cause personal injury, including death.

HM

WARNING! Reactive material! Never clean any aluminum componentor flush Nordson equipment with halogenated hydrocarbon fluids.Nordson melters and applicators contain aluminum components thatmay react violently with halogenated hydrocarbons. The use ofhalogenated hydrocarbon compounds in Nordson equipment cancause personal injury, including death.

HM, CAWARNING! System pressurized! Relieve system hydraulic pressurebefore breaking any hydraulic connection or seal. Failure to relieve thesystem hydraulic pressure can result in the uncontrolled release of hotmelt or cold adhesive, causing personal injury.

Continued...



General Safety Warnings and Cautions (contd)

Table 1 General Safety Warnings and Cautions (contd)

EquipmentType Warning or Caution

HM

WARNING! Molten material! Wear eye or face protection, clothing thatprotects exposed skin, and heat‐protective gloves when servicingequipment that contains molten hot melt. Even when solidified, hot meltcan still cause burns. Failure to wear appropriate personal protectiveequipment can result in personal injury.

HM, PC

WARNING! Equipment starts automatically! Remote triggering devicesare used to control automatic hot melt applicators. Before working onor near an operating applicator, disable the applicator's triggeringdevice and remove the air supply to the applicator's solenoid valve(s).Failure to disable the applicator's triggering device and remove thesupply of air to the solenoid valve(s) can result in personal injury.

HM, CA, PC

WARNING! Risk of electrocution! Even when switched off andelectrically isolated at the disconnect switch or circuit breaker, theequipment may still be connected to energized auxiliary devices.De‐energize and electrically isolate all auxiliary devices beforeservicing the equipment. Failure to properly isolate electrical power toauxiliary equipment before servicing the equipment can result inpersonal injury, including death.

HM, CA, PC

WARNING! Risk of fire or explosion! Nordson adhesive equipment isnot rated for use in explosive environments and has not been cerfifiedfor the ATEX directive or as nonincendive. In addition, this equipmentshould not be used with solvent‐based adhesives that can create anexplosive atmosphere when processed. Refer to the MSDS for theadhesive to determine its processing characteristics and limitations.The use of incompatible solvent‐based adhesives or the improperprocessing of solvent‐based adhesives can result in personal injury,including death.

HM, CA, PC

WARNING! Allow only personnel with appropriate training andexperience to operate or service the equipment. The use of untrainedor inexperienced personnel to operate or service the equipment canresult in injury, including death, to themselves and others and candamage to the equipment.



Warning or CautionEquipment

Type

HM

CAUTION! Hot surfaces! Avoid contact with the hot metal surfaces ofapplicators, hoses, and certain components of the melter. If contactcan not be avoided, wear heat‐protective gloves and clothing whenworking around heated equipment. Failure to avoid contact with hotmetal surfaces can result in personal injury.

HM

CAUTION! Some Nordson melters are specifically designed toprocess polyurethane reactive (PUR) hot melt. Attempting to processPUR in equipment not specifically designed for this purpose candamage the equipment and cause premature reaction of the hot melt. Ifyou are unsure of the equipment's ability to process PUR, contact yourNordson representative for assistance.

HM, CA

CAUTION! Before using any cleaning or flushing compound on or inthe equipment, read and comply with the manufacturer's instructionsand the MSDS supplied with the compound. Some cleaningcompounds can react unpredictably with hot melt or cold adhesive,resulting in damage to the equipment.

HM

CAUTION! Nordson hot melt equipment is factory tested with NordsonType R fluid that contains polyester adipate plasticizer. Certain hot meltmaterials can react with Type R fluid and form a solid gum that canclog the equipment. Before using the equipment, confirm that the hotmelt is compatible with Type R fluid.



Other Safety Precautions � Do not use an open flame to heat hot melt system components.

� Check high pressure hoses daily for signs of excessive wear, damage, or

leaks.

� Never point a dispensing handgun at yourself or others.

� Suspend dispensing handguns by their proper suspension point.

First Aid

If molten hot melt comes in contact with your skin:

1. Do NOT attempt to remove the molten hot melt from your skin.

2. Immediately soak the affected area in clean, cold water until the hot melthas cooled.

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 hotmelt to the medical personnel providing treatment.



Safety Labels and Tags Figure 1 illustrates the location of the product safety labels and tags affixed tothe equipment. Table 2 provides an illustration of the hazard identificationsymbols that appear on each safety label and tag, the meaning of thesymbol, or the exact wording of any safety message.

1

Figure 1 Safety labels and tags

Table 2 Safety Labels and Tags

Item Part Description

1. 1021984

WARNING! Hazardous voltage. Disconnect all power supplyconnections before servicing.



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

The Fulfill system is shipped with the components illustrated in Figure 2.

2 3

1

6

7

5

4

8

Figure 2 Fulfill system components

1. Adhesive storage bin

2. Transfer hose

3. Suction lance

4. Control box and mounting bracketwith level sensor, filter-regulator w/gauge, and solenoid

5. Hose clamp (2)

6. Air line (4m)7. Wire tie (5)

8. Lid assy

Optional accessories available for the Fulfill Retrofit include:

� a vibrator kit for the adhesive storage bin

� a remote mount kit

� a light tower kit for audio/visual fill/fault indication of the Fulfill processes.

Contact your Nordson representative for more information on these kits.



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 regularintervals, reducing the possibility of adhesive char, contaminants, thermalshock and incorrect adhesive temperatures that result in poor bonding.

A capacitance sensor located in the melter detects low adhesive level, andthen sends a signal to the system control. A delay timer prevents the fillsystem from frequently cycling on and off.

At the end of the delay the control activates the vacuum via a solenoid valve.Air pressure flows to a suction lance that is placed in the supplied bulkadhesive container. Using vacuum, the system conveys adhesive from thebulk container to the adhesive melter tank.

