Series 5000 Bulkmelter/Applicator with Vista...

NORDSON CORPORATION D AMHERST, OHIO D USA

Series 5000 Bulkmelter/Applicatorwith Vista Controller

Model 505/506V

Customer Product Manual1004197A

E 2000 Nordson CorporationAll rights reserved

1004197AIssued 7/00

Manual 47--506V--MA--01 (formerly 7--505/6V--MA--01)

Nordson Corporation welcomes requests for information, comments and inquiries about its products.

Address all correspondence to

Nordson Corporation11475 Lakefield Drive

Duluth, Georgia 30097-1511

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1999. No part ofthis 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.

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100 Plus, Blue Box, ChromaFlex, CleanSleeve, CleanSpray, Control Coat, Cross-Cut, Easy Coat, Econo-Coat,Excel 2000, Flow Sentry, Isocoil, Isocore, Iso-Flo, Nordson, the Nordson logo, PRX, Pro-Flo, RBX, Ready-Coat,Rhino,SelectCoat, SelectCure, Shur-Lok,Smart Spray,SystemSentry, ThreadCoat, Tribomatic, andVersa-Spray

are registered trademarks of Nordson Corporation.

CPX, CanWorks, Excel 2000, PowderGrid, Pulse Spray, SCF, Versa-Coat, Versa Screen, Package of Values, andSwirl Coat are trademarks of Nordson Corporation.

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Table of Contents

1. Operate Safely 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Safety Symbols 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Qualified Personnel 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Intended Use 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Installation and Electrical Connections 1-4. . . . . . . . . . . . . . . . . . . . . . .

6. Operation 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Less-Obvious Dangers 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Action in the Event of Unit Malfunction 1-5. . . . . . . . . . . . . . . . . . . . .

Danger of Burns 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Maintenance/Repair 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Cleaning 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. Thermoplastic Hot Melt Material 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10. Equipment and Material Disposal 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

11. Polyurethane Reactive (PUR) Hot Melt Material 1-8. . . . . . . . . . . . . . .

1. Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Basic Functions 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Basic Operating 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heating 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dispensing Material 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning Beacon 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Pails 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1Safety

Section 2Description

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3. Vista Control System 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Features of the Operator Panel 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . .

System Status Area 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULT Light 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

READY Light 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Displays Area 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selector Display and Up Key 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . .

Multipurpose Display and Keys 2-10. . . . . . . . . . . . . . . . . . . . . . . .

Actual Temperature Display 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . .

Enter Key 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Setup Area 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Move Up and Move Down Keys 2-10. . . . . . . . . . . . . . . . . . . . . . .

Move Right Key 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TEMPERATURE Area 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYSTEM SETTINGS Area 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLOCK Area 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Controls Area 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MONITOR/SCAN Key and Light 2-14. . . . . . . . . . . . . . . . . . . . . . .

STANDBY Key and Light 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEATERS Key and Light 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLOCK Key and Light 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP Key and Light 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEAR FAULTS Key 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POWER Switch 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Overview of the Control System 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Assembly 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit-Specific Boards 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Input/Output Board 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Specifications 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2Description (contd)

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1. Introduction 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Unpacking 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Inspection 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Installation 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Installation 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Installation 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Gun Installation 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Setting Up the Vista Controller 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Programming Procedures 3-10. . . . . . . . . . . . . . . . . . . . . . .

Keeping a Record of System Settings 3-10. . . . . . . . . . . . . . . . . .

Programming System Controls 3-11. . . . . . . . . . . . . . . . . . . . . . . .

Programming Optional Features 3-13. . . . . . . . . . . . . . . . . . . . . . . . .

Programming SYSTEM SETTINGS Controls 3-13. . . . . . . . . . . . . .

Programming TEMPERATURE Controls 3-17. . . . . . . . . . . . . . . . . .

To Program Setpoint & Standby TemperaturesIndividually 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Program All Zones to the Same Temperature 3-21. . . . . . . . .

Programming CLOCK Controls 3-22. . . . . . . . . . . . . . . . . . . . . . . . . .

To Set the Clock 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Set Standby and Heater Times 3-25. . . . . . . . . . . . . . . . . . . . .

To Change a Standby or Heater Set Time 3-27. . . . . . . . . . . . . . .

To Delete a Standby or Heater Set Time 3-27. . . . . . . . . . . . . . . .

To Delete Times for an Entire Day 3-28. . . . . . . . . . . . . . . . . . . . .

An Example of How to Use the Seven-dayClock Feature 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Description 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Safety Precautions 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Initial Equipment Preparation 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3Installation

Section 4Operation

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4. Operating Procedures 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Start Up 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Shut Down 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Start Up 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Shut Down 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Temperatures 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Place System in Standby 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remove System from Standby 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Warning Beacon 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Loading a Pail 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Changing the Pail 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Safety Precautions 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Relieve System Pressure 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. General System Maintenance 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Daily Maintenance 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspecting Hose Hydraulic Connections 5-5. . . . . . . . . . . . . . . . . . . .

Cleaning the Exterior 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Check the Speed Reducer Lubricant 5-6. . . . . . . . . . . . . . . . . . . . . . . . .

7. Change the Speed Reducer Lubricant 5-7. . . . . . . . . . . . . . . . . . . . . . .

8. Flush the System 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Pail 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Flushing Material 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . .

Pumping the Flushing Material Through the System 5-11. . . . . . . .

1. Introduction 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Opening the Electrical Enclosure with Power On 6-3. . . . . . . . . . . . . .

3. Adhesive Application Troubleshooting Procedures 6-4. . . . . . . . . . . . .

4. Hydraulic Troubleshooting Procedures 6-9. . . . . . . . . . . . . . . . . . . . . . .

5. Pneumatic Troubleshooting Procedures 6-11. . . . . . . . . . . . . . . . . . . . .

Section 4Operation (contd)

Section 5Maintenance

Section 6Troubleshooting

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6. Electrical Troubleshooting Procedures 6-20. . . . . . . . . . . . . . . . . . . . . .

Electrical Safety During Troubleshooting 6-20. . . . . . . . . . . . . . . . . .

Opening and Closing the Electrical Enclosure 6-20. . . . . . . . . . . . . .

Opening 6-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Closing 6-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opening the Electrical Enclosure with Power On 6-22. . . . . . . . .

Electrical Cabinet Interior 6-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting the Electrical System 6-24. . . . . . . . . . . . . . . . . . . .

7. Vista Troubleshooting Procedures 6-33. . . . . . . . . . . . . . . . . . . . . . . . .

Platen, Hose, or Gun Zone Not Heating 6-33. . . . . . . . . . . . . . . . . . .

Settings Changed or Lost 6-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Not Powering On 6-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control System Indicating a Warning 6-37. . . . . . . . . . . . . . . . . . . . .

Out-of-Band Warning 6-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Under-Temperature (UT) Warning 6-38. . . . . . . . . . . . . . . . . . . . .

Control System Indicating a Fault 6-41. . . . . . . . . . . . . . . . . . . . . . . .

Over-Temperature (OT) Fault 6-42. . . . . . . . . . . . . . . . . . . . . . . . .

Resistance Temperature Detector (RTD) Fault 6-44. . . . . . . . . .

Fault--Code Fault (F1--F7) 6-45. . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Troubleshooting Procedures 6-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the POWER Switch 6-46. . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking a Heater or Heater Circuit 6-47. . . . . . . . . . . . . . . . . . . . . .

Checking a Thermostat 6-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking an RTD or RTD Circuit 6-50. . . . . . . . . . . . . . . . . . . . . . . . .

9. Correcting System Faults Using the Vista Controller 6-54. . . . . . . . . .

Running a System Test 6-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Fault Log 6-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking System Faults 6-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Correcting Control Board Faults 6-58. . . . . . . . . . . . . . . . . . . . . . . . .

To Enable the Display Heater Proportioning Feature 6-58. . . . . .

To Solve Zone Faults 6-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10. Electrical Schematics and Wiring Diagrams 6-62. . . . . . . . . . . . . . . . . .

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1. Introduction 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Light Tower Bulb Replacement 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Hydraulic System 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparing for Hydraulic System Repairs 7-4. . . . . . . . . . . . . . . . . . .

Replacing the O-ring 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Platen Seal 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a Platen RTD 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Remove the RTD 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Install the New RTD 7-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a Platen Thermostat 7-11. . . . . . . . . . . . . . . . . . . . . . . . . .

To Remove the Thermostat 7-11. . . . . . . . . . . . . . . . . . . . . . . . . . .

To Install the New Thermostat 7-12. . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Platen 7-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Remove the Platen 7-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Install the Platen 7-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing or Rebuilding the Gerotor Pump 7-16. . . . . . . . . . . . . . . .

To Remove the Gerotor Pump 7-17. . . . . . . . . . . . . . . . . . . . . . . . .

To Disassemble the Gerotor Pump 7-21. . . . . . . . . . . . . . . . . . . . .

To Assemble the Gerotor Pump 7-27. . . . . . . . . . . . . . . . . . . . . . .

Pump Bearings and Seals 7-27. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upper Pump Plate and Gerotor Set 7-29. . . . . . . . . . . . . . . . . . . .

Pump Shaft 7-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lower Pump Plate 7-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Relief Valve and O-rings 7-33. . . . . . . . . . . . . . . . . . . . .

Manifold 7-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Install the Gear Pump 7-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Drive Assembly 7-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Drive Motor 7-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Remove the Drive Motor 7-37. . . . . . . . . . . . . . . . . . . . . . . . . . .

To Install the New Drive Motor 7-38. . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Speed Reducer 7-38. . . . . . . . . . . . . . . . . . . . . . . . . . .

To Remove the Speed Reducer 7-39. . . . . . . . . . . . . . . . . . . . . . .

To Install the New Speed Reducer 7-41. . . . . . . . . . . . . . . . . . . . .

Section 7Repair

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5. Pneumatic System 7-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rebuilding the Air Cylinder Assembly 7-42. . . . . . . . . . . . . . . . . . . . .

To Remove the Air Cylinder Assembly 7-43. . . . . . . . . . . . . . . . . .

To Rebuild the Air Cylinder Assembly 7-45. . . . . . . . . . . . . . . . . .

To Install the Air Cylinder Assembly 7-48. . . . . . . . . . . . . . . . . . . .

6. Servicing the Vista Controller 7-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preventing Damage to Circuit Boards 7-50. . . . . . . . . . . . . . . . . . . . .

To Ensure a Proper Ground 7-50. . . . . . . . . . . . . . . . . . . . . . . . . . .

To Use an Electrostatic Discharge Wrist Strap 7-51. . . . . . . . . . .

Safely Accessing Electrical Components 7-51. . . . . . . . . . . . . . . . . .

Replacing a Surge Guard 7-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a Fuse 7-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a Power Board Fuse 7-56. . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Circuit Boards 7-58. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a Control Assembly Board 7-58. . . . . . . . . . . . . . . . . . . . .

Preparation for Removal 7-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Remove the Power Board 7-59. . . . . . . . . . . . . . . . . . . . . . . . . .

To Remove the Control Board 7-62. . . . . . . . . . . . . . . . . . . . . . . . .

To Remove the Display Board 7-64. . . . . . . . . . . . . . . . . . . . . . . . .

To Install the Display Board 7-65. . . . . . . . . . . . . . . . . . . . . . . . . . .

To Install the Control Board 7-65. . . . . . . . . . . . . . . . . . . . . . . . . . .

To Install the Power Board 7-67. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a Unit-Specific Board 7-72. . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Operator Panel 7-72. . . . . . . . . . . . . . . . . . . . . . . . . . .

To Remove the Operator Panel 7-72. . . . . . . . . . . . . . . . . . . . . . . .

To Install the Operator Panel 7-74. . . . . . . . . . . . . . . . . . . . . . . . . .

System Restoration 7-76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Control Assembly 7-76. . . . . . . . . . . . . . . . . . . . . . . . .

To Remove the Control Assembly 7-77. . . . . . . . . . . . . . . . . . . . .

To Install the Control Assembly 7-81. . . . . . . . . . . . . . . . . . . . . . . .

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1. Introduction 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Illustrated Parts List 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Crossover Assembly 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Frame Assembly 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Motor Assembly 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump and Manifold Assembly 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Platen Assembly 8-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Junction Box Assembly 8-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Electrical Enclosure Assembly 8-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Electrical Kit 8-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. Control Assembly 8-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10. Warning Beacon 8-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11. Platen Removal Assembly 8-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12. Pneumatic Assembly 8-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13. Recommended Spare Parts and Kits 8-26. . . . . . . . . . . . . . . . . . . . . . .

Spare Parts and Kits for the Main Assemblies 8-26. . . . . . . . . . . . .

Supplies for Maintenance and Repair 8-28. . . . . . . . . . . . . . . . . . . . .

14. Replacement Parts 8-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transformers 8-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Platens -- Model 505 8-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Platen -- Model 506 8-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15. Hose Parts Lists 8-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hoses for Manual Guns 8-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hoses for Automatic Guns 8-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transfer Hoses 8-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 8Parts

Table of Contents ix


1004197AIssued 7/00


1. Introduction 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Descriptions 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Platen Guard Kit 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Hood 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caster Kit 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pail Hold Down Kit 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Changeover 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch Kit 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Run-Up Control 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Exhaust Hood 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Pail Hold Down Assembly 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 9Options

Table of Contentsx


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E 1994 Nordson CorporationAll rights reserved Issued 11/94

A1EN--02--[XX--SAFE]--4

Section 1

Safety

Safety1-0

E 1994 Nordson CorporationAll rights reservedIssued 11/94

A1EN--02--[XX--SAFE]--4

Safety 1-1


A1EN--02--[XX--SAFE]--4

Section 1Safety

Safety instructions contained in this section and throughout thisdocument apply to tasks that may be performed with or on the unit.Warnings related to specific safety concerns are included within the textas appropriate. It is very important that these safety instructions arealways followed. Failure to do so could result in personal injury and/ordamage to the unit or other equipment.

With this in mind, here are some basic safety recommendations:

S Read and become familiar with this Safety section prior to installing,operating, maintaining, or repairing the unit.

S Read and follow the warnings which appear within the text and arerelated to specific tasks.

S Store this document within easy reach of personnel operating ormaintaining the unit.

S Wear personal protective equipment and clothing such as safetygoggles and gloves.

S Familiarize yourself with and follow all safety instructions prescribedby your company, general accident-prevention regulations, andgovernment safety regulations.

1. Operate Safely

Safety1-2


A1EN--02--[XX--SAFE]--4

The following symbols are used to warn against dangers or possiblesources of danger. Become familiar with them! Failure to heed awarning could lead to personal injury and/or damage to the unit or otherequipment.

WARNING: Failure to observe may result in personal injury,death, or equipment damage.

WARNING: Risk of electrical shock. Failure to observe mayresult in personal injury, death, or equipment damage.

WARNING: Disconnect equipment from the line voltage.

WARNING: Hot! Risk of burns. Wear heat-protective clothing,safety goggles, and/or heat-protective gloves depending on thesymbols shown.

WARNING: Risk of explosion or fire. Fire, open flames, andsmoking prohibited.

WARNING: System or material pressurized. Relieve pressure.Failure to observe may result in serious burns.

CAUTION: Failure to observe may result in equipmentdamage.

CAUTION: Hot surface. Failure to observe may result inburns.

2. Safety Symbols

Safety 1-3


A1EN--02--[XX--SAFE]--4

“Qualified personnel” is defined here as individuals who thoroughlyunderstand the equipment and its safe operation, maintenance, andrepair. Qualified personnel are physically capable of performing therequired tasks, familiar with all relevant safety rules and regulations, andhave been trained to safely install, operate, maintain, and/or repair theequipment. It is the responsibility of the company operating theequipment to see that its personnel meet these requirements.

The unit is designed and intended to be used only for the purposedescribed in the Description section. Uses not in accordance with thatsection or as described in this document are considered unintended usesand not in accordance with governing regulations.

WARNING: Use of this equipment in ways other thandescribed in this document may result in personal injury, death,or equipment damage.

The following actions of the owner or operator of the unit are some, butnot all, examples of unintended use which would permit Nordson to claimit is not responsible for personal injury or property damage arising fromsuch unintended use:

S Unapproved modifications or changes to the unit

S Failure to comply with the safety instructions

S Failure to comply with instructions concerning installation, use,operation, maintenance, or repair, or when these tasks are carried outby unqualified personnel

S Use of inappropriate or incompatible foreign materials or auxiliaryequipment

S Failure to observe workplace safety rules or regulations issued bygovernment authorities or safety councils

3. Qualified Personnel

4. Intended Use

Safety1-4


A1EN--02--[XX--SAFE]--4

WARNING: Failure to follow the safety procedures can result ininjury or death.

S All electrical, pneumatic, gas, and hydraulic connections andinstallations of hot melt equipment may only be carried out byqualified personnel. Be sure to observe installation instructions forcomponents and accessories.

S Equipment must be properly grounded and fused according to itsrated current consumption (see ID plate).

S Cables which run outside the unit must regularly be checked for wearor damage.

S Power supply wire gauge and insulation must be sufficient to handlerated current consumption.

S Cables must never be squeezed or pinched. Do not locate cables orhoses in high traffic areas.

The unit should be operated by qualified personnel in accordance withthe instructions presented in this document.

WARNING: Failure to follow the safety procedures can result ininjury or death.

S Never allow the unit to be operated by personnel under the influenceof substances which reduce their reaction times, or who are not ableto operate the equipment for physical reasons.

S Prior to each start-up of the unit, check protection and warningdevices and make sure they are fully functional. Do not operate theunit if these devices are not functioning properly.

S When the removal of safety equipment is required for installation,maintenance, or repair of the unit, it must be re-connectedimmediately upon completion of the work.

S Prior to start-up of the unit, check to make sure all safety guards andsafety equipment are in place and functioning properly.

5. Installation and ElectricalConnections

6. Operation

Safety 1-5


A1EN--02--[XX--SAFE]--4

S In a humid environment, only equipment featuring a correspondingclass of protection may be operated.

S Do not operate the unit in an explosive environment.

S Keep parts of the body or clothing away from rotating parts. Do notwear loose articles of clothing when operating or servicing units withrotating parts. Take off wrist watches, rings, necklaces, or similarpieces of jewelry and pin up or cover long hair before performing anywork on or with the unit.

S To carry out measurements on work pieces, switch off the unit andwait until it comes to a standstill.

S Never point hand guns or applicator nozzles at yourself or otherpersons.

WARNING: An operator or service technician working with theunit should be aware of less-obvious dangers that often cannotbe completely minimized at production sites:

S Exposed surfaces of the unit which cannot be practicallysafeguarded. They may be hot and take time to cool after the unithas been operating.

S The possibility that electrical potentials may remain in the unit afterthe unit was de-energized

S Hot melt material and vapors

S Hydraulically or pneumatically operated parts of the unit

S Parts winding something up or down which are not covered

If the unit malfunctions, switch it off immediately.

S Turn the circuit breaker or main power switch OFF.

S Have the unit repaired by qualified personnel only.

6. Operation (contd)

Less-Obvious Dangers

Action in the Event of UnitMalfunction

Safety1-6


A1EN--02--[XX--SAFE]--4

Contact with hot melt materials or hot areas of the unit may produce asevere skin burn.

WARNING: Hot! Risk of burns. Wear heat-protective clothing,safety goggles, and/or heat-protective gloves depending on thesymbols shown.

S Be extremely careful when using hot melt material. Even solidifiedmaterial may still be very hot.

S Always wear protective clothing which safely covers all exposed partsof the body.

In case of burns:

S Immediately cool affected skin areas using cold, clean water.

S Do not forcefully remove hot melt material from the skin.

S Immediately seek medical attention.

Allow only qualified personnel to perform the procedures described in thisdocument. When performing such tasks, wear protective clothing, andequipment.

WARNING: Even when the circuit breaker or main powerswitch is OFF, the unit is still electrically energized. Completethe following steps prior to maintenance or repair:

S Disconnect, lock out, and tag external power supply.

S To ensure the external power supply is disconnected, attempt tooperate the unit. If the unit does not energize, proceed withmaintenance or repair work.

S If the unit energizes, repeat the disconnect, lock out, and tagprocedure. Re-test the unit.

Danger of Burns

7. Maintenance/Repair

Safety 1-7


A1EN--02--[XX--SAFE]--4

S Follow the specific instructions provided in this manual to relieve thesystem pressure in the entire unit.

S Secure pneumatically- or hydraulically-operated equipment againstuncontrolled movement.

S Only use parts which do not compromise the safety of the unit. Onlyuse genuine Nordson parts.

S Always use tools with insulated handles when removing or installingcomponents.

NOTE: Always refer to the material manufacturer’s Material Safety DataSheet (MSDS) or material information sheet before working with any ma-terial.

WARNING: Never clean any aluminum part or flush anysystem using halogenated hydrocarbon fluids. Examples ofcommon halogenated hydrocarbons are: dichloromethylene,1,1,1-trichloroethylene, and perchloroethylene. Halogenatedhydrocarbons may react violently with aluminum parts.

WARNING: Fire, open flame, and smoking are prohibited whencleaning fluids are used. Observe all explosion preventionregulations. Cleaning fluids may only be heated usingtemperature-controlled and explosion-protected heaters.

S Never use an open flame to clean the unit or components of the unit.

S Use only cleaning fluids designed or intended to be used with the hotmelt material being used in the unit. Never use paint fluids under anycircumstances.

S Note the flash point of the cleaning fluid used. Only use a controlledheating method to heat fluids.

S Ensure sufficient room ventilation to draw off generated vapors.Avoid prolonged breathing of vapors.

7. Maintenance/Repair(contd)

8. Cleaning

Safety1-8


A1EN--02--[XX--SAFE]--4

NOTE: Always refer to the material manufacturer’s Material Safety DataSheet (MSDS) or material information sheet before working with any hotmelt material.

S Ensure the work area is adequately ventilated.

S Do not exceed recommended processing temperatures. Doing socreates a danger to personnel due to decomposition of the material.

Dispose of equipment and materials used in operation and cleaningaccording to local regulations.

9. Thermoplastic Hot MeltMaterial

10.Equipment and MaterialDisposal


100 4197AIssued 7/00


Section 2

Description

Description2-0


100 4197AIssued 7/00


Description 2-1


100 4197AIssued 7/00


Section 2Description

The Nordson Series 5000 Model 505 and Model 506 pailmelter/applicators are non-circulating systems which melt and pumpthermoplastic materials directly from straight-sided, 20 liter or (5-gallon)shipping pails in applications requiring high volume and rapid delivery ofmaterial to the substrate. While the Model 505 is suited forgeneral-purpose applications, the Model 506 is specially equipped tohandle moisture-curing and other reactive materials. The advantage of aSeries 5000 unit is the ability to eliminate the need to keep a holding tankfilled with material.

Some of the main assemblies on all Model 505 and Model 506 units areshown in Figure 2-1.

4705010A

3

2

14

Fig. 2-1 Series 5000 Model 506 Pail Melter/Applicator

1. Motor Drive2. Junction Box

3. Platen Assembly4. Electrical Enclosure

1. Introduction

Description2-2


100 4197AIssued 7/00


WARNING: Exercise extreme caution when dispensingreactive materials with the Series 5000 system. Prior tooperating the system using these materials, be sure tothoroughly read the material Safety Data Sheet (MSDS)provided by the material supplier. Follow all recommendationsof the adhesive manufacturer and those in the MSDS pertainingto the storage, handling and use of these materials. Payparticular attention to those sections of the MSDS addressingtoxicity, health effects, temperature limits, reactivity conditionsand use of protective equipment to avoid personal injury anddamage to equipment.

Standard on both the Model 505 and Model 506 units are:

S A positive-displacement gear pump featuring modular design for easyremoval, disassembly and replacement

S Direct drive to pump shaft for most applications

S One-piece aluminum platen with two cast-in heaters for even heatdistribution and one-piece platen seal

S Solid-state digital setpoint with over-temperature control of a heatedplaten and five hose/gun pairs (11 zones)

S Enclosed temperature controls inside a lockable electrical enclosureto prevent tampering

S Digital temperature display of each zone in _F or _C as determinedby the equipment operator

S Easy-to-read “System Ready” and “Sensor Fault” LED indicators

S Exterior controls for “power on”, “stop”, “pump off/on” and “pumpspeed”

S Resistance temperature detector (RTD) temperature control withbackup over-temperature thermostat on the platen

S Manually-operated platen removal air line/adapter assembly

S Temperature standby circuitry to lower setpoint temperatures topredetermined level during periods of inactivity

1. Introduction (contd)

Description 2-3


100 4197AIssued 7/00


S Digital, 7-day timer for automatic startup

S Warning beacon to show low pail/empty pail condition visiblefrom 360_

S Auto shutdown when gun is not triggering

Features standard on the Model 506 but optional on the Model 505include:

S PTFE-coated platen equipped with a PTFE-encapsulated silicone(TES) platen seal

Optional features available for both units include:

S Integral, permanently-plumbed platen removal system

S Electric clutch to reduce motor wear at high-cycling applications

S Pail hold-down assembly to keep pail secure during platen insertionand removal

S Casters to increase mobility

S Run-up control to keep consistent bead size for varying line speeds

S Hinged platen guard to increase safety of equipment operator andnearby personnel

S Automatic Changeover option for two-unit systems for continuousapplication of adhesive with no downtime during pail changeover

Description2-4


100 4197AIssued 7/00


The following basic functions are common to all Series 5000 units.

1. Heat material to the recommended application temperature in theshipping container.

2. Transfer the material and dispense it onto a substrate whilemaintaining the application temperature.

3. Provide a method of convenient pail changeover when the shippingcontainer reaches empty level.

4. Provide labor-saving controls and indicators for equipment operation.

After the unit is powered up and all temperature zones have reachedsetpoint, an opened, straight-sided, 20-liter or 5-gallon pail of material iscentered on the frame base directly below the platen. The heated,one-piece platen equipped with the gear pump is then lowered by twopneumatic pistons into the adhesive. An air-tight compartment is createdbelow the platen by the platen seal.

The pump transfers heated material through a port in the bottom of theplaten and forces it through the manifold. Material away from the platenremains solid until the platen moves further down the pail.

Material is pumped through one or two heated hose(s) into the heatedautomatic or hand-operated gun(s) and dispensed as needed onto thesubstrate. This concept is illustrated in Figure 2-2.

2. Basic Functions

Basic Operating

Description 2-5


100 4197AIssued 7/00


4701134A

1

9

2

7

6

4

3

5

8

Fig. 2-2 Material Flow Diagram

1. Hose2. Gear pump3. Drum4. Pneumatic piston

5. Platen6. Solid material7. Melted material

8. Gun9. Manifold10. Fixed, overpressure relief valve

Material is brought to/kept at application temperature at three points inthe Series 5000 system:

S In the shipping container by the platen which is equipped with twocast-in resistive heaters.

S In the hoses by a spirally-wound heating element in each hose.

S In the gun by a replaceable cartridge heater.

An explanation of platen, hose and gun heating and temperature controlcan be found later in this section.

Heating

Description2-6


100 4197AIssued 7/00


Material first flows into the pumping chamber at the bottom of the platen,then into the pump body and through the pump exit port into thedistribution manifold. One or two hoses are connected to the manifold.Automatic or hand-operated guns at the delivery end of the hoses aretriggered to dispense the material onto the substrate on demand.

The drive train consists of a 1/2 hp variable speed AC drive coupled to a30:1 speed reducer. A drive shaft with U-joints at each end connects thespeed reducer to the gear pump shaft.

In units with no clutch, the motor and drive train components rotate eachtime the gun is triggered.

In units equipped with the optional clutch, the motor continues to rotatebut is only coupled to the pump drive shaft when a gun is triggered.Because this arrangement prevents constant motor stops/starts while theunit is in operation, motor life can be extended considerably.

The Nordson Warning Beacon is composed of a preassembledlens-and-bulb light tower assembly with mounting hardware. Thewarning beacon is visible for at least 10.7 m (35 ft.) and is useful inassisting the equipment operator with maintaining an adequate supply ofmaterial at the unit, especially when the operator cannot be physicallypresent at the unit at all times. The green light indicates a readycondition, amber indicates adhesive material is getting low, and redindicates a fault condition exists.

Changing pails involves raising the platen out of the empty pail,exchanging the old pail for a full one and lowering the platen.

The Models 505 and 506 are equipped with a low pressure platenremoval air line/adapter assembly to force air below the platen to preventa vacuum and aid in forcing the platen up and out of the pail.

Before the platen is raised, the platen T-handle is removed. The platenremoval air line/adapter assembly is then installed in its place to force airinto the chamber under the platen as the platen is raised. Then the pailis removed and a full one installed in its place.

The entire pail changeover procedure is detailed in the Operation sectionof this manual.

Dispensing Material

Warning Beacon

Changing Pails

Description 2-7


100 4197AIssued 7/00


The control system regulates the temperature of all heated zones andcontrols how the unit functions. The operator panel allows you toprogram the system to meet changing needs:

S Heated zones are controlled individually, giving you more flexibility insetting up your system.

S With the seven-day clock feature you can tailor operations for a weekat a time, with different schedules for each day of the week.

S The control system is designed so that a brownout or power failurewill not cause a loss of your programmed settings.

The operator panel of the control system is divided into four functionalareas:

S System StatusS DisplaysS System SetupS System Controls

4705032A

1

2

3

4

Fig. 2-3 Operator Panel

1. System status area2. Displays area

3. System setup area4. System controls area

3. Vista Control System

Features of the OperatorPanel

Description2-8


100 4197AIssued 7/00


The System Status area of the operator panel gives you a quicksummary of the status of your system. The FAULT and READY lights letyou know if the system is prepared for operation.

4103926

1 2

Fig. 2-4 System Status

1. FAULT light 2. READY light

FAULT Light

The red FAULT light indicates different types of fault conditions. Refer toTable 2-1.

Table 2-1 System Notification of FAULT Conditions

FAULT Light Status (see Note) System Condition

FAULT light turns on and stayson.

A heater zone is overtemperature.

FAULT light flashes for twominutes, then stays on.

A sensor (RTD) in any zone isopen or shorted.

FAULT light flashes continuously. A heater zone is out of band,either high or low.A heater zone is more than19.5 _C (35 _F) under thesetpoint temperature.

NOTE: When the FAULT light turns on and stays on, the systemremoves heater power for all zones. When the FAULT light flashes,heater power stays on.

System Status Area

Description 2-9


100 4197AIssued 7/00


READY Light

The green READY light turns on when all the following conditions exist:

S All zones are + 3 _C (+ 5 _F) of the setpoint temperatures.S The system-ready time delay has elapsed.S No fault exists.

The Displays area of the operator panel gives you detailed informationabout the status of your system. When you are running the system, itshows the status of each operating zone. When you are enteringsetpoints, it shows your current system setup.

4130011

1 2 3

46 5

Fig. 2-5 Displays

1. Selector display2. Multipurpose display3. Actual temperature display

4. Enter key5. Up and down keys6. Up key

Selector Display and Up Key

The Selector display allows you to access information about the status ofyour system during operation and system setup. The display

S shows the selected zone number when used with TEMPERATUREand when scanning

S shows the day when used with CLOCK

S shows the feature number when used with SYSTEM SETTINGS

The Up key, which is located below the Selector display, changes thevalue of a setting. Refer to System Setup Area for a detailed descriptionof viewing or changing system setpoints.

Displays Area

Description2-10


100 4197AIssued 7/00


Multipurpose Display and Keys

During normal operation, the Multipurpose display shows the setpointtemperature for a selected zone. This allows you to compare the actualtemperature of the displayed zone with its setpoint temperature.

Actual Temperature Display

The Actual Temperature display shows the actual temperature of theheated zone. When the scan mode is enabled, each zone is displayed insequence. When the scan mode is disabled, only the temperature for theselected zone is displayed.

Enter Key

The Enter key saves the setpoint entered in the Multipurpose display.

The System Setup area of the operator panel allows you to customize thesystem to your needs. From this area you can control

S the temperature at which each zone operates (TEMPERATURE)S how the unit operates (SYSTEM SETTINGS)S when the heaters automatically turn ON or OFF (CLOCK)

To customize system controls, use the keys in the System Setup area inconjunction with the keys in the Displays area.

Move Up and Move Down Keys

The Move Up and Move Down keys select features within the SystemSetup area, allowing you to tailor the system to your needs. You canselect the following features using the Move Up and Move Down keys:

S SETPOINT temperatureS STANDBY temperatureS SYSTEM SETTINGSS SET TIMES ENTER STANDBYS EXIT STANDBYS HEATERS ONS HEATERS OFF

System Setup Area

4705036A

3

1

4

5

2

Description 2-11


100 4197AIssued 7/00


Move Right Key

The Move Right key selects features within the System Setup area,allowing you to tailor the system to your needs. You can select thefollowing features using the Move Right key:

S INTERNAL TEMPERATURE zoneS HOSE TEMPERATURE zoneS GUN TEMPERATURE zone (can be used for fill valve zone)S INTERVAL 1S INTERVAL 2

Fig. 2-6 System Setup

1. Move Up and Move Down keys2. Move Right key3. TEMPERATURE4. SYSTEM SETTINGS5. CLOCK

TEMPERATURE Area

The TEMPERATURE area of System Setup allows you to program thesetpoint or standby temperature for three types of heated zones:internal, hose, or gun (fill valve).

