ProBlue Fulfill Integrated Fill System - Welcome to …emanuals.nordson.com/adhesives/English_Manuals/1121787.pdfTable of Contents i 2013 Nordson Corporation Part 1121787_02 ProBlue

ProBlue Fulfill Integrated FillSystem

Customer Product ManualPart 1121787_02

Issued 5/13

NORDSON CORPORATION DULUTH, GEORGIA USAwww.nordson.com

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

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

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

Part 1121787_02 � 2013 Nordson CorporationAll rights reserved

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

Address all correspondence to:

Nordson CorporationAttn: Customer Service11475 Lakefield Drive

Duluth, GA 30097

Notice

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

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

Trademarks

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

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

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

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

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

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

ContourCoat, CPX, cSelect, Cyclo‐Kinetic, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, e.dot+,E‐Nordson, Equalizer, EquiBead, FillEasy, Fill�Sentry, Flow Coat, Fluxplus, Get Green With Blue, G‐Net, G‐Site, IntelliJet, iON, Iso‐Flex, iTrend,

Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros, MiniEdge, Minimeter, Multifill, MultiScan, Myritex, Nano, NexJet, OmniScan, OptiMix, OptiStroke,Partnership+Plus, PatternJet, PatternPro, PCI, PharmaLok, Pinnacle, Plasmod, Powder�Pilot, Powder Port, Powercure, Process Sentry, Pulse Spray,

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

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

Table of Contents i

Part 1121787_02� 2013 Nordson Corporation

ProBlue Fulfill Integrated Fill System 1. . . . . . . . . . . . . . . . . . . . . . . .

Manual Coverage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Getting Started 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Restrictions to System Use 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unintended Use 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Melter Firmware Requirements 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Theory of Operation 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Modes of Operation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overview of Pneumatic and Mechanical Components 5. . . . . . . . . . . . . .

(A). Adhesive Transfer Hose 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(B). Adhesive Storage Bin 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(C). Filter Housing and Lid Assembly 6. . . . . . . . . . . . . . . . . . . . . . . . . .(D). Air Pressure Regulator/Solenoid Assembly 6. . . . . . . . . . . . . . . . .(E). Suction Lance 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview of Electrical Components 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .(F). Control Panel 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Refill Board 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Level Sensor 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation Clearances 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation Components 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assemble the Lid Components 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assemble the Transfer Hose, Air Line, and Suction Lance 14. . . . . . . . . .Set Up the Fill System 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To change a Fulfill system parameter 16. . . . . . . . . . . . . . . . . . . . . . .Test the Fill System 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Remove the Inlet Air Deflector (Optional) 19. . . . . . . . . . . . . . . . . . . . . . . . .

Operation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monitoring Refill Operation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clearing a Refill Alarm 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Restoring ProBlue Fulfill Factory Settings 23. . . . . . . . . . . . . . . . . . . . . . . .

To restore saved settings 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Level Sensor Adjustment and Calibration 24. . . . . . . . . . . . . . . . . . . . . . . .

Baseline Setting 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Final Setting 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsii

Part 1121787_02 � 2013 Nordson Corporation

Parts 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using the Illustrated Parts Lists 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Melter Assembly Part Numbers 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation Kit Parts 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Installation Kit 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Splash‐Resistant Installation Kit 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lid Assembly Parts 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Regulator/Solenoid Assembly Parts 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Circuit Board and Membrane Panel Service Kits 33. . . . . . . . . . . . . . . . . .Miscellaneous System Parts 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Optional Accessories 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Service Kits and Recommended Spare Parts 37. . . . . . . . . . . . . . . . . . . . .

Technical Data 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fulfill System Specifications 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dimensions 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Diagram 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Integrated Refill System With Nordson Level Sensor A‐1. . . . . . . . . .

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

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

Sensor Calibration A‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Calibration Summary A‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Basic (Empty Level) Calibration A‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Precision (Full Level) Calibration A‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting A‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fault LED/Red Status LED A‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fill Enable LED/Yellow PCA LED/Yellow Light Tower A‐9. . . . . . . . . . . . . .

Service Parts A‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ProBlue Fulfill Integrated Fill System 1


ProBlue Fulfill Integrated Fill System

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

Manual Coverage

This manual provides information specific to the installation, operation, andtroubleshooting of the integrated fill sub‐system (Fulfill) incorporated intoyour ProBlue adhesive melter.

NOTE: For ProBlue Fulfill melters (generation 1) with fill system controls inthe sub‐base, refer to manual P/N 1081444.

Safety

Before installing and operating the fill system, read the safety informationprovided in the melter product manual in Section 1, Safety.