The controller activates the suction lance for a limited amount of time toprevent over‐fill conditions. If the maximum fill time is exceeded, thecontroller activates a fault that stops the system from filling.



Pneumatic & Mechanical Components Refer to Figure 3 as you learn about the components of the Mesa Fulfillretrofit assembly.

1

2

3

4 5

6

Figure 3 Assembled Mesa Fulfill retrofit assembly.

(1). Adhesive Storage Bin

Place adhesive in the adhesive storage bin. The bin contains a gasket thatprevents debris from entering the bin. For best results, break up theadhesive as much as possible when emptying into the bin. Do not get theadhesive wet.

(2). Air Pressure Regulator/Solenoid Assembly

The supplied air pressure regulator is permanently set at 65 psig, the optimalsetting for most adhesives.

The solenoid valve turns on after the sensor indicates level state and the timedelay has been reached. The solenoid directs compressed air to flow to thesuction lance.



(3). Suction Lance

The suction lance draws adhesive from the adhesive storage bin. Thesuction lance includes:

� A venturi pump to draw in and transport the adhesive.

� A vibrator to keep the adhesive in loose condition. The vibrator is active

as long as compressed air is supplied to the suction lance.

Air line tubing and the adhesive transfer hose are connected to the suctionlance. The lance is placed in the PVC pipe located in the adhesive storagebin.

(4). Adhesive Transfer Hose

The adhesive transfer hose connects the suction lance to the lid assembly.The transfer hose conveys adhesive from the adhesive storage bin to themelter tank.

(5). Lid Assembly

The lid assembly includes the filter stack, lid, fill tube, baffle and deflector:

� The filter stack contains a replaceable filter sock to prevent adhesive

fines and talc/powder in the adhesive from being emitted into the ambientair.

� The fill tube attaches to the adhesive transfer hose.

� The baffle prevents adhesive from entering the filter sock.

� The deflector distributes adhesive evenly in the tank.

The thumb screws mount the lid to the melter. The thumbscrews can bereplaced by Allen head screws supplied in the ship with kit. Do not removethe lid during operation, unless the system is disabled by turning power off atthe control box.



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 themelter via the supplied bracket. An optional remote mount kit is available tomount the control box away from the melter.

Membrane Panel

The front panel of the electrical control box shown in Figure 4 contains threeLEDs that have different colored lights to indicate the unit condition:

� Enable LED (green light) - Indicates that the system is enabled.

Pressing the Enable button will toggle the indicator.

� Enable button - Press the enable button to turn the fill system on or

off.

� Adhesive transfer LED (blue light) - Indicates adhesive delivery is

active. When a low level is detected, the indicator notes thatadhesive is being transferred from the adhesive storage bin into themelter tank through the transfer hose.

� Fault LED (red light) - activates if the system exceeds the user

defined fill time limit. The system will not resume operation until thefault is cleared with the clear fault button.

� Clear fault button - Press the clear fault button to reset fault and

resume normal activity.

1 2 3

4

Figure 4 Fill system controls and indicators

1. Enable On/Off

2. Filling activated symbol and blue LED

3. Fault symbol and red LED

4. Clear fault



PCA

� NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updatedinformation.

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. Power can be supplied from the plant service to thecontrol box or directly from the Mesa melter using the optional powerharness kit.

� A potentiometer labeled ”Delay” is for a fill time delay. This delay is

the time duration between the level sensor calling for more adhesiveand when the fill system activates. The delay time prevents thesystem from frequently turning on and off. The delay time is presetfrom the factory at 60 seconds, but can be adjusted from 0 to 119seconds. The factory sets the potentiometer at the 12 o'clockposition, sufficient for the majority of applications. For reference, 9o'clock is 20 seconds and 3 o'clock is 100 seconds.



PCA (contd)

� A potentiometer labeled fault limits the amount of filling time in case of

level sensor failure. t is only for overflow protection. The factorysetting is at the 12 o'clock position, sufficient in most applications.The time can be adjusted from 5 to 115 seconds. For reference, the 9o'clock position is 22 seconds and the 3 o'clock position is 98seconds.

� A potentiometer labeled ”AIR” is a pre‐vibrate timer for the optional

storage bin vibrator kit. The range for this potentiometer is 0 to 20seconds. When installed, this vibrator will activate up to 20 secondsbefore the fill system activates and stay on until the level sensor issatisfied. This kit is well suited for adhesives and plant conditionsthat are prone to bridging.

� A dip switch labeled SW1 is preset at the factory. Position M1 should

always be OFF and position M2 should always be ON.

� A terminal block labeled ”XT2”. An optional light tower may be

attached here. The functions of the light tower are

‐ Fill (Blue) - visual

‐ Fault (Red) - visual

‐ Fault (Alarm) - audible.

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 theadhesive falls below the set point, the level sensor sends a signal to the Fulfillcontrol box.

The sensor will require calibration when the adhesive is molten. See theLevel Sensor Adjustment and Calibration detailed later in the manual.



Installation WARNING! Allow only personnel with appropriate training and experience tooperate or service the equipment. The use of untrained or inexperiencedpersonnel to operate or service the equipment can result in injury, includingdeath, to themselves and others, and damage to the equipment.

Prepare the Melter 1. Operate the melter until the tank is empty.

2. De‐energize the system as directed in the Maintenance section of theMesa manual.

3. Remove the right side panel from the Mesa melter. Set the screws asidefor reassembly.

4. Remove the pump cover.

5. See Figure 6. Remove the existing tank lid by inserting a small flat‐tipscrewdriver in the gap between the lid and the melter frame, pressing inon the end of the spring‐loaded lid hinge rod to release the rod from thepivot point, and then lifting the lid out.