When used in the TEMPERATURE area,

S The Move Up and Move Down keys select SETPOINT or STANDBY.

S The Move Right key selects the zone (internal, hose, or gun) for theselected temperature (standby or setpoint).

S The UP key located below the selector display allows you to selectwhich hose or gun is being set.

Description2-12


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SYSTEM SETTINGS Area

From the SYSTEM SETTINGS area, you can customize or check thesettings of the following system features:

S passwordS system-ready time delayS overtemperature setpointS Celsius or Fahrenheit unitsS global temperature bandsS individual temperature bandsS sequential startup or simultaneous startupS display heater proportioningS warning or power notificationS ready or pump notificationS auto-energize pumpS auto-energize heatersS time with heaters onS fault log

CLOCK Area

From the CLOCK area you can program the system to turn heaters on oroff or to place the system in standby or operating mode at a time that youselect. The clock stores two sets of times referred to as intervals. Eachinterval stores four settings as shown in Table 2-2.

Table 2-2 Interval Settings

INTERVAL 1 INTERVAL 2

Standby Settings EnterExit

EnterExit

Heater Settings OnOff

OnOff

4103929

1

2

3

4

5

6 7

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The System Controls area of the operator panel allows you to controlbasic system operations and override programmed controls. The lights inthis area tell you whether a feature is on or off. Using the keys andswitches in this area, you can:

S Monitor the status of a particular zone, or scan each zone to check itsstatus.

S Take the system into or out of standby.

S Turn the heaters on or off.

S Turn the clock feature on or off. (This is useful when you want thesystem to startup automatically.)

S Turn the pump on or off.

S Run a system test to determine whether a fault that the system hasdetected was corrected.

S Turn main power to the series 5000 unit on or off. (Disconnect switchon side of cabinet.)

Fig. 2-7 System Controls

1. MONITOR/SCAN key and light2. STANDBY key and light3. HEATERS key and light4. CLOCK key and light5. PUMP key and light6. CLEAR FAULTS key7. POWER switch

System Controls Area

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MONITOR/SCAN Key and Light

Pressing the MONITOR/SCAN key places the system in the monitor orscan mode. In the scan mode,

S The system scans each heated zone, displaying each zone’stemperature in sequence.

S If the system-ready time delay feature is active, the system shows thenumber of minutes remaining until the system is ready for operation.

S The MONITOR/SCAN light turns on and stays on.

In the monitor mode,

S The system displays the temperature of only the zone currentlyselected.

S If the system-ready time delay feature is active, the system shows thenumber of minutes remaining until the system is ready for operation.

S The MONITOR/SCAN light stays on.

STANDBY Key and Light

Pressing the STANDBY key takes the system into or out of the standbymode. When the standby feature is active,

S The STANDBY light turns on.

S The READY light turns off.

S The pump is turned off.

S Temperatures on all zones drop until the temperature of each zonereaches the preselected standby temperature.

S The heaters light remains on. If the HEATERS light is not on, youcannot place the system in the standby mode.

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When the standby feature is disabled,

S The STANDBY light turns off.

S The heaters turn on and all zones begin heating.

S If the auto-energize pump feature is active, the pump turns on.

S After all zones have reached their preselected setpoint temperature,the READY light turns on.

HEATERS Key and Light

Pressing the HEATERS key turns power to the heaters on and off. Theheaters must be turned on for the unit to operate.

The HEATERS light turns on when this feature is active.

NOTE: If the system is set for auto-energize heaters, the heaters areautomatically enabled and the HEATERS light turns on when thePOWER switch is turned on.

CLOCK Key and Light

Pressing the CLOCK key turns the seven-day clock on and off. Whenthe clock is on, the system is controlled by the settings for ENTERSTANDBY, EXIT STANDBY, HEATERS ON, and HEATERS OFF.

The CLOCK light turns on when this feature is active.

NOTE: If the clock feature is enabled when the POWER switch is turnedoff, it will automatically be enabled when the switch is turned back on.The CLOCK light will turn on to show that the clock feature is enabled.

PUMP Key and Light

Pressing the PUMP key enables the pump. The PUMP light turns onwhen the READY light is on.

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CLEAR FAULTS Key

Pressing the CLEAR FAULTS key runs a system test. The test lasts fiveseconds and verifies that the problem causing a system fault wascorrected. If the problem was corrected, the FAULT light in the SystemStatus area of the operator panel will turn off once the test is completed.If the problem was not corrected, the FAULT light will stay on.

POWER Switch

Pressing the POWER switch turns power to the Vista Controller on or off.To turn power on to the pail melter turn the disconnect on the side of theelectrical cabinet to the ON position.

The Vista control system controls how your unit operates. The controlsystem includes a variety of printed circuit boards (hereafter referred toas boards) and other components that you should be familiar with tosafely troubleshoot and repair your unit.

See Figure 2-8. The main components of the control system are thecontrol-end frame, the control assembly, and the operator panel. Thecontrol assembly is mounted on the inside of the control-end frame. Theoperator panel is mounted on the front of the control-end frame. Thecontrol assembly is made up of three boards that are required for yourunit to function properly. Refer to the following table.

Table 2-3 Control Assembly Boards

Control AssemblyBoard

Function

Power board Provides power to the unit and supplies theheater power for most of the unit’s heatedcomponents

Control board Contains the Vista software chip and controlshow the unit operates

Display board Allows the displays to function

4. Overview of the ControlSystem

Control Assembly

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4130076

1

+

12

34

5

Fig. 2-8 Control Assembly Components

1. Power board2. Control board3. Display board

4. Control-end frame5. Operator panel

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The control system also includes any unit-specific boards that arerequired for your unit to function properly. The presence of these boardsvaries depending on the configuration of the unit. Refer to the followingtable.

Table 2-4 Unit-Specific Boards

Unit-SpecificBoard

Function

Contactor board Provides the additional switching circuitryneeded when a unit has certain features.

5/6 hose/gunboard

Expands a unit’s temperature-control capacityfrom four hoses/guns to six hoses/guns,supplying the heater power for hoses 5--6 andguns 5--6

Your unit may have an optional input/output (I/O) board. The I/O board isnot required for a unit to function properly. Refer to Series 3000VInput/Output Board in the Options section at the end of this manual forinformation about the I/O board, including troubleshooting procedures,repair procedures, and a parts list.

Unit-Specific Boards

Optional Input/Output Board

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Table 2-5 provides physical and operational specifications for theModel 505/506 pail melter/applicators.

Table 2-5 Specifications

Specification Model 505 Model 506 Notes

Motor/Drive 1/2 hp, 30:1 gear reducer 1/2 hp, 30:1 gear reducer

Pump 3/4 in. gerotor , 11.6 cc/rev 3/4 in. gerotor , 11.6 cc/rev

Platen Material, HeatingMethod

One-piece pinned aluminum; twocast-in heaters

One-piece smooth, PTFE-coated

Platen Seal PTFE encapsulated silicone PTFE encapsulated silicone

Platen Surface Area 1303 cm@ (202 in@) 613 cm@ (95 in@)

Maximum Melt Rate 45.36 kg/hr (100 lb/hr) 45.36 kg/hr (100 lb/hr) A

Maximum Pump Rate 37.6 kg/hr (83 lb/hr) 37.6 kg/hr (83 lb/hr) A

Maximum PowerConsumption (ServiceRequired)

Depends on line voltage Depends on line voltage

Weight 181.4 kg (400 lb) 181.4 kg (400 lb) B

Dimensions (H x W x D) w/elevator up

161.29 x 60.96 x 76.2 cm (63.5 x24 x 30 in.)

161.29 x 60.96 x 76.2 cm (63.5 x24 x 30 in.)

Operating Voltage andCurrent

200 VAC, 50 Hz, 3 phase, 71A240 VAC, 60 Hz, 3 phase, 77A380 VAC, 50 Hz, 3 phase, 43A415 VAC, 50 Hz, 3 phase, 45A480 VAC, 60 Hz, 3 phase, 67A

200 VAC, 50 Hz, 3 phase, 71A240 VAC, 60 Hz, 3 phase, 77A380 VAC, 50 Hz, 3 phase, 43A415 VAC, 50 Hz, 3 phase, 45A480 VAC, 60 Hz, 3 phase, 67A

Inside Drum Diameter 571 mm (22 1/2 in.) 571 mm (22 1/2 in.)

Capacity 20 l (5 gal) 20 l (5 gal)

Supply Air Pressure 413.6--689.5 kPa (80--100 psi) 413.6--689.5 kPa (80--100 psi)

Operating Temperature 38--232 _C (100--450 _F) 38--232 _C (100--450 _F)

Maximum Hose Capacity 5 5

Exhaust Hood Air FlowRequirements

57 l/min.

NOTE A: Depends on adhesive material type and viscosity.B: Depends on configuration.

5. Specifications

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Section 3

Installation

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Section 3Installation

This section contains information necessary for the proper installation ofthe Models 505 and 506 Pail Melter/Applicators. Specifically:

S UnpackingS InspectionS Installation of the unit (including electrical connections), hoses and

guns.

Other than using normal care, no special unpacking instructions arerequired. All equipment (including extrusion hoses and guns) ispre-assembled and shipped in its own container.

After unpacking, make the following inspections:

1. Examine all surfaces for evidence of dents, scratches, corrosion andother physical damage.

2. Check the platen seal for damage (cracks, slits, etc.).

3. Unlatch and open the electrical enclosure door. Ensure that allelectrical connections inside the enclosure and on the inside of thedoor are tight.

4. Check the hoses for broken connectors, tears in the outer cover,evidence of kinks or other damage.

5. Examine all fasteners and mechanical connections for tightness.

Report any damage to your Nordson representative.

1. Introduction

2. Unpacking

3. Inspection

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Installation is divided into three parts:

S Unit InstallationS Electrical ConnectionsS Automatic Gun Installation

Follow these instructions to install the unit.

WARNING: Allow only qualified personnel to perform thefollowing tasks. Follow the safety instructions in this documentand all other related documentation.

1. Position the unit at a location that allows access to the controls andplaten area. Refer to Specifications in the Description section.

NOTE: See Figure 3-1. Ensure that there is at least 145.5 cm(57.3 in) overhead clearance for units without casters or 160.8 cm(63.3 in.) overhead clearance for units with casters so the platen canbe raised to its maximum height.

NOTE: (Automatic guns) Ensure that the unit is positioned so thehose will reach from the gun to the pump without straining or crimpingthe hose.

2. If your unit is not equipped with casters, level the unit as necessaryby installing shims near the four bolt holes in the frame base. Thenuse 5/16 in. bolts and washers to secure the unit to the floor.

3. Coat the hose connector threads on the pump with Never Seezr.Thread the female swivel hose fitting onto the pump connector.

NOTE: (Dual-hose gerotor pump manifold). If no second hose will beused, install a pipe plug in the unused hose port.

NOTE: Nordson recommends that a hose support be used to preventhose damage in applications where the hose is suspended by anoverhead tool balancer or similar device.

4. Installation

Unit Installation

Installation 3-3


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4705012A

145.5 cm (57.3 in.)without casters

with casters160.8 cm (63.3 in.)

(36.9 in.)93.7 cm

22.1 cm(8.7 in.)

Fig. 3-1 Model 505/506 Pail Melter/Applicator Overhead Clearance)

NOTE: Route hoses to prevent kinking and abrasion. To preventcompression of the internal tubing, do not install any hose thatrequires a bend radius of less than 165 mm (6.5 in.).

NOTE: Hot melt hoses should not be secured or supported so that alarge surface area of the hose contacts a cold floor, cold steel, angleiron or other cold material. Doing so may result in poor hoseperformance.

NOTE: Hot melt hoses should not be placed inside any closed coverwhere heat dissipation is restricted or prevented. This includeselectrical conduit, insulation of any type or tight metal covers. Hosefailure can occur if the hose is insulated beyond the factory-installedinsulation.

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WARNING: Risk of electrical shock. Complete gun-to-hosehydraulic and electrical connections before completinghose-to-unit electrical connections. Failure to observe couldresult in personal injury or death.

4. Set the main filter/regulator to 0 kPa/psi.

5. Ensure that the elevator control valve is in the neutral (center)position. See Figure 3-2.

4701215B

ELEVATORCONTROL

Fig. 3-2 Elevator Control Valve and Platen Removal Switch

6. Secure an external, unlubricated air supply of at least 414 kPa(60 psi) to the quick disconnect fitting (1). See Figure 3-3.

NOTE: Nordson recommends that a customer-supplied shut-off valvebe installed in the air supply line in order to isolate the unit formaintenance or other procedures.

Unit Installation (contd)

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4701139

4

3

1

2

Fig. 3-3 Air Filter/Regulator and Air Pressure Gauge

1. Quick disconnect fitting2. Filter/Regulator handle

3. Filter/Regulator4. Air pressure gauge

The models 505 and 506 Pail Melter/applicators are available with thefollowing input voltages:

S 200 VAC; 3-wireS 230 VAC; 3-wireS 400 VAC; 3-wireS 230/400 VAC; 4-wireS 480 VAC; 3-wire

The input voltage for the unit is stamped on the nameplate on the front ofthe electrical enclosure.

Electrical Installation

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The following procedure applies to all voltages.

1. In order to meet electrical code requirements, install acustomer-supplied disconnect switch with a lockout in the input powersupply line to the unit.

WARNING: Risk of electrical shock. Lock out input power asdirected. The input terminal block remains charged even whenthe main disconnect switch is set to OFF. Failure to observecould result in personal injury or death.

2. Remove the knockout plug in the top of the electrical enclosure andinstall a customer-supplied strain relief at this access hole.

NOTE: The input power supply line may be routed into the electricalenclosure by way of another location. However, this will require acustomer-produced hole in the electrical enclosure.

3. Route a 3-phase input power supply line through the strain relief andinto the electrical enclosure.

4. Unlatch and open the electrical enclosure and connect the powersupply line to terminals L1, L2 and L3 at the main disconnect switch.

NOTE: The power supply must be rated to at least 30 amps(60 amps minimum for 200 VAC units) and be within 10% of thevoltage rating specified on the unit’s nameplate.

5. Connect the input power supply line ground wire to the copperterminal at the ground stud.

6. Connect a reliable, non-floating earth ground to the ground studinside the enclosure by way of the input power supply line accesshole.

NOTE: Do not apply input power to the unit until directed to do so inthe Operation section of this manual.

Electrical Installation (contd)

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WARNING: Risk of electrical shock. Complete gun-to-hosehydraulic and electrical connections before completinghose-to-unit electrical connections. Failure to observe couldresult in personal injury or death.

NOTE: Refer to the Troubleshooting section for wiring diagrams andschematics. Also, refer to the product manual for your particularextrusion gun.

1. See Figure 3-4. Install the gun on the parent machine in properalignment with the substrate (1). If the mounting retainer is used forthis purpose, use a 13 mm (0.5 in.) diameter bar. For optimumcontrol of bead position, optimum response time and minimum heatloss, nozzles should be positioned approximately 13 mm (0.5 in.)from the substrate.

4201071A1 2 3Fig. 3-4 Automatic Gun Installation

1. Installing the gun on the parentmachine

2. Making the hydraulic and electricconnections

3. Tightening the hydraulic connection

2. Coat the gun fitting threads with Never Seez and connect the hoseswivel connector to the gun fitting (2).

3. Insert the gun electrical plug into the socket at the end of thehose (2).

4. Use two wrenches to tighten the hose connection—one wrench tohold the gun fitting stationary, and the other to tighten the hose swivelconnector (3).

Automatic Gun Installation

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5. Wrap the hose/gun hydraulic connection with insulation.

6. Install a filter/regulator and solenoid (both customer-supplied) onthe gun.

7. Set the gun filter/regulator to 0 kPa/psi.

NOTE: Nordson recommends that a customer-supplied 3-waylockout valve be installed in the air supply line in order to isolate thegun for maintenance or other procedures.

8. Connect an external, unfiltered and unlubricated air supply to thegun solenoid. The air supply pressure must not exceed689 kPa (100 psi). The recommended operating pressure is276--482 kPa (40--70 psi).

9. Remove wires 20K and 20L (at XT2--3), 46.100 (1/12 and 1/13 AP6).Then connect the timer or triggering device output leads (must be dry,normally open) to the following terminals inside the electricalenclosure.

S Single-Hose Units--XT2--3—1/12 AP46

S Dual-Hose Units--XT2--3—1/13 AP46 (Gun 1) andXT2--3—1/12 AP46 (Gun 2)

NOTE: The timer outputs should be dry contact closure or anothertype of solid-state switching device capable of switching 12 VDC.

10. Insert the hose electrical plug at the unit end of the hose into theupper socket on the side of the electrical enclosure. On dual-hoseunits, insert the Hose 2 electrical plug into the lower socket.

Automatic Gun Installation(contd)

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Your unit was set up at the factory prior to shipping. If you need tochange any settings, you may do so by following the procedures in thissection for programming the system. The Vista control system simplifiesprogramming system functions: all programming is done from theSystem Setup area of the operator panel.

CAUTION: Be sure you understand the result of changingsystem settings before you change any settings. An incorrectsystem setup may cause damage to your unit.

From the operator panel, you can control and monitor your unit’soperations.

4705032A

1

2

3

4

Fig. 3-5 Operator Panel

1. System Status area2. Displays area

3. System Setup area4. System Controls area

5. Setting Up the VistaController

4705033A

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Before running the unit, customize system operations by following theprocedures in this section for programming the system. The Vista controlsystem simplifies programming system functions: all programming isdone from the System Setup area of the operator panel.

From the System Setup area of the operator panel, you can control

S how the unit operates (SYSTEM SETTINGS)S the temperature at which each zone operates (TEMPERATURE)S when the system operates (CLOCK)

Keeping a Record of System Settings

Before you begin programming the system, take a few minutes to removethe system settings forms found in Records of System Settings at the endof this section.

Fig. 3-6 System Setup Area of theOperator Panel

System ProgrammingProcedures

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Programming System Controls

1. To begin programming system controls, turn power on to the unit bypressing the POWER switch. The following occurs:

S The system scans each heated zone, displaying each zone’stemperature in sequence.

S The Multipurpose display shows four dashes (- - - -) for each zoneuntil a setpoint temperature is entered. After a setpoint is entered,the display will show the setpoint that was entered as the defaultwhen power is turned on.

S The Actual Temperature display shows the room temperaturebecause no heat has been applied to the zones.

2. Customize the system to your operations by completing theprocedures listed below. Refer to Table 3-1 for a summary of all thefeatures that you can customize.

S Programming Optional FeaturesS Programming SYSTEM SETTINGS ControlsS Programming TEMPERATURE ControlsS Programming CLOCK Controls

Fig. 3-7 Turning Power On

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Programming System Controls (contd)

Table 3-1 Summary of Features to Customize

Control Area Features to Customize

SYSTEM SETTINGS From SYSTEM SETTINGS, you can customize the following features, which areexplained in more detail in Table 3-2:S Password EnableS System-Ready Time Delay periodS Overtemperature SetpointS Celsius or Fahrenheit displayS Global Temperature Band settingS Individual Temperature Bands settingS Sequential or Simultaneous StartupS Display Heater ProportioningS Warning or Power notificationS Ready or Pump notificationS Auto-Energize PumpS Auto-Energize Pump Temperature SettingS Auto-Energize HeatersS Time With Heaters On

TEMPERATURE SETPOINT Temperature: This feature sets the temperature that a zone will maintainduring normal operation.STANDBY Temperature: This feature sets the desired temperature to which a zonewill be reduced when the system is in the standby mode.

CLOCK SET TIME: This feature keeps the current day and time. The clock must be on beforeyou can use the features HEATERS ON, HEATERS OFF, ENTER STANDBY, and EXITSTANDBY.ENTER STANDBY and EXIT STANDBY: This feature sets the time that you want thesystem to automatically enter and exit the standby mode.HEATERS ON and HEATERS OFF: This feature sets the time that you want heatersto automatically turn on and off.

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If you have selected the enhanced I/O option with your applicator, itprovides optional features that you can program. Refer to the Optionssection, for information on programming these optional features.

Use this procedure to program the SYSTEM SETTINGS feature shownin Table 3-1.

1. If you have not already done so, turn power on to the unit by pressingthe POWER switch.

2. See Figure 3-8. Press the Move Up (1) and Move Down (2) keys untilthe SYSTEM SETTINGS light turns on. When you select SYSTEMSETTINGS, the following occurs:

S The values in the Displays area change.

S The number in the Selector display changes to a feature number.

S The Multipurpose display changes to the current value for thefeature selected.

4103988

1

2

Fig. 3-8 Selecting the SYSTEM SETTINGS Feature

1. Move Up key 2. Move Down key

WARNING: Risk of fire. The default for the overtemperaturesetpoint is 218 _C (425 _F). If the Material Safety Data Sheet(MSDS) for your adhesive gives a flash point that is below218 _C (425 _F), be sure to reset the overtemperature setpointto at least 42 _C (75 _F) below the flashpoint. Otherwise, a firecan occur.

Programming OptionalFeatures

Programming SYSTEMSETTINGS Controls

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NOTE: If you have enabled the Password feature, you must changethe number in the Multipurpose display (500) to the password (321)and press the Enter key before the system will allow you to changeany SYSTEM SETTINGS features.

3. Determine which SYSTEM SETTINGS feature to customize. Refer toTable 3-2 for a list of defaults and options for customizing eachfeature.

4. See Figure 3-9. Press the Up key below the Selector display until thenumber of the feature you want appears on the display. As thefeature number changes, the Multipurpose display (3) changes toshow the setting of each feature selected.

4130012

2 3

4 5

1

Fig. 3-9 Changing the Setting of a Selected Feature

1. Up key2. Selector display3. Multipurpose display

4. Up and Down keys5. Enter key

5. Press the Up or Down keys (4) below the Multipurpose display tochange the setting. The display flashes.

6. Press the Enter key (5) to save the new setting. The display stopsflashing.

7. Record your setting in the forms provided at the end of this section.Refer to Records of System Settings.

8. Repeat steps 4 through 7 for each feature you wish to change.

9. To exit the System Setup area, press the MONITOR/SCAN key.

Programming SYSTEMSETTINGS Controls (contd)

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Table 3-2 SYSTEM SETTINGS FeaturesFeatureNo.

Feature Description DefaultSetting

Optional Settings

0 Password Provides a password if the password-enable feature isturned on. The password (321) cannot be changed.

321 none

1 PasswordEnable

Allows you to turn the password-enable feature on oroff. When the password-enable feature is on,operators can view settings for TEMPERATURE,SYSTEM SETTINGS, or CLOCK. To change thesettings, operators must enter the correct password(321). When the feature is off, operators can changeall these settings without entering a password.

0

(off)

0 (off)

1 (on)

2 System-ReadyTime Delay

Allows you to specify the amount of additional timeneeded for adhesive material to melt after all zoneshave reached their setpoint temperatures. At the endof the time delay, the READY light turns on.

60(minutes)

0-60(minutes)

3 Over-temperatureSetpoint

Allows you to specify the maximum temperature anyzone can reach before the system initiates a faultcondition. This setting should be at least 14 _C(25 _F) above the highest operating setpoint. Thesystem will not allow you to set the overtemperaturesetpoint lower than this, or the operating setpointhigher. (See Note A.)

149/300

(_C/_F)

52--246/125--475

(_C/_F)

4 Celsius/Fahrenheit

Allows you to display temperature measurements inCelsius or Fahrenheit.

F(Fahrenheit)

F (Fahrenheit)

C (Celsius)

5 GlobalTemperatureBand

Allows you to specify the degree to which atemperature may deviate from any zone before thesystem indicates an out-of-band warning.(See Note B.)

17/30

(_C/_F)

6--28/10--50

(_C/_F)

6--19 IndividualTemperatureBands

Allows you to specify the degree to which atemperature may deviate for an individual zone beforethe system initiates a warning. (See Note C.)

17/30

(_C/_F)

6--28/10--50

(_C/_F)

20 Sequential orSimultaneousStartup

Allows you to specify whether the system will performa sequential startup (internal zones and hose zonesheat first, then gun zones) or simultaneous startup (allzones heat at once).

1

(sequential)

0 (simultaneous)

1 (sequential)

21 Display HeaterProportioning

Allows you to display the heater proportioning (aflashing INTERNAL, HOSE, or GUN light).

0

(no display)

0 (no display)

1 (show display)

22 System Warningor PowerNotification

Allows you to change the System Warning outputcontact to alert remotely located operators that asystem warning has occurred or that power is on.

1

(warning)

0 (power)

1 (warning)

23 System Readyor PumpNotification

Allows you to change the System Ready outputcontact to alert remotely located operators that thesystem is ready (up to temperature) or that the pumpis on.

1

(ready)

0 (pump)

1 (ready)

NOTE A: The overtemperature setting should be at least 42 _C (75 _F) below the flashpoint temperature.

B: If you enter a new setting for this feature, the new setting is immediately entered for the individual zones(Feature Nos. 6--19). However, it is not saved as the setting for Feature No. 5. Feature No. 5 always returns to thedefault setting of 17 _C (30 _F).

C: Feature nos. 8--13 = hoses 1--6, feature nos. 14--19 = guns 1--6.

Continued on next page

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FeatureNo.

Feature Description DefaultSetting

Optional Settings

24 Auto-EnergizePump

Allows you to turn the auto-energize pump feature onor off. If this feature is on, the system turns the pumpon automatically once the tank reaches the presettemperature of Feature No. 32. If the auto-energizepump feature is off, you must turn the pump on bypressing the PUMP key until the PUMP light turns on.

0

(off)

0 (off)

1 (on)

25 Auto-EnergizeHeaters

Allows you to turn the auto-energize heaters featureon or off. If the feature is on, the system turns heaterson automatically once the POWER switch is turned on.However, if you have programmed the system to turnheaters on and off automatically, using the clockfeature, your clock settings override the auto-energizeheaters feature. If the auto-energize heaters feature isoff, you must turn heaters on manually, or allow anyclock settings you have programmed to turn heaterson or off.

1

(on)

0 (off)

1 (on)

26 Time WithHeaters On

Allows you to display the total time (in hours) that theheaters have been running to assist with servicing andmaintenance.

See Note A none

27 Fault Log(most recent)

Allows you to display the cause of the most recentsystem fault. Refer to Checking the Fault Log in theTroubleshooting section for a list of fault codes.

See Note A none

28 Fault Log(second mostrecent)

Allows you to display the cause of the second mostrecent system fault. Refer to Checking the Fault Login the Troubleshooting section for a list of fault codes.

See Note A none

29 Fault Log(third mostrecent)

Allows you to display the cause of the third mostrecent system fault. Refer to Checking the Fault Login the Troubleshooting section for a list of fault codes.

See Note A none

30 & 31 Auto StandbyTimeout & InStandbyTimeout

These features are available only on units with I/Oboards. Refer to Series 3000V Input/Output Board inthe Options section, for information on customizingthese features.

32 Auto-EnergizePumpTemperatureSetting

Allows you to determine when the pump automaticallystarts if you are using the Auto-Energize Pump feature(Feature No. 24). You can have the pump start eitherwhen the system reaches the READY condition orwhen the tank reaches the temperature you havespecified. (See Note B.)

0 (ready) 0 (ready condition) or

1--232/1--450

(_C/_F)

NOTE A: Features 26--29 are always on. There is no default setting.

B: If you enter a setting that is higher than the platen setpoint, the pump will start when the platen reaches its setpoint.

Programming SYSTEMSETTINGS Controls (contd)

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From the operating panel you can control each of the system’s heatedcomponents at a temperature specific to your needs. You can programindividual setpoints for the platen, each hose, and each gun. Forprogramming purposes, each heated system component is referred to asa zone.

In addition to being able to heat each zone individually, you can assigntwo different temperature settings to each active zone: a setting for thesetpoint (operating) temperature and one for the standby temperature.

Table 3-3 Types of Temperature Settings

Setting Description

Setpoint Temperature Desired temperature of a zoneduring normal operation.

Standby Temperature Temperature to which a zone willbe reduced when the system is inthe standby mode.

If you do not enter standby temperatures, the standby default of OFF willremain in effect for each zone. If you place the system in the standbymode, the zones will cool to room temperature (while the HEATERS lightremains on). If you make the standby temperatures equal to thesetpoints, pressing the STANDBY key will have no effect on thetemperatures, but it will turn the READY light off and disable the pump.

NOTE: The default setting for all zones is OFF (less than 38 C or100 F). To turn a zone on, set the setpoint temperature to 38 C(100 F) or higher.

Because Model 505/506 applicators can have up to six hose and gunzones and one or two internal zones, zone numbers are used to identifyspecific zones of each type. When you program TEMPERATUREsettings, the number in the Selector display represents a particular zonenumber.

ProgrammingTEMPERATURE Controls

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Table 3-4 Heating Zone Numbers

ZoneNumber

Zone TypeNumber

(See Note A) INTERNAL HOSE GUN

0 Set All (See Note B)

1 Platen Hose 1 Gun 1

2 Hose 2 Gun 2

3 Hose 3 Gun 3

4 Hose 4 Gun 4

5 Hose 5 Gun 5

6

NOTE A: Your unit may be able to control the temperature of two,four, or six hoses and guns, depending upon the unit andfeatures you have selected.

B: Use Set All to set all zones to the same temperature.Only zones that are turned on are affected.

Follow these guidelines when programming temperature settings:

S Check the Manufacturer’s Safety Data Sheet (MSDS) for therecommended operating temperature of the hot melt material that youwill use.

S For a zone to be on, the operating temperature must be set at 38 C(100 F) or higher.

S Set the standby temperature 56 C (100 F) lower than the operatingtemperature.

S Before programming any temperature settings, make sure that theovertemperature setpoint is at least 14 _C (25 _F) higher than thehighest operating setpoint used. Refer to Programming SYSTEMSETTINGS Controls, Feature No. 3.

ProgrammingTEMPERATURE Controls(contd)

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Use this tip to program temperature settings quickly:

Zone Procedure

All zones to the sametemperature

Follow the procedure To Program All Zonesto the Same Temperature.

Most zones to the sametemperature

1. First, follow the procedure To Program AllZones to the Same Temperature.

2. Then, follow the procedure To ProgramSetpoint and Standby TemperaturesIndividually to change the settings thatyou wish.

To Program Setpoint and Standby Temperatures Individually

Follow this procedure to set the setpoint and standby temperatures foreach zone.


2. In the System Setup area, press the Move Up and Move Down keysuntil the SETPOINT or STANDBY light turns on. The system defaultsto the internal zone type and the INTERNAL light turns on. (SeeFigure 3-11.)

NOTE: If you have enabled the Password feature, you must changethe number in the Multipurpose display (500) to the password (321)and press the Enter key before the system will allow you to changeany of the temperature setpoints.

3. If you want to select the hose-zone type or the gun-zone type insteadof the internal-zone type, press the Move Right key until the lightbeneath the zone type you want to set turns on.

4. See Figure 3-10. In the Displays area, press the Up key (1) belowthe Selector display (2) until the zone number you want appears onthe display. (Refer to Table 3-4.) The Multipurpose display (3)changes to show the current temperature setting for the zone youselected.

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To Program Setpoint and Standby Temperatures Individually(contd)

4103931

2 3

4 5

1

Fig. 3-10 Using the Displays Keys to Set the Temperature of a Zone(Displays Area)

1. Selector Up key2. Selector display3. Multipurpose display


5. In the Displays area, press the Up or Down key (4) below theMultipurpose display to change the temperature. The display flashes.

NOTE: Pressing the Up or Down keys in the Displays area oncechanges the number shown in increments of one. Pressing andholding the key changes the number in increments of five.

6. Press the Enter key (5) to save the setting. The display stopsflashing.


8. Press the Up key below the Selector display to select the next zonenumber for the zone that you wish to customize, and repeat thisprocedure until you have set temperatures for all zones.

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To Program All Zones to the Same Temperature

Follow this procedure to set all zones to the same temperature. Also usethis procedure along with the procedure To Program Setpoint andStandby Temperatures Individually to set most zones to the sametemperature.

NOTE: This procedure works only for zones that have been previouslyturned on. The default setting for all zones is OFF. To turn a zone on,refer to the previous procedure, To Program Setpoint and StandbyTemperatures Individually, and set the temperature of each zone youwant to turn on to at least 38 _C (100 _F).


2. See Figure 3-11. In the System Setup area, press the Move Up (2)and Move Down (3) keys until the SETPOINT or STANDBY light turnson. The system defaults to the internal-zone type and the INTERNALlight turns on.

NOTE: If you have enabled the Password feature, you must changethe number in the Multipurpose display (500) to the password (321)and press the Enter key before the system will allow you to changeany of the temperature setpoints.

4705034A

1

2

4

3

Fig. 3-11 Selecting the Set All Feature (System Setup Area)

1. Zone lights2. Move Up key

3. Move Down key4. Move Right key

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100 4197AIssued 7/00


To Program All Zones to the Same Temperature (contd)

3. In the Display area, press the Up key below the Selector display until0 (Set All) appears on the display. All three zone-type lights turn onand the Multipurpose display shows a default temperature of 177 _C(350 _F).