Getting Started

Step 1—Refer to the installation guide provided with the melter forinformation about installing the melter (steps 1 through 5 in the installationguide).

Step 2—Refer back to this manual for information about installing the fillsystem.

Step 3—Refer to the operation section of both the melter manual and thismanual for information about operating your melter and the fill system.

ProBlue Fulfill Integrated Fill System2


Restrictions to System Use

Before installing the fill system, ensure that your application DOES NOTrequire:

� the transfer of solid‐formed adhesive material greater than 12 mm

across the largest dimension.

� adhesive temperatures exceeding 205 �C (400 �F).

Description The Fulfill system extends proven ProBlue adhesive melter technology byproviding automatic delivery of solid‐formed adhesive to the melter tank.

For a complete ProBlue Fulfill integrated fill system, both the melter and aninstallation kit must be ordered.

Figure 1 ProBlue Fulfill melter (installation kit not shown)



Intended Use � Same as the melter. Refer to the melter manual.

Unintended Use � Same as the melter. Refer to the melter manual.

Melter Firmware Requirements

Operation of the fill system requires that melter firmware version 2.076 orlater be installed in the melter. Firmware updates are available fromwww.enordson.com/support.

Theory of Operation

The fill system adds small quantities of adhesive to the sealed melter tank atregular intervals, reducing the possibility of adhesive char, contaminants,thermal shock, and incorrect adhesive temperatures that result in poorbonding.

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

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

The controller activates the suction lance for a limited amount of time toprevent overfill conditions. If the maximum fill time is exceeded, the controllergenerates a refill alarm that stops the system from filling but does not disablethe melter heaters or take the melter out of ready status. If used, a refill alarmoutput is generated when the maximum fill time is exceeded. A refill alarmcan be cleared via the control panel or the Clear Refill Alarm input, if used.

NOTE: The low level LED present on a standard ProBlue melter is notpresent on a Fulfill integrated melter.



Modes of Operation

The default mode of operation is the automatic mode. When the melter isoperating in the automatic mode, the fill system tracks the melter readysignal. When the melter is ready, the fill system is enabled. If the melterstatus changes to not ready, then the fill system is disabled.

When the melter is operating in the manual mode, the fill system must bemanually enabled via the control panel or a remote input. The fill system canonly be enabled when the melter is ready. If the melter is placed into standbywhen the system is operating in the manual mode, the fill system will bedisabled. The fill system will remain disabled until the melter is again readyand the fill system is manually enabled via control panel or remote input.

NOTE: If remote inputs are used for fill system operation (RemoteEnable/Disable and Clear Refill Alarm), then the Fill System Enable key onthe control panel will not function.



Overview of Pneumatic and Mechanical Components

C

B

E

A

D

F

Figure 2 Overview of Fulfill system components

(A). Adhesive Transfer Hose

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

(B). Adhesive Storage Bin

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



(C). Filter Housing and Lid Assembly

The Fulfil lid assembly includes the filter stack, lid, fill tube, baffle, anddeflector:

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

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

� The fill tube attaches to the adhesive transfer hose.

� The baffle prevents adhesive from entering the filter sock.

� The deflector distributes adhesive evenly in the tank.

A safety interlock switch detects whether the removable melter tank lid is inplace. If the tank lid is not in place, the fill system will not operate.

(D). Air Pressure Regulator/Solenoid Assembly

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

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

(E). Suction Lance

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

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

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

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

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



Overview of Electrical Components

The integrated Fulfill system includes a Fulfill‐specific control panel. A refillboard located inside the electrical enclosure and a level sensor locatedinside the tank control fill system operation.

(F). Control Panel

The Fulfill control panel shown in Figure 3 provides the following controls andindicators:

� (1) Refill alarm symbol and LED (red light)—Activates if the system

exceeds the user defined fill time limit. The system will not resumeoperation until the fault is cleared by pressing the Clear Fault key.

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

active. When a low level is detected, the indicator notes that adhesiveis being transferred from the adhesive storage bin into the melter tankthrough the transfer hose.

� (3) Fill system enable key and LED (green light)—Pressing the fill

system enable key turns the fill system on or off. The LED turns greenwhen the system is enabled.

32

1

Figure 3 Fulfill system controls and indicators

1. Refill alarm symbol and LED2. Adhesive transfer LED

3. Fill system enable key (on/off)and LED



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

information.

See Figure 4. The refill board is located inside the electrical enclosure. Notethat:

� The FAULT, DELAY, and AIR potentiometer functions are controlled

through parameters. Refer to Set Up the Fill System under Installationfor parameter descriptions.

� A dip switch labeled SW1 is preset at the factory. Positions M1 and

M2 should always be ON.