Figure 6 Remove the existing tank lid

CAUTION! Remove dirt and debris from the melter before proceeding withthese procedures.

6. See Figure 7. Remove the five screws that secure the pump/lid supportbracket, and then remove the bracket. Set the screws aside forreassembly.



Prepare the Melter (contd)

Figure 7 Remove the tank lid

Install the Control Box 1. See Figure 8. Remove the three screws (1) from the left side panel and

the two screws (2) from the back panel.

2. Place the standoffs provided into the screw holes in the rear panel of theMesa melter. Secure the pneumatic and control assembly bracket ontothe melter (1). Replace the screws previously removed into thestandoffs.

3. Place the control box with bracket onto the melter at the left panel withthe two 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 tieand anchor provided.

1

2

2

1

1

Figure 8 Install the Fulfill control box onto the melter



5. See Figure 9. Attach one end of the ground wire to the solenoid bracket.

Figure 9 Secure the ground wire

6. Secure the provided anchor to the rear of the Mesa melter above themanifold.

7. Route the ground wire through the anchor.

8. See Figure 10. Route the ground wire around the manifold and into theinterior of the Mesa melter.



Install the Control Box (contd)

Figure 10 Secure the ground wire

9. Secure the ground wire to the melter tank.

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 intothe control box.

12. Connect the power wiring to the terminal blocks in the control box.



21

3

Figure 11 Connect the customer‐supplied power cord to the control box

1. L1-L2/N wire power cord connection(interchangeable)

2. Ground wire power cord connection

3. Power cord strain relief

13. Tighten the strain relief.



Install the Tank Lid Components 1. See Figure 12. Install the new tank gasket (1) onto the melter tank.

2. Install the new lid support (2) using existing screws.

NOTE: Position the level sensor probe with the fill line 2 inches from thebottom of the probe holder. The level can be reduced by loosening theholder's hex nut, and then sliding the probe lower. Tighten the nut to keep theprobe from moving.

3. Mount the level sensor bracket (3) onto the lid support. Secure with thetwo nuts (4) and washers (5) provided.

1

4

5

3

2

6

Figure 12 Installing the tank 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 thethreaded holes in the lid support (2).



Assemble the Transfer Hose, Air Line, and Suction Lance

CAUTION! Allow for 10 in. bend radius for installation/use of the adhesivetransfer hose.

1. Using one hose clamp, attach the transfer hose (A) to the end of thesuction lance (B).

2. Insert the suction lance into the PVC pipe inside the adhesive storagebin.

3. Use the remaining hose clamp to attach the transfer hose to the feedsystem inlet tube (C). The hose should be routed without sharp bends orkinks.

NOTE: If necessary, loosen the inlet tube retaining screws and thenreposition the inlet tube.

4. Connect the air line (D) to the suction lance air inlet (E).

5. Route the air line along the transfer hose, securing it with wire ties as yougo. The hose should be routed without sharp bends or kinks.

6. Leaving enough air line to reach the outlet (F) of the air solenoid, cut theair line to length and then insert the end of the air line into the outlet.

7. Connect plant air to the regulator. For best results, run the air pipingfrom the main header.

B

A

CD

E

F

Figure 13 Assembling the transfer hose, air line, and suction lance



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 probepermanently connects to the control box by a wire. The level probe has ablack line around its diameter near the tip to note the maintained adhesivelevel.

CAUTION! Do not raise the fill line of the probe above 2 inches from bottomof the probe holder. Doing so will degrade the level sensor's performance.

Figure 14 Adjustment potentiometer

See Figure 14. The LED indicator next to the adjustment potentiometer onthe control box changes color from green to amber, depending on theadhesive level that the probe detects. When adhesive drops below thedesired level, the LED will turn green. When adhesive reaches or exceedsthe desired level, the LED will turn amber. The adjustment potentiometersets the sensitivity of the level sensor. Different adhesives require differentcalibration settings. Adhesives that build up on the level probe require lesssensitivity, while adhesives that do not build up on the level probe requiremore sensitivity. The level sensor should be recalibrated any time the levelprobe's height is changed or the type of adhesive being used changes.



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 controlbox to reveal the adjustment potentiometer.

2. Fill the tank with adhesive and allow it to melt completely.

3. Adjust the liquid level to coincide with the black line on the level probe.

4. If the LED on the control box is amber, turn the adjustment potentiometercounter‐clockwise until it turns green. If the LED on the control box isgreen, turn the adjustment potentiometer clockwise until it just turnsamber. The point at which the LED transitions from green to amber is theswitching point.

5. Once the switching point is found, rotate the adjustment potentiometer 1/2turn clockwise and leave it at that position.

Final Setting � NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated

information.

1. Begin normal operation. Check the adhesive level in the tank after 30minutes of operation.

2. If the adhesive level is satisfactory, the calibration procedure is complete.Re‐install the plug over the calibration pot to discourage tampering.

3. If unmelted adhesive is piled up to the top of the tank or the system hasalready faulted due to overfilling, rotate the adjustment pot 1/2 turnclockwise to increase the level sensor's sensitivity. Wait 10 minutes andcheck the adhesive level again. If the adhesive level is still too high,repeat this process until the adhesive level is satisfactory. Whenfinished, reinstall the plug over the calibration potentiometer.

4. If unmelted adhesive has built up on the probe and the adhesive level inthe tank has dropped below the black line on the probe, rotate theadjustment potentiometer 1/2 turn counter‐clockwise to decrease thelevel sensor's sensitivity. If the adhesive level is still too low, repeat thisprocess until the adhesive level is satisfactory.



Operation � NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated

information.

Once enabled, the fill system immediately begins operation. Maintainadhesive level in the storage bin to maintain automatic operation.