4. Press the Up or Down keys below the Multipurpose display to changethe temperature. The Multipurpose display flashes.

5. Press the enter key to change the temperature setting of all zonesthat are turned on to the temperature shown in the MultipurposeDisplay. The display stops flashing.

NOTE: When you exit the Set All feature, it always returns to thedefault setting of 177 _C (350 _F).


The seven-day clock feature turns the heaters on and off or takes the unitinto and out of the standby mode at preset times that you program. Thisfeature works in conjunction with the clock on the unit, which keeps thecorrect day and time. It does not matter whether you set the current dayand time first, or set the standby and heater times. However, bothfeatures must be set for the heaters to turn on and off correctly.

NOTE: If you experience a power outage, the unit’s internal clock willcontinue to keep time. Once power is restored and the unit is turned on,the unit will resume normal operations. You do not need to reprogramany features controlled by the clock.

NOTE: The clock does not automatically adjust for seasonal time shiftssuch as daylight savings time.

Programming CLOCKControls

4103934

2

1

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To Set the Clock

Follow this procedure to set the clock for the current time and day.

NOTE: The clock uses a seven-day, 24-hour format.


2. See Figure 3-12. In the System Setup area, press the Move Up andMove Down keys (1) until the SET TIME light (2) turns on.

NOTE: If you have enabled the Password feature, you must changethe number in the Multipurpose display (500) to the password (321)and press the Enter key before the system will allow you to changethe clock settings.

3. See Figure 3-13. Check the Selector display. The display flashes anumber representing the day of the week as shown in Table 3-5.

Fig. 3-12 Selecting SET TIME

1. Move Up and Move Down keys2. SET TIME light

Table 3-5 Selector Display Codes ShownWhen Clock Feature Activated

Day Code Day of Week

1 Monday

2 Tuesday

3 Wednesday

4 Thursday

5 Friday

6 Saturday

7 Sunday

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To Set the Clock (contd)

4103935

1 2 3

6 5 4

Fig. 3-13 Setting the Correct Day and Time

1. Day code2. Hours3. Minutes

4. Enter key5. Up and Down keys6. Selector Up key

4. Check that the day code is correct.

Correct? Action

Yes Press the Enter key (4) to savethe setting.

No Press the Up key (6) below theSelector display until the correctcode appears on the display, andthen press the Enter key to savethe setting.

5. When you press the Enter key, the Selector display stops flashingand the hour shown in the Multipurpose display begins flashing.Check that the hour shown in the Multipurpose display is correct.

Correct? Action

Yes Press the Enter key to save thesetting.

No Press the Up or down key belowthe Multipurpose display until thecorrect hour appears on thedisplay, and then press the Enterkey to save the setting.

4103936

1

2

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6. When you press the Enter key, the hour shown in the Multipurposedisplay stops flashing and the minutes shown begin flashing. Checkthat the minutes shown in the Multipurpose display are correct.

Correct? Action

Yes Press the Enter key to save thesetting.

No Press the Up or Down key belowthe Multipurpose display until thecorrect minutes appear on thedisplay, and then press the Enterkey to save the setting.

NOTE: Once the clock is set, all displays stop flashing.

To Set Standby and Heater Times

The clock feature turns the heaters on or off, or takes the unit into andout of the standby mode at preset times. Using a seven-day, 24-hourformat, the clock can store two sets of times, referred to as intervals, foreach day of the week. Each interval can store four time settings:

S one to enter standbyS one to exit standbyS one to turn the heaters onS one to turn the heaters off

Follow this procedure to set times for entering and exiting standby and forturning heaters on and off. After you have programmed the clock, usethe CLOCK key to turn the clock feature on and off. The CLOCK lightturns on when the clock feature is active.

Fig. 3-14 Selecting Standby andHeater Times

1. Move Up and Move Down keys2. INTERVAL lights

NOTE: If you have enabled the Password feature, you must change thenumber in the Multipurpose display (500) to the password (321) andpress the Enter key before the system will allow you to change the clocksettings.

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To Set Standby and Heater Times (contd)

1. In the System Setup area, press the Move Up and Move Down keysuntil the light next to the feature you wish to set turns on.

NOTE: When you select any of the standby or heater on/off settings,the unit selects an interval. The INTERVAL 1 light turns on as adefault.

2. Check the Selector display. The display flashes a number (the daycode) representing the day of the week as shown in Table 3-6.

Table 3-6 Selector Display Codes ShownWhen Clock Feature Activated

Day Code Day of Week

1 Monday

2 Tuesday

3 Wednesday

4 Thursday

5 Friday

6 Saturday

7 Sunday

4103935

1 2 3

6 5 4

Fig. 3-15 Setting the Correct Day and Time

1. Day code2. Hours3. Minutes

4. Enter key5. Up and Down keys6. Selector Up key

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100 4197AIssued 7/00


3. See Figure 3-15. Press the Up key (6) below the Selector display toselect the day code (1) for which you want to set a time.

4. Press the Enter key (4) to save the day code setting. The Selectordisplay stops flashing and the hour (2) shown in the Multipurposedisplay flashes.

5. Press the Up or Down keys (5) below the Multipurpose display untilthe hour for which you want to set a time appears in the display.

6. Press the Enter key to save the hour setting. The hour shown in theMultipurpose display stops flashing and the minutes flash.

7. Press the Up or Down keys until the minutes (3) for which you want toset a time appear on the Multipurpose display.

8. Press the Enter key to save the minutes setting. All displays stopflashing.


10. To set a second time for the same day, press the Move Right key untilthe INTERVAL 2 light turns on. Press the Enter key to save the dayand repeat steps 5 through 9.

To Change a Standby or Heater Set Time

To change a set time, follow the same procedure for setting the standbyand heater times.

To Delete a Standby or Heater Set Time

Follow this procedure to delete a Standby or Heater set time.

1. From the System Setup area, press the Move Up and Move Downkeys until the light next to the feature you wish to change turns on.

NOTE: If you have enabled the Password feature, you must changethe number in the Multipurpose display (500) to the password (321)and press the Enter key before the system will allow you to changethe clock settings.

2. Check the Selector display. The display flashes the day coderepresenting a day of the week.

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To Delete a Standby or Heater Set Time (contd)

3. Refer to Table 3-6, and press the Up key below the Selector displayuntil the day code of the day that you want to change appears in theSelector display.

4. Press the Enter key to save the setting. The Selector display stopsflashing and the hour shown in the Multipurpose display flashes.

5. Press the Up or Down keys below the Multipurpose display until fourdashes (- - - -) appear on the display. (The dashes indicate that nosetting has been entered.)

6. Press the Enter key to save the setting. All displays stop flashing.


To Delete Times for an Entire Day

To delete times for an entire day, follow the procedure To Delete aStandby or Heater Set Time and turn the clock off for each feature:entering standby, exiting standby, turning heaters on, turning heaters off.

An Example of How to Use the Seven-day Clock Feature

At one company, the production line runs for two shifts each day andshuts down on weekends. Both shifts shut down for 45 minutes twiceeach day: once at 12:00 noon for lunch and again at 6:00 in the eveningfor dinner. By using the clock feature, the company can have the unitstart and stop by setting the clock feature to

S Put the applicator into the standby mode (ENTER STANDBY) at12:00 P.M. (INTERVAL 1) and again at 6:00 P.M. (INTERVAL 2).

S Take the applicator out of the standby mode (EXIT STANDBY) at12:30 P.M. (INTERVAL 1) and at 6:30 P.M. (INTERVAL 2), allowing15 minutes for the system to reach application temperature.

S Turn the heaters on (HEATERS ON) Monday through Friday30 minutes before the start of the first shift (INTERVAL 1).

S Turn the heaters off (HEATERS OFF) Monday through Friday at theend of the second shift (INTERVAL 1).

NOTE: The clock is not set for Saturday or Sunday when the companyis closed.


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Section 4

Operation

Operation4-0


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Operation 4-1


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Section 4Operation

This portion of the manual provides specific Model 505/506 unit operationprocedures, including:

S Safety PrecautionsS Initial Equipment PreparationS Routine Operating Procedures (startup/shutdown and pail changing)S Changing to a Different Material

Nordson recommends that you read the Description section of thismanual before proceeding. This will help you gain an understanding ofthe equipment operation, controls and indicators.

Also, before attempting any of the procedures in this section:

S Read through the entire procedure while at the unit and becomefamiliar with the required steps. It may be necessary to refer to theillustrated parts lists in the Parts section for exact componentlocations and sizes.

S Be sure that the required tools, replacement parts and service itemsare at hand.

S Read and follow all safety precautions.

WARNING: Allow only qualified personnel to perform thefollowing tasks. Observe and follow the safety instructions inthis document and all other related documentation.


1. Description

2. Safety Precautions

Operation4-2


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WARNING: Hot! Risk of burns. Wear heat-protective clothing,safety goggles, and heat-protective gloves.

WARNING: Never point a hand-operated gun at anyoneincluding yourself. Failure to observe this warning could resultin serious injury to personnel if the gun is triggered accidentally.

WARNING: (Hand-operated guns) Do not operate a handgunwith the pivot sleeve shells or handles removed or damaged.Handguns contain electrical potentials that could be fatal.

CAUTION: Do not touch the guns during operation. Failure toobserve this caution could result in personal injury from burns.

NOTE: Do not trigger a cold gun. Do not force a cold handgun to swivel.Doing so could damage the gun seat or seal and cause the gun to leakafter it has been heated and put into operation.

2. Safety Precautions (contd)

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Complete the following procedures before operating the pailmelter/applicator for the first time or when changing operational settingsor adhesive types.

1. Ensure that the unit, hoses and guns have been installed as detailedin the Installation section.

2. Ensure that input electrical power to the unit is OFF and that the maindisconnect switch on the side of the electrical enclosure is at the OFFposition.

3. Ensure that the elevator control valve is in the neutral (center)position as shown in Figure 4-1.

4701215B

ELEVATORCONTROL

Fig. 4-1 Elevator Control Valve

3. Initial EquipmentPreparation

Operation4-4


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You can start the melter/applicator automatically by using the seven-dayclock feature on the Vista controller, or you can bypass or disable theautomatic start up and use the manual start up procedure.

4103929

1

2

3

4

5

6 7

Fig. 4-2 System Controls

1. MONITOR/SCAN key and light2. STANDBY key and light3. HEATERS key and light4. CLOCK key and light

5. PUMP key and light6. CLEAR FAULTS key7. POWER switch

Follow this procedure to start up the unit with the seven-day clock.

1. Check to see if your temperature settings are correct.2. Wait for the READY light to turn on and press the PUMP key.

The system is ready for routine operation.

If the CLOCK light is on (and the system is set for the heaters to turn offautomatically), the system will shut itself down.

4. Operating Procedures

Automatic Start Up

Automatic Shut Down

Operation 4-5


100 4197AIssued 7/00


Use this procedure for the following situations.

S Turn the unit on before it is time for automatic startup to occur.

S Start the unit up on a day for which the clock feature is turned off (byhaving - - - - as the entry).

S Start the unit up because the CLOCK key was not turned on.

1. Turn on the power. The HEATERS light turns on and the unit beginsto heat up.

2. Check to see if your temperature settings are correct.

3. Wait for the READY light to turn on and press the PUMP key.

The system is ready for routine operation.

You can use this procedure to shut the unit down at any time.

1. Press the HEATERS key. The HEATERS light will turn off.2. Press the POWER switch.

The control system allows you to check the temperatures of all zones insequence (to scan) or to continuously monitor the temperature of a singlezone (to monitor).

The scan mode activates and the MONITOR/SCAN light turns on whenthe system is powered up. In this mode, the unit scans through theheated zones and monitors each zone in sequence. Pressing theMONITOR/SCAN key takes the unit out of the scan mode, the light stayson, and the unit monitors only the selected zone.

NOTE: Selecting a setting in the System Setup area takes the unit out ofthe monitor/scan mode. The MONITOR/SCAN light turns off. Pressingthe MONITOR/SCAN key at this time puts the system back into themonitor/scan mode. Also, if no action is taken after two minutes, thecontrol system automatically switches back to the monitor/scan mode.

Manual Start Up

Manual Shut Down

Check Temperatures

4105018A

3

1

2

Operation4-6


100 4197AIssued 7/00


Follow this procedure to manually place the system in standby.

1. Press the STANDBY key.

2. Wait for the STANDBY light to turn on and the READY light to turn off.The pump is disabled, and temperatures drop to standby setpoints.

Follow this procedure to return from standby to normal operation.

1. Press the STANDBY key. The STANDBY light will turn off and thesystem will heat each active zone to its operating setpoint.

2. Wait for the READY light to turn on and press the PUMP key.

The Nordson Warning Beacon is composed of a preassembledlens-and-bulb light tower assembly. The amber portion of the warningbeacon will go ON when a relay switch on the Series 5000 unit sensesthat the amount of material in the 20 liter (5-gallon) pail or has dropped toa preset “low level”.

When the relay switch on the unit senses that the amount of material inthe pail has dropped to a preset “empty level”, the red portion of thewarning beacon will flash ON and OFF and the bulk melter clutch isdisengaged (units with clutch) or the motor disabled (units without clutch).

The warning beacon is visible for at least 10.7 m (35 ft.) and is useful inassisting the equipment operator with maintaining an adequate supply ofmaterial at the unit, especially when the operator cannot be physicallypresent at the unit at all times.

Figure 4-3 and the following table show what the various combination oflights indicate.

Fig. 4-3 Warning Beacon

1. Green, system ready2. Amber, warning3. Red, fault condition exists

Place System in Standby

Remove System fromStandby

5. Warning Beacon

Operation 4-7


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When Condition is Light Tower will show

Ready (Heaters at temp -- Vista)Sufficient glue

Steady green

Ready (Heaters at temp -- Vista)Low glue

Steady greenFlashing amber

Ready (Heaters at temp. -- Vista)No glue

Flashing Red

Not Ready (Heaters not at temp. on Vista)Sufficient glue

No lights

Not ready (Heaters not at temp. on Vista)Low Glue

Flashing amber

Not Ready (Heaters not at temp. on Vista)No glue

Flashing red

Warning (Vista)Sufficient glue

Steady green

Warning (Vista)Low glue

Steady green

Warning (Vista)No glue

Flashing red

Fault (Vista)Sufficient glue

Steady red

Fault (Vista)Low glue

Flashing amber

Fault (Vista)No glue

Steady red

Operation4-8


100 4197AIssued 7/00


WARNING: Hot! Risk of burns. Wear heat-protective clothing,safety goggles, and heat-protective gloves.

CAUTION: Do not attempt this procedure unless the unit is atapplication temperature. Failure to observe could causedamage to the platen seal.

1. Center a new pail of material free of dents or other damage on theframe base (or in the pail hold-down assembly) directly under theplaten.

NOTE: Ensure that the unit base is free of adhesive so that the pailsits squarely on the base. Failure to do so may result in a poor sealor incomplete emptying of the pail.

NOTE: A dented or otherwise damaged pail may cause damage tothe platen seal, resulting in faulty equipment operation andreplacement of the platen seal.

2. Coat the platen seal with high temperature grease.

NOTE: Do not use a petroleum-based grease on the silicone platenseal or damage to the seal may result.

3. Disconnect the platen removal air line from the platen removaladapter.

4. Unscrew the platen removal adapter from the T-handle adapter.

5. Place a small tray or metal pan under the bleed tray beforecontinuing.

6. Close the platen guard (if installed).

7. Use the elevator control valve to slowly lower the platen into the pail.

WARNING: Trapped air or hot material could be ejected out ofthe platen bleed hole with enough force to cause burns tonearby personnel. Wear safety glasses and long-sleeved,protective clothing and gloves when performing this procedure.DO NOT PEER DOWN DIRECTLY INTO THE PLATEN BLEEDHOLE UNDER ANY CIRCUMSTANCES. Failure to observeand follow this warning may result in serious personal injury.

6. Loading a Pail

4705014A

ONPLATENREMOVAL

AIRPRESSURE

OFF

Operation 4-9


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8. Continue to lower the platen until there is a steady flow of materialfrom the platen bleed hole, then reinstall the platen T-handle.

9. When the digital display on the front panel of the electrical enclosureindicates that the application temperature has been reached, turn thepump on.

10. Begin normal operation.

1. Verify that the unit is at application temperature.

NOTE: Do not attempt this procedure unless the unit is at applicationtemperature. Failure to observe and follow this note may causedamage to the platen seal.

2. Turn the pump off.

3. Place the elevator control valve in the neutral (center) position.

4. Unscrew and remove the platen T-handle from the T-handle adapter.Refer to Platen Assembly in the Parts section.

5. Thread the platen removal adapter into the T-handle adapter.

6. Attach the quick disconnect fitting at the end of the removal air line tothe platen removal adapter.

7. Place the elevator control valve in the UP position.

8. See Figure 4-4. Set the PLATEN REMOVAL selector switch to theON position.

9. When the platen clears the pail, set the PLATEN REMOVAL selectorswitch to the OFF position.

10. When the platen has reached its maximum height, leave the elevatorcontrol valve in the UP position.

11. Open the platen guard (if installed).

12. Remove the pail.

Fig. 4-4 Platen Removal SelectorSwitch

7. Changing the Pail

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100 4197AIssued 7/00


13. Center a new pail of material free of dents or other damage on theframe base (or in the pail hold-down assembly) directly under theplaten.

NOTE: Ensure that the unit base is free of adhesive so that the pailsits squarely on the base. Failure to do so may result in a poor sealor incomplete emptying of the pail.

NOTE: A dented or otherwise damaged pail may cause damage tothe platen seal, resulting in faulty equipment operation andreplacement of the platen seal.

14. Coat the platen seal with high temperature grease.

NOTE: Do not use a petroleum-based grease on the silicone platenseal or damage to the seal may result.

15. Disconnect the platen removal air line from the platen removaladapter.

16. Unscrew the platen removal adapter from the T-handle adapter.

17. Place a small tray or metal pan under the bleed tray beforecontinuing.

18. Close the platen guard (if installed).

19. Use the elevator control valve to slowly lower the platen into the pail.

WARNING: Trapped air or hot material could be ejected out ofthe platen bleed hole with enough force to cause burns tonearby personnel. Wear safety glasses and long-sleeved,protective clothing and gloves when performing this procedure.DO NOT PEER DOWN DIRECTLY INTO THE PLATEN BLEEDHOLE UNDER ANY CIRCUMSTANCES. Failure to observeand follow this warning may result in serious personal injury.

20. Continue to lower the platen until there is a steady flow of materialfrom the platen bleed hole, then reinstall the platen T-handle.

21. When the digital display on the front panel of the electrical enclosureindicates that the application temperature has been reached, turn thepump on.

22. Resume normal operation.

7. Changing the Pail (contd)


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Section 5

Maintenance

Maintenance5-0


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Maintenance 5-1


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Section 5Maintenance

This portion of the manual provides a schedule of maintenanceprocedures designed to keep your Model 505/506 unit operating at topefficiency.

These procedures are listed according to their recommended frequency:

S DailyS After first 250 hours of serviceS WeeklyS MonthlyS Every six monthsS As required

CAUTION: Faulty or damaged hoses are not field-repairableand must be replaced. Contact your Nordson representative forreplacement and return information.

Gun disassembly and repair information is included in the gun manual.

Before attempting any of the procedures in this section:

S Read the entire procedure while at the unit and become familiar withthe required steps. Refer to the disassembly and repair information inthe Repair section and the illustrated parts lists in the Parts sectionfor exact component locations and sizes.

S Be sure the required tools, replacement parts and service items are athand.

S Read and follow all safety precautions.

1. Introduction

Maintenance5-2


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WARNING: Risk of electrical shock. Disconnect and lock outimput electrical power from the unit before opening theelectrical enclosure door. The input terminal block remainscharged even when the main disconnect switch is set to OFF.Failure to observe and follow this warning could result in death.


WARNING: Hot! Risk of burns. Wear heat-protective clothing,safety goggles, and heat-protective gloves. Failure to observemay result in personal injury.

CAUTION: Never use a torch or other open flame device toheat a component. Use only a flameless electric heat gun orelectric oven with forced air circulation. Failure to observecould result in personal injury and/or damage to the unit andnearby property.

2. Safety Precautions

Maintenance 5-3


100 4197AIssued 7/00


WARNING: Hot! Risk of burns. Do not attempt to loosenany manifold, hose, or gun connection until system hydraulicpressure has been relieved. Failure to observe could result inserious personal injury.

Relieve system hydraulic pressure as follows:

1. Place the elevator control valve in the neutral (center) position,

2. Manually trigger the gun(s) until no material flows.

3. See Figure 5-1. Open the gerotor pump manifold flush valve torelieve residual hydraulic pressure.

4. Disconnect the air supply from the unit.

4701190C

Fig. 5-1 Opening the Manifold Drain Valve

3. Relieve System Pressure

Maintenance5-4


100 4197AIssued 7/00


Use the guidelines in Table 5-1 to maintain your pail melter/applicator.

Table 5-1 Maintenance Schedule

Frequency Procedure

Daily Inspect the hose hydraulic connections. Refer to Inspecting the HoseHydraulic Connections in this section.

Keep the adhesive material supply clean and free of contaminants thatcan lead to poor pump performance and/or clogged gun nozzles.

Clean all applicator and hose exterior surfaces. Refer to Cleaning theExterior in this section.

Weekly Clean the top of the platen, frame, air cylinders, and electrical enclosure.Remove dirt, dust, and excess material buildup on the platen.

Inspect the platen seals for excess material leakage. Replace the seals ifnecessary as described in the Repair section.

Inspect the pneumatic tubing for kinks and bends. Repair or replace asnecessary.

Monthly Inspect blow-off valve. Repair or replace as needed.

Check the speed reducer lubricant level as described in this section.

Inspect the electrical connections inside the electrical enclosure. Tightenany loose connections.

After the First 250 Hours of Serviceand Every Six Months of ServiceThereafter

Change the speed reducer lubricant as described in this section.

As Required Flush the system, especially when changing to a different adhesive.Refer to Flushing the System in this section.

4. General SystemMaintenance

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The following maintenance procedures should be performed on a dailybasis.

Inspect the hose hydraulic connections as follows:

1. Relieve hydraulic pressure as described earlier in this section.

2. Inspect the hose fittings for tightness or cross-threading.

3. If the hose fittings are loose, use one wrench on the hose connectorand another wrench on the hose fitting to tighten the hose connection.

4. If the hose fittings are cross-threaded, unscrew and reconnectproperly.

5. Replace the hoses if damaged.

6. Close the manifold manual valve and reconnect the input air supply.

Clean the exterior as follows:

1. Wipe off dirt, dust, and debris from the top of the platen, frame, aircylinders, and electrical enclosure.

2. Wipe off adhesive residue from the platen and manifold.

3. Wipe off adhesive residue from the hose fittings and the hose braid.

NOTE: It is important to keep the braid of the hose free of adhesive.Built-up material can cause kinking when the hose is moved from oneposition to another.

5. Daily Maintenance

Inspecting Hose HydraulicConnections

Cleaning the Exterior

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The speed reducer lubricant should be checked at least every month andmore frequently under severe conditions (moist, dirty, or corrosiveenvironments or where rapid temperature changes occur).

Use the following procedure to check the speed reducer lubricant level.

You will need a small tray or metal pan and a hex wrench to complete thisprocedure.

1. Turn power off and set the main disconnect switch to OFF.

2. See Figure 5-2. Unscrew the plastic plug (1) from the filler hole.

4701153A

2

3

4

1

5

Fig. 5-2 Speed Reducer Filler Hole and Drain Opening

1. Plastic filler hole and plug2. Speed reducer3. Speed reducer driven shaft

4. Drain plug5. Oil level plug

3. Place a small tray or metal pan under the oil level hole on the rear ofthe gerotor housing, then use a hex wrench to remove the sockethead oil level plug (5).

4. The oil level should be up to the bottom of this hole.

5. If the level is low, add oil through the filler hole until oil begins to flowfrom the oil level hole.

6. When the oil stops draining from the oil level hole, replace the sockethead oil level plug.

7. Reinstall the plastic filler plug.

8. Set the main disconnect switch to ON and resume normal operation.

6. Check the SpeedReducer Lubricant

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The speed reducer lubricant should be changed after the first 250 hoursof service and every six months or 2,500 hours of service afterwards.

NOTE: Oils of various types may be incompatible. Check the oil typereceived with the unit and continue to use this type or an equivalent.Drain and flush the speed reducer housing with a light oil beforechanging to a different oil.

NOTE: A speed reducer stored for an extended period of time as aspare should be filled completely with oil prior to storage. Drain the oil tothe proper level before placing the reducer in service.

Use the following procedure to change the speed reducer lubricant.

You will need a small tray or metal pan, a hex wrench, and therecommended lubricant to complete this procedure.

1. Turn power off and set the main disconnect switch to OFF.

2. See Figure 5-2. Place a tray or metal pan under the speed reducerdrain hole, then use a hex wrench to remove the drain plug (4).

3. Use a hex wrench to remove the oil level plug (5).

4. Unscrew the plastic plug (1) from the filler hole.

5. After the old lubricant has drained from the housing, reinstall thebottom drain plug.

CAUTION: Do not overfill or underfill the gerotor housing.Failure to observe may cause excessive friction in the gerotorhousing and premature equipment wear and failure.

7. Change the SpeedReducer Lubricant

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6. Refer to Table 5-2. Pour the recommended lubricant into the fillerhole until it begins to flow from the oil level hole.

7. When oil stops draining from the oil level hole, reinstall the sockethead oil level plug.

8. Reinstall the plastic filler plug.

9. Set the main disconnect switch to ON, press the POWER ON button,and resume normal operation.

Table 5-2 Recommended Lubricants

AmbientTemperature Range

Boston GearLubricant*

ISO Grade Viscosity cSt@40C AGMA LubricantNo.

-9.4 to 15.5 C(15 to 60 F)

R&O Gear Oil-100HD Gear Oil-100

100 90 to 110 3 or 3 EP

10 to 51.7 C(50 to 125 F)

R&O Gear Oil--150HD Gear Oil--150

150 135 to 165 4 or 4 EP

* Equivalent lubricant must conform to AGMA Standard Specification #250.03 or AGMA lubricant numberindicated and pour point should be equal to or below the minimum ambient temperature encountered.

WARNING: Hot! Risk of burns. Wear heat-protective clothingand safety goggles. Failure to observe may result in seriouspersonal injury.

Use the following procedure periodically to remove dirt and charredmaterial from adhesive passages and surfaces. You should also use thisprocedure before changing from one adhesive type to another when thetwo adhesives are not compatible.

If you are changing adhesives and need to determine whether the oldand new adhesives are compatible, contact your adhesive suppler.

To determine the best flushing material to use, contact your adhesivesupplier.

You will need a small tray or metal pan, an empty pail, high temperaturegrease, and the recommended flushing material to complete thisprocedure.

7. Change the SpeedReducer Lubricant (contd)

8. Flush the System

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1. Verify that the unit is at application temperature.

NOTE: Do not attempt this procedure unless the unit is at applicationtemperature. Failure to observe and follow this note may causedamage to the platen seal.

2. Turn pump off through the VISTA controller.

3. Place the elevator control valve in the neutral (center) position.

4. Unscrew and remove the platen T-handle from the T-handle adapter.Refer to Platen Assembly in the Parts section.

5. Thread the platen removal adapter into the T-handle adapter.

6. Attach the quick disconnect fitting at the end of the removal air line tothe platen removal adapter.

7. Place the elevator control valve in the UP position.

8. Set the PLATEN REMOVAL selector switch to the ON position.

9. When the platen clears the pail, set the PLATEN REMOVAL selectorswitch to the OFF position.

10. When the platen has reached its maximum height, leave the elevatorcontrol valve in the UP position.

11. Open the platen guard (if installed).

12. Remove the pail.

13. Trigger all guns until no material flows.

Removing the Pail

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Install the pail of flushing material as follows:

1. Relieve system hydraulic pressure as described in this section.

2. Remove the gun(s) from the hose(s), then secure the free hose endsto an empty pail which will be used to collect flushing materialpumped through the system.

3. Clean each gun in the system as needed. Refer to the gun manualfor information on gun disassembly, cleaning, and rebuilding.

WARNING: Risk of electrical shock. Failure to disconnect andlock out input power may result in personal injury or death.

4. Turn power off, set the main disconnect switch to the OFF position,and lock out input power to the unit.

5. Refer to the wiring diagram for your unit in the Troubleshootingsection. So the pump will activate and force flushing material throughthe system with the gun(s) removed, open the electrical enclosuredoor and install a jumper wire between terminals C4-12 and C2-3.

WARNING: Use the flushing material at the manufacturer’srecommended temperature which is below the flushingmaterial’s flash point. Failure to observe could result in afire hazard.

6. Adjust the platen and hose setpoints to the flushing materialmanufacturer’s recommended temperature.

7. Close and latch the enclosure door.

Installing the FlushingMaterial

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CAUTION: Check that the unit base is free of adhesive so thatthe pail of flushing material sits squarely on the frame base.Failure to do so may result in a poor seal or incompleteemptying of the pail.

CAUTION: A dented or otherwise damaged pail may causedamage to the platen seal, resulting in faulty equipmentoperation.

8. Load a pail of flushing material on the frame base (or in the pailhold-down assembly) directly under the platen as described in theLoading the Pail procedure in the Operation section.

Pump the flushing material through the system as follows:

1. Pump the flushing material through the system and into the emptypail until the material is free of char and other contaminants.

NOTE: You can reuse the flushing material if you place a strainerover the top of the pail used to collect it.


3. Open the electrical enclosure door and remove the jumper wire fromterminals C4-12 and C2-3. Reset the platen and hose setpointtemperatures. Close the electrical enclosure door.

4. Reattach the hose(s) to the gun(s).

5. Restore input power to the unit, set the main disconnect switch to ON,and press the POWER ON pushbutton.

6. Replace the pail of flushing material with a new pail of adhesive asdescribed in the Drum Changeover procedure in the Operationsection.

7. Turn the PUMP potentiometer to the ON position and trigger thegun(s) until all traces of the flushing material have been removedfrom the system.

The pail melter/applicator is ready for routine operation.

Pumping the FlushingMaterial Through the System

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Section 6

Troubleshooting

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Section 6Troubleshooting



This section contains fault isolation and correction procedures forproblems that can occur during operation of the pail melter/applicator. Ifyou cannot solve the problem with this information, contact your Nordsonrepresentative.

General troubleshooting procedures for the hose and gun are included.Refer to your hose or gun manual for specific troubleshootinginformation.

The procedures are presented in tables that list the problems, possiblecauses, and corrective actions. Note that a problem may have more thanone possible cause. Therefore, refer to all tables before beginning tocorrect a problem. Also, check that the required tools, replacement parts,and service items for the corrective action procedure are at hand.

During the daily visual inspection, correct obvious causes of malfunctionsuch as broken or missing electrical pins or wires or damaged hoseplugs.

1. Introduction

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Problem Page

Adhesive Application Troubleshooting Procedures

1. Adhesive spitting on extrusion 6-4

2. Waviness in bead deposit 6-4

3. Excessive adhesive at beginning of bead 6-4

4. Excessive adhesive at end of bead 6-6

5. Adhesive stringing at cut-off 6-6

6. Adhesive drooling from gun 6-6

7. Unequal deposits between nozzles in multi-moduleinstallations

6-7

8. Adhesive bouncing or splashing from substrate 6-7

9. Adhesive not penetrating substrate 6-8

10. Adhesive gelling 6-8

11. Adhesive charring in system 6-8

12. Adhesive fuming or smoking 6-8

Hydraulic Troubleshooting Procedures

1. No or little adhesive output 6-9

2. Adhesive leaking at hose connection 6-10

Pneumatic Troubleshooting Procedures

1. Platen elevator not working 6-11

2. Platen removal mechanism not working 6-16

Electrical Troubleshooting Procedures

1. System ready light not illuminated 6-24

2. Unstable temperature readings on channel 6-24

3. Display on Vista controller dark and not functional 6-24

4. Heating zone overheats 6-24

5. No or little adhesive output 6-24

6. Drive shaft rotating counterclockwise 6-25

7. Drive shaft not rotating 6-25

8. Drive motor not rotating 6-26

9. Platen not heating 6-28

10. Hose or gun not heating 6-30

11. Vista fault light comes on 6-32

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WARNING: Risk of electrical shock. This procedure is usedwhen measuring voltages across wiring connections. Exerciseextreme caution when performing voltage checks. Do not touchor hold the meter probes. Failure to observe could result inpersonal injury or death.

See Figure 6-1. Some of the following troubleshooting procedures willrequire that you open the electrical enclosure door with the power to theunit on:

1. Loosen the slot-head screws (1) on the front of the cabinet.

2. Open the door.

4705022A

1

Fig. 6-1 Opening the Electrical Enclosure Door with Power On

1. Slot-head screw

2. Opening the ElectricalEnclosure with Power On

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The following table provides procedures for troubleshooting adhesiveapplication problems.

Problem Possible Cause Corrective Action

1. Adhesive spitting onextrusion

Adhesive output exceeds maximumcontinuous delivery rate of system

Lower the pump speed until a constantstream of adhesive is produced.