SW1

XT1

XT2M1M2

ON

Figure 4 Refill board (located inside the electrical enclosure)

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

information.

The level sensor detects the level of adhesive in the melter tank. When theadhesive falls below the set point, the level sensor sends a signal to the refillboard.

The sensor comes preset from the factory for an average application in whichthe adhesive in the tank is typically molten. To adjust the level sensorsettings, refer to Level Sensor Adjustment and Calibration underTroubleshooting.



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Installation Before installing the fill system, familiarize yourself with Section 3,Installation, in the melter manual.

Installation Clearances

Figure 5 Minimum installation clearances (top and side views shown; refer to Table 1)



Table 1 Installation Clearances (see Figure 5)

Item Description Required Clearance

A

The distance from the outside edge of a 5/16‐in. Nordson hoseto the front face of the melter when a short 90‐degree hosefitting is used to connect the hose to the melter

P4 = 370 mm (14.5 in.)

P7 = 370 mm (14.5 in.)

P10 = 391 mm (15.4 in.)

B

The clearance required to open the pump enclosure door P4 = 243 mm (9.6 in.)

P7 = 243 mm (9.6 in.)

P10 = 268 mm (10.55 in.)

C

The distance from the melter base to the top surface of the tanklid when it is closed.

P4 = 567.4 mm (22.34 in.)

P7 = 565.2 mm (22.25 in.)

P10 = 654.3 mm (25.76 in.)

D

The clearance required on the left side of the melter to open theelectrical enclosure door or remove a hose/gun module.

P4 = 648 mm (25.5 in.)

P7 = 711 mm (28.0 in.)

P10 = 714 mm (28.1 in.)

E The clearance required to access the fill system filter. All = 50.8 mm (2.00 in.)

F

The clearance required to open the tank lid. P4 = 895.9 mm (35.27 in.)

P7 = 977.7 mm (38.49 in.)

P10 = 974 mm (38.35 in.)

559 mm(22 in.)

940 mm(37 in.)

534 mm(21 in.)

559 mm(22 in.)

1397 mm

(55 in.)

Figure 6 Adhesive storage bin clearances



Installation Components

In addition to the components contained in the melter installation kit, theFulfill system is shipped with the components shown in Figure 7.

NOTE: These components are shipped inside the adhesive storage bin.Refer to Installation Kit Parts under Parts for component part numbers.

1 2 3 4

5 6 7 8 9

Figure 7 Fulfill system components shipped inside the adhesive storage bin

1. Adhesive storage bin (tote)

2. Transfer hose (standard)

3. Suction lance

4. Air line (4 m)

5. Inlet tube

6. Hose clamp (2)

7. Wire tie (5)

8. Filter housing

9. Filter sock

Note: Extension kits are available if longer hose/air line lengths are needed. Refer to Parts for the extension kit partnumbers.



Assemble the Lid Components

See Figure 8. Install the filter enclosure, filter sock and inlet tube on the tanklid of the Fulfill melter.

1. Remove the three M4 socket‐head screws (5) and spacers (6) from thetank lid assembly (7).

2. Insert the inlet tube (4) and rotate it to the desired position.

3. Reinstall the spacers (5) and socket‐head screws (6).

4. Remove the tag from the filter sock (3).

5. Insert the filter sock (3) into the filter enclosure (1).

6. Set the filter enclosure on top of the tank lid and snap the filter enclosurelocks (2) onto the lid.

5

4

1

2

3

6

7

Figure 8 Fulfill lid assembly components

1. Filter enclosure

2. Filter enclosure locks

3. Filter sock

4. Inlet tube

5. M4 socket‐head screw

6. Spacer

7. Melter tank lid



Assemble the Transfer Hose, Air Line, and Suction Lance

See Figure 9.

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

2. Use the remaining hose clamp to attach the transfer hose to the feedsystem inlet tube (C).

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

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

NOTE: Extension kits are available if longer hose/air line lengths areneeded. Refer to Parts for the extension kit part numbers.

4. Route the air line along the transfer hose, securing it with cable ties asyou go.

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

CAUTION! Risk of equipment damage. To keep the suction lance fromclogging, do not

� put adhesive in the white PCV tube that houses the suction lance, and

� do not apply excessive force to the suction lance when inserting it in

the tube.

6. Insert the suction lance into the adhesive storage bin.

7. Connect a regulated, clean, dry air supply to the regulator inlet (F). Theair supply must be capable of supplying 3.45-5.51 bar (50-80 psi) at24�scfm.



G

B

E

D

A

C

F

F

G

Figure 9 Assembling the transfer hose, air line, and suction lance

1

2

3



Set Up the Fill System

Fulfill system setup involves connecting inputs/outputs and adjusting systemparameters as desired. If no changes are needed, skip to the next procedure,Test the Fill System.