NOTE: During warm‐up, the melter's ready-delay time may need to beincreased for the Fulfill to operate properly. The proper ready-delay timedepends on the tank size and shape, adhesive type, and applicationtemperature.

Time Settings See Figure 15. There are three timers found on the PCA board in the controlbox:

� Fault - The overfill timer. A fault is generated if the Fulfill unit dispenses

longer than the time allotted. Time range is 5 to 115 seconds.

� Delay - The time duration the Fulfill unit waits to transfer adhesive from

the storage bin to the melter once a signal from the level sensor has beentransmitted to the control box. Time range is 1 to 119 seconds.

� Air - Used only with the optional vibrator kit. The air timer signals the

amount of time the vibrator actuates once the filling process begins.Time range is 0 to 20 seconds.

Figure 15 PCA timer settings (located inside the control box)

Use a flat head screwdriver to turn the timers clockwise to increase the timesettings, counterclockwise to decrease the timer settings.



Monitoring Refill Operation See Figure 16.

Under normal conditions, the operator need not monitor or intervene in theoperation of the fill system.

However, if the fill system is unable to satisfy the tank sensor in the time limitset for the Fill Time, the refill alarm LED will illuminate. Refer toTroubleshooting for a list of possible fault causes and solutions.

1 2 3

4

Figure 16 Fill system controls and indicators

1. Enable On/Off2. Filling activated symbol and blue LED

3. Fault symbol and red LED

4. Clear fault

Maintenance Inspect the system daily to ensure that hose fittings are secure and that theunit is free from dirt and debris. Inspect the filter sock weekly to ensure thatit's not clogged; replace as needed.



Troubleshooting � NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated

information.

Problem Possible Cause Corrective Action

1. System overfilled Solenoid stuck open Clean or replace.

Sensor ground wire not connected Connect.

Refill board not working Replace if defective. See Refill PCATroubleshooting Instructions shownlater in the Troubleshooting section.

Sensor not calibrated properly Calibrate the sensor. Refer to LevelSensor Adjustment and Calibrationprovided earlier.

2. System underfilled No adhesive Add adhesive.

No power Ensure that power is available to thesystem.

Adhesive bridging Dislodge adhesive. Add optionalvibrator kit if problem persists.

Clogged wand/hose/lid Inspect the parts for improperconnections, clogs or kinks. Replaceas needed.

Clogged filter sock Replace if needed.

No/low air pressure Verify that sufficient air pressure andflowrate is supplied to the Fulfill unitfrom your factory. Static pressureshould be 65 psi min.; operatingpressure should be 45 psi min.Replace the regulator if defective.

No power to the level sensor Verify that power is being supplied tothe level sensor (LED not lit = nopower) and that the power cord isinstalled properly.

Deflector bent Repair or replace.

No power to fill board Verify power to the control box and atthe board. Replace if needed.

Solenoid failure Verify the connections to thesolenoid. Replace if defective.

Bad fill board Replace. See Refill PCATroubleshooting Instructions shownlater in the Troubleshooting section.

Overfill timer too short Adjust timer.

Sensor not calibrated properly Calibrate the sensor. Refer to LevelSensor Adjustment and Calibrationprovided earlier.

3. Frequent overfillalarms with no cause

Timers not properly set Adjust the timer settings. See TimeSettings provided earlier.



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 thePCA board or to eliminate the PCA board as a cause. These tests shouldonly be performed by personnel qualified to work on high voltage circuits.

1. Verify input power is reaching the PCA. Measure line voltage across theinput side (side of the fuse closest to the input connectors J1 and J2) offuses F1 and F2. The input voltage should be between 100−240 VAC.If input voltage not present, correct input power.

2. Verify that the 24 VDC power supply on the Refill PCA board is workingby measuring the voltage between XT1 pin ”24V” and XT1 pin ”COM”. Itshould be 24 VDC (+/− 5%). If not 24 VDC, verify fuses are not blown. Iffuses have been blown, replace fuses. If fuses blow again, replaceRefill PCA. If fuses OK but 24 VDC not present, replace Refill PCA.

3. Check to make sure the DIP switch settings have not been changed.SW1 DIP switch settings: M1 should be OFF; M2 should be ON.

4. Make sure the timer potentiometers are set as expected:

� FAULT potentiometer adjustment range: 5 to 115 seconds (60

seconds at 12:00 position),

� DELAY potentiometer adjustment range: 1 to 119 seconds (60

seconds at 12:00 position),

� AIR (optional pre‐vibrator) potentiometer adjustment range: 0 to 20

seconds (10 seconds at 12:00 position).

5. Make sure the Refill PCA is enabled by verifying that the ”ENA” LEDclose to the membrane panel connector (X1) is illuminated. If not, pressthe ENABLE button on the membrane panel to enable the Refill PCA. Ifthe ”ENA” LED does not turn on with the membrane panel, themembrane panel or PCA may be bad. With a piece of wire, briefly touchX1 pin 1 to X1 pin 2 (the membrane tail will need to be unplugged toperform this test). If the ”ENA” LED illuminates after this test, replacethe membrane panel. If not, then replace the Refill PCA.

6. To ensure that the level sensor signal is getting to the Refill PCA with thelevel sensor calling for adhesive, verify that there is 24 VDC (+/− 5%)between XT1 pin ”SIG” and XT1 pin ”COM”. If not, repair the levelsensor cable, recalibrate level sensor, or replace level sensor.

7. To ensure that the Refill PCA fill output is working correctly with the levelsensor calling for adhesive and after waiting the DELAY time duration,verify that 24 VDC (+/−5%) is applied to the fill control output (XT2 pin”FILL” measured to any ”COM” pin). Verify with the level sensor is NOTcalling for adhesive that the fill control output is 0 to 0.5V.