Air trapped under platen Stop the system and open the bleedvalve to remove trapped air.

Adhesive level in pail is low If the amber light on the light tower isflashing, complete the pail changeoverprocedure as described in the Operationsection.

2. Waviness in beaddeposit

Temperature setpoints lower thanrecommended applicationtemperature

Increase the temperature setpoints torecommended application temperature.

Low ambient temperature inapplication area

Increase the ambient temperature inthe application area (minimumrecommended temperature is 0_C(32_F)).

Guns and nozzles subject to draft orbreeze

Prevent draft or breeze at the nozzles.

Nozzle too far from substrate Reposition the nozzle closer to thesubstrate (recommended distance is13 mm (0.5 in.) from the substrate).

3. Excessive adhesive atbeginning of bead

Nozzle too large, resulting inexcessive instantaneous delivery rate

Use the proper size nozzle.

Nozzle too far from substrate Reposition the nozzle closer to thesubstrate (recommended distance is13 mm (0.5 in.) from the substrate).

Partially plugged nozzle Clean or replace the nozzle.

Insufficient air pressure to gun Increase the air pressure to the gun asrequired.

3. Adhesive ApplicationTroubleshootingProcedures

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Table 6-1 Light Tower Decoder Chart

When Condition is Light Tower will show

Ready (Heaters at temp -- Vista)Sufficient glue

Steady green

Ready (Heaters at temp -- Vista)Low glue

Steady greenFlashing amber

Ready (Heaters at temp. -- Vista)No glue

Flashing Red

Not Ready (Heaters not at temp. on Vista)Sufficient glue

No lights

Not ready (Heaters not at temp. on Vista)Low Glue

Flashing amber

Not Ready (Heaters not at temp. on Vista)No glue

Flashing red

Warning (Vista)Sufficient glue

Steady green

Warning (Vista)Low glue

Steady green

Warning (Vista)No glue

Flashing red

Fault (Vista)Sufficient glue

Steady red

Fault (Vista)Low glue

Flashing amber

Fault (Vista)No glue

Steady red

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4. Excessive adhesive atend of bead

Adhesive too cold Increase the channel setpoints asrequired.

Insufficient air pressure to gun Increase the air pressure to the gun asrequired.

5. Adhesive stringing atcut-off

Nozzle positioned too far fromsubstrate

Reposition the nozzle closer to thesubstrate (recommended distance is13 mm (0.5 in.) from the substrate).

Adhesive viscosity too high Increase the channel setpoints slightlyor change to an adhesive with a lowerviscosity.

Cold adhesive Increase the gun channel setpoint(s) asrequired.

Gun speed too slow Use a faster-acting gun, use anair-piloted relay valve between thesolenoid and the gun, or reduce thedistance between the solenoid and thegun.

Gun temperature too low Increase the gun temperature asrequired.

6. Adhesive drooling fromgun

Spring tension of gun too low Re-adjust the gun spring tension asrequired. Refer to the gun manual.

Ball or needle and/or seat of gunmodule worn or partially clogged bychar

Clean or replace the gun module.

3. Adhesive ApplicationTroubleshootingProcedures (contd)

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7. Unequal depositsbetween nozzles inmulti-moduleinstallations

Different size nozzles are being used Use the same size nozzles.

Unequal spring tension or improperneedle lift adjustment in zero-cavityguns

Adjust the gun modules as instructed inthe gun manual.

Nozzle clogged or damaged Clean or replace the nozzle asinstructed in the gun manual.

Foreign adhesive in gun module Rebuild or replace the gun module.

Insufficient and/or unequal airpressure to guns

Adjust the air pressure as required.

Hydraulic pressure not equal at guns Compensate for the difference by usingdifferent nozzle sizes or adjusting thegun travel as described in the gunmanual.

Debris or slight imperfections innozzles

Clean or replace the nozzles.

Adhesive in air motor section of gunmodule

Rebuild or replace the gun module.

8. Adhesive bouncing orsplashing fromsubstrate

Adhesive too hot Decrease the channel setpoints asrequired.

Adhesive viscosity too low Decrease the channel setpoints slightlyor change to an adhesive with a higherviscosity.

Nozzle diameter too small Change to a larger diameter nozzle.

Too much adhesive Lower the pump speed.

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9. Adhesive notpenetrating substrate

Adhesive temperature too low Increase the channel setpoints slightly.

Special coating on substrate Increase the channel setpoints slightly.If problem persists, check with theadhesive manufacturer for a compatibleadhesive.

Not enough adhesive being applied Use a higher flow-rated nozzle, increasethe channel setpoints slightly, orincrease the pump speed.

Adhesive viscosity too high Increase the channel setpoints slightlyor change to an adhesive with a lowerviscosity.

10. Adhesive gelling System not properly flushed beforechanging adhesives

Attempt to pump the remaining adhesivefrom the system. Then, flush thesystem.

Type-R cleaning fluid used to flush asystem that was operating withPolyamide, Surlyn, Polyester, or otherhigh performance hot melt adhesives

Attempt to pump the remaining adhesivefrom the system. Then, flush thesystem. Consult with the adhesivemanufacturer for recommendations.Refer to the Adhesive Safety Data Sheetfor information about Type-R cleaningfluid.

Adhesive heated for too long Do not heat adhesive longer thanrecommended. Use the systemSTANDBY during prolonged holdingperiods.

Adhesive temperature too high Reduce the temperature or consult withan adhesive manufacturer about therecommended adhesive temperaturerange.

11. Adhesive charring insystem

Temperature setpoints too high Decrease the channel setpoints asrequired.

Zone overheats Complete the troubleshooting procedureto locate and repair the overheatingcomponent.

System maintained at operatingtemperature with no delivery

Use the system STANDBY duringprolonged holding periods.

12. Adhesive fuming orsmoking

Temperature setpoints too high Decrease the channel setpoints asrequired.

Use of unstable adhesive Flush the system and change to adifferent adhesive.

3. Adhesive ApplicationTroubleshootingProcedures (contd)

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The following table provides troubleshooting procedures for the pailmelter/applicator’s hydraulic system.

NOTE: Some materials may require 1--2 hours to reach applicationtemperature.


1. No or little adhesiveoutput (Refer to electricaltroubleshooting also)

Lack of hydraulic flow due tomalfunctioning hose, gun or nozzle

Verify that all zones are up totemperature. If yes:

a. Place the elevator control valve in theneutral (center) position.

b. Check that the T-handle bleed rod isin the bleed port.

c. Place a small tray or pan under thepump manifold drain valve.

d. Open the pump manifold drain valveand place the elevator control valvein the down position.

e. Turn the pump on at low speed.

f. If the adhesive output is normal at themanifold, turn off the pump, close themanifold drain valve, and remove thegun nozzle.

g. Turn the pump on and open the gun.If the output is normal without thenozzle, clean and replace the nozzle.

h. If there is no or little output with thenozzle removed, turn off pump.Bleed off hydraulic pressure atmanifold drain valve, then re-closevalve. Remove gun from hose.

i. Turn pump on. If material does notflow freely through hose with gunremoved, replace the hose.

j. If material flows freely from the hosewith the gun removed, rebuild orreplace the gun (refer to specific gunmanual).

4. HydraulicTroubleshootingProcedures

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1. No or little adhesiveoutput (contd.)

Air trapped in pump/platen Check for trapped air:

a. Turn the PUMP off through the VISTAcontroller and place the elevatorcontrol valve in the neutral (center)position.

b. Unscrew and remove the T-handlebleed rod from the platen.

c. Place a small tray or metal pan underthe platen bleed port.

d. Use the elevator control valve tolower the platen into the pail. If air isdischarged from the bleed port, purgethe trapped air from the systembefore resuming operation.

Gear pump malfunctioning Check that the drive shaft is rotatingproperly and in a clockwise direction asdescribed in the Drive shaft rotatingcounterclockwise and Drive shaft notrotating problems in this section.Replace or rebuild the gear pumpassembly as described in the Repairsection.

Cured Polyurethane Reactive (PUR)in pump cavity

Disassemble the pump as described inthe Repair section and clean the pumpas recommended by the adhesivesupplier.

Sheared coupling key or gerotor key Disassemble the pump as described inthe Repair section and replace the key ifworn.

Pressure relief valve open Disassemble the pump as described inthe Repair section and replace thepressure relief valve if open.

2. Adhesive leaking athose connection

Loose or cross-threaded connection Check the hose to manifold connection.

Faulty hose connector O-ring at thehose-to-gun connection

Replace the O-ring as described in theRepair section.

4. HydraulicTroubleshootingProcedures (contd)

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Refer to the following tables for troubleshooting procedures for the pailmelter/applicator’s pneumatic system. See Figure 6-2 to familiarizeyourself with the pneumatic system.


1. Platen elevator notworking

Air filter/regulator malfunctioning Check the air filter/regulator:

a. Set the air filter/regulator pressure to0 kPa/psi (never disconnect the inputair line without first turning off theinput (shop) air). Then disconnectthe input air supply from the quickdisconnect fitting.

b. Disconnect the air line from theoutput side of the filter/regulator andreconnect the input air supply to theunit at the quick disconnect fitting

c. Turn the filter/regulator handleclockwise to increase the air flow andlisten for air exhaust. Also, turn thehandle counterclockwise and listenfor exhaust.

d. If there is no air exhaust from theoutput side of the filter/regulator whenthe handle is turned clockwise, or ifthere is air exhaust when the handleis turned counterclockwise, set thefilter/regulator pressure to 0 kPa/psiand disconnect the input air supplyfrom the quick disconnect fitting.

e. Replace the filter/regulator.

5. PneumaticTroubleshootingProcedures

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1. Platen elevator notworking (contd.)

Elevator solenoid control valvemalfunctioning

Check the elevator control valve:

a. Verify that air is being supplied to theelevator solenoid control valve by firstsetting the filter/regulator to 0 kPa/psiand then disconnecting the input airline from the solenoid valve. Set thefilter regulator to 128 kPa/20 psi andverify air is flowing from thedisconnected line. If it is, then set thefilter/regulator to 0 kPa/psi andreconnect the line to the input of theelevator solenoid control valve. If airis not flowing, check the lines, verifyshop air is present or check thefilter/regulator.

b. Place the elevator solenoid controlswitch in the neutral position and setthe air filter/regulator pressure to0 kPa/psi, then disconnect both airlines from the output side of theelevator solenoid control valve. Tageach air line for re-connection later.

c. Set the filter/regulator pressure to103 kPa (15 psi).

d. Manually pilot elevator solenoid“OUT/A” or “OUT/B” by pressing thespring loaded solenoid spool andcheck for platen movement. If platenmoves refer to “No Control Signal toElevator Solenoid Control Valve”. Ifplaten does not move during manualpilot check next step.

e. There should be no air flowing out“OUT/A” or “OUT/B” when theelevator control valve is not manuallypiloted. With air lines stilldisconnected from the output of theelevator control valve, verify that aircomes out when each of the twosolenoids are manually piloted. If airdoes not come out, replace the valve.

5. PneumaticTroubleshootingProcedures (contd)



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No control signal to elevator solenoidcontrol valve

Check the programmable logic controller(PLC) which is AP6 for proper inputsand outputs:

a. To check UP Platen control, place theelevator control switch in the neutralposition.

Verify 24 VDC between SB1-14 (+)and XT3-1 (--).

If 24 VDC is not present, check24 VDC power supply (GS1) andfuses FU3 and FU2.

If 24 VDC is present at SB1-14 toXT3-1, then place the elevator controlswitch in the UP position. Measurethe voltage between AP6-I/0 (+) toXT3-1 (--). If 24 VDC is not present,then replace switch SB1.

If it is present, then check for 24 VDCacross the output of the PLC atAP6-0/4 and XT2-5. If 24 VDC is notpresent, check PLC, AP6.

If 24 VDC is present then checkwiring to elevator solenoid controlvalve.

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No control signal to elevator solenoidcontrol valve (contd.)

b. To check DOWN Platen control, placethe elevator control switch in theneutral position.

Verify 24 VDC between SB2-24 (+)and XT3-1 (--).

If 24 VDC is not present, check24 VDC power supply (GS1) andfuses FU3 and FU2.

If 24 VDC is present at SB2-24 toXT3-1, then place the elevator controlswitch in the DOWN position.Measure the voltage between AP6-I/2(+) to XT3-1 (--). If 24 VDC is notpresent, then replace switch SB1.

If it is present, then check for 24 VDCacross the output of the PLC atAP6-0/5 and XT2-5. If 24 VDC is notpresent, check PLC, AP6.

If 24 VDC is present then checkwiring to elevator solenoid controlvalve.

PLC not operating Check input voltage at PLC AP6-L1 andAP6-L2. Voltage should be between204 and 264 VAC. If not check wiringand fuses FU1, FU2, FU10, and FU11.




100 4197AIssued 7/00




Piston assemblies malfunctioning Check the piston assemblies:

a. Set the filter/regulator pressure to0 kPa/psi and place the elevatorcontrol valve in the neutral (center)position.

b. Disconnect the air line from the upperportion of the air cylinder.

c. Set the filter/regulator pressure to103 kPa (15 psi) and place theelevator control valve in the upposition.

d. If the crossover assembly does notrise or it rises and air continues toflow from the open air line after thecrossover reaches maximum height,set the filter/regulator pressure backto 0 kPa/psi and disconnect the inputair supply from the quick disconnectfitting.

e. Replace or rebuild the pistonassemblies as described in theRepair section.

If necessary, repeat the aboveprocedure but remove the air line fromthe lower portion of the air cylinder andplace the elevator control valve in thedown position.

Troubleshooting6-16


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Air cylinder head leaking Check for air leakage:

a. Use leak detector fluid around theshaft at the cylinder heads to checkfor excessive air leakage with theelevator control valve in the DOWNposition.

b. If the air is leaking from the cylinderhead, set the filter/regulator pressureto 0 kPa/psi and disconnect the inputair supply from the quick disconnectfitting.

c. Replace or rebuild the cylinder headassemblies as described in theRepair section.

2. Platen removalmechanism not working(see Figure 6-2)

Platen blow-off valve malfunctioning Check the blow-off valve:

a. Disconnect the platen removaladapter from the platen T-handleadapter and from the platen removalair line. Check the platen removaladapter for clogging.

- Adapter tube is clogged: cleanor replace the platen removaladapter, then restore the unit tonormal operation.

- Adapter tube is not clogged, goto next cause.




100 4197AIssued 7/00



2. Platen removalmechanism not working(contd.)

Platen removal switch malfunctioning Check the removal switch:

a. Set the air filter/regulator pressure to0 kPa/psi.

b. Disconnect the air line from theoutput side of the platen removalswitch.

c. Place the elevator control valve in theup position.

d. Set the filter/regulator to 103 kPa(15 psi), then turn the platen removalselector switch to ON.

- Air flows from the platen removalswitch: Set pressure to0 kPa/psi, reconnect the air lineto the platen removal switch,disconnect the air line from theoutput side of the regulator, andgo to next cause.

- No air flows from the platenremoval switch: Set filter/regulator pressure to 0 kPa/psiand replace the platen removalswitch.

2. Platen removalmechanism not working(contd.)

Preset regulator malfunctioning Check the regulator:

a. Set the air filter/regulator pressure to0 kPa/psi.

b. Disconnect the large, flexible air linefrom the fitting at the platen blow-offvalve.

c. Set the filter/regulator to 103 kPa(15 psi).

d. Place the elevator control valve in theup position, then engage the platenremoval selector switch.

- Air flows from regulator: normalindication. Set pressure back to0 kPa (0 psi), reconnect the airline to the preset regulator, andgo to step next cause.

- Air does not flow from regulator,set pressure to 0 kPa (0psi),replace regulator.

Troubleshooting6-18


100 4197AIssued 7/00



Platen clogged with adhesive a. Manually remove the platen from thepail (refer to Changing the Pail in theOperation section) and remove theplaten from the unit (refer toReplacing the Platen in the Repairsection).

NOTE: It may be necessary to ventthe pail from the bottom by punchinga hole in it, forcing the platen from thepail. Take care not to damage theplaten or platen seal when ventingthe pail or removing it from the pail.

b. Remove the gear pump assembly.Refer to the Repair section.

c. Thoroughly clean the platen T-handleport and chamber at the bottom ofthe platen.

d. Reassemble the unit and resumenormal operation.




100 4197AIssued 7/00


4705001A

FILTER/REGULATOR

SHOP AIRSUPPLY

FACTORYPRESET7 PSI

TO BLOWOFF

RIGHTLEFTCYLINDER CYLINDER

4 WAY VALVE(ELEVATOR CONTROLS)

IN/PEXH

OUT1/AOUT2/B

2-WAYVALVE

Fig. 6-2 Pneumatic Schematic Diagram

Troubleshooting6-20


100 4197AIssued 7/00


Before performing troubleshooting activities inside the unit’s electricalenclosure, you should exhaust all methods of troubleshooting theproblem with the electrical enclosure closed or with the power off. Thetroubleshooting tables and procedures in this section are organized usingthis methodology. In general, you should perform troubleshootingactivities as follows:

S Check the displays and lights for warnings, faults, and other statusinformation.

S Check your programmed settings to make sure they haven’t beenchanged. Refer to Records of System Settings in the Installationsection.

S Check for continuity and grounding between system components(unit, guns, hoses, and other equipment).

S Make sure your branch circuit disconnect switch is properly installed.

S Make sure your power supply is supplying the proper voltage.

S Prioritize troubleshooting activities to limit exposure to live power.Perform troubleshooting activities involving live power last.

S Understand your system electrically and mechanically before openingthe electrical enclosure. Pay special attention to system powerdistribution and to I/O interfaces with other equipment.

S Identify and eliminate potential electrical shock hazards in theenvironment surrounding your unit.

To troubleshoot control system problems or to make any repairs, you mayneed to access the electrical enclosure. Use these procedures asneeded to safely access the electrical enclosure.

6. ElectricalTroubleshootingProcedures

Electrical Safety DuringTroubleshooting

Opening and Closing theElectrical Enclosure



100 4197AIssued 7/00


Opening

WARNING: Risk of equipment damage, personal injury, ordeath. Disconnect and lock out electrical power to the unit,including input/output (I/O) lines.

1. Place the unit’s POWER switch in the off position, turn the disconnectswitch to off, lock out electrical power to the unit at the branch circuitdisconnect switch, and disconnect and lock out electrical powersupplied through any I/O wiring.

2. See Figure 6-3. Loosen the screws on the door of the electricalpanel.

5940580A

1 2

1 2

12

WARNING

VistaTM READYFAULT

O

1

Fig. 6-3 Securing the Electrical Enclosure

1. Screws

3. Avoid direct contact with internal electrical connections, components,or wiring.

4. Make sure all ground wires are securely connected.

Troubleshooting6-22


100 4197AIssued 7/00


Closing

1. Reconnect any ground wires that were disconnected duringtroubleshooting or repair activities.

2. Close the electrical panel door and tighten the screws.

3. Remove the lock-out and restore power to the system.

Opening the Electrical Enclosure with Power On

WARNING: Risk of electrical shock. This procedure is usedwhen measuring voltages across wiring connections. Exerciseextreme caution when performing voltage checks. Do not touchor hold the meter probes. Failure to observe could result inpersonal injury or death.

See Figure 6-3. Some of the following troubleshooting procedures willrequire that you open the electrical enclosure door with the power to theunit on:

1. Loosen the slot-head screws (1) on the front of the cabinet.

2. Open the door.



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4705020A

XS2

XS5

XS1

XS3

XS4

Input

Pow

er

AB160V/FDRV

Motor

Output

FU5,FU6MotorDriveGould

TransPrimFuse

FU1,FU2

Gould

FU10,FU11TranSecFuseGould

KM1Contactor

CB1

AB

CB

XT1

InputP

WR

Entrelec

GND

XT6

FU7,8,9

G1--G14

AB

Pow

erAB

Platen

Gould

Relay

Driver

AP5

ABRelay

ABRelay

KA6 KA5

+24V

AB AB

24Vcom

XT3XT2

AP6ABPLC

GS1XT4VariousSignal Omron24VP/S

FU3,FU12

24VOutput

Gould

AB

QS1 R2

CABINETRIGHTSIDE,

INSIDE

CABINETLE

FTSIDE,

INSIDE

CABINETBACKPA

NEL

R1

SB1

AP7

Fig. 6-4 Electrical Cabinet Layout

Electrical Cabinet Interior

Troubleshooting6-24


100 4197AIssued 7/00


Follow the steps in this table to troubleshoot electrical problems in yourpail melter/applicator. Refer to the Repair section, for repair proceduresand to the Parts section, for replacement parts.

Refer to the electrical schematics found at the end of this section.


1. System ready lightnot ON

Empty pail -- flashing red light Replace pail.

One or more temperature zone is notwithin 6 _C (11 _F) of setpoint (outsidetemperature band).

Use the zone selector switch and thedigital display to check the platen, hose,and gun channel temperatures. If anyzone fails to reach setpoint temperature,refer to the Platen not heating or theHose or gun not heating problem in thissection.

Start delay timer has not timed out Verify the amount of time set on thetimer. Timer starts when system isturned on.

2. Unstable temperaturereadings on channel

Miswired or loose cable connection Check for loose connections on RTDs.Tighten or replace as needed.

Excessive electrical noise Shield or separate AC wires and sensorwires.

Faulty controller Replace controller.

3. Display on Vistacontroller dark andnot functional

Vista controller not turned on Place Vista controller on/off switch in theON position.

No power to Vista controller Check power supply and fuses.


4. Heating zoneoverheats


Faulty relay driver for platen Replace driver.

Shorted solid-state relay (platen) Replace relay.

Ground Fault Correct faulty wiring or heater.

5. No or little adhesiveoutput (Refer tohydraulictroubleshooting also)

No input power to the applicator Check that input power is connected tothe pail melter/applicator.

Main disconnect switch not on Set the main disconnect switch to theON position.

Heaters not switched on Set the heaters switch on the Vistacontroller to ON; the heaters light shouldcome on. Wait until unit heats up andyou get a system ready light.

Troubleshooting theElectrical System



100 4197AIssued 7/00



5. No or little adhesiveoutput (contd)

Pump not on Turn the PUMP selector switch to ON.

Green SYSTEM READY light is off Wait until all active heated zones havereached setpoint temperature, theparent machine time delay hastranspired (if applicable), and the greenlight goes on.

One or more zones are not heating Use the zone selector switch and thedigital display to check the platen, hose,and gun channel temperatures. If anyzone fails to reach setpoint temperature,refer to the Platen not heating or theHose or gun not heating problem in thissection.

Vista fault light is on and “rtd” isdisplayed

Refer to the Vista fault light comes onproblem in this section.

Temperature settings of one or morechannels are too low for the adhesive

Increase the channel setpoints asrequired.

Gun solenoid valve not operating Ensure operating air reaches valve.

Drive shaft not turning Refer to Drive Shaft not Rotating in thissection.

6. Drive shaft rotatingcounterclockwise

Wire connections reversed Press Vista heater off button, turn off,disconnect and lock out input power.Correct wiring between motor controllerand motor according to the schematicand wire list.

7. Drive shaft not rotating Wires loose or damaged Press Vista heater off button, turn off,disconnect and lock out input power.Open the electrical enclosure door andreposition or replace any loose ordamaged wires.

Gun trigger switch malfunctioning Press Vista heater off button, turn off,disconnect and lock out input power.Open the electrical enclosure door andcheck for continuity between terminalsXT2-3 and AP6-I/12 for gun 1 triggerand XT2-3 and AP6-I/13 for Gun 2trigger with the gun trigger switchactivated. If continuity does not exist,replace the gun trigger switch.

Vista pump enable switch not on Turn pump on through Vista controller.

Troubleshooting6-26


100 4197AIssued 7/00



8. Drive motor not rotating System not ready Refer to System ready light not onproblem in this section.

Over-temperature condition exists If the Vista fault light is on and “ot” is indisplay, refer to the OVER-TEMP lightcomes on problem in this section.

Wires loose or damaged Press Vista heater off button, turn off,disconnect and lock out input power.Open the enclosure door and check forloose or broken wire connectionsthroughout the circuit path. Repair orreplace wires as necessary.

Fuse is open With heaters on, there should bebetween 204 and 264 VAC across motordrive AC line input AP7-TB1-L2 toAP7-TB1-L3. If not, press the heatersoff switch, disconnect and lock out inputpower.Remove fuse FU5 and FU6 and test forcontinuity. Replace if necessary.

Motor speed potentiometer set toolow

With system ready and pump turned on,rotate motor speed pot clockwise toincrease speed.

Drive motor malfunctioning Check the wiring between the motorcontroller and the motor:

a. Press Vista heater off button, turn off,disconnect and lock out input power.

b. Refer to the system schematic andverify all wires are connectedproperly between the motor controllerand the motor, including the wiresgoing to and coming from thecrossover junction box.

Troubleshooting theElectrical System (contd)



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8. Drive motor not rotating(contd.)

Motor controller malfunctioningbecause of lacking motor start signal

Bring the unit up to applicationtemperature. Check the motorcontroller:

a. Press Vista heater off button, turn off,disconnect and lock out input power.

b. Open the enclosure door and installan 18 GA jumper wire between motorcontroller AP7-TB3-6 andAP7-TB3-7. Verify jumper is alreadyinstalled across AP7-TB3-7 toAP7-TB3-8 (placing a jumper acrossAP7-TB3-6 and AP7-TB3-7 simulatesthe contact closure normally providedby the Vista controller to turn on themotor).

c. Close and latch the enclosure doorand apply input power. Set the maindisconnect switch to ON, press theHeaters ON button, and wait for thesystem ready light to come on. Motorshould start to rotate after system isready.

Motor controller malfunctioningbecause of no input power tocontroller

a. Open the electrical enclosure door asdescribed in Opening the ElectricalEnclosure Door with Power On in thissection.

b. Measure the voltage across wires 23and 24 at the motor control terminalsL2 and L3. The voltage should be inthe range of 204--264 VAC.

c. If the voltage is not within range,remove input power and check fusesFU5, FU6, FU10, FU11, FU1, FU2,AP10-F1, AP10-F2. Refer to systemschematic and check wiring betweeninput power to TM1, AP10, AP7motor controller line input.

Speed reducer malfunctioning Replace the speed reducer as describedin the Repair section of this manual.

Troubleshooting6-28


100 4197AIssued 7/00



9. Platen not heating (Referalso to Troubleshootingthe Vista Controller)

Over-temperature condition exists If the Vista fault light is on and “ot” is inthe display, refer to the VistaTroubleshooting section.

Sensor fault condition exists If the Vista fault light is on and “rtd” is onthe display, refer to the VistaTroubleshooting section.

Fuse is open Press Vista heater off button, turn off,disconnect and lock out input power.Open the electrical enclosure door andremove and check fuses FU7, FU8, andFU9 for continuity. Replace asnecessary.

Wires loose or damaged Press Vista heater off button, turn off,disconnect and lock out input power.Open the enclosure door and check forloose or damaged wires at input powerterminals L1, L2, and L3 and throughoutthe circuit path to the platen includingthe crossover electrical junction box.Reposition or replace as necessary.

Relays have failed off Check the relays:

a. Open the enclosure door asdescribed in Opening the ElectricalEnclosure Door with Power On in thissection.

b. Measure the input voltage to the solidstate relays NK1 and NK2 atterminals 3 (+) and 4 (--). Thevoltage should be 24 VDC when theplaten is heating.

c. If the measured voltage across thesolid state relay input terminals 3 and4 is less than 3 VDC, then check the24 VDC power supply GS1 or relaydriver AP5.

d. If the measured voltage across theinput terminals 3 and 4 of the solidstate relay is 3--24 VDC, measure theoutput voltage of the solid state relayacross terminals 1 and 2. If thevoltage is equal to the unit line inputvoltage, then replace the relay.




100 4197AIssued 7/00



9. Platen not heating (contd.) Master contactor has failed Check the contactor:


b. Turn heaters on. Verify 24 VDC onKM1 coil at KM1-A1 (+) toKM1-A2 (--).

c. Verify contacts are closed bymeasuring the voltage across thefollowing contactor contacts:

- KM1-1 and KM1-2

- KM1-3 and KM1-4

- KM1-5 and KM1-6

d. If the contactor input 24 VDC ispresent but the contactor is notclosing, replace the contactor.

Platen thermostat has failed Check the thermostat:NOTE: Platen overtemperaturethermostat is normally closed, open onrise.

a. Press the Vista heaters off button,turn off, disconnect and lock outpower.

b. Remove the platen covers asdescribed in the Repair section anddisconnect the platen thermostatleads from the porcelain wireconnectors and check for continuityacross the thermostat contacts.

c. Replace the faulty thermostat asdescribed in the Repair section ifnecessary.

Troubleshooting6-30


100 4197AIssued 7/00



9. Platen not heating (contd.) Platen heaters have failed Check the heaters:

a. Press the Vista heater off button, turnoff, disconnect and lock out power.

b. Remove the junction box cover.

c. Measure the resistance across thefollowing wire pairs with the wiresremoved from terminal block XT6:

- 95A and 96A

- 96A and 97A

- 97A and 95A

d. Compare the resistances withTable 6-2. Refer to system schematicfor platen heater connections.

e. Call your Nordson representative ifany heater is not within specification.

10. Hose or gun not heating(Refer also toTroubleshooting the VistaController)

Sensor fault condition exists If the Vista fault light is on with “rtd” inthe display and the gun is not heating,replace the gun RTD as described in thegun manual.If Vista fault light is on with “rtd” in thedisplay and the hose is not heating,replace the hose as described in theInstallation section.

Table 6-2 Platen Heater Cold Resistance Values in Ohms

Unit Input Voltage(VAC)

Cast-In HeaterCold Resistance

(Ohms)Wire Pairs95/96

Wire Pairs96/97

Wire Pairs97/95

200 or 208 21--24 42--48 21--24 21--24

240 34--38 68--76 34--38 34--38

400 21--24 42--48 n/a n/a

480 34--38 68--76 n/a n/a




100 4197AIssued 7/00



10. Hose or gun notheating (contd.)

Fuse is open Press Vista heater off button, turn off,disconnect and lock out input power.Open the enclosure door. Removefuses AP3-F1, F2, F3, F4, F5, F6, F7,F8, F9, and F10; AP10-F1 and F2. andcheck for continuity. Replace any openfuses.

Incorrect temperature control settings Refer to Programming TEMPERATUREControls in the Installation section.

Power to hose off Check for broken or missing pins ordamaged hose electrical plugs.

Wires loose or damaged Press Vista heater off button, ,disconnect and lock out input power.Open the enclosure door and check forloose or damaged wires throughout thecircuit path. Reposition or replace wiresas necessary.

Broken or missing pins or damagedhose electrical plugs

Repair using hose end repair kit. Referto the Recommended Spare Parts List inthe Parts section for the kit part number.

Gun heater cartridge malfunctioning If the heater resistance is outside thespecified range, replace the gun heatercartridge. Refer to the gun manual.


Troubleshooting6-32


100 4197AIssued 7/00



11. Vista fault light comeson

Over-temperature settings too low Check the OVER-TEMP settings andensure that the settings are at least28_C (50_F) above the applicationsetpoint temperatures.

Wires loose or damaged Press Vista heater off button, turn off,disconnect and lock out input power.Open the enclosure door and check forloose or damaged wires throughout thecircuit path. Reposition or replace asnecessary.

Platen relays have failed on Check the relays:


b. Measure the input voltage to the solidstate relays NK1 and NK2 atterminals 3 (+) and 4 (--). Thevoltage should be 0 VDC when theplaten is heating.

c. If the measured voltage across thesolid state relay terminals 3 and 4 isgreater than 3 VDC when the platenheater should be off, check the platensolid state relay driver AP5 or theVista control boards.

d. If the measured voltage across thesolid state relay is less than 3 VDC,measure the output voltage of thesolid state relay across terminals 1and 2. If the voltage is less than5 VAC, then the solid state relay hasfailed (shorted on) and should bereplaced.

Hose or gun is overheating Refer to the Channels overheatingproblems in this section.




100 4197AIssued 7/00


The following troubleshooting tables describe the kinds of control systemproblems you may encounter and provide corrective actions for handlingthose problems. When necessary, the tables refer to more detailedtroubleshooting procedures.

Refer to the appropriate troubleshooting table for the type of problem youare experiencing:

S Platen, Hose, or Gun Zone Not HeatingS Settings Changed or LostS Unit Not Powering OnS Control System Indicating a Warning

- Out-Of-Band Warning- Under-Temperature (UT) Warning

S Control System Indicating a Fault- Over-Temperature (OT) Fault- Resistance Temperature Detector (RTD) Fault- Fault-Code Fault (F1--F7)

If the platen, hose, or gun will not heat, use this troubleshooting table.


Platen, hose, or gun zonenot heating

Zone setpoint temperature below38 _C (100 _F)

Check the setpoint temperature for thezone. The setpoint temperature must be38 _C (100 _F) or above for the zone toheat. Refer to ProgrammingTEMPERATURE Controls in theInstallation section to program setpointtemperatures.

7. Vista TroubleshootingProcedures

Platen, Hose, or Gun ZoneNot Heating

Troubleshooting6-34


100 4197AIssued 7/00


Use the following table to troubleshoot changed or lost settings(memory). Because the control system memory is stored on themicroprocessor chip and does not require the protection of a batterybackup, your settings cannot be lost during a brownout or a power failure.