1. Refer to the Fulfill system parameters shown in Table 2 and makechanges to the parameters as desired. Refer to To change a Fulfillsystem parameter as needed.

2. Connect inputs/outputs as desired for your operation. Refer to Table 3 foravailable inputs/outputs. Refer to the installation section of the meltermanual for the procedures for connecting and setting up inputs/outputs.

NOTE: For ProBlue Fulfill melters (generation 1) with fill system controls inthe sub‐base, refer to manual P/N 1081444.

To change a Fulfill system parameter

See Figure 10.

1. Press the Setup key.

The left display flashes parameter 1.

2. Using the numeric keypad, enter (or scroll to) the desired parameter.Refer to Table 2 For Fulfill system parameters or to Table 3 forparameters that need to be changed for any inputs/outputs.

NOTE: If you incorrectly enter the parameter number, press theClear/Reset key to return to parameter 1 and then re‐enter the correctparameter.

3. Press the Enter key.

4. Using the numeric keypad, enter the new value for parameter.

5. Press the Enter key.

6. Press the Setup key to exit the setup mode.

7. Test the system.

8. When you are satisfied that the fill system is operating correctly, save allof the current melter setting into memory by simultaneously pressing thenumber 1 key and the Setup key.

Figure 10 Keys used forparameter setup

1. Setup key

2. Clear/reset key

3. Enter key



Table 2 Fulfill System Parameters

Parameter Name Values Description

47 Fill Time Delay Default: 60 (seconds)

Range: 0-1000 (seconds)

The continuous time delay (in seconds)between when a tank low level condition isdetected and when the fill system activates.The Fill Time Delay setting prevents thesystem from frequently turning on and off.

48 Fill Time Limit Default: 60 (seconds)


The time allowed (in seconds) for the fillsystem to attempt to fill the tank before the refillalarm is activated.

69 FulfillEnable/Disable

Default: 1 (automaticoperation)

or

0 (manual operation)

The Fulfill system can be enabled or disabledeither manually or automatically.

Manual enable/disable can be performedlocally or remotely. Local enable/disable isthrough the membrane panel. Remoteenable/disable is through a remote input. Referto Table 3.

If the system is set for automatic operation andthe melter ready light is on, then the fill systemwill be automatically enabled (on). If the melterready light is off, then the fill system will bedisabled (off). For example, if the melter isplaced in standby, the Fulfill systemautomatically turns off.

79 Tote Vibrator Timer Default: 10 (seconds)


An optional vibrator can be purchased for theadhesive storage bin (tote). When installed,this vibrator will activate for the user‐specifiedtime before the fill system activates, and thenwill stay on until the level sensor is satisfied.The vibrator helps prevent adhesive bridgingand ensures consistent adhesive delivery fromthe tote to the melter.

Table 3 Fulfill System Inputs/Outputs

Name Type Description

Refill Alarm Output This output will signal when an F9 alarm occurs. To use this output,set one of parameters 40-46 to 11.

RemoteEnable/Disable

Input This input allows remote enabling/disabling of the Fulfill system. Touse this output, set one of parameters 30-39 to 30.

Clear Refill Alarm Input This input allows remote clearing of a refill alarm. To use this input, setone of parameters 30-39 to 29. This is a momentary switch. The resetwill be executed on change‐of‐state (on to off or off to on).

2

1

+

Saving current settings



Test the Fill System

The melter is shipped from the factory preprogrammed for automatic refilloperation. The factory settings that control the operation of the fill system canbe adjusted to meet specific application requirements. Refer to the previousprocedure, Set Up the Fill System.

To test the system 1. Manually fill the tank with solid adhesive.

2. Ensure that the tank lid is closed.

3. Switch the melter on and wait for the system to reach ready status.

4. Enable the fill system by pressing the fill system enable key.

The green LED turns on indicating that the fill system is enabled.

NOTE: The Fulfill system will not operate until the melter reaches readystatus.

1. Melter switch (on/off)2. Fill system enable key (on/off)

5. Run your production application.

6. Monitor the frequency and the volume of adhesive delivered to the tank.To ensure that there is sufficient molten adhesive to supply yourproduction application, it is preferable to have adhesive delivered to thetank in small batches (less than 1/8 of the tank volume) rather thaninfrequent large batches.

NOTE: The level sensor is factory‐set and should not requireadjustment. However, if your application requires sensor adjustment,refer to Level Sensor Adjustment and Calibration under Troubleshooting.

7. (Optional) If adhesive is clogging in the inlet air deflector, remove thedeflector. Refer to Remove the Inlet Air Deflector (Optional).

8. (Optional) If you need to adjust the performance of the fill system, refer toSet Up the Fill System.