If the problem has not be isolated to this point, replace the Refill PCA and/ormembrane panel.



Parts This section provides information about parts that are associated with the fillsystem. Refer to the melter manual for information about all other meltercomponents.

Using the Illustrated Parts Lists To order parts, call the Nordson Customer Service Center or your localNordson representative. Use these five-column parts lists, and theaccompanying illustrations, to describe and locate parts correctly. Thefollowing chart provides guidance for reading the parts lists.

The number in the Item column corresponds to the circled item number in theparts list illustration. A dash in this column indicates that the item is anassembly.

The number in the Part column is the Nordson part number you canuse to order the part. A series of dashes indicates that the part isnot saleable. In this case, you must order either the assembly inwhich the part is used or a service kit that includes the part.

The Description column describes the part and sometimesincludes dimensions or specifications.

The Note column contains letters that refer to notes at thebottom of the parts list. These notes provide importantinformation about the part.

The Quantity column tells you how many of the part isused to manufacture the assembly shown in the partslist illustration. A dash or AR in this column indicatesthat the amount of the item required in the assembly isnot quantifiable.

Item Part Description Quantity Note— 0000000 Assembly A —1 000000 � Part of assembly A 2 A2 - - - - - - � � Part of item 1 13 0000000 � � � Part of item 2 AR

NS 000000 � � � � Part of item 3 2NOTE A: Important information about item 1

AR: As Required

NS: Not Shown



Mesa Retrofit Kit Assemblies

Item Part Description Quantity Note------- 1101880 Kit, Fulfill retrofit, Mesa 4------- 1101881 Kit, Fulfill retrofit, Mesa 6------- 1101882 Kit, Fulfill retrofit, Mesa 9------- 1101883 Kit, Fulfill retrofit, Mesa 14

1 1101838 � Control box / reg.assy,Mesa Fulfill 1 A2 1101214 � Lid assy, Mesa 4, Fulfill retrofit 1 B2 1101215 � Lid assy, Mesa 6, Fulfill retrofit 1 B2 1101216 � Lid assy, Mesa 9, Fulfill retrofit 1 B2 1101217 � Lid assy, Mesa 12, Fulfill retrofit 1 B3 1101859 � Kit, ship w/, fasteners, Fulfill Mesa, retro 14 11101837 � Harness, sensor, ground, Mesa Fulfill 1

NOTE A: Further listing provided in Control box/regulator table provided later in the Parts section.

B: Further listing provided in Lid Assembly table provided later in the Parts section.

Ship With Fastener Kit

Part Description Quantity984706A Nut, hex, M5, stl, zn 2983401A Washer, lk, M, spt, M5, stl, zn 2982594A Scr, skt, M4 X 10mm, bl 4983402A Washer, flt, M, narrow, M4, stl, zn 41094834A Standoff, m/f, 10mm hex, M5 thd, stl/zinc 31017010A Scr, btn, skt, M5 X 10, bl 3982202A Scr, btn, skt, M5 X 25, zn 2983418A Washer, flt, M, oversized, 5, stl, z 2



Lid Assembly Parts See Figure 17.

Item Part Description Quantity1101214 Lid assy, Mesa 4 Fulfill retrofit —1101215 Lid assy, Mesa 6 Fulfill retrofit —1101216 Lid assy, Mesa 9 Fulfill retrofit —1101217 Lid assy, Mesa 14 Fulfill retrofit —

1 1095342 � Enclosure assy, filter, lid, Fulfill 12 1088282 � Filter, sock, 200 micron, Fulfill 13 982374 � Scr, skt, M5X40, bl 44 1096978 � Collar, lid, Fulfill 15 1097018 � Tube, exhaust, Fulfill 16 1097866 � Retainer, filter housing, Fulfill, 3000 17 1101226 � Cover, Mesa 4 lid, Fulfill retrofit 17 1101227 � Cover, Mesa 6 lid, Fulfill retrofit 17 1101228 � Cover, Mesa 9 lid, Fulfill retrofit 17 1101229 � Cover, Mesa 12 lid,Fulfill retrofit 18 1097663 � Spacer, lid, Fulfill retrofit 19 1101222 � Insulation, Mesa 4 Fulfill retrofit 19 1101223 � Insulation, Mesa 6 Fulfill retrofit 19 1101224 � Insulation, Mesa 9 Fulfill retrofit 19 1101225 � Insulation, Mesa 14 Fulfill retrofit 110 1101218 � Lid,inner, Mesa 4 Fulfill retrofit 110 1101219 � Lid,inner, Mesa 6 Fulfill retrofit 110 1101220 � Lid, inner, Mesa 9 Fulfill retrofit 110 1101221 � Lid, inner, Mesa 14 Fulfill retrofit 111 1099398 � Baffle, 3000 Fulfill retrofit 112 982780 � Scr, skt, M5X10, ZN 413 1099399 � Deflector, 3100 Fulfill retrofit 114 1097016 � Tube, inlet, Fulfill 115 983163 � Washer, flt, M, oversized, M4, zn 116 982025 � Scr, skt, M4X14, bl 317 1098021 � Knob, black plastic with M5 X 30 lg stud 3NS 983408 � Washer, flt, M, narrow, M5, stl, zn 3NS 940073 � O ring, Viton, .145ID X .070W .BR, 10407 3

NS: Not Shown



Figure 17 Lid assembly parts



Control Assembly with Bracket See Figure 18.