1. One or more settingschanged

Someone entered programmingmode and changed one or moresettings

Use the password-enable feature toprotect your settings. Refer to SystemProgramming Procedures in theInstallation section. Be sure to recordyour settings in the Records of SystemSettings at the end of the Installationsection.

2. All settings lost Software upgraded to latest versionby replacing software chip (all customsettings are lost during this procedureand are replaced by the factorydefault settings)

Reprogram your unit. Refer to SystemProgramming Procedures in theInstallation section.

Defective microprocessor chip Replace the control board. Refer toReplacing a Control Assembly Board inthe Repair section.

If your unit will not power on, use this troubleshooting table.

WARNING: Risk of equipment damage, personal injury, ordeath. Some troubleshooting procedures require you toperform work inside the electrical enclosure with the power on.Follow electrical safety procedures and observe all high-voltageindicators. Refer to Electrical Safety During Troubleshootingand Opening and Closing the Electrical Enclosure beforeperforming any troubleshooting procedure.

Settings Changed or Lost

Unit Not Powering On



100 4197AIssued 7/00



Displays do not illuminate

or

displays illuminate but unitwill not power on and nofaults are displayed

No input power Make sure the power is turned on atyour branch circuit disconnect switchand that your power supply is supplyingthe proper voltage to the unit. Checkthe voltage at AP3-TB1 on the powerboard. If necessary, check yourelectrical connections at TB1. Refer toElectrical Installation in the Installationsection.

Defective POWER switch Check the POWER switch. Refer toChecking the POWER Switch in thissection.

Blown fuse or fuses Use an ohmmeter to check fuses F9 andF10 on the power board. Replace blownfuses. Refer to Replacing a Fuse in theRepair section.

Contactor K1 on power board notengaging

While pressing the unit’s POWER switchon and off, listen for the K1 contactor toengage. You can also open the unit andvisually examine the contactor to see if itengages. See Figure 6-5 for thelocation of K1 on the power board. If K1is not engaging, replace the powerboard. Refer to Replacing a ControlAssembly Board in the Repair section.

Power board not properly connectedto control board

Make sure the power board is properlyconnected to the control board at XP1.The pins from the control board shouldextend through XP1 on the power board.

Defective power board or controlboard

Replace the control assembly. Refer toReplacing the Control Assembly in theRepair section.

Troubleshooting6-36


100 4197AIssued 7/00


4705030A

TB1

L1 L2 L3 NJ2

TB2123456

J4

X2

X1

XS2 XS1J9

Q17

X3

X4

XP1

XS4XS3

X3H

XS2H

XS1H

X2H

X2CJ2C

J1C

X1C

XS4A XS4B XS4C

XS3A XS3B XS3C XS3D

XS2A XS2B

XS1AL1

L2

L3

1 3

4

X1H

2

XP6

XP4A

XP1

XP5

XP3

XP2

K1

Fig. 6-5 Location of Connectors on Boards

1. Power board2. Control board

3. 5/6 hose/gun board 4. Contactor board



100 4197AIssued 7/00


During a warning condition, the unit continues to function normally. Thecontrol system indicates a warning as follows:

S The FAULT light flashes and turns off or flashes continuously.

S The Selector display shows a zone number.

NOTE: Each heated component (each hose, each gun, and theplaten) is referred to as a zone.

S When the Selector display shows a zone number, the PLATEN,HOSE, or GUN light turns on. In combination, these indicationsidentify which zone is affected. Refer to Table 6-3.

S The Multipurpose display shows either a temperature reading or aflashing UT for the affected zone.

Table 6-3 Determining the Affected Zone

ZoneNumber inSelectorDisplay

(See Note A)

Affected Zone

PLATENLight On

HOSELight On

GUNLight On


2 Hose 2 Gun 2

3 Hose 3 Gun 3

4 Hose 4 Gun 4

5 Hose 5 Gun 5

NOTE A: For example, if the Selector display shows the number 3and the GUN light is on, then the affected zone is gun 3.

Control System Indicating aWarning

Troubleshooting6-38


100 4197AIssued 7/00


Out-of-Band WarningWhen theFAULTlight.

And the Selectordisplay

And theMultipurposedisplay

It means Do this

Flashes(See Note A)

Shows a zone number(refer to Table 6-4)

Shows the setpointtemperature of theaffected zone

The actualtemperature of theindicated zone isout-of-band.

Wait to see if thetemperature stabilizesat the setpoint. Youmay want to changeyour out-of-bandtemperature setpoints.See Note B.

NOTE A: When the FAULT light flashes, the warning output contact is open and the fault output contact isclosed. When the FAULT light is off, both output contacts are closed. For more information on theseoutput contacts, refer to Connecting Input/Output (I/O) Contacts in the Installation section.

B: You can choose the degree to which a zone’s temperature may deviate from its temperature setpoint(Features 5--19) and still stay within the temperature band setpoints. You should base yourout-of-band temperature setpoints on your adhesive application requirements. Refer to SystemProgramming Procedures in the Installation section to program out-of-band temperature setpoints.

Under-Temperature (UT) Warning


When theFAULTlight.

And theSelectordisplay


It means Do this

Flashes(See Note A)

Shows a zonenumber (refer toTable 6-4)

Flashes UT(See Note B)

The indicatedzone’s actualtemperature ismore than19.5 _C (35 _F)below thesetpointtemperature.

Refer to the following procedure.

NOTE A: When the FAULT light flashes, the warning output contact is open and the fault output contact isclosed. When the FAULT light is off, both output contacts are closed. For more information on theseoutput contacts, refer to Connecting Input/Output (I/O) Contacts in the Installation section.



100 4197AIssued 7/00


1. Press the CLEAR FAULTS key and wait for the system to return tothe system-ready state.

2. If the warning disappears and the unit appears to be working again,the voltage to the unit may have temporarily sagged or you may havean intermittent problem. Repetitive warnings in the same zoneindicate a problem with the circuitry in that zone or an intermittentRTD failure. Take the following steps to troubleshoot intermittentunder-temperature warnings:

a. Check for a change in environmental conditions, such as addedventilation or sources of drafts. A cold draft can keep your unit,hoses, and guns from heating.

b. Make sure the power is turned on at your branch circuitdisconnect switch and that your power supply is supplying theproper voltage to the unit.

c. Check all hose and gun electrical plugs. Make sure theconnections are tight and free of corrosion.

d. Check your operating temperature setpoints to make sure theyhaven’t been changed. Refer to Records of System Settings inthe Installation section.

e. If the affected zone is a hose or gun, replace the hose or gun witha hose or gun that is known to be good. If the warningdisappears, replace the defective hose or gun. If the warning stillappears, continue to the next step.

3. If the warning still appears after you press the CLEAR FAULTS keyand after you have taken the actions in step 2, take the followingsteps.

a. Check for loose heater connections on the board that supplies theheater power for the affected zone. Refer to Table 6-5 for heaterconnector locations. For example, check the harnessesconnected to X1 and X2 on the power board to check the heaterconnections for hoses 1--4 or guns 1--4. See Figure 6-5 for thelocation of connectors on boards.

Troubleshooting6-40


100 4197AIssued 7/00


Under-Temperature (UT) Warning (contd)

b. Use an ohmmeter to check the fuse or fuses on the board thatsupplies the heater power for the affected zone. Replace theappropriate fuse or fuses. Refer to Replacing a Fuse in theRepair section. If the fuse blows again, make sure the heater isnot shorted to the ground.

c. If the affected zone is the platen, make sure the harnessconnected to J2 on the power board is secure or check thethermostat. See Figure 6-5 for the location of J2 on the powerboard. To check a thermostat, refer to Checking a Thermostat inthis section.

d. Check the K1 contactor on the power board. While pressing theunit’s POWER switch on and off, listen for the K1 contactor toengage. You can also open the unit and visually examine thecontactor to see if it engages. See Figure 6-5 for the location ofK1 on the power board. If K1 is not engaging, replace the powerboard. Refer to Replacing a Control Assembly Board in theRepair section.

e. Check the heater or heater circuit of the affected zone. Refer toChecking a Heater or Heater Circuit in this section.

f. If the warning condition still appears after you have taken all theactions in this step, replace the control assembly. Refer toReplacing the Control Assembly in the Repair section.



100 4197AIssued 7/00


A fault condition causes the unit to shut down. The control systemindicates a fault as follows:

S The FAULT light either turns on and stays on or flashes for twominutes and then stays on.

S The Selector display shows either a zone number or the letter F.

NOTE: Each heated component (each hose, each gun, and theplaten) is referred to as a zone.

S If the Selector display shows a zone number, the PLATEN, HOSE, orGUN light turns on. In combination, these indications identify thefaulted zone. Refer Table 6-4.

S The Multipurpose display shows either a flashing OT or RTD for thefaulted zone or a fault code (F1--F7).

S The heaters turn off. Whenever the heaters turn off, the pump stops.

Table 6-4 Determining the Faulted Zone

ZoneNumber inSelectorDisplay

(See Note A)

Faulted Zone

PLATENLight On

HOSELight On

GUNLight On


2 Hose 2 Gun 2

3 Hose 3 Gun 3

4 Hose 4 Gun 4

5 Hose 5 Gun 5

NOTE A: For example, if the Selector display shows the number 3and the GUN light is on, then the faulted zone is gun 3.

Control System Indicating aFault

Troubleshooting6-42


100 4197AIssued 7/00


Over-Temperature (OT) Fault


When theFAULTlight



It means Do this

Turns on(See Note A)

Shows a zonenumber (referto Table 6-4)

Flashes OT(See Note B)

A zone’s actualtemperature hasreached theover-temperaturesetpoint entered inFeature 3. Thedefault setting is218 _C (425 _F).

Refer to the following procedure.

NOTE A: When the FAULT light turns on, the warning output contact is closed and the fault output contactis open. When the FAULT light is off, both output contacts are closed. For more information onthese output contacts, refer to Connecting Input/Output (I/O) Contacts in the Installation section.

B: You should base your over-temperature setpoints on your adhesive application requirements.Refer to System Programming Procedures in the Installation section to program over-temperaturesetpoints.

1. Press the CLEAR FAULTS key.

2. If the fault disappears and the unit appears to be working again, youmay have an intermittent problem. Repetitive faults in the same zoneindicate a problem with the circuitry in that zone or an intermittentRTD failure. Take the following steps to troubleshoot intermittentover-temperature faults:

a. Check your operating temperature setpoints to make sure theyhaven’t been changed. Refer to Records of System Settings inthe Installation section.



100 4197AIssued 7/00


b. To verify that something other than the control system is affectinga heated zone, turn on the Display Heater Proportioning feature(Feature No. 21) for the affected zone. When the display blinkson and off, it means the control system is proportioning heatcontrol to the heater. During proportioning, the temperaturedisplayed for the zone should stay fairly constant, within +/--1 F.If the temperature continues to rise during proportioning, thensomething other than the control system is closing the triacs onthe power board and causing the heaters to heat. Electrical noisefrom other machines in the factory containing DC drives maycause the overheating problem. Take the following steps to solveelectrical noise problems:

S Install the proper line reactor. Consult with the DC drivemanufacturer for the appropriate line reactor size.

S Electrically ground the hot melt unit to the parent machineusing as short a length of twisted cable as possible.

S If the triacs continue to close after the hot melt unit isgrounded to the parent machine, install a line filter on eachinput power line to the Vista power board AP3-TM1-L2 andAP3-TB1-L3. Connect the filter line-to-line. Refer to Parts forthe filter part number. For a three-phase system, order threefilters.

c. If the faulted zone is a hose or gun, replace the hose or gun with ahose or gun that is known to be good. If the fault disappears,replace the defective hose or gun. If the fault remains, continue tothe next step.

3. If the fault remains after you press the CLEAR FAULTS key and afteryou have taken the actions in step 2, check the heater or heatercircuit of the faulted zone. Refer to Checking a Heater or HeaterCircuit in this section.

4. If the fault remains after you have taken all the actions in thisprocedure, replace the control assembly. Refer to Replacing theControl Assembly in the Repair section.

Troubleshooting6-44


100 4197AIssued 7/00


Resistance Temperature Detector (RTD) Fault

Nordson offers two test plugs that simplify the troubleshooting of RTDfaults. These test plugs help you quickly and easily determine whetherthe problem is a gun, hose, or tank RTD problem or a control systemproblem. Refer to Parts for the kit part number.

When theFAULTlight



It means Do this

Flashes fortwo minutesthen stays oncontinuously(See Note A)

Shows a zonenumber (refer toTable 6-4)

Flashes RTD(See Note B)

The RTD or RTDcircuit of theindicated zone isopen or shorted.

Refer to Checking an RTD or RTDCircuit in TroubleshootingProcedures.

NOTE A: When the FAULT light flashes, the warning output contact is open and the fault output contact isclosed. After a two-minute delay, the warning output contact closes and the fault output contactopens. When the FAULT light is off, both output contacts are closed. For more information on theseoutput contacts, refer to Connecting Input/Output (I/O) Contacts in the Installation section.

B: The actual-temperature display will show 260 _C (500 _F) if the RTD is open. It will show 0 _C (0 _F)if the RTD is shorted.



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Fault-Code Fault (F1-F7)When theFAULTlight



It means Do this

Turns on(See Note A)

Shows theletter F

Shows thenumber 2

The power boardscrews areloose, causing afaulty groundconnection.

Tighten the power board screws.

Shows theletter F

Shows thenumber 1, 2, 3,5, or 6

The controlboard isdefective.

Turn the unit off, then back on againto see if the problem recurs. If itrecurs, replace the control board orreplace the control assembly. Referto Replacing a Control AssemblyBoard or Replacing the ControlAssembly in the Repair section.

Shows theletter F

Shows thenumber 4

There is abrownoutcondition.(See Note B)

Correct the cause of the brownout.

Shows theletter F

Shows thenumber 7

The seven-dayclock battery isdead.(See Note C)

Replace the control board or thecontrol assembly. Refer to Replacinga Control Assembly Board orReplacing the Control Assembly inthe Repair section.

NOTE A: When the FAULT light turns on, the warning output contact is closed and the fault output contact isopen. When the FAULT light is off, both output contacts are closed. For more information on theseoutput contacts, refer to Connecting Input/Output (I/O) Contacts in the Installation section.

B: A brownout occurs when the power supply voltage falls below the voltage needed to maintain systemoperation. When this happens, the control system stops normal operation. The system will resumenormal operation once the brownout condition is corrected.

C: If the unit and the seven-day clock feature are turned on and the clock battery dies, the CLOCK lightwill flash. If the unit is then subject to a power cycle or power interruption, the displays will indicatefault code 7. However, if the clock feature is not turned on and the clock battery dies, the unit will notindicate a fault. When the clock battery is dead, the unit will continue to operate normally except forclock-related functions.

Troubleshooting6-46


100 4197AIssued 7/00


Use these procedures as directed in Vista Troubleshooting Tables tofurther troubleshoot control system problems.

Follow this procedure to check the POWER switch.


1. Place the unit’s POWER switch in the off position, turn disconnectswitch to off, lock out electrical power to the unit at the branch circuitdisconnect switch, and disconnect and lock out electrical powersupplied through any I/O wiring.

2. Open the electrical enclosure. Refer to Opening and Closing theElectrical Enclosure.

3. Check the continuity between AP3-J4 pins 1 and 4 on the powerboard. You should find continuity regardless of the position of theunit’s POWER switch. See Figure 6-5 for the location of J4 on thepower board.

S No continuity: replace the POWER switch and harness.S Continuity exists: normal indication. Go to the next step.

4. With the unit’s POWER switch in the off position, check the continuitybetween J4 positions 2 and 5 on the power board.

S No continuity: replace the POWER switch and harness.S Continuity exists: normal indication. Continue to the next step.

WARNING: Risk of equipment damage, personal injury, ordeath. This procedure requires you to perform electricaltroubleshooting with the power on. Use extreme caution andrefer to Electrical Safety During Troubleshooting and Openingand Closing the Electrical Enclosure for instructions on safelyworking inside the electrical enclosure.

5. Turn on power to the unit at the branch circuit disconnect switch.

8. TroubleshootingProcedures

Checking the POWER Switch



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6. With the unit’s POWER switch in the off position, measure the voltageacross J4 positions 1 and 4 on the power board.

S Voltage does not measure 230 VAC: replace the POWER switchand harness.

S Voltage measures 230 VAC: normal indication. Continue to thenext step.

7. With the unit’s POWER switch in the on position, measure the voltageacross J4 positions 2 and 5 on the power board.

S Voltage does not measure 230 VAC: replace the POWER switchand harness.

S Voltage measures 230 VAC: normal indication. Return to the UnitNot Powering On troubleshooting table.

Follow this procedure to check a heater or heater circuit.


1. Place the unit’s POWER switch in the off position, disconnect andlock out electrical power to the unit at the branch circuit disconnectswitch, and disconnect and lock out electrical power supplied throughany I/O wiring.


Checking a Heater or HeaterCircuit

Troubleshooting6-48


100 4197AIssued 7/00


3. Check the heater by measuring its resistance at the heater connectorharness pins. Refer to Table 6-5 to determine which board the zone’sheater connectors are located on. See Figure 6-5 for the location ofthe connectors on the boards. Remove the harness from theconnector and measure the resistance across the harness pinsidentified in Table 6-5.

S Resistance reading of zero (0): heater short circuit. Check for ashort in the heater circuit and repair the short.

S Infinite resistance reading: open heater circuit or heater. Go tothe next step.

Table 6-5 Heater Connector Locations and Harness Pins for Measuring Resistance

Problem Zone Connector Location Connector: Pin Resistance Range

Hose 1 Power board (AP3) X1: 1 and X2: 1 1400--50 ohms




Hose 5 5/6 hose/gun board (AP10) X1H: 4 and X2H: 3 1400--50 ohms

Hose 6 5/6 hose/gun board (AP10) X1H: 2 and X2H: 1 1400--50 ohms

Gun 1 Power board (AP3) X1: 2 and X2: 2 600--100 ohms




Gun 5 5/6 hose/gun board (AP10) X1H: 3 and X2H: 4 600--100 ohms

Gun 6 5/6 hose/gun board (AP10) X1H: 1 and X2H: 2 600--100 ohms

Checking a Heater or HeaterCircuit (contd)



100 4197AIssued 7/00


4. Check the continuity of the heater circuit by measuring the heaterresistance at a point in the circuit that is closer to the heater.

S If the faulted zone is a hose or gun, measure the resistance at thehose or gun electrical plug. Refer to your hose or gun manual fora diagram of the electrical plug and for procedures for replacingthe gun heater. If a hose heater is defective, replace the hose.

S If the faulted zone is the platen, measure the resistance at theplaten heater connectors (refer to Table 6-5). If you measureinfinite or zero (0) resistance at the platen heater connectors, youmust install a platen.

5. If you do not find a continuity problem, replace the control board orthe control assembly. Refer to Replacing a Control Assembly Boardor Replacing the Control Assembly in the Repair section.

Use this procedure to check a thermostat.

WARNING: System or material pressurized. Relieve pressure.Failure to observe this warning may result in serious burns.

1. Relieve system pressure. Refer to Relieve System Pressure in theMaintenance section.


2. Place the unit’s POWER switch in the off position, turn disconnectswitch off, lock out electrical power to the unit at the branch circuitdisconnect switch, and disconnect and lock out electrical powersupplied through any I/O wiring.


4. Remove the thermostat. Refer to Replacing a Platen Thermostat inthe Repair section.

Checking a Thermostat

Troubleshooting6-50


100 4197AIssued 7/00


5. The thermostat is an open on rise type thermostat. The temperatureat which the thermostat opens is printed on the thermostat.

6. Connect an ohmmeter set on the lowest resistance scale acrossthe thermostat; then heat the thermostat with a flameless electricheat gun.

S Short circuit before thermostat reaches opening temperature andopen circuit when thermostat reaches temperature or aboveopening temperature: normal indication. Return to theappropriate troubleshooting table.

S Short circuit or low resistance when above opening temperatureor open circuit below opening temperature: defective thermostat.Replace the thermostat. Refer to Replacing a Platen Thermostatin the Repair section.

Follow this procedure to check an RTD or RTD circuit.

NOTE: If the faulted zone is a hose or a gun, you can remove the hoseor gun and replace it with a hose or gun that is known to be good. If thefault disappears, then the problem is in the hose or gun, not inside theunit. As an alternative to using this procedure, you can refer to your hoseor gun manual for instructions on checking and replacing the hose orgun RTD.


1. Check the operator panel to determine which zone is faulted.

2. Place the unit’s POWER switch in the off position, turn disconnectswitch to off, lock out electrical power to the unit at the branch circuitdisconnect switch, and disconnect and lock out electrical powersupplied through any I/O wiring.


Checking a Thermostat (contd)

Checking an RTD or RTDCircuit



100 4197AIssued 7/00


4. Check the RTD by measuring its resistance. Refer to Table 6-6.

S If the RTD is defective, replace the RTD. If a hose RTD isdefective, you must replace the hose. To replace a gun RTD,refer to your gun manual. To replace a platen RTD, refer toReplacing a Platen RTD in the Repair section.

NOTE: Flex the hose when you are checking a hose RTD. Somehose RTDs exhibit problems intermittently.

S If the RTD is good, go to the next step.

Table 6-6 Measuring RTD Resistance

Quick Methods In-Depth Methods

Using a surface-temperature sensing device, such asa thermocouple, measure the temperature of the RTDat or near the end of the RTD that is accessible. Thenuse an ohmmeter to measure its resistance(see Note A). See Figure 6-6 and compare theresistance reading to the RTD’s normal resistance atthe known temperature.

Let the system cool down to room temperature. Whenthe RTD has had time to reach room temperature, usean ohmmeter to measure its resistance (see Note A).See Figure 6-6 and compare the resistance reading tothe RTD’s normal resistance at room temperature.

Roughly estimate the temperature of the RTD to thenearest 50 _C (100 _F). Use an ohmmeter tomeasure its resistance (see Note A). See Figure 6-6and compare the resistance reading to the RTD’snormal resistance at the estimated temperature.Because RTDs usually fail open or closed, anyresistance reading from approximately 100--400 ohmsstrongly indicates that the RTD is good.

Remove the RTD and heat it to a known temperature byusing an oven or by placing it in boiling water (protectthe wires and hold them above the water). Then use anohmmeter to measure its resistance (see Note A). SeeFigure 6-6 and compare the resistance reading to theRTD’s normal resistance at the known temperature.

NOTE A: If the faulted zone is a hose or gun, measure the RTD resistance at the hose or gun electrical plug.Refer to your hose or gun manual for a diagram of the electrical plug and for procedures forchecking RTD resistance. Because the core elements of a hose are not accessible, you cannot usesome of the methods described in this table to measure the temperature of a hose RTD. If thefaulted zone is the platen, measure the RTD resistance at the control board. For a platen RTD,measure the resistance at the connector that plugs into AP3-XP2 at positions 33 and 34.

Troubleshooting6-52


100 4197AIssued 7/00


5. Check the continuity of the RTD circuit by measuring the RTDresistance at other points in the circuit. Refer to Table 6-7 for the plugor harness pins for each check. For a gun RTD, you can checkcontinuity at two points: first at the hose electrical plug and then atthe harness connected to XP2 on the control board. For a hose RTD,you can check continuity at the hose electrical plug or at the harnessconnected to XP2 on the control board. See Figure 6-5 for thelocation of XP2 on the control board. For the platen RTD, there areno further checks you can make: go to the next step.

Table 6-7 Pins for Checking RTD Continuity

Zone withFaulted RTD

Circuit Board AP3, ConnectorXP2 Harness Pins

Gun 1 2 and 9

Hose 1 1 and 10

Gun 2 4 and 11

Hose 2 3 and 12

Gun 3 6 and 13

Hose 3 5 and 14

Gun 4 8 and 15

Hose 4 7 and 16

Gun 5 25 and 26

Hose 5 29 and 30

Gun 6 25 and 26

Hose 6 31 and 32

Platen 33 and 34

6. If you find a continuity problem in the gun RTD circuit, replace thehose or replace the gun RTD harness inside the unit as appropriate.If you find a continuity problem in the hose RTD circuit, replace thehose RTD harness inside the unit. If you do not find a continuityproblem, go to the next step.

7. Replace the control board or the control assembly. Refer toReplacing a Control Assembly Board or Replacing the ControlAssembly in the Repair section.

Checking an RTD or RTDCircuit (contd)



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_F

5940833

_F (130 )

_C54_F _F

_C_C_C

(170 )

_C_C77 99 121 143 166 188 210 232_C _C _C

_F (290 )(210 )_F (250 )_F (370 )_F (410 )_F (450 )_F(330 )_F

160

360

340

320

300

280

260

240

220

200

180

140

120

RESISTA

NCEIN

OHMS

(90 )

_C32(50 )

_C10

Fig. 6-6 RTD Resistance vs. Temperature

Troubleshooting6-54


100 4197AIssued 7/00


The control system helps you diagnose system faults. When a faultoccurs, the system indicates this in the following ways:

S Heater power turns off.

S The displays show only information of the faulted zone.

S The fault light flashes or turns on and stays on depending upon thetype of fault that has occurred.

S The Selector display shows the number of the affected zone.

S The zone type light indicates the type of component that is faulted(platen, hose, or gun).

S The multipurpose display flashes a code that represents the cause ofthe fault.

S If you have used the fault output contact, the contact turns on aftertwo minutes. The warning contact turns on immediately. For moreinformation on these output contacts, refer to the procedureConnecting Output Contacts in the Installation section.

After correcting a problem which causes the system to register a fault,press the CLEAR FAULT key to run a system test. During this fiveseconds, the following occurs:

S All lights on the control panel turn on.S Information in the Displays area changes.

If the problem was corrected, the FAULT light will turn off once the test iscompleted and the system will resume normal scanning. If the problemremains, the FAULT light will stay on.

9. Correcting System FaultsUsing the VistaController

Running a System Test



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Follow this procedure to check the fault log. The log lists the causes ofthe three most-recent faults.

1. Press the Move Up and Move Down keys until the SYSTEMSETTINGS light turns on.

2. Press the Up key below the Selector display until feature number ofthe item you want to check appears in the display. Refer to Table 6-8.

Table 6-8 Fault Log

Fault No. Fault Displayed

27 Information is displayed about the most recentfault.

28 Information is displayed about the second mostrecent fault.

29 Information is displayed about the third mostrecent fault.

3. Check the Multipurpose display to find the code of the fault currentlydisplayed. Refer to Table 6-9.

Table 6-9 Fault Log

Fault No. Fault Displayed

0 No fault has occurred

1 Zone below the setpoint temperature

2 Open RTD

3 Shorted RTD

4 Zone overtemperature

5 Microprocessor board bad

6 Brown-out occurred

Checking the Fault Log

Troubleshooting6-56


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Checking System Faults

Use Table 6-10 to identify and correct common system faults. Unlessspecified in the table, displays and lights continue to function as theywould during normal operation.

Table 6-10 Identifying and Correcting System Faults, Flashing Fault Light

When theFAULT light . . .(See Note A)

And theMultipurposedisplay . . .

And theSelectordisplay . . .

It means . . . Do this . . .

Flashes Shows thesetpointtemperature ofthe faultedzone.

Shows thezone numberof theaffectedzone.

The zone is outof band.

Wait for 5 minutes to see if thetemperature stabilizes at the setpoint.

Flashes UT. Shows thezone numberof theaffectedzone.

The system isundertemperature(UT) because:

S No orinsufficientpower isbeing appliedto the unit.

Check that the unit is connected to themain power supply. If it is connected,check that electrical service connectionsare correct. Refer to the procedureElectrical Installation in the Installationsection.

S The heater ofthe faultedzone is bad.

Replace the heater of the faulted zone.For an internal (platen) fault, the cast-inheaters of the platen require that youreplace the component. Refer to theprocedure replacing the platen in theRepair section.

S Zone fusesare bad.

Replace appropriate fuses. Refer to theprocedure Replacing a Power Board Fusein the Repair section.

S The powerboard orcontrol boardis defective.

Replace the power board or control board.Refer to the procedure Replacing theCircuit Boards in the Repair section.

S The heaterconnection ofthe faultedzone is notsecure.

Check the heater connection on the mainpower board for the corresponding zone.

NOTE A: When the FAULT light flashes, the Warning contact is activated. After the two-minute delay period,the Warning contact is deactivated and the fault contact is activated.




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When theFAULT light . . .(See Note A)

And theMultipurposedisplay . . .

And theSelectordisplay . . .

It means . . . Do this . . .

Flashes for twominutes thenstays oncontinuously.

Flashes RTD.(See Note B.)

Shows thezone numberof theaffectedzone.

The RTD is openor shorted.

Check resistance. If you have more thanone hose, remove the hose on thefaulted zone and replace it with a hosethat is known to be good. If the faultdisappears, repair or replace the faultyhose. If the fault remains, troubleshootthe unit circuitry of the faulty zone. Referto the procedure Checking theResistance Temperature Detector in thissection.

Turns on. Flashes OT. Shows thezone numberof theaffectedzone.

The system hasexceeded thecustomer-definedovertemperature(OT) settingbecause:

S The heater ofthe faultedzone is bad.

Replace the heater of the faulted zone.For an internal fault, the cast-in heatersof the platen require that you replace thecomponent. Refer to the procedureReplacing the Platen in the Repairsection.

S The powerboard or thecontrol boardis defective.

Replace the power board or controlboard. Refer to the procedure Replacingthe Circuit Boards in the Repair section.

S Solid staterelay shorted.

Locate relay and replace.

S Relay driver isdefective.

Replace relay driver.

Shows thenumber 4.

Shows theletter F.

There is abrown-outcondition(Note C).

Correct the cause of the brown-out.

Shows any ofthe numbers1, 2, 3, 5, or 6.

Shows theletter F.

The control boardis bad.

Replace the control board or replace thecontrol assembly. Refer to theprocedures Replacing the Circuit Boardsin the Repair section. Turn the unit offand then back on again to see if theproblem reoccurs.

NOTE A: When the FAULT light flashes, the warning contact is activated. After the two-minute delay period,the warning contact is deactivated and the fault contact is activated.

B: The actual temperature display will show 260 _C (500 _F) if the RTD is open and 0 _C (0 _F) if theRTD is shorted.

C: A brown-out occurs when the incoming voltage level falls below the level needed to maintain systemoperations. When this happens, the control system stops normal operations. The system willresume normal operations once the brown-out condition is removed.

Troubleshooting6-58


100 4197AIssued 7/00


A faulty control board will cause the following to occur:

S A heating zone will not heat.S A heating zone will overheat.S The control system will not operate at all.

If the control system is not operating at all, call your Nordsonrepresentative for assistance in correcting any of the problems listedabove.

To help determine why a heating zone isn’t heating or is overheating, usethe Display Heater Proportioning diagnostic feature. The feature enablesyou to monitor power pulses to the heater zones. Normally, zone lights inthe TEMPERATURE System Setup area identify the zone for which atemperature is being displayed. While Display Heater Proportioning isenabled, the zone light turns on and off as power to the zone’s heatercycles on and off, thereby indicating the lack or presence and frequencyof power to the heater.

To Enable the Display Heater Proportioning Feature

NOTE: If you have activated the Password feature, you will need toenter the password (321) in the Multipurpose display so the systemallows you to change SYSTEM SETTINGS features.

1. Press the Move Up and Move Down keys until the SYSTEMSETTINGS light turns on.

NOTE: Pressing and holding the key causes the light to skip oversome of the SYSTEM SETTINGS. If this happens, release the keyimmediately after pressing it.

4103988

1

2

Fig. 6-7 Selecting the SYSTEM SETTINGS Feature

1. Move Up key 2. Move Down key

Correcting Control BoardFaults

4705035A



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2. Press the Up key below the Selector display until the number 21 (thecode for Display Heater Proportioning) appears in the display.

3. Press the Up or Down keys below the Multipurpose display until thenumber 1 appears in the display, activating the Display HeaterProportioning feature. The Multipurpose display flashes.

4130136

2 3

4 5

1

Fig. 6-8 Changing the Setting of a Selected Feature

1. Up key2. Selector display3. Multipurpose display


4. Press the Enter key to save the setting. The display stops flashing toindicate that the Display Heater Proportioning feature is enabled.

Fig. 6-9 Using the Display HeaterProportioning Feature toPinpoint Zone Faults(Shown with a fault onthe platen zone.)

Troubleshooting6-60


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To Solve Zone Faults

1. Return to Monitor mode to check the status of the zone lights(PLATEN or HOSE). When the Display Heater Proportioning featureis enabled, the PLATEN or HOSE light flashes as power is cycled onand off to the selected zone’s heater. A light that is eithercontinuously on or off helps diagnose the fault condition.

NOTE: Because the zone light flashes slowly, it may appear to be oncontinuously. After a few seconds, the light will flash.

2. Select the zone you need to troubleshoot and then refer to Table 6-11to diagnose and correct the cause of the fault.

After you have finished solving zone faults, disable the Display HeaterProportioning feature by repeating the procedure Enabling the DisplayHeater Proportioning Feature and setting the value of Code 21 to zeroduring Step 3.