9. When you are satisfied that the fill system is operating correctly, save allof the current melter settings into memory by simultaneously pressing thenumber 1 key and the Setup key.



Remove the Inlet Air Deflector (Optional)

The inlet air deflector redirects the incoming air away from the tank surface.The deflector is an optional part that is used in most applications in which theadhesive in the top of the tank stays primarily or fully molten. In someapplications, better performance is achieved without the deflector.

NOTE: If the inlet tube is clogging, Nordson Corporation recommendsremoving the air deflector.

See Figure 11. To remove the inlet air deflector, open the tank lid andremove the deflector screws (1) and the deflector (2).

2

1

Figure 11 Removing the inlet air deflector

1. Deflector screws 2. Deflector



Operation Once enabled, the fill system immediately begins operation. All that isrequired to maintain automatic refill operation is to maintain the level ofadhesive in the adhesive storage bin.

Monitoring Refill Operation

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

Under normal conditions, there is no need for the operator to monitor orintervene in the operation of the fill system. However, if the fill system isunable to satisfy the level sensor in the time limit set for the Fill Time Delay(parameter 48), the claxon alarm will sound, the refill alarm LED willilluminate, and the melter display will indicate F9.

Refer to the next procedure, Clearing a Refill Alarm, to clear a refill alarm.Refer to Troubleshooting for information about diagnosing and correctingpotential fill system problems.

NOTE: A refill alarm (F9) is a warning. The melter will not shut down whenthis alarm occurs. This alarm occurs when the fill system has tried to fill themelter for the amount of time specified in parameter 47 (Fill Time Delay) buthas not satisfied the level sensor.

NOTE: If the lid is open, the fill system will not operate. An open lid conditionis indicated by a flashing fill system enable key LED.

NOTE: If the air supply is shut off by the parent machine, a fault conditionwill occur.

4

5

1 2 3

6



Clearing a Refill Alarm

NOTE: When the refill alarm output is activated, the melter heaters stay onand the melter ready remote output remains active.

1. Press the Fill System Enable key (4) to disable the fill system andalarm.

2. Correct the fault condition.

3. Press the Clear/Reset key (5).

4. Press the Fill System Enable key (4) to re‐enable the fill system.

NOTE: It may take up to 30 seconds for the reset command to take effect.

1. Melter fault light (red)

2. Melter ready light (green)

3. Refill alarm LED (red)

4. Fill system enable key

5. Clear/reset key

6. Enter key



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

information.

If the fill system fails and the condition cannot be corrected, to continueoperating the melter (and filling it manually), disable the fill system (ensurethat the fill system power key LED is not illuminated).

Problem Possible Cause Corrective Action

1. System overfilled Solenoid stuck open Clean or replace.

Sensor ground wire not connected Connect.

Refill board not working Replace if defective.

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

2. System underfilled No adhesive in storage bin Add adhesive to storage bin.

No power Ensure that power is available.

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

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

Clogged filter sock Replace if needed.

Lid not closed Ensure that the lid is closed and thatthe lid switch is operational.

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

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

Deflector bent Repair or replace.

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

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

Bad refill board Replace the refill board.

Overfill timer too short Adjust the timer.

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

3. Frequent overfillalarms with no cause

Timers not properly set Adjust the timer settings. Refer to SetUp the Fill System under Installation.

+

Restoring saved settings



Restoring ProBlue Fulfill Factory Settings

There are two methods for restoring the melter to the ProBlue Fulfill factorysettings: using the “restore saved settings” feature or re‐entering the fillsystem operating parameters.

To restore saved settings

If you previously saved the melter settings, you can restore them bysimultaneously pressing the number 2 key and the Setup key.



Level Sensor Adjustment and Calibration


The level sensor consists of a level probe and a control box. The level probehas a black line around its diameter near the tip to note the maintainedadhesive level.

The level sensor comes pre‐adjusted at the factory. This adjustment will besuitable for most applications. Follow these procedures only if the settingsfrom the factory require adjustment for your application.

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

1

2

Figure 12 Location of the level sensor amplifier light and adjustment screw

1. Level sensor amplifier 2. Level adjustment screw (coveredby plug)



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

information.

Upon setting the probe's height, calibrate the level sensor.

1. Remove the threaded plug on the front face of the level sensor controlbox to reveal the adjustment potentiometer.

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

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

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

5. Once the switching point is found, rotate the adjustment potentiometerone‐half turn clockwise and leave it at that position.

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

information.

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

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

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

4. If unmelted adhesive has built up on the probe and the adhesive level inthe tank has dropped below the black line on the probe, rotate theadjustment potentiometer one‐half turn counter‐clockwise to decreasethe level sensor's sensitivity. If the adhesive level is still too low, repeatthis process until the adhesive level is satisfactory.