Item Part Description Quantity Note— 1101838 Control box/reg. assy, 3000 Fulfill −−−−−−1 1101502 � Bracket, reg. assy, 3000, Fulfill 12 1093650 � Valve, solenoid, 3−way, 24V, 1/4 NPT 13 972125 � Conn, male, elbow, 10mm T X 1/4 uni 14 1040003 � Scr, skt, M4x25, zn 25 1096668 � Regulator/filter, 40 mic, 1/4 NPT, 65 psig 16 1101987 � Kit, service, level sensor, Fulfill 17 233785 � Elbow,male,1/4 NPT 18 982059 � Scr, skT, M4X8, bl 29 1058059 � Muffler polyethylene 1/4 NPT, Saturn 110 1099250 � Holder assy, leve;l probe 111 271221 � Lug, 45, double, .250, .438 112 983401 � Washer, lk, M, spt, M5, st, zn 113 982780 � Scr, skt, M5 x 10, zn 114 983021 � Washer, flt, E, .203 x .406 x .040, br 115 1098169 � Control box assembly 1 A16 1101397 � Bracket, control box, 117 1098106 � Knob, black plastic, M5 x 10 118 1101395 � Bracket, control 119 1101398 � Bracket, nut bar 120 982680 � scr, hex, washhd, tf, M5 x 12, blk 421 306005 � Wire mount, cable strap, 4 way 122 939110 � Cabletie, 3.9 in., nylon 623 1101099 � Harness assy, solenoid, 3.5 ft 1

NOTE A: Parts for the control box are provided later in this section.



Figure 18 Control assy. with bracket parts



Control Box Assembly See Figure 19.

Item Part Description Quantity— 1098169 Control box assy, Fulfill retrofit −−−−−−1 1097912 � Enclosure, poly, machined 12 982360 � Scr, skt, M3X10, zn 43 983520 � Washer, lk, M, int, M3, stl, zn 44 982604 � Scr, panhd, thd form, M4X12, bl 45 982780 � Scr, skt, M5X10, zn 16 983401 � Washer, lk, M, spt, M5, stl, zn 17 230261 � Termlug, ground, 6−14 AWG 18 982157 � Scr, skt, M3X14, B 19 933747 � Block, terminal, 2 station 110 1098483 � Domeplug, .500 in. D, .250 in. pnl thk 211 1099525 � Membrane panel 112 1097950 � Panel, mtg, ckt. bd. 113 1094486 � Block, heat sink, Easy−Pac 114 1054073 � Scr, skt, hd, M3x20 mm, steel, zn 115 1096221 � PCA, refill controller 116 1098484 � Domeplug, .750 in.D, .250 in. pnl thk 117 1046998 � Connector, strain relief, PG7, nylon 218 933607 � Connector, strain relief ,PG11 119 1098475 � Harness, AC power 1



17

Figure 19 Control box assembly



Container/Wand Kit

Part Description1097984 Kit, container, wand1097983 � Container7408012 � Suction wand1095962 � Transfer hose1095965 � Tubing, 10 mm OD x 8 mm ID, nylon, 15 ft1095983 � Cable tie231362 � Clamp, hose, worm dr, 1.06−2 in., ss

Service Kits Part Description

1099525 Kit, membrane panel

1101987 Kit, service, level sensor

1096221 Kit, service, PCA

1082942 Kit, service, sock filter, 5 pc

Accessories Part Description

1098962 Kit, vibrator, adhesive container

1099057 Kit, light tower

1099106 Kit, remote mount

Service Parts Part Description

1096668 Regulator/filter, 40 mic, 1/4 NPT, 65 psig

1093639 Regulator/filter, 40 mic, 1/4 NPT, 5-100 psig

1093650 Valve, solenoid, 3-way, 24V, 1/4 NPT

1097983 Container assembly, 120L

7408012 Suction wand

7408022 Vibrator, Suction Wand

1095962 Hose, transfer, 15 ft

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



Specifications Parameter Specification

Adhesive Forms

Maximum size

Pellets, pastilles, mini-slats

� Pastilles: 12 mm (0.472 in.) diameter

� Mini‐slats:

12 mm X 12 mm (0.472 in. X 0.472 in.) in length

Input voltage 100−240/1 VAC, 1 A

Power cord Customer supplied, 14−18 AWG

Adhesive Transfer Maximum Rate 227 kg (500 lb)/hour (dependent on adhesive type)

Transfer Hose Length 4 m (13 ft)

Operating Air Minimum 4.5 bar (0.45 MPa or 65 psi)Maximum 8.6 bar (0.86 MPa or 125 psi)

Total Air Consumption 679 Liters/min (24 SCFM) when feeding

Conditioning Dry, non−lubricated

Inlet Air Connection 1/4 in. NPT female1/4 BSPP femaleG 1/4 female

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



Wiring Diagram



Dimensions

RetroFit Refill System with Nordson Level Sensor A-1


Appendix A

RetroFit Refill System with Nordson LevelSensor

WARNING! Allow only personnel with appropriate training and experience tooperate or service the equipment. The use of untrained or inexperiencedpersonnel to operate or service the equipment can result in injury, includingdeath, to themselves and others, and damage to the equipment.

Sensor Features

The Nordson level sensor features include a wide sensing area, simplifiedmechanical mounting, push button calibration, RTD temperaturecompensation, new diagnostics to help identify sensor problems and aseparate low level output.

Wide Sensing Area

The Nordson level sensor has a wide sensing range that is the nearly equalto the length of the sensor rod. The fill control point can be adjustedelectronically without the need to mechanically move the sensor.

Simplified Mechanical Mounting

The Nordson level sensor simply drops into the tank with no heightadjustments required.

RetroFit Refill System with Nordson Level SensorA-2


Push Button Calibration

The Nordson level sensor uses two push buttons to set levels as opposed tothe previous level sensor’s potentiometer.

Two buttons on the Refill board provide two types of calibration. Informationon calibration can be found later in this section.