Table 6-11 Using the Display Heater Proportioning Feature to Solve Zone Problems

Fault Condition Zone Light Problem Solution

The zone doesnot heat.

OFF The setpoint temperatureof the affected zone islower than 37 _C (100 _F).

Set the temperature to above 37 _C (100 _F).Refer to the procedure ProgrammingTEMPERATURE Controls in the Installationsection.

ON Heater circuit of theaffected zone is open.

Replace the heater of the faulted zone. For ahose, refer to the manual that came with yourhose. For an internal (platen) fault, the cast-inheaters of the platen require that you replace theplaten. Refer to the procedure Replacing thePlaten in the Repair section.

A fuse has blown. Replace the fuses of the faulted zone. Hose/gunfuses are on the power board and platen fusesare in the electrical cabinet. Refer to theprocedure Replacing a Power Board Fuse in theRepair section. (See Note A.)

Control board is damaged. Replace the control board or replace the controlassembly. Refer to the procedures ReplacingCircuit Boards in the Repair section.

Platen driver board isdamaged.

Replace board.

Connector J2 (thermostatconnector) on the powerboard is not connected.

Connect J2 to the power board. To locate J2,refer to Figure 6-5.

NOTE A: If the fuse blows again, check that the heater is not shorted to the ground.Continued on next page



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Fault Condition SolutionProblemZone Light

The zoneoverheats.

ON Control board is damaged. Replace the control board or replace the controlassembly. Refer to the procedures ReplacingCircuit Boards in the Repair section.

OFF Power board is damaged. Replace the power board or replace the controlassembly. Refer to the procedures ReplacingCircuit Boards in the Repair section.

Platen driver boarddamaged.

Replace board.

Platen solid state relayshorted.

Locate and replace.

The controlpanel does notoperate at all.

OFF The cause of the controlpanel not operating mustbe determined by aNordson representative.

Call your Nordson representative for assistance.

Troubleshooting6-62


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See Figure 6-10 for the hose and gun wiring diagram.

See electrical schematic and wiring diagams for the Model 505/506 pailmelter/applicator included at the end of this section.

4705031A

C1A1A2

C4

A4

GND

C3B4B3A3B1

HOSE RTD

HOSE HEATER

HOSE-TO-UNIT CONNECTOR

WIRES FROM HOSE GUN-TO-HOSE CONNECTOR

GUN RTD

GUN

WIRE NUTGND

HOSE-TO--GUN CONNECTOR

AUTOGUN

JLIHB

HEATER

GND12356

GND12356

HOSE HEATER


JLIHB

C1A1A2

C4

A4

C3B4B3A3B1

B2C2

GND

HOSE-TO--GUNCONNECTOR

GUN-TO-HOSECONNECTOR

GUNHEATER

GUN RTD

GND

3-STATIONTERMINAL BLOCKS

GUNMANUAL

NORMALLY-OPEN LIMIT SWITCHACTIVATED BY TRIGGER

ABC

ABC

GND

WIRES FROM HOSE

C1A1A2

C4

A4

GND


1

2

3

HOSE RTD

HOSE RTD

HOSE HEATER

Fig. 6-10 Hose and Gun Wiring Diagram

1. Automatic gun and hose wiringdiagram

2. Manual gun and hose wiringdiagram

3. Transfer hose wiring diagram

10.Electrical Schematicsand Wiring Diagrams


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Section 7

Repair

Repair7-0


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Repair 7-1


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Section 7Repair


WARNING: Risk of electrical shock. Remove input power asdirected. The input terminal block remains charged even whenthe main disconnect switch is set to OFF. Failure to observecould result in personal injury or death.

CAUTION: Faulty or damaged hoses are not field-repairableand must be replaced. Contact your Nordson representative forreplacement and return information.

This section describes repair and replacement procedures for the Model505/506 pail melter/applicator. Repair and/or replacement of parts maybe necessary as routine maintenance or if a component has failed andbeen detected through the procedures in the Troubleshooting section.

Gun disassembly and repair information is included in the gun manual.

Do the following before attempting any of the procedures in this section:

S Be sure you are performing the correct procedure to repair the unit. Ifa fault condition has occurred, refer to the Troubleshooting section todetermine the appropriate procedure before attempting to repair orreplace a part. If the fault condition is not covered in theTroubleshooting section, or if there is question about the propercourse of action, contact your Nordson representative.

S Read the entire procedure while at the unit and become familiar withthe required steps. It may be necessary to refer to the illustratedparts lists in the Parts section for exact component locations andsizes.

1. Introduction

Repair7-2


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S Check that the required tools, replacement parts, and service itemsare at hand.

S Read and follow all safety precautions in the Safety section and inthis section.

S Review Figure 7-1 shown below. Although detailed parts illustrationsaccompany each repair procedure, Figure 7-1 provides exactlocations of those parts on the pail melter/applicator unit.

4705115A

8

9

10

12

4

11

13

15

14

7

5

6

23

1

Fig. 7-1 Model 505/506 Assemblies and Parts

1. Motor/Speed reducer screws andwashers

2. Speed reducer3. Speed reducer/Crossover screws

and washers4. Air cylinder shaft screws and

washers

5. Upper yoke assembly6. Driveshaft7. Air cylinder head assembly8. Air cylinder shaft9. Air cylinder10. Column collar

11. Air piston12. Platen assembly13. Lower yoke assembly14. Crossover15. Junction box

1. Introduction (contd)

4705029A

4

21

3

Repair 7-3


100 4197AIssued 7/00


See Figure 7-2.

1. Disconnect and lock out input electrical power from the unit.

2. Remove the screw from the warning beacon cover (1). Lift the coverfrom the unit.

3. Remove the screw from the green lens assembly (1). Lift the lensassembly (with bulb) from the unit.

4. (Skip this step if this bulb is not burned out) Rotate the bulbone-quarter turn counterclockwise and remove the bulb from theassembly. Replace the bulb with a new one.

5. Remove the screw from the orange lens assembly (3). Lift the lensassembly (with bulb) from the unit. Repeat step 4.

6. Remove the screw from the red lens assembly (4) Lift the lensassembly (with bulb) from the unit. Repeat step 4.

7. Reassemble the warning beacon, reconnect input power and resumenormal operation.

Fig. 7-2 Warning Beacon

1. Cover2. Green lens assembly3. Amber lens assembly4. Red lens assembly

2. Light Tower BulbReplacement

Repair7-4


100 4197AIssued 7/00


WARNING: Do not attempt to loosen any manifold, hose, orgun connection until system hydraulic pressure has beenrelieved. Refer to Relieve System Pressure in the Maintenancesection for this procedure.

WARNING: Hot! Risk of burns. Wear heat-protective clothingand safety goggles. Failure to observe may result in seriouspersonal injury.

WARNING: Never use a torch or other open flame device toheat a component. Use only a flameless electric heat gun orelectric oven with forced air circulation. Failure to observe mayresult in personal injury and/or damage to the unit and nearbyproperty.

Use the following procedures to repair components of the pailmelter/applicator’s hydraulic system.

If the pump is operable, the entire system should be flushed as describedin the Maintenance section before disassembly.

If the pump is not operable, but the heating system is functioning, bringthe unit to application temperature before beginning disassembly. Thiswill soften material throughout the system and make it easier to performdisassembly procedures.

If neither the pump nor heating system are functional, use only aflameless electric heat gun or similar device to melt solidified materialduring disassembly.

3. Hydraulic System

Preparing for HydraulicSystem Repairs

Repair 7-5


100 4197AIssued 7/00


Use the following procedure to replace the O-ring at the gun-to-hoseconnection if there is leakage or the connection is broken.

You will need a Nordson replacement O-ring and O-ring lubricant tocomplete this procedure.

1. Relieve system pressure as described in the Maintenance section.

2. Unscrew the hose connector from the gun fitting and removethe hose.

3. Remove the existing O-ring from the gun fitting.

4. Clean the O-ring groove in the gun fitting. Lubricate with O-ringlubricant.

5. Stretch the new O-ring enough to roll it over the hose connector orpipe plug threads and into its groove. Do not stretch the new O-ringany more than necessary.

6. Coat the fitting and O-ring with additional O-ring lubricant.

7. Install the fitting back into the gun. Apply torque of9.5--13.6 NSM (7--10 ft-lb)

8. Connect the hose to the gun fitting and tighten with twowrenches—one to hold the gun fitting stationary and the other to turnthe hose swivel connector.

Use the following procedure to replace the platen seal.

You will need a piece of plywood or similar heat-resistant material slightlylarger than the platen, a blade, and high temperature grease to completethis procedure.

NOTE: Do not use a petroleum based grease. Petroleum products candamage the platen seal.

1. Bring the unit to application temperature.

2. If a pail is installed on the unit, remove the platen from the pail asdescribed in Changing the Pail in the Operation section. Position theplaten so there is workspace between the platen and the top of thepail.

Replacing the O-ring

Replacing the Platen Seal

4701200A

Repair7-6


100 4197AIssued 7/00


3. Place the plywood on top of the pail.

4. Place the seal on the plywood. Use the elevator control valve tolower the platen until it touches the seal. Heat the seal with theplaten for 30--45 minutes while performing steps 5 and 6.

5. See Figure 7-3. Carefully cut the old platen seal from the platen sealgroove.

6. Clean the platen lower seal groove. Then lubricate the groove withhigh temperature grease.

7. Use the elevator control valve to raise the platen off of the seal.

Fig. 7-3 Cutting the Seal from thePlaten Groove

8. See Figure 7-4. Use a screwdriver or similar tool to aid in stretching the seal over the platen and into the lower seal groove. Use an electric heat gun and tools as required until the seal seats in its groove. Be careful not to damage the PTFE covering around the seal.

NOTE: This may require the assistance of another person.

4701199A

Fig. 7-4 Replacing the Platen Seal

9. Apply a coating of high temperature grease to the platen seal.

10. Remove the plywood and resume normal operation.

Replacing the Platen Seal(contd)

Repair 7-7


100 4197AIssued 7/00


Use the following procedure to replace a platen RTD.

You will need a piece of plywood or other heat-resistant material slightlylarger than the platen diameter, heat conductive paste, Never Seez, anda replacement RTD (refer to the Parts section for the part number) tocomplete this procedure.

To Remove the RTD

1. If a pail of material is installed on the unit, remove it as described inChanging the Pail in the Operation section.

2. Place the piece of plywood on the frame (or across the pail hold-downassembly).

3. Use the elevator control valve to lower the platen onto the plywood.

WARNING: Risk of electrical shock. Failure to disconnect andlock out power may result in death or personal injury.


5. See Figure 7-5. Remove the hex-head screws and washers thatsecure the front and rear cover plates to the platen. Remove theplates.

4710077A

Fig. 7-5 Removing the Cover Plates

Replacing a Platen RTD

Repair7-8


100 4197AIssued 7/00


To Remove the RTD (contd)

6. Remove the RTD from the platen by unscrewing the connector nut.

7. See Figure 7-6. Cut the RTD leads at the platen. Remove theconnector nut and attached RTD.

8. Discard the RTD and connector nut.

4710084B

2

1

Fig. 7-6 Removing the RTD

1. RTD 2. Connector nut

Repair 7-9


100 4197AIssued 7/00


To Install the New RTD

1. Coat the replacement RTD with heat-conductive paste.

2. See Figure 7-7. Place the new connector nut from the RTD servicekit onto the new RTD. Tie or tape the replacement RTD wires to theold RTD wires, which will be used to pull the new RTD wires throughthe conduit.

4710085B

Fig. 7-7 Preparing to Route the Replacement RTD Wires

3. Remove the junction box cover.

4. See Figure 7-8. Disconnect platen RTD wires 58B and 59B frompositions 1 and 2 at terminal block XT3.

4701161

1 2 3 4 5 6 7 8 9 10 11 12

TO PLATEN

XT3

Fig. 7-8 Platen RTD Wire Connections

Repair7-10


100 4197AIssued 7/00


To Install the New RTD (contd)

5. Route the RTD wires through the conduit and into the junction box bypulling the old RTD wires out at the junction box.

6. Once you have pulled the replacement wires through the conduit andinto the junction box, remove the ties or tape connecting the old RTDwires to the replacement wires and discard the old RTD wires.

7. Connect the wires of the replacement RTD to positions 1 and 2 atterminal block XT3.

8. See Figure 7-9. Insert the RTD into the platen and push it down asfar as it will go. Secure with the connector nut.

4710086B

Fig. 7-9 Installing the Replacement RTD

9. Apply Never Seez to the threads of the hex-head screws. Replacethe front and rear cover plates to the platen with the hex-head screwsand washers.

10. Restore input power to the unit, set the main disconnect switch to theON position, and turn the power on.

11. Make sure there are no system electrical faults before continuingsystem restoration. If necessary, refer to the Troubleshooting section.

Repair 7-11


100 4197AIssued 7/00


Use the following procedure to replace a platen thermostat.

You will need a piece of plywood or other heat-resistant material slightlylarger than the platen diameter, heat conductive paste, Never Seez, anda replacement thermostat (refer to the Parts section for the part number)to complete this procedure.

To Remove the Thermostat

1. If a pail of material is installed on the unit, remove it as described inChanging the Pail in the Operation section.

2. Place the piece of plywood on the frame (or across the pail hold-downassembly).

3. Use the elevator control valve to lower the platen onto the plywood.

WARNING: Risk of electrical shock. Failure to disconnect andlock out power may result in death or personal injury.

4. Turn power off, set the main disconnect switch to OFF, and lock outinput power to the unit.

5. See Figure 7-5. Remove the hex-head screws and washers thatsecure the front and rear cover plates to the platen. Remove theplates.

6. Disconnect the thermostat to be replaced from the platen terminalblock.

7. See Figure 7-10. Remove the two screws that secure the thermostatto the platen. Remove and discard the thermostat.

4710110

Fig. 7-10 Removing the Thermostat

Replacing a PlatenThermostat

Repair7-12


100 4197AIssued 7/00


To Install the New Thermostat

1. Coat the mating surface of the replacement thermostat with heatconductive paste.

2. Secure the thermostat to the platen with the screws.

3. Make the thermostat terminal block connections.

4. Apply Never Seez to the threads of the hex-head screws. Replacethe front and rear cover plates to the platen with the hex-head screwsand washers.


6. Make sure there are no system electrical faults before continuingsystem restoration. If necessary, refer to the Troubleshooting section.

Repair 7-13


100 4197AIssued 7/00


Refer to Preparing Hydraulic System for Repairs before proceeding.

You will need a piece of plywood or other heat-resistant material slightly larger than the platen diameter; wood blocks or similar items; replacement platen, platen seal, and gasket; TFE joint sealant; heat conductive paste; Loctite No. 620 adhesive; PTFE paste and a torque wrench to complete this procedure.

To Remove the Platen

1. If a pail of material is installed on the unit, remove it as detailed inChanging a Pail in the Operation section.

2. Place the piece of heat-resistant material on the frame (or across thepail hold-down assembly) under the platen to act as a support for theplaten assembly.

3. Use the elevator control valve to lower the platen to within 12.7 cm(5 inches) of the heat-resistant material.

4. Secure the crossover in place.

5. See Figure 7-11. Disconnect the platen removal air line (1) from theplaten removal adapter (2).

4705024A

1

2

ONPLATENREMOVAL

AIRPRESSUREOFF

Fig. 7-11 Platen Removal Components

1. Platen removal air line 2. Platen removal adapter

Replacing the Platen

Repair7-14


100 4197AIssued 7/00


To Remove the Platen (contd)

NOTE: The standard platen removal feature requires manualconnection and disconnection of a low pressure air line built into theunit and use of a two-position platen removal switch.

6. Unscrew the platen removal adapter (Figure 7-11 (2)) from theT-handle adapter (Figure 7-12 (4)).

4705025A

1

2

6

7

10 9

12

11

3

5

4

8

Fig. 7-12 Platen Assembly

1. Hex-head screw2. Split lockwasher3. T-handle4. T-handle adapter5. T-handle adapter threads6. TFE joint sealant

7. Gasket8. Lockwasher9. Fillister-head screw10. Thermostat11. RTD12. RTD connector

Repair 7-15


100 4197AIssued 7/00


7. Remove the T-handle adapter (4) from the platen.

8. Remove the three hex-head screws (1) and lockwashers (2) thatsecure the platen cover plate to the platen, then carefully lower theplaten until the wiring connections are accessible.

NOTE: Brace the platen from underneath with wood blocks so thatno stress is placed on the wiring connections.

9. Disconnect the ground wire from its screw connection at the platen,then disconnect the heater wires from the top of each platen heater.

10. Remove the platen RTD (11) and RTD connector (12).

11. Remove the thermostat (10) along with its securing screws (9) andlockwashers (8). Remove the platen from the unit.

To Install the Platen

1. Apply the TFE joint sealant (6) to the top surface of the new platen sothat it makes a completely sealed ring, then position the new platengasket (7) on the new platen. See Figure 7-12.

2. Center the new platen under the cover plate so the holes in the coverplate align with their matching holes in the platen, then install theplaten RTD connector and RTD.

3. Coat the mating surface of the thermostat with heat conductive paste,then reinstall the thermostat, lockwashers and fillister-head screws.

4. Connect the ground wire to its screw connection at the platen, thenconnect the heater wires to the top of each platen heater as detailedin the wiring diagram in the Troubleshooting section.

5. Position the heater, RTD, thermostat and ground leads inside theplaten away from the outer rim.

6. Remove the crossover support, then use the elevator control valve toslowly lower the column and cover plate until it touches the platen.

NOTE: It may be necessary to heat the pump with a flamelesselectric heat gun before inserting the pump into the platen.

Repair7-16


100 4197AIssued 7/00


To Install the Platen (contd)

7. Reinstall the three hex-head screws and split lockwashers that securethe platen and cover plate together. Torque the screws to 20.3 Nm(15 ft-lbs).

8. Coat the threads of the T-handle adapter (5) with Loctite No. 620adhesive, then install and tighten the adapter in the platen.

9. Install the platen seal as described in Replacing the Platen Seal.

10. Use the elevator control valve to raise the platen enough toaccommodate a pail of material, then remove the heat-resistantmaterial positioned under the platen at the start of this procedure.

11. Place the main disconnect switch in the ON position, then restorepower to the unit.

12. Bring the unit to application temperature, then lower the platen intothe pail of material as described in Loading the Pail in the Operationsection.

Use the following procedures to remove, rebuild, and install the gerotorpump. A comprehensive rebuild includes removing, disassembling,assembling, and installing the gerotor pump.

If you are removing and installing a new gerotor pump, you will need atorque wrench and O-ring lubricant to complete these procedures.

If you are removing the existing gerotor pump, replacing specific parts,and installing the existing gerotor pump, you will need a torque wrench, ahex wrench, O-ring lubricant, and specific Nordson parts (refer to theParts section for part numbers) to complete these procedures.

If you are removing the existing gerotor pump, rebuilding it, and installingthe existing gerotor pump, you will need a torque wrench, a hex wrench,O-ring lubricant, high-temperature grease, anti-seize compound, and theNordson Uptime Plus Service Kit (refer to the Parts section for the partnumber) to complete these procedures.

Replacing or Rebuilding theGerotor Pump

4710111A

Repair 7-17


100 4197AIssued 7/00


To Remove the Gerotor Pump

1. Bring the unit to application temperature.

2. If a pail is installed on the unit, remove the platen from the pail asdescribed in Changing a Pail in the Operation section.

3. Use the elevator control valve to position the platen at a comfortableworking height. Then place the elevator control valve in the neutralposition.

4. Secure the crossover in place.

5. See Figure 7-13. Loosen the two round-head screws and hex nutsthat secure the column collar in place. Slide the collar up to giveaccess to the drive shaft-to-pump connection. Tighten theround-head screws and hex nuts to secure the collar in place.

Fig. 7-13 Raising the Column Collar

6. See Figure 7-14. Use the PUMP OFF/ON button on the Vistacontroller to turn the driveshaft until the lower yoke assemblysetscrew is accessible.

4710161A

Fig. 7-14 Turning the Driveshaft to Access the Lower Yoke AssemblySetscrew

4710132A

Repair7-18


100 4197AIssued 7/00


To Remove the Gerotor Pump (contd)


8. Relieve system pressure as described in the Maintenance section.

9. See Figure 7-15. Remove the hose(s) from the hose connector(s) atthe manifold.

10. See Figure 7-16. Loosen the lower yoke assembly setscrew, lift theyoke assembly free of the pump shaft, and reposition the universaljoint enough that the assembly can be removed from the driveshaft.

Fig. 7-15 Removing the Hose fromthe Manifold

4710107AA B C

Fig. 7-16 Removing the Lower Yoke Assembly from the Driveshaft

Repair 7-19


100 4197AIssued 7/00


11. See Figure 7-17. Loosen the manifold clamp nut and reposition themanifold clamp.

4710093A

Fig. 7-17 Repositioning the Manifold Clamp

12. See Figure 7-18. Use a flat blade screwdriver or similar tool to prythe pump manifold away from the platen. Lift the pump/manifoldassembly free of the platen and place it in a clean location for storageor disassembly.

Repair7-20


100 4197AIssued 7/00


To Remove the Gerotor Pump (contd)

4710094B

Fig. 7-18 Lifting the Pump Assembly Out of the Platen

13. If not rebuilding the gerotor pump, skip to Install the Gerotor Pump.

Repair 7-21


100 4197AIssued 7/00


To Disassemble the Gerotor Pump

1. Remove the gerotor pump/manifold assembly as described in theprevious procedure.

2. See Figure 7-19. Loosen the socket setscrew (1). Remove thecoupling block (2), key (4), and bearing washer (3) from the pumpshaft.

4710100A

1 2

3

4

Fig. 7-19 Removing the Coupling Block, Key, and Washer

1. Socket setscrew2. Coupling block

3. Bearing Washer4. Key

3. See Figure 7-20. Remove the three socket head screws (1).Remove the manifold (2) from the pump body.

4710103

Repair7-22


100 4197AIssued 7/00


To Disassemble the Gerotor Pump (contd)

4710101A

1

2

Fig. 7-20 Removing the Manifold

1. Socket head screws 2. Manifold

4. Remove the pipe plugs, hose connector(s), and manifold drain valvefrom the end of the manifold.

NOTE: There are no pipe plugs on dual-hose systems.

5. See Figure 7-21. Remove and discard the pump body O-rings.

Fig. 7-21 Removing the Pump BodyO-rings

Repair 7-23


100 4197AIssued 7/00


6. See Figure 7-22. Remove the pressure relief valve (1) from the pumpbody. Discard both O-rings (2) from the valve.

4710003

1

2

Fig. 7-22 Removing the Pressure Relief Valve and O-rings

1. Pressure relief valve 2. O-rings

Repair7-24


100 4197AIssued 7/00



7. See Figure 7-23. Remove the six socket head screws (1) from thelower pump plate (2). Remove the lower pump plate from the pumpbody. Discard the bearing and seal inside the plate. Keep the platefor rebuild.

4710004

1

2

Fig. 7-23 Removing the Lower Pump Plate

1. Socket head screws 2. Lower pump plate

Repair 7-25


100 4197AIssued 7/00


8. See Figure 7-24. Remove the two socket head screws (5) from thegerotor retainer (4). Remove the gerotor retainer from the pumpbody.

9. Remove the outer gerotor gear (3) from the gerotor retainer. Discardthe outer gerotor gear.

10. Carefully remove the pump shaft (1), complete with the inner gerotorgear (2) and Woodruff key, from the pump body. Discard the innergerotor gear, the pump shaft, and the Woodruff key.

4710005B

2

1

5

3

4

Fig. 7-24 Removing the Gerotor Assembly and Pump Shaft

1. Pump shaft2. Inner gerotor gear3. Outer gerotor gear

4. Gerotor retainer5. Socket head screws

4710104

Repair7-26


100 4197AIssued 7/00



11. See Figure 7-25. Remove the upper pump plate from the pump body.Discard the upper pump plate.

Fig. 7-25 Removing the Upper PumpPlate

12. See Figure 7-26. Press the upper needle bearing (1) and lowerneedle bearing (2) out of the pump body. Discard the needlebearings and the shaft seals (3).

4710009

3

1

2

3

Fig. 7-26 Removing the Upper and Lower Open Needle Bearings

1. Upper open needle bearing2. Lower open needle bearing

3. Shaft seal

Repair 7-27


100 4197AIssued 7/00


WARNING: Do not clean components in halogenatedhydrocarbon fluids. Using this fluid could cause an explosion.

WARNING: Contact your material supplier for therecommended cleaning fluid for your application. Failure toobserve may cause damage to the equipment or personalinjury.

13. Excluding the needle bearings and seals, clean the pump andmanifold parts with a cleaning solution recommended by youradhesive supplier.

To Assemble the Gerotor Pump

Assemble the gerotor pump components as follows:

Pump Bearings and Seals

1. See Figure 7-27. Coat the interior and exterior of the new openneedle bearings (1, 2) with high temperature grease.

2. Press one of the open needle bearings into the top of the pump bodyuntil it is 10 mm (0.38 in.) below the top surface.

3. Press the other open needle bearing into the bottom of the pumpbody until it is 6 mm (0.25 in.) above the bottom surface.

4. Apply a light coating of high temperature grease to both of the newshaft seals (3). Install one shaft seal and backup ring into the top ofthe pump body with the exposed spring facing out. Install the othershaft seal and backup ring into the bottom with the exposed springfacing out. The backup rings seat against the bearings.

Repair7-28


100 4197AIssued 7/00


Pump Bearings and Seals (contd.)

4710271C

10 mm(0.38 in.)

6 mm(0.25 in.)

3

1

2

3

3

1

2

3

Fig. 7-27 Installing the Open Needle Bearings, Shaft Seals, and RetainingRing

1. Upper open needle bearing2. Lower open needle bearing

3. Shaft seal and backup ring

Repair 7-29


100 4197AIssued 7/00


Upper Pump Plate and Gerotor Set

1. See Figure 7-28. Position the new upper pump plate (1) against thepump body.

2. Position the gerotor retainer (2) against the upper pump plate.

3. Coat the threads of the two socket head screws (1) with an anti-seizecompound. Hand-tighten the screws into the pump body, plate, andretainer.

4710010

1

2

3

Fig. 7-28 Attaching the Upper Pump Plate and Gerotor Retainer

1. Upper pump plate2. Gerotor retainer

3. Socket head screws

4. Coat the mating surfaces of the gerotor retainer and new outergerotor gear with a light oil.

5. Place the outer gerotor gear inside the gerotor retainer.

Upper Pump Plate and Gerotor Set (contd.)

6. See Figure 7-29. Align the new inner gerotor gear (3) with the outergerotor gear (1) until the inner gear goes in place and is flush with thegerotor retainer (2) surface.

Repair7-30


100 4197AIssued 7/00


4710011

31

2

Fig. 7-29 Aligning the Gerotor Gears

1. Outer gerotor gear2. Gerotor retainer

3. Inner gerotor gear

Repair 7-31


100 4197AIssued 7/00


Pump Shaft

1. Apply a light coating of high temperature grease to the new pumpshaft.

2. Install the new Woodruff key on the pump shaft.

3. See Figure 7-30. Align the Woodruff key on the pump shaft with theinner gerotor gear keyway.

CAUTION: Do not let the shaft keyway rub against the shaftseals. The keyway can damage the seals.

4. Turn the gears and shaft until the shaft can be pushed into place.

4710012

Fig. 7-30 Aligning the Shaft Key with the Inner Gerotor Keyway

5. Tighten both screws on the gerotor retainer. Apply torque of16.2 NSM (12 ft-lb). Turn the shaft to check that it rotates freely. Ifit does not rotate, tap the gerotor retainer lightly with a hammer andrecheck.

Repair7-32


100 4197AIssued 7/00


Lower Pump Plate

1. See Figure 7-31. Coat the interior and exterior of the new closedneedle bearing (1) with high temperature grease.

2. Press the closed needle bearing into the bottom of the new lowerpump plate until the open end of the bearing is 6 mm (0.24 in.) fromthe inner face of the pump plate.

3. Install a new shaft seal and backup ring (2) into the lower pump platewith the exposed spring facing out. The seal and backup ring seatagainst the bearing.

4. Insert the new internal retainer ring (3) in the groove above the shaftseal in the lower pump plate.

4710218C

6 mm(0.24 in.)

3

2

1

3

2

1

Fig. 7-31 Installing the Closed Needle Bearing, Shaft Seal, and InternalRetainer Ring

1. Closed needle bearing2. Shaft seal and backup ring

3. Internal retainer ring

Repair 7-33


100 4197AIssued 7/00


5. See Figure 7-23. Coat the threads of the six socket head screws (1)with an anti-seize compound. Position the lower pump plate (2)against the gerotor retainer and secure with the screws.

6. Tighten the screws alternately. Apply torque of 16.2 NSm (12 ft-lb).Turn the pump shaft to check that it rotates freely. If it does notrotate, tap the lower pump plate lightly with a hammer and recheck.

Pressure Relief Valve and O-rings

1. See Figure 7-22. Coat the pressure relief valve O-ring grooves withO-ring lubricant. Place the new O-rings in the grooves and applyadditional lubricant to the O-rings.

2. Install the pressure relief valve into the pump body.

3. See Figure 7-21. Coat the O-ring groove on the pump body withO-ring lubricant. Place the new O-ring in the groove and applyadditional O-ring lubricant to the O-ring.

Manifold

1. Coat the O-ring groove on the bottom of the manifold with O-ringlubricant. Place the new O-ring in the groove and apply additionalO-ring lubricant to the O-ring.

2. Coat the threads of the manifold drain valve, pipe plugs, and hoseconnector(s) with anti-seize compound and thread them into themanifold ports and tighten. Do not overtighten or damage to thethreads may occur.

3. See Figure 7-20. Attach the manifold (2) to the pump body (3) andsecure with the three socket head screws (1). Apply torque of13.6--16.2 NSm (10--12 ft-lb) to the screws.

4. See Figure 7-19. Install the bearing washer (3), key (4), and shaftcoupling block (2) onto the pump shaft.

5. Allow 0.38--0.76 mm (0.015--0.030 in.) of end play between the shaftcoupling block and the manifold. Tighten the socket setscrew (4) andcheck the end play.

4710096B

Repair7-34


100 4197AIssued 7/00


To Install the Gear Pump

1. Check that the pump pocket inside the platen is clean and free ofadhesive and other debris.

2. See Figure 7-32. Coat the pump body O-ring with O-ring lubricantand slide the gerotor pump assembly into the pump pocket.

Fig. 7-32 Placing the PumpAssembly in the Platen

3. See Figure 7-33. Reposition the manifold clamp until it secures themanifold in place. Tighten the manifold clamp nut.

4710097A

Fig. 7-33 Repositioning the Manifold Clamp

4710131A

Repair 7-35


100 4197AIssued 7/00


4. See Figure 7-34. Position the universal joint so that the lower yokeassembly can be slid onto the bottom of the driveshaft. Lower theyoke assembly onto the pump shaft and tighten with the setscrew.

4710163AA B C

Fig. 7-34 Attaching the Lower Yoke Assembly to the Driveshaft

5. See Figure 7-35. Reinstall the hose(s) onto the connector(s) at thepump manifold.

6. Close the manifold drain valve.

Fig. 7-35 Installing the Hose on theManifold

4710108A

Repair7-36


100 4197AIssued 7/00


To Install the Gear Pump (contd)

7. See Figure 7-36. Loosen the two round head screws and machinehex nuts that secure the column collar in place. Slide the collar downuntil it seats on the follower plate across the drive shaft-to-pumpconnection. Tighten the round head screws and hex nuts to securethe collar in place.

8. Remove the crossover support.

9. Set the main disconnect switch to the ON position and turn the poweron.

10. Bring the unit to application temperature. Lower the platen into thepail of material as described in Changing the Pail in the Operationsection and resume normal operation.

Fig. 7-36 Lowering the ColumnCollar

Use the following procedures to repair and replace components of thepail melter/applicator’s drive assembly.

Use the following procedure to replace the drive motor.

You will need a lifting device certified for at least 11.34 kg (25 lb) tocomplete this procedure.

4. Drive Assembly

Replacing the Drive Motor

Repair 7-37


100 4197AIssued 7/00


To Remove the Drive Motor


2. Remove the junction box cover and disconnect the motor leads.

3. Disconnect the motor conduit connector at the junction box.

4. Secure the lifting device to the motor.

5. See Figure 7-37. Remove the four hex head screws and splitlockwashers (2) that secure the motor (1) to the speed reducer (3).

6. Lift the motor free of the unit while carefully guiding the motor leadsfree of the junction box.

4705011A

1

4

23

Fig. 7-37 Drive Assembly Details

1. Motor2. Motor/Speed reducer screws and

washers

3. Speed reducer4. Speed reducer/Crossover

screws and washers

Repair7-38


100 4197AIssued 7/00


To Install the New Drive Motor

1. Secure the lifting device to the replacement motor and lower themotor onto the speed reducer.

2. Align the motor keyway with the speed reducer keyway and install thekey.

3. Replace the four hex head screws and split lockwashers that securethe motor to the speed reducer.

4. Reconnect the motor conduit connector at the junction box.

5. Reconnect the motor leads. Wire 45B connects to motor terminal A1and wire 44B connects to motor terminal A2.

6. Restore input power to the unit, set the main disconnect switch to theON position, turn the power on, and resume normal operation.