Parts


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

Using the Illustrated Parts Lists

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

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

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

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

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

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

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

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

AR: As Required

NS: Not Shown



Melter Assembly Part Numbers


Part Description

1100375 Melter, ProBlue Fulfill 4, 2H/G, 200/240V













Installation Kit Parts


Standard Installation Kit

NOTE: For an illustration of most of the components in this installation kit,see Figure 7 under Installation.

Part Description Note

1100151 KIT,FULFILL,INSTALL AND TRANSFER ASSY

1097984 � KIT,CONTAINER,WAND, HOSE ASSY, FULFILL

1097983 � � CONTAINER ASSEMBLY,120L,BLUE, FULFILL

7408012 � � SUCTION WAND W/BOX

1095962 � � HOSE,TRANSFER,4 METERS

1095965 � � TUBING,10MM X 8MM,NYLON,15 FT.

1095983 � � CABLE TIE,14.5 ,NYLON 6.6,4.0 BUNDLE (quantity of 5)

231362 � � CLAMP,HOSE,WORM DR,1.06-2".SS (quantity of 2)

939694 � � STRAP,CABLE,.06-4.00,NATURAL (quantity of 2)

1100170 � KIT,INSTALLATION,FULFILL

1101506 � � FILTER ENCLOSURE,FULFILL, GEN 2

1088282 � � FILTER,SOCK,200 MICRON,FULFILL

1097016 � � TUBE,INLET,FULFILL,PROBLUE



Splash‐Resistant Installation Kit

NOTE: For an illustration of most of the components in this installation kit,refer to the instruction sheet supplied with the kit (P/N 1103791). Visitemanuals.nordson.com to download technical documentation.


1101894 BIN,FULFILL,SPLASH‐RESIST,QD

1102660 � BIN ASSY,WATER‐RESIST,FULFILL

1101890 � � BIN,MODIFIED

1101891 � � TUBE,WAND,MODIFIED

1101892 � � PLATE,BULK HD,BIN,FULFILL

1102963 � � SPACER,RND,1/2‐IN OD,9/16‐IN LG,NYLON (quantity of 3)

1102073 � � PLUG,Q‐D,INDUSTRIAL,AIR,3/8

1102074 � � CAP,PVC,SCH 40,WHITE,4"

1017323 � � WASHER,PISTON,PDV (quantity of 10)

984723 � � NUT,HEX,CAP,M5,STL,NI (quantity of 7)

1018458 � � SCR,PAN,REC,M5X35,ZN (quantity of 3)

760622 � � SCREW,PAN HD,M5 X 12,STL,ZN PL (quantity of 4)

1104720 � � FITTING,TUBE,BLKHD,10MMTXG3/8 FEM,BRASS

984706 � � NUT,HEX,M5,STL,ZN (quantity of 3)

983035 � � WASHER,FLT,M,REG,M5,STL,ZN (quantity of 3)

1102070 � KIT,SHIP/W,BIN,WATER‐RESIST

1095962 � � HOSE,TRANSFER,4 METERS

1095965 � � TUBING,10MM X 8MM,NYLON,15 FT.

1095983 � � CABLE TIE,14.5 ,NYLON 6.6,4.0 BUNDLE (quantity of 5)

231362 � � CLAMP,HOSE,WORM DR,1.06-2".SS (quantity of 3)

7403056 � � SHORT SUCTION WAND W/BOX

1102080 � � TUBING,WAND,INSIDE,SHORT

1102078 � � HOSE,WAND,INSIDE,SHORT

939694 � � STRAP,CABLE,.06-4.00,NATURAL (quantity of 2)

1102082 � � COUPLING ASSY,BIN,WATER‐RESIST

1100170 � KIT,INSTALLATION,FULFILL

1101506 � � FILTER ENCLOSURE,FULFILL, GEN 2

1088282 � � FILTER,SOCK,200 MICRON,FULFILL



Lid Assembly Parts

See Figure 13.