The level sensor uses the calibration points to control the level of adhesive inthe tank. The system determines the appropriate fill level based on thecalibration information. When the tank is less than this point, the fill systemturns on. When the tank level is higher than this point, the fill system turnsoff.

RTD Temperature Compensation

Most capacitive sensor readings will vary with temperature. To minimizesensor reading inaccuracies due to temperature effects, the Nordson levelsensor incorporates a RTD to accurately measure the probe temperature andto compensate for changes in probe temperature.

Sensor Diagnostics

The Nordson level sensor offers several diagnostic functions not present inthe previous Fulfill level sensor. These new diagnostic functions are reportedwith LED flash codes. The flash codes are displayed on the membranepanel.



Unit Features

Figure A‐1 shows the Retrofit system and its components.

Level sensor

Fill Enable Button Fill Active LED

Fault LED

Reset Fault Button

Siren

Fill Enabled LED

Air filter/regulator

Fill Control Solenoid

Figure A‐1 Control box assembly and bracket



Unit Features(contd)

The picture shows the major components of the RetroFit control box.

Figure A‐2 Control box

Delay Timer

The delay timer determines how long the Refill board waits when the sensorcalls for adhesive before the vacuum system is activated. The delay timerpotentiometer is adjustable from 1 to 60 seconds.

Overfill Fault Timer

The overfill fault timer determines how long the vacuum system is operatedwhile trying to fill the unit. If the level sensor is not satisfied before the overfillfault timer expires, an overfill fault is generated. The overfill fault timerpotentiometer is adjustable from 5 to 300 seconds.

Siren

Refill PCA

24VDC power supply



Status Relay Contact Output

A formC electromechanical relay contact output is available for to monitorthe fill system status. This relay provides a common (COM), normally closed(NC), and normally open (NO) potential free contact. These contacts arelabeled COM, NC, and NO on the PCB and are located at terminal blockTB3.

If the fill system is working properly (powered, fill enabled, and no alarmspresent) the COM contact will be connected to the NC contact anddisconnected from the NO contact. Any other system state will deenergizethe relay and change the output state.

The relay contacts are rated for 30 VDC maximum at 1 Amp maximum.

If a 24 VDC signal is desired instead of a potential free contact, connect 24VDC to the COM contact and then use the NC and NO contacts. Use the NCcontact for a signal that supplies 24 VDC when the fill system is workingnormally and the NO contact for a signal that supplies 24 VDC when aproblem with the fill system exists. See Figure A‐3.

TB3

Figure A‐3 Photo of TB3



Configuration Switch

The configuration switches are used to set various system modes. Refer tothe following table for the configuration switch settings on your unit.

Melter Configuration Switch Settings

Switch 1 Switch 2 Switch 3 Switch 4

ProBlue 4 Integrated INTEGR INT TcA 150

ProBlue 7 Integrated INTEGR INT TcA 150

ProBlue 10 Integrated INTEGR INT TcB 150

ProBlue 4 Retrofit RETRO INT TcA 150

ProBlue 7 Retrofit RETRO INT TcA 150

ProBlue 10 Retrofit RETRO INT TcB 150

ProBlue 15, 30/50 RETRO INT TcB 150

Mesa 4 RETRO INT TcA 150

Mesa 6 RETRO INT TcA 150

Mesa 9 RETRO INT TcB 150

Mesa 14 RETRO INT TcB 150

Series 3100 RETRO INT TcA 150

Series 3400 RETRO INT TcA 150

Series 3500 RETRO INT TcB 150

Series 3700 RETRO INT TcB 150

Series 3860/3960 RETRO INT TcB 300

DuraBlue 10 RETRO INT TcB 150

DuraBlue 16 RETRO INT TcB 150

DuraBlue/VersaBlue 25 RETRO INT TcB 300



NOTE: Each board setting is configured to the specific melter at the factory.

NOTE: Switch 2 is used to select an external (EXT) external amplifier sensorsuch as the level sensor used on previous Fulfill units.



Figure A‐4 shows the features of the Refill PCA.

Unit Low LED

Configuration switches

Power LED

Fill low

LEDStatus LED

Full calibration button

Empty calibration button

Delay timer

potentiometer

Overfill fault

potentiometer

Fault LED Siren LED

Vibrator LED

Fill enabled LED

Fill active LED

Figure A‐4 PCA board (ProBlue 4 Fulfill integrated settings shown)



Sensor Calibration

The following sections will describe the various methods available tocalibrate the level sensor. For all calibrations, the button(s) must be held for5 seconds in order to be recognized. For best results, the unit should be atapplication temperature when calibration is performed.

The sensor also detects if the calibration is done out of sequence. Forexample, if a full calibration is attempted before an empty calibration wasperformed, then the calibration is ignored and the STATUS and LOW LEDson the circuit board will turn red for 5 seconds after attempting the calibrationindicating a bad calibration attempt.

The unit can also report the last calibration successfully performed. If theENABLE and RESET buttons on the front panel are held simultaneously, thepanel LEDs will illuminate to indicate the last calibration. An illuminatedgreen Enable LED indicates that a basic (empty level) calibration wasperformed and an illuminated blue FILLING LED indicates that a precision(full level) calibration was performed.

Two levels are stored in nonvolatile memory, the calibrated empty point andthe calibrated full point. The level at which the unit fills to is computed basedon the empty and full calibration points

Calibration Summary

The table below summarizes the different types of calibration available. Thedifferent calibrations should be performed in the specific order shown below.

Order toPerform

TypeCalibration

ButtonsUsed

DataPoints

Affected

Notes

1 BasicCalibration

(EmptyLevel)

BlueButton(SW3)

Emptyand Full

Full point is set to a predetermined level aboveempty that is suitable for a wide range ofadhesives. This is the only calibration that mostunits will require.