The speed reducer is not field-repairable and can only be replaced.

Use the following procedure to replace the speed reducer.

You will need a lifting device certified for at least 13.3 kg (25 lb), and aflat-head screwdriver to complete this procedure.

Replacing the Speed Reducer

Repair 7-39


100 4197AIssued 7/00


To Remove the Speed Reducer


2. Remove the drive motor or drive motor/clutch assembly as describedin this section.

3. Secure the lifting device to the speed reducer.

4. Remove the hex head screws and split lockwashers that secure thespeed reducer to the crossover.

5. See Figure 7-38. Lift the speed reducer until the upper yokeassembly is visible.

4710175B

Fig. 7-38 Lifting the Speed Reducer to Access the Upper Yoke Assembly

Repair7-40


100 4197AIssued 7/00


To Remove the Speed Reducer (contd)

6. Secure the drive shaft/yoke assembly in place by sliding ascrewdriver through the yoke to prevent the drive shaft from droppingdown into the column. The drive shaft will slide out of the lower yokeassembly which is coupled to the gerotor pump.

7. See Figures 7-39 and 7-40. Loosen the setscrews in the upper yokeassembly and lift the speed reducer free of the unit.

4710176B

Fig. 7-39 Loosening the Upper Yoke Assembly Setscrews

4710178B

Fig. 7-40 Lifting the Speed Reducer from the Unit

Repair 7-41


100 4197AIssued 7/00


To Install the New Speed Reducer

1. Secure the lifting device to the replacement speed reducer and lowerthe speed reducer onto the unit.

2. See Figure 7-39. Tighten the setscrews in the upper yoke assemblyonto the speed reducer output shaft.

3. Remove the screwdriver and lower the speed reducer until it seats onthe crossover. Check that the driveshaft is inserted in the lower yokeassembly.

4. Replace the hex head screws and split lockwashers that secure thespeed reducer to the crossover.

5. Remove the lifting device from the speed reducer.

6. Reinstall the drive motor assembly as described in this section.

7. Restore input power to the unit, set the main disconnect switch to theON position, turn the power on, and resume normal operation.

Repair7-42


100 4197AIssued 7/00


Use the following procedures to repair and replace components of thepail melter/applicator’s pneumatic system.

Use the following procedure to rebuild an air cylinder(s). You will needthe following items to complete this procedure:

S A piece of plywood or other heat-resistant material slightly larger thanthe platen diameter

S A spanner or similar tool

S A lifting device certified for at least 136.1 kg (300 lb)

S Snap-ring pliers

S A pair of cylinder head V-block packings

S A pair of cylinder head O-rings

S A pair of piston O-rings

S A pair of piston seals

S A pair of piston wear rings

S Thread locking adhesive

S Parker O-ring Lubricant

S Petroleum jelly

You will need the following items if the existing parts are damaged:

S Cylinder head assembly

S Air cylinder shaft

S Spacer

5. Pneumatic System

Rebuilding the Air CylinderAssembly

Repair 7-43


100 4197AIssued 7/00


To Remove the Air Cylinder Assembly

1. If a pail of material is installed on the unit, remove it as described inChanging the Pail procedure in the Operation section.

2. Place the piece of heat-resistant material on the frame (or across thepail hold-down assembly) under the platen.

3. Use the elevator control valve to lower the platen onto theheat-resistant material.

4. Turn power off, set the main disconnect switch to the OFF position,and lock out input electrical power to the unit.

5. Disconnect the input air supply from the unit.

6. Set the elevator control valve to the UP position to vent residual airpressure from above the air pistons. Then place the elevator controlvalve in the DOWN position as a safety to vent any remaining airpressure from below the air pistons. Set the elevator control valve tothe center position.

7. See Figure 7-41. Using the spanner or a similar tool to keep the aircylinder shafts stationary, remove the hex head screws and splitlockwashers that secure the crossover in place.

4710346A

Fig. 7-41 Removing the Screws and Washers from the Crossover

Repair7-44


100 4197AIssued 7/00


To Remove the Air Cylinder Assembly (contd)

8. Secure the lifting device to the crossover. Lift the crossover androtate it enough to provide access to the air cylinder assembly.

CAUTION: Failure to observe and follow this procedure mayresult in personal injury or equipment damage.

9. Secure the crossover to prevent it from falling or interfering with yourwork in the air cylinder.

10. See Figure 7-42. Remove the cylinder head assembly bycompressing the internal retaining ring with a pair of snap-ring pliersand lifting the assembly out of the air cylinder.

4710315

A B

Fig. 7-42 Removing the Cylinder Head Assembly

CAUTION: Do not bend, scratch, or otherwise damage the aircylinder shaft when performing the following step.

11. Carefully pull the air cylinder shaft straight up and out of the aircylinder. A piston assembly is attached to the bottom of the shaft.

Repair 7-45


100 4197AIssued 7/00


To Rebuild the Air Cylinder Assembly

1. See Figure 7-43. Remove the V-block packing (2) and Buna O-ring(1) from the cylinder head (3). Clean the cylinder head surfaces andgrooves thoroughly.

4710311

1

2

3

Fig. 7-43 Removing the O-ring and Packing from the Cylinder Head

1. O-ring2. V-block packing

3. Cylinder head

2. Inspect the cylinder head for damage. If damaged, replace the entirecylinder head assembly, including the O-ring and packing. If it is notdamaged, replace only the O-ring and packing.

3. See Figure 7-44. Remove the hex head screw (4), washer (2), andsplit lockwasher (3) that secures the piston assembly (1) to the aircylinder shaft.

Repair7-46


100 4197AIssued 7/00


To Rebuild the Air Cylinder Assembly (contd)

4710312

1

2

3

4

Fig. 7-44 Removing the Piston Assembly from the Shaft

1. Piston assembly2. Washer

3. Split lockwasher4. Hex head screw

4. Remove the wear rings, piston seals, and Buna O-rings from thepiston. Clean the piston surfaces and grooves thoroughly.

5. Remove the piston spacer from the end of the air cylinder shaft.

6. Inspect the interior surfaces of the air cylinder for nicks, scratches orother damage. If the cylinder is damaged, contact your Nordsonrepresentative for further advice on replacement or repair.

7. Inspect the air cylinder shaft for nicks, scratches, bending, or otherdamage. If damaged, replace the shaft.

Repair 7-47


100 4197AIssued 7/00


8. See Figure 7-45. Orient the air cylinder shaft with the spanner hole atthe top. The spanner hole is 10.8 cm (4.25 in.) from the top of theshaft.

9. Inspect the spacer for damage. If damaged, replace the spacer.

10. Slide the spacer onto the piston end of the shaft.

11. Install a new Buna O-ring on the piston.

4701162A

10.8 cm(4.25 in.)

Fig. 7-45 Air Cylinder Shaft Orientation

CAUTION: The Buna O-ring must be installed before the sealor wear ring. Failure to observe and follow this procedure mayresult in a faulty seal and poor operation.

12. Install a new seal and wear ring on the piston.

13. Coat the threads of the hex head screw with thread locking adhesive.Secure a piston to the bottom of the air cylinder shaft with the hexhead screw, washer, and split lockwasher.

14. Apply O-ring Lubricant to the inside surfaces of the air cylinder wall.

15. Coat the air cylinder shaft with petroleum jelly.

Repair7-48


100 4197AIssued 7/00


To Install the Air Cylinder Assembly

1. Insert the shaft with attached piston assembly into the air cylinder.Do not bend, scratch, or otherwise damage the shaft.

2. Guide the shaft to the bottom of the cylinder.

3. See Figure 7-46. Place the retaining ring in its groove on the cylinderhead assembly.

4710313

A B

Fig. 7-46 Installing the Retaining Ring on the Cylinder Head Assembly

Repair 7-49


100 4197AIssued 7/00


4. See Figure 7-47. Using the snap-ring pliers, compress the retainingring and install the cylinder head assembly into the top of the aircylinder.

4710316

A B

Fig. 7-47 Installing the Cylinder Head Assembly in the Air Cylinder

5. Rotate the crossover into position over the air cylinder shafts. Lowerthe crossover onto the air cylinder shafts.

6. See Figure 7-41. With the washers in place, hand thread the hexhead screws that secure the crossover to the air cylinder shafts.

7. Using the spanner or similar tool to keep the air cylinder shaftsstationary, tighten the hex head screws.

8. Remove the lifting equipment.

9. Restore input air pressure to the unit.


11. Check for proper operation of the platen elevator.

12. Install a pail of material on the unit, as described in Changing the Pailin the Operation section and resume normal operation.

Repair7-50


100 4197AIssued 7/00


You can access the Vista controller through the electrical enclosure toservice the fuses, the circuit boards, the operator panel, and the controlassemblies. Refer to the Parts section, for part numbers.

WARNING: Risk of electrical shock. Failure to observeelectrical safety procedures may result in personal injury ordeath. Allow only qualified personnel to perform this task.Observe all high voltage indicators.

WARNING: Disconnect equipment from line voltage. Failure toobserve may cause personal injury or death.

To prevent damage from electrostatic discharge, follow theseprecautions:

S Minimize a buildup of electrostatic energy by transporting and storingparts that are electrostatic-sensitive in static-safe containers.

S Keep electrostatic-sensitive parts in their containers until they arriveat static-free workstations.

S Ground yourself and place parts on a grounded surface beforeremoving them from static-safe containers. Refer to the followingguidelines To Ensure a Proper Ground.

S Avoid touching pins, leads, or circuitry when possible.

To Ensure a Proper Ground

Use one or more of the following grounding methods when handling orinstalling electrostatic-sensitive parts:

S Use a wrist strap connected by a ground cord to a properly groundedunit. Be sure that the unit is disconnected from all power sources. Ifyou are replacing a circuit board, a wrist strap is provided along withthe replacement circuit board. Refer to the procedure To Use anElectrostatic Discharge Strap.

S Use conductive service tools.

S Use a static-dissipating work mat.

S If you do not have the suggested equipment for proper grounding,have a Nordson representative install the part.

6. Servicing the VistaController

Preventing Damage to CircuitBoards

Repair 7-51


100 4197AIssued 7/00


To Use an Electrostatic Discharge Wrist Strap

Wrist straps are flexible straps with a minimum of 1 megohm +10 percentresistance in the ground cords. To provide a proper ground and protectyour unit from damage caused by electrostatic discharge, follow thisprocedure when working within the unit’s electrical enclosure.

CAUTION: Risk of equipment damage. To dissipate staticelectricity, always wear a static strap when installing or handlingany printed circuit board. Failure to oberve can result indamage to electrical components.

1. Wrap the copper end of the wrist strap securely around the groundlug of a unit that is properly grounded.

2. Wrap the other end of the strap snugly around your wrist.

3. After you have completed the electrical repair, remove the strap fromthe ground and your wrist, taking care not to touch any pins, leads, orother circuitry while securing the electrical enclosure.

To make any electrical repair, you will need to access the electricalenclosure. Open the door of the electrical enclosure by loosening the 2screws on the front of the door.

5940580A

1 2

1 2

12

WARNING

VistaTM READYFAULT

O

1


1. Screws

Safely Accessing ElectricalComponents

Repair7-52


100 4197AIssued 7/00


Use this procedure to replace a defective surge guard on 400 VAC 3units.



2. Open the electrical enclosure by loosening the screws on theenclosure door.

WARNING: Risk of burns. Surge guards can reachtemperatures as high as 81 _C (177 _F). Wear heat-protectivegloves.

CAUTION: Risk of equipment damage. Make sure surgeguards do not contact each other or any other component withinthe enclosure. Maintain 10-mm spacing.

3. See Figure 7-49. Disconnect the defective surge guard and replace itwith a new one. Position the surge guards so they do not contacteach other or any other component within the enclosure.

4. Close and secure the electrical enclosure by tightening the screws onthe enclosure door.

4601105

2

1

1

Fig. 7-49 Surge Guards

1. Surge guard 2. Transformer

Replacing a Surge Guard

Repair 7-53


100 4197AIssued 7/00


Follow this procedure to replace a fuse. A fuse may be secured by avertical or horizontal fuse holder.




3. See Figure 7-50 and use the following table to locate the fuse to bereplaced.

Table 7-1 Board Fuses

Board Fuse for Fuse Numbers

Power board Hose 1, gun 1 F1, F5

Hose 2, gun 2 F2, F6



Control power F9, F10

5/6 hose/gun board(5/6 hose/gun units only)



Contactor board(200--240 VAC 3 units)

Hoses 5--6, guns 5--6 F1, F2

Replacing a Fuse

Repair7-54


100 4197AIssued 7/00


4130374A

F1F2

F3F4

F5F6F7F8F9F10

F11 F12

1

3

2

F2

F1

F3 F4

F1

F2

F3

F1

F2

4

Fig. 7-50 Location of Fuses on Boards

1. Power board2. Contactor board

3. 5/6 hose/gun board 4. Motor control board

Replacing a Fuse (contd)

Repair 7-55


100 4197AIssued 7/00


4. See Figure 7-51. Remove the fuse from the fuse holder and installthe new fuse. Refer to the following table.

Fuse Holder To Remove To Install

Vertical 1. Press down on thefuse cap and turn itcounterclockwise untilyou feel the caprelease.

1. Pull the fuse from thecap and replace it witha new fuse.

2. Lift the cap and fusefrom the connector.

2. Insert the cap andfuse into the fuseholder. Turn the fuseand cap clockwiseand press down untilyou feel the cap lockinto place.

Horizontal Lift the fuse from itstwo-station connector.

Press the replacementfuse into the two-stationconnector until the fusesnaps into place.

4130079A

2

1

Fig. 7-51 Fuse Holders

1. Vertical 2. Horizontal

3. Close and secure the electrical enclosure by tightening the screws onthe enclosure door.

Repair7-56


100 4197AIssued 7/00


WARNING: Risk of electrical shock. Failure to observe canresult in personal injury, death, or equipment damage. Due torisk of electrocution, never wear a static strap when working ona unit that is still connected to a power source, includingI/O lines.

CAUTION: Risk of equipment damage. Failure to observe canresult in damage to electrical components. To dissipate staticelectricity, always wear a static strap when installing or handlingany printed circuit board.

Use this procedure to locate and replace fuses on the power board.

1. Be sure that you are properly grounded before beginning thisprocedure. Refer to Preventing Damage to Circuit Boards.

2. Determine which fuse to replace by referring to Table 7-2 and toFigure 7-52. Refer to the Vista Controller Assembly Parts List forfuse part numbers.

Table 7-2 Fuse Specifications

Connection Fuse Number Amps

Hose 1/Gun 1 F1/F5 6.3




4130070

F1F2

F3F4

F5F6F7F8F9F10

F11 F12

Fig. 7-52 Location of Fuses on Power Board

Replacing a Power BoardFuse

Repair 7-57


100 4197AIssued 7/00


3. Remove the fuse from the fuse holder. Refer to Table 7-3.

Table 7-3 Fuse Replacement for Two Connectors

Type ofHolder

To Remove To Install

Vertical 1. Press down on the fusecap and turn itcounterclockwise untilyou feel the caprelease.

2. Lift the cap and fusefrom the connector.

1. Pull the fuse from thecap and replace it with anew fuse of the sametype and rating.

2. Insert the cap and fuseinto the connector on thepower board. Turnclockwise and pressdown until you feel thecap lock into place.

Horizontal Lift the fuse from itstwo-station connector onthe power board.

Press the replacement fuseof the same type and ratinginto the two-stationconnector on the powerboard until the fuse snapsinto place.

4130079

Fig. 7-53 Vertical Fuse Holder (Front) and Horizontal Fuse Holder (Back)

Repair7-58


100 4197AIssued 7/00


WARNING: Risk of electrical shock. Failure to observe canresult in personal injury, death, or equipment damage. Due torisk of electrocution, never wear a static strap when working ona unit that is still connected to a power source, includingI/O lines.


Follow this procedure to remove the power and control circuit boards.

Use these procedures to replace the power board, control board, ordisplay board. As an alternative, you can save time by replacing theentire control assembly. Refer to Replacing the Control Assembly.

Preparation for Removal



2. Open the electrical enclosure by loosening the 2 screws on theenclosure door.

3. Unscrew the support strap from the control-end frame and disconnectthe electrical service from TB1 on the power board.

Removing the Circuit Boards

Replacing a ControlAssembly Board

Repair 7-59


100 4197AIssued 7/00


To Remove the Power Board

1. Cut the plastic tiewrap that holds the X1 and X2 harness anddisconnect the main electrical service from connector TB1.

5940645

Fig. 7-54 Cutting the Tiewrap on the X1 and X2 Harness

2. Disconnect the following from the power board:

S X1 and X2 (white connectors)S J2 (thermostat connector)S J4 (power switch connector)S J9 (solenoid valve connector)S TB2 (output contacts) if used

4130071A

TB1

L1 L2 L3 NJ2

TB2123456

J4

X2

X1

XS2 XS1J9

Fig. 7-55 Location of Connections on Power Board

Repair7-60


100 4197AIssued 7/00


To Remove the Power Board (contd)

3. Remove the following from the power board and save them for lateruse:

S X3 (jumper plug)S two triac clamps and attaching screwsS the screw for the large triac (Q17), left of TB1S the nine screws holding the power board to the control-end panel

5940641

1

+

4

3

21

Fig. 7-56 Power Board Components

1. Jumper plug2. Triac screw

3. Triac clamp4. Mounting screws

Repair 7-61


100 4197AIssued 7/00


CAUTION: Do not bend pins of the circuit board connectors.Otherwise, connections can be damaged and the controlsystem will not operate.

4. Starting from the TB1 side of the power board, carefully separate thepower board from the control board. Take care not to bend the pinsof connector XP1, which connects the microprocessor and powerboards.

5940642

1

+

Fig. 7-57 Removing the Power Board

Repair7-62


100 4197AIssued 7/00


To Remove the Control Board

Follow this procedure to remove the control board.

1. Disconnect the following from the control board:

S XP2 (orange-colored connector)S ribbon stripS five screws that hold the board to the control-end panel

5940783

1

1

2

3

Fig. 7-58 Control Board Connections and Components

1. Connecting screws2. Ribbon strip

3. Connector XP2

2. Disconnect jumper plug J2 from the control board.

NOTE: Save the plug for use on the new board.

Repair 7-63


100 4197AIssued 7/00


5940784

J2

Fig. 7-59 Location of J2 on Control Board

3. Carefully separate the control board from the display board. Takecare not to bend the pins of connector XP4A, which joins the controland display boards.

5940776

1

Fig. 7-60 Removing the Control Board

Repair7-64


100 4197AIssued 7/00


To Remove the Display Board

1. Remove the four screws holding the display board to the control-endpanel.

5940777

Fig. 7-61 Removing the Securing Screws

2. Remove the display board from the control-end panel.

5940778

Fig. 7-62 Removing the Display Board

5940682

Repair 7-65


100 4197AIssued 7/00


To Install the Display Board


1. Remove the replacement board from its static-safe package and alignthe board with the control-end panel.

2. Once the board is aligned, replace the 4 screws that hold the board tothe control-end panel. Torque to 2.48--2.93 Nm (22--26 lb-in.).

To Install the Control Board

1. Remove the replacement board from its static-safe package and alignthe board with the display board. Before pressing the board intoplace, be sure that the pins of the blue connector, XP4A, are alignedwith the connector on the display board.

2. Once the board is aligned and connector XP4A is secure, replace thefive screws that hold the control board to the control-end panel.Torque to 2.48--2.93 Nm (22--26 lb-in.).

3. Connect the ribbon strip to connector XP1 on the control board.

4. Connect XP2, the orange-colored connector.

Fig. 7-63 Aligning Pins of the BoardConnector

Repair7-66


100 4197AIssued 7/00


To Install the Control Board (contd)

5. Remove jumper from J2 of the old board and install on J2 of the newboard.

5940784

J2


6. Press the POWER switch on the Operator Control Panel.

CAUTION: You may cause damage to your equipment if youdo not change the Default Settings of the new control board tothe Factory Settings as described in the following step.

7. Program the controller by following the procedure ProgrammingSystem Settings Controls in the Installation section, and using thesettings you recorded in System Settings at the end of the Installationsection. If you did not record your system settings, you can start bychanging the standard Default Setting of the following features tothese values. These values are the customized Factory Settings thatare programmed into the controllers of new bulk melters.

5940643

1

Repair 7-67


100 4197AIssued 7/00


Table 7-4 SYSTEM SETTINGS Features to Change

FeatureNo. Feature Description Default

SettingFactorySetting

2 System Ready Time Delay Allows you to set the amount of additionaltime for material to melt after all zones havereached their setpoint temperatures. At theend of the time delay, the READY light turnson.

60 minutes 30 minutes

3 Over-temperature setpoint Allows you to set the maximum temperatureany zone can reach before the systeminitiates a fault condition.

149 _C(300 _F)

204 _C(400 _F)

5 Global temperature band Allows you to specify the degree to which atemperature may deviate for any zonebefore the system gives a warning.

17 _C(30 _F)

11 _C(20 _F)

6 Individual temperatureband

Allows you to specify the degree to which atemperature may deviate for an individualzone before the system gives a warning.

17 _C(30 _F)

11 _C(20 _F)

To Install the Power Board

CAUTION: Do not bend pins of the circuit board connectors.Otherwise, connections can be damaged and the controlsystem will not operate.

1. Remove the replacement board from its static-safe package and alignthe board over the control board. Before pressing the board intoplace, be sure that the pins of XP1 are aligned with the connector onthe control board.

2. Starting from the long side of the connector, press the board intoplace.

3. Once the board is aligned and connector XP1 is secure, replace thenine screws that hold the power board to the control-end panel.Torque to 2.48--2.93 Nm (22--26 in.-lb).

Fig. 7-65 Aligning Pins of the BoardConnector

Repair7-68


100 4197AIssued 7/00


To Install the Power Board (contd)

5940644

1

+

Fig. 7-66 Installing the Power Board

4. Install the screw for the large triac (Q17), which is to the left of TB1.Torque the screw to 1.35--1.58 Nm (12--14 in.-lb).

5. Install the two triac clamps and torque the securing screws to2.48--2.93 Nm (22--26 in.-lb).

6. Install the jumper plug to connector X3 on the power board.

Repair 7-69


100 4197AIssued 7/00


5940641

1

+

4

3

21

Fig. 7-67 Power Board Components

1. Jumper plug2. Triac screw

3. Triac clamp4. Connecting screws

7. Make the following connections:

S X1 and X2 (white connectors)S J2 (thermostat connector)S J4 (power switch connector)S J9 (solenoid valve connector)S TB2 (output contacts) if used

Repair7-70


100 4197AIssued 7/00


To Install the Power Board (contd)

4130071A

TB1

L1 L2 L3 NJ2

TB2123456

J4

X2

X1

XS2 XS1J9


8. Secure the X1 and X2 wire harnesses to the bottom of thecontrol-end panel using a tiewrap.

5940646

Fig. 7-69 Tiewrapping the X1 and X2 Harness

Repair 7-71


100 4197AIssued 7/00


9. Connect power to the Vista controller.

5940647

321

Fig. 7-70 Connecting Power

1. Ground wire (green)2. Wire number 12A

3. Wire number 11A

10. Close and secure the electrical enclosure.

5940580A

1 2

1 2

12

WARNING

VistaTM READYFAULT

O

1


1. Screws

Repair7-72


100 4197AIssued 7/00


Your unit may include one or more unit-specific boards, depending on theconfiguration of the unit. Instructions for replacing unit-specific boardsare supplied with the replacement board repair kits. Refer to Parts for therepair kit part numbers.

Refer to the procedure for Preventing Damage to Circuit Boards.

Follow this procedure to replace the operator panel.

To Remove the Operator Panel

1. Remove the power board. Refer to the procedure Removing thePower Board in this section.

2. Disconnect the ribbon strip from the control board.

5940780

1

Fig. 7-72 Disconnecting the Ribbon Strip

Replacing a Unit-SpecificBoard

Replacing the Operator Panel

Repair 7-73


100 4197AIssued 7/00


3. Close and secure the electrical enclosure door by tightening thescrews.

5940580A

1 2

1 2

12

WARNING

VistaTM READYFAULT

O

1


1. Screws

4. Using a flat-blade screwdriver and pliers, pull the operator panel fromthe control-end panel and guide the ribbon strip through the hole inthe control-end panel.

5940685A

Fig. 7-74 Removing the Operator Panel

4130098

4130099

Repair7-74


100 4197AIssued 7/00


To Install the Operator Panel

CAUTION: Mount the operator panel to a surface that is cleanand smooth. Otherwise, the panel can lose contact and causepoor unit performance. Additional damage can occur ifoperators attempt to run the unit using a panel that is notsecurely mounted.

1. Remove any adhesive that remains on the control-end panel with acitrus industrial cleaner.

2. Thoroughly clean the control-end panel with denatured alcohol toremove any residue left by the adhesive cleaner.

3. Remove the new operator panel from its static-safe package.

4. With clean hands, peel the paper backing from the operator panel.Make certain to thoroughly remove all the paper, especially aroundthe ribbon strip.

Fig. 7-75 Removing Paper BackingFrom the Operator Panel

5. Connect the plastic ground tab, which is located behind the selectordisplay, by lifting the tab up and pressing it against the adhesivebacking.

Fig. 7-76 Connecting theGround Tab

Repair 7-75


100 4197AIssued 7/00


6. Insert the ribbon strip through the hole in the control-end panel and,starting from the ribbon strip side of the operator panel, carefully alignthe operator panel to the control-end panel.

5940686A

Fig. 7-77 Installing the Operator Panel

7. Firmly press the panel into place with a rubber roller or similar tool.

8. Unlock the electrical enclosure door and open it. Connect the ribbonstrip to the control board.

9. Install the power board. Refer to the procedure Installing the PowerBoard in this section.


Repair7-76


100 4197AIssued 7/00


System Restoration

1. Reattach the support strap to the control-end frame. Tighten thescrew to 2.0--2.3 NSm (18--20 in.-lb).

2. Make sure the electrical service connections at TB1 on the powerboard are correct. If necessary, refer to Connecting Electrical Servicein the Installation section.


4. If you replaced the control board, re-enter your customized systemsettings, if any. Refer to System Programming Procedures andRecords of System Settings in the Installation section.

Refer to the procedure for Preventing Damage to Circuit Boards.

Follow this procedure to remove and install the control assembly. Thecontrol assembly includes the following components:

S power boardS control boardS display boardS control-end panelS operator panel

Replacing the ControlAssembly

Repair 7-77


100 4197AIssued 7/00


To Remove the Control Assembly


2. Cut the tiewraps that fasten the harnesses to the Vista controller.

5940690

+

Fig. 7-78 Cutting the Tiewraps

Repair7-78


100 4197AIssued 7/00


To Remove the Control Assembly (contd)

3. Disconnect the following from the power board:

S X1 and X2 (white connectors)S J2 (thermostat connector, 4-pin)S J4 (power switch connector)S J9 (solenoid valve connector)S TB2 (output contacts) if usedS X3 (jumper plug)—save the plug for later use.

NOTE: Save connector X3, the jumper plug, for later use.

4. Disconnect main electrical service connections, including the groundwire.

4130071A

TB1

L1 L2 L3 NJ2

TB2123456

J4

X2

X1

XS2 XS1J9

Q17

X3

X4

XP1


Repair 7-79


100 4197AIssued 7/00


5. Disconnect XP2 (orange-colored connector) from the control board.

4130089

XP2

1

2

Fig. 7-80 Location of Connector XP2 on Control Board

1. Power board 2. Control board

6. Disconnect jumper J2 from the board and save it for use on the newboard.

5940784

J2


Repair7-80


100 4197AIssued 7/00


To Remove the Control Assembly (contd)

WARNING: Support the control panel before removing the lastof the four mounting screws.

7. Remove the screws which mount the control assembly to theelectrical enclosure door.

8. Remove the Vista control assembly.

4705021A

Fig. 7-82 Removing the Control Assembly

Repair 7-81


100 4197AIssued 7/00


To Install the Control Assembly

1. Remove the control assembly from the static-safe package.

2. Position the Vista controller in the electrical enclosure door opening,align the holes in the control assembly and the door, and thread in thescrews.

3. Tighten the mounting screws.

4. Connect XP2 (orange-colored connector) and jumper J2 to the controlboard.

5. Connect main electrical service connections, including the groundwire.

6. Connect the following to the power board:

S X1 and X2 (white connectors)S J2 (thermostat connector)S J4 (power switch connector)S J9 (solenoid valve connector)S TB2 (output contacts) if usedS X3 (jumper plug)

7. Install and tighten the tie wraps to fasten the harnesses to the bottomof the control panel.

8. Make main electrical service connections, including the ground wire.


10. Press the POWER switch on the Operator Control Panel.

CAUTION: You may cause damage to your equipment if youdo not change the Default Settings of the new control board tothe Factory Settings as described in the following step.

11. Program the controller by following the procedure ProgrammingSystem Settings Controls in the Installation section, and using thesettings you recorded in System Settings at the end of the Installationsection. If you did not record your system settings, you can start bychanging the standard Default Setting of the following features tothese values. These values are the customized Factory Settings thatare programmed into the controllers of new bulk melters.

Repair7-82


100 4197AIssued 7/00


Table 7-5 SYSTEM SETTINGS Features to Change

FeatureNo. Feature Description Default

SettingFactorySetting

2 System Ready Time Delay Allows you to set the amount of additionaltime for material to melt after all zones havereached their setpoint temperatures. At theend of the time delay, the READY light turnson.

60 minutes 30 minutes

3 Over-temperature setpoint Allows you to set the maximum temperatureany zone can reach before the systeminitiates a fault condition.

149 _C(300 _F)

149 _C(350 _F)

5 Global temperature band Allows you to specify the degree to which atemperature may deviate for any zonebefore the system gives a warning.

17 _C(30 _F)

11 _C(20 _F)

6 Individual temperatureband

Allows you to specify the degree to which atemperature may deviate for an individualzone before the system gives a warning.

17 _C(30 _F)

11 _C(20 _F)


100 4197AIssued 7/00


Section 8

Parts

Parts8-0


100 4197AIssued 7/00


Parts 8-1


100 4197AIssued 7/00


Section 8Parts

To order parts, call the Nordson Customer Service Center or your localNordson representative. Use this five-column parts list, and theaccompanying illustration, to describe and locate parts correctly.

Numbers in the Item column correspond to numbers that identify parts inillustrations following each parts list. The code NS (not shown) indicatesthat a listed part is not illustrated. A dash (—) is used when the partnumber applies to all parts in the illustration.

The six-digit number in the Part column is the Nordson Corporation partnumber. A series of dashes in this column (- - - - - -) means the partcannot be ordered separately.

The Description column gives the part name, as well as its dimensionsand other characteristics when appropriate. Indentions show therelationships between assemblies, subassemblies, and parts.

Item Part Description Quantity Note

— 000 000 Assembly 1

1 000 000 S Subassembly 2 A

2 000 000 S S Part 1

S If you order the assembly, items 1 and 2 will be included.S If you order item 1, item 2 will be included.S If you order item 2, you will receive item 2 only.

The number in the Quantity column is the quantity required per unit,assembly, or subassembly. The code AR (As Required) is used if thepart number is a bulk item ordered in quantities or if the quantity perassembly depends on the product version or model.

Letters in the Note column refer to notes at the end of each parts list.Notes contain important information about usage and ordering. Specialattention should be given to notes.

1. Introduction

Using the Illustrated PartsList

Parts8-2


100 4197AIssued 7/00


Use this listing to order replacement parts for the crossover assembly.


— - - - - - - Frame/Crossover assembly, Model 505 —

— - - - - - - Frame/Crossover assembly, Model 506 —

1 - - - - - - Assembly, Frame, Models 505/506 — A

2 - - - - - - Assembly, junction box — A

3 981 214 4

4 276 990 1

4 335 955 1

5 981 551 2

6 983 501 2

7 324 187 1

8 272 059 2

9 324 020 1

— 981 591 2

— 324 059 1

— 324 060 1

— - - - - - - 1

— 900 301 —

10 273 550 1

11 981 310 6

12 983 150 6

13 324 000 1

14 981 905 4

15 273 806 1

16 981 054 2

17 984 111 2

18 276 874 1

19 272 887 1

20 981 069 2

21 983 111 2

22 984 111 2

23 272 888 2

24 272 058 2

25 324 392 1

26 324 391 1

27 982 046 2

NS 333 747 1

28 272 885 1

NS 983 401 2

NS 983 418 2

NS 981 407 4

NS 983 061

S Screw, fillister-head, 1/4-20 x 0.75 in.

S Crossover, painted, Model 505S Crossover, PTFE-coated, Model 506VS Screw, hex-head, 7/8-14 x 1.125 in., cap

S Lockwasher, split, 0.875 in.S Conduit, formed, 3/4 EMT

S Connector, compression, 3/4 (Model 505)

S Assembly, driveshaft, 5-gallon bulk melterS S Screw, w/Nylok, set, 3/8-16 x 5/16 in.