Item Part Description Quantity Note

— ‐ ‐ ‐ ‐ ‐ ‐ LID,ASSEMBLY,P4F — A

— ‐ ‐ ‐ ‐ ‐ ‐ LID,ASSEMBLY,P7/10 F — A

1 1099187 � LID,INNER,P4F 1

1102912 � LID,INNER,P7/10 FILL 1

2 1093724 � ACTUATOR,SWITCH,MAGNETIC 1 B

3 1099185 � LID,SINGLE,P4F 1

1099186 � LID,SINGLE,P7/10 F 1

4 1099200 � SPACER,LID,P4F 2

1099201 � SPACER,LID,P7/10 F 2

5 1099202 � RISER,LID,P4/7/10 F 1

6 1097055 � RETAINER,FILTER HOUSING,FULFILL,PROBLUE

1

7 1096978 � COLLAR,LID,FULFILL 1

8 1100675 � BRACKET,HINGE,LID,P4 F 1

1100676 � BRACKET,HINGE,LID,P7/10 F 1

9 940293 � O RING,VITON, 1.500X1.625X.063,‐029 1

10 1079598 � PLATE,HINGE,FULFILL 1

11 1097738 � BAFFLE,EXHAUST,FULFILL RETROFIT,PROBLUE

1

12 1097739 � DEFLECTOR,FULFILL RETROFIT,PROBLUE 1

13 983401 � WASHER,LK,M,SPT,M5,STL,ZN 4

14 982374 � SCR,SKT,M5X40,BL 4

15 983067 � WASHER,FLT,M,REG,M3,ZINC PLATE 2

16 984700 � NUT,HEX,M3,STL,ZN 2

17 1082080 � CAPSCR,BTN‐HD,SKT,M5 X 6.0,STL/ZNC 3

18 983035 � WASHER,FLT,M,REG,M5,STL,ZN 4

19 983163 � WASHER,FLT,M,OVERSIZED,M4,ZN 3

20 1099530 � SCREW,LOW‐HD,SKT‐HD,M4X12,STL,ZI 5

21 982201 � SCR,SKT,M5X8,BL 4

22 1099531 � SCREW,LOW‐HD,SKT‐HD,M4X20,STL,ZI(P4 units)

2

982481 � SCR,SKT,LOW,M4X25,BL (P7/P10 units) 2

23 982025 � SCR,SKT,M4X14,BL 3

24 178475 � TAG,HOT SURFACE 1

NOTE A: Refer to Service Kits and Recommended Spare Parts for the service kit part number.

B: This part is included in service kit 1100174.

AR: As Required

NS: Not Shown



TIGHTEN TO15-20 IN‐LBS

01

02

03

04

05

06

07

08

09

10

13

14

15

16

11

1718

1218

20

TIGHTEN TO15-20 IN‐LBSOF TORQUE



22

OF TORQUE22


21

23

19

15-20 IN‐LBSOF TORQUE

TIGHTEN TO 21

24


Figure 13 Lid assembly parts



Regulator/Solenoid Assembly Parts

See Figure 14.


— 1098248 REGULATOR/SOL.ASSY,FULFILL —

1 1093650 � VALVE,SOLENOID,3‐WAY,24V,1/4 NPT 1

2 1058059 � MUFFLER POLYETHYLENE 1/4" NPT,SATURN

1

3 327029 � ELBOW,PIPE,HYD,1/4NPT,BR,BAR 1

4 1096668 � REGULATOR/FILTER,40 MIC,1/4 NPT,65PSIG

1

5 972125 � CONN,MALE,ELBOW,10MM T X 1/4UNI 1

6 973085 � NIPPLE,STEEL,SCHED 40,1/4, .87 1

3

2

4

5

1

Figure 14 Regulator/solenoid assembly parts



Circuit Board and Membrane Panel Service Kits

See Figure 15.


1 1100171 KIT,SVCE,FULFILL,CONTROLS MEMBRANE,P4/P7

1

1100172 KIT,SVCE,FULFILL,CONTROLS MEMBRANE,P10 1

2 1101718 KIT,SVCE,FULFILL,CPU (display/CPU board) 1

3 1096221 SERVICE KIT,REFILL CONT.,PROBLUE (refillboard)

1

NS 939995 � Fuse, time‐lag, 2A, 5X20MM, ceramic 2

4 1120837 KIT,SERVICE,FULFILL ADAPTER BOAD 1

NS 1120411 � CABLE, FULFILL ADAPTER 1

NS: Not Shown

2

4

3

1

Figure 15 Circuit boards and membrane panel



Miscellaneous System Parts

See Figures 16-17.

Item Part Description Quantity Note1 1100558 AMPLIFIER,SENSOR,RECHNER,FULFILL,G2

(level sensor amplifier)1

2 1100015 BRACKET,AMPLIFIER,FULFILL 1

3 1100173 KIT,SVCE,FULFILL,SENSOR,150MM W/CONN(capacitive level sensor with 150 mm probe)

1

4 1098584 BRACKET,SOLENOID,FULLFILL 1

5 1099258 GASKET,PUMP COVER,P4/7,FULLFILL (underpump tower cover)