2(optional)

PrecisionCalibration

(Full Level)

WhiteButton(SW2)

Full only The empty calibration point is not changed, onlythe full. Use this calibration (after an emptycalibration) to provide more precise levelcontrol than an empty calibration alone



Basic (Empty Level) Calibration

CAUTION! Do not attempt empty calibration with a full melter. Doing so willresult in an overfill condition.

1. Allow tank to reach application temperature.

2. Adhesive level should be at or below the bottom of the probe.

3. Close lid.

4. Press SW3 (blue button) until all LEDs stop changing color(approximately 5 seconds).

Precision (Full Level) Calibration1. Allow tank to reach application temperature.

2. Hand fill the adhesive level so that the pellets are at the top of the probe.

3. Close lid.

4. Within 30 seconds, press SW2 (white button) until all LEDs stopchanging color (approximately 5 seconds).



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 alsoperformed on the FAULT LED located on the membrane panel.

Number ofRed Flashes

(DS3) andPanel Fault

LED

Diagnostic Action Required

1 Overfill fault. Unit did not fill in the allowedtime.

Check adhesive level in bin. Checkhose lines for blockage. Increase overfilltimer value.

2 Blown Fuse. The fuse supplying 24V to theoutputs is blown.

Find and fix the source of the excessivecurrent draw and replace the fuse (2Amp max.)

3 Shorted Cable. There is a problem with thesensor cable.

If sensor was calibrated, replace sensor. If sensor needed calibration, calibratesensor. If persists, replace sensor.

4 Communications failure. There is a problemwith the communications to the CPU board(integrated unit only)

Check cable between the Refill boardand the CPU board. If this is a RetroFitunit, check DIP switch settings on Refillboard.

5 RTD shorted. The temperature compensationRTD is electrically shorted.

Replace sensor

6 Internal memory failure. Unit was not able tostore calibration settings.

Replace Refill board if fault persists



Fill Enable LED/Yellow Status LED/Yellow Light Tower

The table below lists the diagnostic warning (yellow flashes) messages forthe STATUS LED (DS3, located on Refill PCA). These flash codes are alsoshown on the FILL ENABLE LED located on the membrane panel.

Number ofYellow

Flashes(DS3) and

PanelEnable LED

Diagnostic Action Required

1 Pressure switch open (if used). Check air supply to pressure switch. If airsupply good, replace pressure switch. Check jumper if pressure switch notused.

2 Lid switch open (if used). Replace or realign lid switch, if used. Check jumper if not used.

3 RTD open. Unit will still function, but probetemperature compensation will be disabled.

Replace sensor

4 Sensor is disconnected. Reconnect or tighten sensor connector. If persists, recalibrate the sensor. If stillpersists, replace sensor.

5 Melter ready input open (if used) This is normal during melter warm up. Ifoccurs while melter is ready, checkconnections to input. If melter readysignal not used, check jumper.

6 Unstable sensor readings Check the sensor cable connections. Ifthe problem persists, replace the sensorand/or refill PCA.

7 Probe temperature is under 175 �F(80 �C)) and filling is prevented.

Allow probe to heat above 175 �F(80 �C)



Installation

Common Chassis Connection

CAUTION! Failure to install a wired connection as described below willcause the Fulfill unit to not function.

There must be a wired connection between the Retrofit box chassis and themelter chassis for stable operation. This connection is normally made fromthe Refill PCA ground tab to the quick connect tab on the Retrofit mountingbracket, but any terminal on the Refill PCA labeled “COM” can be used toconnect to the melter chassis.

Service Parts Part 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

1121492 Harness, siren, Retrofit

1121493 Harness, low level

1121599 Harness, T.B. Plug, jumpered, Retrofit

1121794 Harness, AC, unit powered, Retrofit

1105320 Splitter, power supply, FM, sensor, 16 AWG

1121818 Control box assy, Fulfill Retrofit

1120695 Alarm, audible, panel mount, 24 VDC

1099525 Kit, membrane panel, Fulfill Retrofit

1121806 Kit, light tower



Retrofit Wiring Diagram



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EC Declaration of Conformity

for Adhesive and Sealant Application Equipment conforming to European Council Directives

PRODUCTS:

AltaBlue� Melters, Models 15, 30, 50, 100

AltaBlue� TT Melters, Models A4, A10, A16

Cobalt� GR Series Bulk Material Unloaders

DuraBlue��Melters

FoamMelt� FM‐200 Melter

Fulfill� Retrofit Kit

Mesa� Melters

MiniPUR� Melters

ProBlue� Melters, Models P4, P7, P10, P15, P30 and P50

ProBlue� Fulfill�, Models P4F, P7F, P10F

PURBlue� Melters

Series 3000V Melters

SureFoam� Foam Dispensing System

APPLICABLE DIRECTIVES:

Machinery Directive: 2006/42/EC

Electromagnetic Compatibility Directive: 2004/108/EC

STANDARDS USED TO VERIFY COMPLIANCE:

EN ISO 12100 EN 60204‐1

EN ISO 13732‐1 EN 61000‐6‐2

EN 55011 (Class A, Group 2 for industrial environments. Use in

other environments may pose potential difficulty ensuring

electromagnetic compatibility due to conducted as well as

radiated disturbances.)

PRINCIPLES:

This product has been manufactured according to good engineering practice.

The product specified conforms to the directives and standards described above.

Technical File Contact:

Dieter Ziesmer

Nordson Engineering GmbH

Lilienthalstrasse 6

21337 Lueneburg

GERMANYDate: 14 December 2012

Peter Lambert, Senior Vice PresidentAdhesives Dispensing Systems

1105311A03

DOC074R4

Nordson Corporation � 28601 Clemens Road ��Westlake, Ohio

Model Number_________________________

Serial Number______________________________________

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