S S Yoke assembly, upper, driveshaftS S Yoke assembly, lower, driveshaftS S Driveshaft

S S Grease, lubricating siliconeS Weldment, hose hangerS Screw, hex-head, 3/8-16 x 1.250 in., cap

S Lockwasher, split, 0.375 in.S Speed reducer, worm gear, 30:1S Screw, drive, 2.000 x 0.187 in.S Collar, column, 5-gallon bulk melterS Screw, round-head, 8-32 x 0.750 in.S Nut, hex, machine, 8-32S Tag, warning, high pressureS Spring, compression, 19.400 x 3.846OD x 0.192 in. S Screw, cap, socket-head, 8-32 x 0.500 in.S Lockwasher, split, no. 8S Nut, hex, machine, 8-32S Cap, end, vinylS Seal, conduit fitting, 3/4 NPT

S Clip, wire, flat, nylon, 2.750 x 0.750 in.S Clip, wire, molded nylon, 0.750 in. diameterS Screw, hex-head, cap, M5 x 14S Plate, mounting, electrical enclosure, 506VS U-bolt, 4 in., 5/16-24, dis

S Washer, lock, split, M5S Washer, flat, oversized, M5S Screw, hex-head, 3/8-16 x 2.000, cap

S Washer, flat, ext, 0.406 x 0.812 x 0.065 8

2. Crossover Assembly

Parts 8-3


100 4197AIssued 7/00


Item NoteQuantityDescriptionPart

NS 983 160 S Washer, lock, ext., split, 3/8 4

NS 984 163 S Nut, hex, machine, 3/8-16 4

NS 982 637 S Screw, hex-head, machine, M8 x 12 5

NS 983 013 S Washer, flat, reg, M8 5

NOTE A: Refer to separate parts list and illustration.

NS: Not Shown

AIRPRESSURE

4

ONPLATENREMOVAL

OFF

4705003A

Hose Cable

View A--A(CROSSOVER)

11

2

1

5

19

30

3

26

14

6

1312

10 1311

21 2322

16 1817

27

20 24

9

8

25

7

Fig. 8-1 Crossover Assembly Parts

Parts8-4


100 4197AIssued 7/00


Use this parts list to order replacement parts for your frame assembly.


— - - - - - Frame Assembly, Models 505/506 1

1 939 813 S Switch, limit, heavy duty 1

NS 981 161 S Screw, pan-head, 10-32 x 0.375 in. 2

2 112 323 S Actuator, limit switch 1

3 972 808 S Connector, strain relief, 1/2 NPT 1

4 320 598 S Connector, strain relief, 90_ 1

5 335 920 S Frame, 506V 1

6 324 223 S Shaft, air cylinder, 1.50 in. diameter 2 A

7 272 441 S Head, cylinder, 5-gallon 2

8 - - - - - - S S Head, cylinder 1

9 - - - - - - S S Scraper, wiper, 1.500 in. ID 1

10 262 444 S S Packing, V-block, 1.500 in. ID 1

11 - - - - - - S S Bushing, 1.500 ID x 2.000 OD x 1.000 in. 1

12 942 360 S S O-ring, Buna N 1

13 986 309 S Ring, retaining, internal 2

NS 931 938 S Cable, shielded, 4-cond., pair, 20G 1

14 981 021 S Screw, socket heat, 6-32 x 1/4 in. 2

15 272 459 S Spacer, 1.900 x 1.620 x 1.000 in. 2

16 272 456 S Piston, 5-gallon 2

17 272 457 S Seal, piston, 5-gallon 2

18 272 458 S Ring, wear, 3.500 in. OD 2

19 981 552 S Screw, hex-head, 7/8-14 x 2.250 in. 2 B

20 983 501 S Lockwasher, split, 0.875 in. 2 B

21 941 510 S O-ring, Buna N, 3.000 x 3.188 x 0.094 in. 2

NS 900 223 S Lubricant, O-ring, Parker, 4-oz. container — C

NOTE A: Lubricate with petroleum jelly.

B: Lubricate with thread locking adhesive, part 900 439.

C: Coat inside of cylinders with this lubricant.

NS: Not Shown

3. Frame Assembly

Parts 8-5


100 4197AIssued 7/00


4705002A

SECTION A--A

SEEDETAIL A

4

1

2

6

17

16

15

14

13

7

18

19 20

21

12

8 9

10

11

DETAIL A

3

5

ONPLATENREMOVAL

AIRPRESSURE

OFF

A

A

Fig. 8-2 Frame Assembly Parts

Parts8-6


100 4197AIssued 7/00


Use the following list to order parts for the motor assembly.


— - - - - - - Motor assembly

1 335 924 S Motor, electric, AC, 1/2 HP, 1725 RPM 1

2 981 408 S Screw, hex-head, 3/8-16 x 1.250, cap 4

3 983 160 S Washer, lock, split e, 3/8 4

4 933 077 S Conduit, flex, bulk, 3/8 in. 2 ft.

5 933 079 S Connector, conduit 1

6 939 122 S Seal, conduit fitting, 1/2 2

7 804 486 S Connector, 3/8 conduit 1

4. Motor Assembly

Parts 8-7


100 4197AIssued 7/00


4705006AView A--A

A

A

1

2 3

5 6

76

4

5 6

Fig. 8-3 Motor Assembly Parts

Parts8-8


100 4197AIssued 7/00


See Figure 8-4.


— 272 034 Pump and manifold assembly, single, 5/16 in. ID hose

— 272 035 Pump and manifold assembly, single, 5/8 in. ID hose

— 324 185 Pump and manifold assembly, dual, 5/16 in. ID hose

— 324 186 Pump and manifold assembly, dual, 5/8 in. ID hose

1 274 312 S Body, pump 1

2 942 371 S O-ring, Viton, 3 3/8 x 3 5/8 x 1/8 in. 1

3 271 916 S Plate, pump, upper 1

4 271 889 S Retainer, gerotor 1

5 271 917 S Plate, pump, lower 1

6 981 557 S Screw, socket-head, 1/4-20 x 1.750 in. 6 A

7 271 888 S Gerotor set, 6-tooth 1

8 273 803 S Shaft, pump 1

9 940 201 S O-ring, Viton, 0.875 x 1.000 x 0.063 in. 1

10 271 919 S Valve, relief, pressure, 1,500 psi (5/16 in. ID hose) 1

10 272 045 S Valve, relief, pressure, 1,200 psi (5/16 in. ID hose) 1

11 945 025 S S O-ring, Viton, 0.755 x 0.970 in. 1 B

12 940 141 S S O-ring, Viton, 0.500 x 0.625 x 0.063 in. 1 B

13 272 047 S Seal, shaft 1

14 274 300 S Bearing, needle, open 2 C

15 271 087 S Key, woodruff 1

16 273 800 S Bearing, needle, closed 1 C

17 981 233 S Screw, socket-head, 1/4-20 x 1.000 in. 2 A

18 167 002 S Manifold, pump, single hose 1

18 272 807 S Manifold, pump, dual hose 1

19 981 556 S Screw, socket-head, 1/4-20 x 1.500 in. 3

20 981 101 S Screw, socket set, 10-32 x 0.187 in. 1

21 272 897 S Block, coupling, shaft, 1.250 in. long 1

22 272 046 S Washer, bearing 1

23 972 619 S Conn., male, 37_, 9/16-18 x 1/2 NPT (5/16 in. ID) 1 A, D

23 972 620 S Conn., male, 37_, 1 1/16-12 x 1/2 NPT (5/8 in. ID) 1 A, D

24 973 431 S Plug, pipe, 1/2 NPT 1 A, D

25 973 402 S Plug, pipe, 1/8 NPTF (single hose version only) 1 A

26 271 884 S Valve, manual, 1/4 NPT 1 E

27 986 310 S Ring, retainer, internal 1

28 272 548 S Key, 1/8 x 1/8 x 1/2 in. 1

29 274 301 S Seal, shaft 2

NOTE A: Apply PTFE paste, part 900 236 when installing.B: These parts are included with either pressure relief valve.C: Apply high temperature grease, part 300 318 when installing.D: Two of these parts are included with a dual hose manifold and pump assembly. E: Apply PTFE tape, part 902 504 when installing.

Pump and Manifold Assembly

Parts 8-9


100 4197AIssued 7/00


16

5

13

8

4705007A

9

14

29

24

26

23

18

22

212019

28

7

17

4

3

14

2

1

12

11

10

6

27

15

29

25

Fig. 8-4 Pump Assembly

Parts8-10


100 4197AIssued 7/00


Use the following information to order replacement parts for your platenassembly.


— - - - - - - Platen Assembly

— - - - - - - 5 A

1 983 100 2

2 - - - - - - 1 A

3 981 818 2

4 900 261 —

— 933 056 2

5 272 279 1

6 335 029 1

7 981 315 3

8 816 008 1

9 324 618 2.75 ft.

10 - - - - - - 1 A

11 984 142 1

12 272 068 1

13 272 466 1

14 981 905 2

15 272 069 1

16 983 150 4

17 984 140 1

18 272 067 1

19 272 474 1

20 900 419 —

21 324 107 1

22 986 029 1

23 324 131 1

24 308 934 1

NS 333 733 1

NS 900 236

S Thermostat AssemblyS S Lockwasher

S S Thermostat

S S Screw, fillister-head, 6-32 x 0.375 in.S S Paste, heat conductiveS S Connector, wire, porcelainS Connector, temperature sensor, 1/4 in. diameter S Sensor, RTD temperature, 1/4 x 2.000S Screw, hex-head, 5/16-18 x 1.000 in.

S Platen, 200/415V, PTFE coatedS Sealant, joint, TFE, 1/4 INC

S Seal, platen, 5-gallonS Nut, hex, jam, 5/16--18

S Spring, compression, 2.000 x 0.328 ID x 0.042 in. S Tag, warning, disconnect powerS Screw, drive, 2.000 x 0.187 in.S Clamp, manifoldS Lockwasher, split, 5/16S Nut, hex, regular, 5/16-18S Stud, 5/16-18 x 3.000 in.

S Gasket, platen, 5-gallonS Adhesive, Loctite no. 620S T-handle

S Ring, retaining, external, push-onS Tray, bleeder valveS Adapter, T-handleS Plug, pipe, socket-head, 3/8 brass

S Paste —

NOTE A: Refer to the recommended spares for listing of available options.

NS: Not Shown

5. Platen Assembly

Parts 8-11


100 4197AIssued 7/00


4705004A

1314

7

16

9

24

8

19

10

12

18

16

17

4

15

10

3

5

6

23

22

26

25

1

2

Fig. 8-5 Platen Assembly Parts

Parts8-12


100 4197AIssued 7/00


Use this list to order parts for the junction box assembly.


— - - - - - - Junction box assembly

1 324 344 S Assembly, cover, junction box w/tag 1

2 981 428 S S Screw, captive, 10-32 2

3 983 122 S S Washer, retainer, no. 10 2

NS 985 101 S S Rivet, pop 2

NS 242 654 S S Gasket, cover 4 ft.

NS 324 357 S S Cover, junction box 1

4 981 020 S Screw, pan-head, 6-32 x 0.25 in. 2

5 983 100 S Lockwasher 2

6 324 608 S Block, terminal, modular, 12-station 1

7 939 355 S Socket, relay, 8-pin 1

8 984 101 S Nut, hex, machine, 6-32 4

9 933 281 S Block, terminal, 4-station 1

10 900 781 S Cap/plug 1

11 324 358 S Box, junction, crossover 1

12 983 120 S Lockwasher, split, no. 10 2

13 984 129 S Nut, hex, machine 10-32 3

14 271 221 S Lug, terminal ground 3

15 240 674 S Tag, ground 1

NS: Not Shown

6. Junction Box Assembly

Parts 8-13


100 4197AIssued 7/00


4705005ASEE DETAIL A

DETAIL A(GROUND STUD ASSEMBLY)

13

98

765

3

2

1

11

5

15

14

12

Fig. 8-6 Junction Box Assembly Parts

Parts8-14


100 4197AIssued 7/00


Use this list to order parts for the electrical enclosure assembly.

Item Part Description Quantity Note— 335 933 Enclosure assembly, basic, 506V

1 - - - - - - S Tag, warning, disconnect power 1

2 136 418 S Name plate, Nordson, oval 1

3 984 529 S Nut, spring, push-on, 0.125 3

NS 985 111 S Rivet, blind, 3/32 x 0.125 4 A

4 933 397 S Gasket, base, connector 2

5 933 392 S Base, connector, Panel mount 1

6 933 395 S Insert, connector, receptacle 1

7 933 396 S Receptacle cover 1

8 240 674 S Tag, ground 2

9 984 129 S Nut, hex, machine, #10-32, brass 5

10 271 221 S Lug, 45_ double, 0.250, 0.438 4

11 983 120 S Washer, lock, e, split, #10 5

12 275 439 S Heat sink, mech, 506V 1

13 939 488 S Terminal, wire, ground 1

14 981 156 S Screw, pan-head, 10-32 x 1.000 in., brass 1

15 242 837 S Mount, cable strap 2

16 939 583 S Coupling, 1,000 NPS thread x 2.000 in. 16

17 981 029 S Screw, fillister-head, 6-32 x 0.500 8

18 984 101 S Nut, hex, machine, #6-32 8

19 983 102 S Washer, lock, e, split, #6 8

20 939 584 S Connector, conduit 90_ male 1

21 272 122 S Seal, conduit fitting 1 in. 1

NOTE A: Use to fasten the disconnect power warning tag to the electrical enclosure.

NS: Not Shown

7. Electrical EnclosureAssembly

Parts 8-15


100 4197AIssued 7/00


4705026A

2

1

7654

3

(INNER PANEL GROUND STUD)

119

14

9

10

13811

(DOOR GROUND STUD)

9

8

10

11

]

19

16

4

18

654

17

15

(HEAT SINK)

7

9 12

Fig. 8-7 Electrical Enclosure Assembly

Parts8-16


100 4197AIssued 7/00


See Figure 8-8.


— 335 929 Kit, electrical, assembly, 506V

1 981 847 S Screw, socket-head, 10-32 x 1.625 in. 4


3 981 544 S Screw, socket-head, 6-32 x 0.500 in. 10

4 333 715 S Block, mounting, power board, 506V 1

5 225 446 S Semimount, Triac, retainer, 3000V 1

6 982 096 S Screw, pan-head, slotted, M4 x 8 8

7 320 624 S Standoff, M4 x 16MM, round 8

8 982 025 S Screw, socket-head, M4 x 14 4

9 335 938 S Heatsink, machined, electrical box, 506V 1

10 816 159 S Nameplate, information, 506 1

11 985 103 S Rivet, pop, 3/32 x 0.250 in. 4

12 804 137 S Connector, 90_ elbow, 1/2 in. conduit 1

13 900 517 S Tubing, poly, spiral cut, 0.620 ID 1 ft.

14 939 582 S Connector, flex, conduit 1

8. Electrical Kit

Parts 8-17


100 4197AIssued 7/00


44705023A

8 6

6

9

5

3

6

2

1

7

10

11

9

14

12

13

14

13

12

4

Fig. 8-8 Electrical Kit

Parts8-18


100 4197AIssued 7/00


See Figure 8-9.


— 234 428 Repair kit, control assembly — A

1 234 423 S Service kit, control-end frame 1

2 225 453 S Nut, spring, U-type 2

3 225 458 S Operator panel, standard, Vista 1

4 225 451 S Power switch, 250 Vac, 16 A, panel-mounted 1

5 225 450 S Power switch boot 1

6 225 448 S Harness, power switch 1

7 234 426 S Repair kit, display board 1

8 982 970 S Screw, hex-head, slotted, M4 x 8 mm, w/nylon patch 6

9 185 092 S Connector, 40-position (display board to control board) 1

10 234 429 S Repair kit, control board 1

11 982 971 S Screw, hex-head, slotted, M4 x 12 mm, w/nylon patch 10

12 234 424 S Service kit, software chip, Vista 1

13 232 540 S Connector, 26-position (control board to power board) 1

14 234 427 S Repair kit, power board, Vista 1

15 982 974 S Screw, hex-head, slotted, M4 x 12 mm, w/lock washer 6

16 982 975 S Screw, hex-head, slotted, M4 x 16 mm, w/lock washer 6

17 302 882 S Screw, socket-head, cap, M3 x 10 mm, w/nylon patch 1

18 225 446 S Clamp, triac, power board 2

19 227 568 S Voltage plug, power board, 200--240 Vac, 3 1 B

20 220 592 S Connector, plug, power board, 6-position, 5 mm 1

21 939 491 S Fuse, power board, 25.0 A, fast-acting, 600 Vac 2 C

22 310 904 S Fuse, power board, 1.0 A, 250 Vac 2 D

23 939 683 S Fuse, power board, 6.3 A, fast-acting, 250 Vac 8 E

24 232 681 S Bracket, ground wire 1

— 125 249 S Mount, cable strap (located on item 24) 2

25 230 261 S Terminal, ground wire, 6--14, AWG 1

NOTE A: Order this part for a complete control assembly.

B: The appearance of this voltage plug will vary slightly depending on the voltage used. On units with 400 Vac 3(without neutral) service, the plug is included in the contactor board harness. Refer to the next parts list,Unit-Specific Parts List, for the part number of the contactor board harness.

C: Fuses for hoses and guns (F1 through F8 on the power board).

D: Fuses for tank heater (F11 and F12 on the power board).

E: Fuses for main power (F9 and F10 on the power board).

9. Control Assembly

Parts 8-19


100 4197AIssued 7/00


4130426B

11

2313

1112

7

2

25

1524

85

4

3

1

2

6

8 9

10

1514

2022

21

17

516

1819

15

161815

11

Fig. 8-9 Control Assembly Parts

Parts8-20


100 4197AIssued 7/00


See Figure 8-10.

Item Part Description Quantity Note— 186 038 Light tower 1

1 336 095 S Light mounting tulip, alarm ind., stack 1

2 336 091 S Light tube, 4” alarm ind., stack 1

3 336 096 S Light, cover and base for alarm ind, 1

4 130 230 S Light, alarm lens, green, stack 1

5 336 090 S Light, alarm lens, orange, stack 1

6 336 089 S Light, alarm lens, red, stack 1

7 220 986 S Lamp, 24V, light tower 3

8 336 098 S Gasket, light alarm, tulip mtg. 1

NS 189 805 S Harness, light tower assembly 1

NS: Not Shown

10.Warning Beacon

Parts 8-21


100 4197AIssued 7/00


4705019A

2

76

8

1

3 4 7

75

Fig. 8-10 Warning Beacon Assembly

Parts8-22


100 4197AIssued 7/00


Use this list to order parts for the platen removal assembly.


— 335 935 Module, blow-off, 506V

1 983 504 1

2 324 241 1

3 981 200 1

4 335 930 1

5 973 117 1

6 973 978 1

7 324 210 1

8 324 240 1

9 324 058 4 ft

10 971 271 1

11 971 266 1

12 324 209 1

13 971 265 1

14 324 242 1

15 324 046 1

16 271 909 1

17 900 571 1.5 ft A

18 900 236

S Washer, flat, 0.2810 x 0.0734 x 0.0630 in. S Disconnect, stem protectorS Screw, fillister-head, 1/4-20 x 0.5000 in.

S Adapter assembly, blow-off, 506VS Nipple, 1/4 NPT x 1.500 in. longS Adapter, bulkhead, 1/4 NPT

S Regulator, miniature, presetS Disconnect, bulkhead, keyedS Hose, line, air, 1/4 in. IDS Fitting, barbed, 1/4 in. IDS Elbow, male, 1/4 NPT x 0.2500 in. tube S Valve, mechanical, 1/4 NPT, 2-wayS Connector, male, 1/4 in. tube x 1/4 NPT S Fitting, 1/4 in. tube x 1/4 in. hose

S Hanger, hoseS Tag, removal, platenS Tube, polyethylene, 1/4 in. OD

S Paste — B

NOTE A: Use for all fittings except where noted.

B: Use on all tapered pipe threads.

11.Platen RemovalAssembly

Parts 8-23


100 4197AIssued 7/00


14

4705009A

A

A

VIEW A--A

ONPLATENREMOVAL

AIRPRESSURE

OFF

4

2

1

1216

7

5

1013

6

11

3

8

15

9

Fig. 8-11 Platen Removal Assembly

Parts8-24


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Use this list to order pneumatic parts.


— 335 953 Pneumatic assembly, 506V

1 972 119 1

2 971 672 1

3 973 562 1

4 973 447 1

5 183 697 1

6 982 168 2

7 236 282 1

8 933 079 1

9 933 077 0.5 ft.

10 804 486 1

11 971 266 4

12 900 571 10

13 939 004 1

14 242 837 1

15 900 556 1.5

16 972 716 1

17 900 236 —

18 973 937 2

19 973 151 2

20 973 117 1

21 972 595 1

22 338 336 1

23 982 046 2

24 983 418 2

25 272 556 1

26 324 392 1

27 335 949 1

28 981 282 2

29 972 672 1

30 972 716

S Elbow, male, 1/4 in. tube x 1/8 NPT

S Connector, 3/8 NPT x 1/4 in. tubeS Bushing, 3/8 NPT x 1/4 in. tubeS Plug, 1 1/4S Valve, air, 4-way, 3 positionS Screw, socket-head, cap, M5S Bushing, 1 1/4 x 1/2 NPT

S Connector, conduit, 1/2 x 3/8, 90S Conduit, 3/8 in. liquid tightS Connector, conduit, 1/2 x 3/8, straight S Elbow, 1/4 NPT x 1/4 in. tubeS Tube, poly, 1/4 in.

S Strap, cableS Mount, cableS Tube, nylon, 1/4S Connector, 1/4 NPT x 1/4 in. tube

S Paste

S Adapter

S Elbow, 1/4 NPT x 1/4 in. tubeS Nipple, steel, 1/4 NPT

S Disconnect, quickS Filter regulator, assemblyS Screw, M5, hex-headS Washer, flat, M5S Muffler

S Clip, wire, nylonS Bracket, crossover guardS Screw, 10-24 x 0.50S Union, Y, 1/4 x 1/4 in. tube, plstS Connector, male, 1/4 in. tube x 1/2 NPT 1

12.Pneumatic Assembly

Parts 8-25


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4705017B

30

14

12

29

11

10

9

8

7 5 4

6

3 2

1

26

17

25

13

2721

22

2419

16

15

17 18 17 191823

20

28

Fig. 8-12 Pneumatic Assembly

Parts8-26


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The following parts lists include spare parts and kits for the Model505/506 pail melter/applicator.


— 324 000 Reducer, speed, worm gear, 30:1 1

— 338 336 Filter/Regulator, 1/4 NPTF, 5-150 psig 1

— 324 208 Valve, rotary, hand, 4-way, 1/4 NPT 1

— 941 510 O-ring, Viton, 3.000 x 3.188 x 0.094 1

— 942 360 O-ring, Buna N (5-gallon cylinder heads) 1

— 335 924 Motor, electric, 1/2 hp 1

— 272 034 Pump and manifold assembly, single hose, 5/16 in. ID 1

— 272 035 Pump and manifold assembly, single hose, 5/8 in. ID 1

— 324 185 Pump and manifold assembly, dual hose, 5/16 in. ID 1

— 324 186 Pump and manifold assembly, dual hose, 5/8 in. ID 1

— 272 040 Pump, replacement, 1200 psi, 5/8 in. ID hose 1

— 272 041 Pump, replacement, 1500 psi, 5/16 in. ID hose 1

— 274 312 Body, pump 1

— 272 045 Valve, relief, pressure, 1200 psi (5/8 in. ID hose) 1

— 271 919 Valve, relief, pressure, 1500 psi (5/16 in. ID hose) 1

— 130 788 Kit, service, uptime 1

— 942 371 S O-ring, Viton, 3 3/8 x 3 5/8 x 1/8 in. 1

— 942 201 S O-ring, Viton, 0.875 x 1.000 x 0.063 in. 1

— 945 025 S O-ring, Viton, 0.750 x 0.950 in. 1

— 940 141 S O-ring, Viton, 0.500 x 0.630 in. 1

— 272 047 S Seal, shaft, 0.625 ID x 0.812 in. OD 1

— 274 301 S Seal, shaft, 0.625 ID x 0.875 in. OD 2

— 900 318 S Grease, fluorinated, 2 oz. tube 1


13.Recommended SpareParts and Kits

Spare Parts and Kits for theMain Assemblies

Parts 8-27


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— 130 787 Kit, service, uptime plus

— 130 788 S Kit, service, uptime 1

— 271 917 S Plate, pump, lower 1

— 271 916 S Plate, pump, upper 1

— 273 800 S Bearing, needle, closed 1

— 274 300 S Bearing, needle, open 2

— 272 548 S Key, 1/8 x 1/8 x 1/2 1

— 271 087 S Key, woodruff, 1/8 x 1/2 1

— 272 046 S Washer, bearing, 0.520 x 0.875 x 0.062 in. 1

— 986 310 S Ring, retainer, internal 1

— 273 803 S Shaft, pump 1

— 271 888 S Gerotor set, 6-tooth 1

— 116 106 Thermostat, platen, 93 _C (200 _F) 1







— 335 029 Sensor, temperature, RTD 1

— 272 279 Connector, sensor, temperature 1

— 276 983 Seal, platen, rubber, 286 mm 1

— 276 984 Seal, platen, rubber, 280 mm 1

— 274 380 Seal, platen, TES, 286 mm 1



Parts8-28


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— 324 104 —

— 900 223 1

— 900 236 —

— 900 302 —

— 900 419 —

— 900 464 —

— 900 439 —

— 900 514

Tape, silicone, foam, high-temperature Lubricant, O-ring, Parker, 4-oz. can Sealant, PasteGrease, high-temperatureAdhesive, retaining, cylindrical Adhesive, threadlockingAdhesive, threadlockingGloves, protective 1

Listed in the following tables are the components that differ with thespecific configuration of your melter/applicator.

Part Description Note

939 823 Transformer, 190/200/380/400/415 V

939 816 Transformer, 240/480 V

939 818 Transformer, 600 V

Supplies for Maintenance andRepair

14.Replacement Parts

Transformers

Parts 8-29


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324 446

109 240

113 758

112 800

324 445

324 447

112 802

112 801

107 859

125 741

125 647

Platen, 200/380/415 V, 280 mmPlaten, 240/480 V, 280 mmPlaten, 240/480 V, 280 mm, PTFE-coated Platen, 200/380/415 V, 280 mm, PTFE-coated Platen, 200/380/415V, 286 mmPlaten, 240/480V, 286 mmPlaten, 200/380/415V, 286 mm, PTFE-coated Platen, 240/480 V, 286 mm, PTFE-coated Platen, 200/380/415 V, 305 mmPlaten, 240/480 V, 305 mmPlaten, 200/380/415 V, 305 mm, PTFE-coated


816 468 Platen, 200/380/415 V, 280 mm, PTFE-coated816 467

816 465

816 466

101 074

111 726

Platen, 240/480 V, 280 mm, PTFE-coated Platen, 200/380/415 V, 286 mm, PTFE-coated Platen, 240/480 V, 286 mm, PTFE-coated Platen, 200/380/415 V, 305 mm, PTFE-coated Platen, 240/480 V, 305 mm, PTFE-coated

816 009 Platen, 240/480 V, PTFE coated

Platens - Model 505

Platen - Model 506

Parts8-30


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The following parts lists include hoses for the Model 505/506 pailmelter/applicator.

See Figure 8-13.


— 276 950 Manual Hose, 10 ft, 5/16 in. ID 1








— 120 958 Manual Hose, 10 ft, 5/16 in. ID 1 A

— 120 959 Manual Hose, 16 ft, 5/16 in. ID 1 A

— 127 317 Manual Hose, 10 ft, 5/8 in. ID 1 B



NOTE A: Equipped with corrugated cover for additional protection from abrasion.

B: For use with Series A-2 handguns only.

4710211

Fig. 8-13 Manual Gun Hose

15.Hose Parts Lists

Hoses for Manual Guns

Parts 8-31


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See Figure 8-14.


— 276 946 Automatic Hose, 10 ft, 5/16 in. ID 1








4710212

Fig. 8-14 Automatic Gun Hose

Hoses for Automatic Guns

Parts8-32


100 4197AIssued 7/00


See Figure 8-15.


— 276 942 Transfer Hose, 10 ft, 5/8 in. ID 1 A




NOTE A: Transfer hoses are used only when there is no gun at the end of the hose

4710216

Fig. 8-15 Transfer Hose

Transfer Hoses


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Section 9

Options

Options9-0


100 4197AIssued 7/00


Options 9-1


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Section 9Options

The following options are available on Models 505 and 506 Series 5000units. Parts lists and accompanying illustrations for factory-installedoptions follow these descriptions.

The platen guard kit consists of a fixed rear panel, hinged front panel andnecessary mounting hardware. The platen guard kit provides safety topersonnel and prevents damage to the platen from objects outside thebulk melter/applicator.

The exhaust hood helps to maintain cleaner air in the work area. Thehood is used to exhaust adhesive fumes away from the operator.

The caster kit consists of a platform equipped with four swivel casters tomake your Nordson 5-gallon bulk melter/applicator easily moveable fromone place to another as required.

This factory-installed option consists of an adjustable clamping devicethat secures the pail to the base of the bulk melter/applicator to ease pailchanging and help prevent accidental spillage of hot material.

1. Introduction

2. Descriptions

Platen Guard Kit

Exhaust Hood

Caster Kit

Pail Hold Down Kit

Options9-2


100 4197AIssued 7/00


This factory-installed option consists of a control enclosure, warningbeacon and circuitry that enables a two-bulk melter system to switch (orchange over) from the empty container of one unit to the full container ofthe other unit without interruption of the material application process.After the changeover has been made, the empty container can bereplaced with a full one, allowing further continuous operation.

This factory-installed option allows the motor to remain on while the unitis powered up and couples the motor to the speed reducer only when agun is triggered. Because this arrangement prevents constant motorstops/starts while the unit is in operation, motor life can be extendedconsiderably.

This feature enables Series 5000 gear pump equipped units to maintainconsistent bead thickness by automatically adjusting pump speed as theproduction line speed varies. Run-up control can be achieved onsingle-hose and dual-hose Series 5000 units. On dual-hose units,however, run-up control will function properly only when gun 1 and gun 2fire simultaneously or alternately. Run-up control will NOT functionproperly on dual-hose units if gun 1 and gun 2 are fired simultaneouslyand alternately.

Requires factory-installed hardware inside the Series 5000 electricalenclosure and a field-installed sensor/gear kit.

Automatic Changeover

Clutch Kit

Run-Up Control

Options 9-3


100 4197AIssued 7/00


Use the following parts list and illustration to order parts for your exhausthood.


1 132 822 Hood, exhaust, 5 gallon 1

NS 335 919 Bracket, vent, 506 1

2 984 140 Nut, hex, reg, 5/16-18 2

3 983 051 Washer, flat, e, 0.344 x 0.688 x 0.065 2

4 982 921 Screw, hex-head, 5/16-18 x 0.750 2

5 982 637 Screw, hex-head, machine, M8 x 12 2

6 983 013 Washer, flat, 8M, regular 2

NS: Not Shown

4705016A

1

2 43

5 6

Fig. 9-1 Exhaust Hood Assembly

3. Exhaust Hood

Options9-4


100 4197AIssued 7/00


Use this parts list to order replacement parts for your pail hold-downassembly.


— 335 927 Module, hold down, 286 pail, 506V —

1 125 095 S Base, retainer, pail 1

2 984 111 S Nut, hex, machine 8-32 32

3 981 075 S Screw, flat-head, 8-32 x 0.375 in. 24

4 125 199 S Hinge, 2.000 W x 7.000 L, 0.25 in. 2

5 816 567 S Clamp, toggle 2

6 984 120 S Nut, hex, machine, 10-32 8

7 981 237 S Screw, fillister-head, 1/4-20 x 0.375 in. 8

8 981 786 S U-bolt, 10-32, 4.000 L x 1.000 in. W 2

9 125 175 S Block, bracket, mount 2



12 981 926 S Screw, flat-head, 8-32 x 0.75 in. 6


14 981 328 S Screw, hex-head, 5/16 -18 x 0.625 in., cap 1

15 983 050 S Washer, flat, ext., 0.344 x 0.625 x 0.063 in.

19 125 110 S Assembly, retainer, can rear 1

20 125 108 S Assembly, retainer, can, side 1

21 125 106 S Assembly, retainer, can, front 1

22 125 201 S Bracket, retainer w/latch 1

N/S 983 527 S Washer, flat, 0.344 x 1.125 in. 3

N/S 982 240 S Screw, hex-head, M8 x 20 3

NS: Not Shown

4. Pail Hold DownAssembly

Options 9-5


100 4197AIssued 7/00


4705008A

NOTE: ASSEMBLEITEM 14 INTOAPPROPRIATE HOLE.

286

305 280

DETAIL ADETAIL B

20

SEEDETAIL A

SEE DETAIL B

NOTE: USE ITEM 16 ONASSEMBLY P/N 125 103 ONLY.

1

21

3

4

5

67

8

910

1112

22

13

13

2

42

2 3

19

1514

Fig. 9-2 Pail Hold Down Assembly

Options9-6


100 4197AIssued 7/00


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