1

1099259 GASKET,PUMP COVER,P10,FULLFILL (underpump tower cover)

2

6 1099611 GASKET,DOOR,EBOX,P4/7,FULFILL 1

1057499 GASKET,DOOR,EBOX,PBII, P10 1

7 1099544 GASKET,NEOPRENE RUBBER, ADH.CONTAINER

1

8 1100174 KIT,SVCE,FULFILL,LID SWITCH,PROXIMITY 1

9 1099781 SCREEN,INLET,PUMP,P4,PUSH‐ON 1

1099782 SCREEN,INLET,PUMP,P10,PUSH‐ON 1

1098375 SCREEN,INLET,PUMP,P7,PUSH‐ON 1

10 1099273 HINGE,TANK,P4F 1

1099203 HINGE,TANK,P7/10 F 1

11 1082369 SCR‐M,SHLDR,M5,6MM‐DIA,4MM‐LG,ST‐STL 2

12 1099250 HOLDER ASSY,LEVEL PROBE,16 mm,PROBLUE 1

13 1099251 � HOLDER,LEVEL PROBE,16mm,PROBLUE 1

14 1099252 � NUT,HOLDER,LEVEL PROBE,16mm 1

15 941144 � O RING,VITON, .625X .813X.094 1

NS 1099597 INSULATION,CHIMNEY,P4/7 1

1099598 INSULATION,CHIMNEY,P10 2

NS: Not Shown



2

4

3

6

1

7

5

Figure 16 Miscellaneous system parts (1 of 2)



Miscellaneous System Parts (contd)

11

9

8

10

12 13 14 15

Figure 17 Miscellaneous system parts (2 of 2)



Optional Accessories


1098962 KIT, VIBRATOR, CONTAINER, FULFILL RETROFIT A

1105581 KIT, HOSE, TRANSFER, FULFILL, 10 M B

1105582 KIT, HOSE, TRANSFER, FULFILL, 20 M B

1093639 FILTER/REGULATOR W/GAGE, 1/4 NPT (optional adjustable regulator)

‐ ‐ ‐ ‐ ‐ ‐ Hose/air line extension kits C

NOTE A: Refer to the instruction sheet provided with the kit for the installation procedure.

B: This kit is required if the adhesive transfer hose is longer than the standard length. Refer to the instructionsheet provided with the kit for the installation procedure.

C: Extension kits are available if longer hose/air line lengths are needed. Contact your Nordsonrepresentative for information.

Service Kits and Recommended Spare Parts

Assembly Part Description

Lid 1100174 KIT,SVCE,FULFILL,LID SWITCH,PROXIMITY1100175 KIT,SVCE,FULFILL,LID ASSY,P4 7F1100176 KIT,SVCE,FULFILL,LID ASSY,P7/P101082942 KIT,SERVICE,SOCK FILTER,5 PCS,FULFILL

Regulator/solenoid 1098248 REGULATOR/SOL.ASSY,FULFILL

Electricalcomponents

1100171 KIT,SVCE,FULFILL,CONTROLS MEMBRANE,P4/P7 (control panelmembrane assembly)

1100172 KIT,SVCE,FULFILL,CONTROLS MEMBRANE,P10 (control panel membraneassembly)

1101718 KIT,SVCE,FULFILL,CPU (display/CPU board)

1096221 SERVICE KIT,REFILL CONT.,PROBLUE (refill board)

939995 � Fuse, time‐lag, 2A, 5X20MM, ceramic (quantity of 2 located on the refillboard)

1120837 KIT,SERVICE,FULFILL ADAPTER BOAD

1120411 � CABLE, FULFILL ADAPTER

1100173 KIT,SVCE,FULFILL,SENSOR,150MM W/CONN (capacitive level sensor with150 mm probe)

1100558 AMPLIFIER,SENSOR,RECHNER,FULFILL,G2 (level sensor amplifier)

1101706 KIT, SVCE, ALARM (includes harness)






Technical Data

Fulfill System Specifications

The following specifications are specific to the Fulfill integrated fill system.For general ProBlue melter specifications, refer to the melter manual.

Parameter Specification

Melter operating temperature range 40-205 �C (104-400 �F)

Adhesive forms

Maximum size

Pellets, pastilles, mini‐slats

� Pastilles: 12 mm (0.472 in.) diameter

� Mini‐slats: 12 mm X 12 mm (0.472 in. X 0.472 in.) in length

Adhesive transfer maximum rate 227 kg (500 lb)/hour (dependent on adhesive type)

Transfer hose length 4 m (13 ft)

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

Air line tubing size (betweensolenoid valve and suction lance)

10‐mm OD, 8‐mm ID

Total air consumption Full system not including optional tote vibrator: 680 l/min (24 scfm)

Optional tote vibrator: 283 l/min (10 scfm)

Conditioning Dry, non‐lubricated

Inlet air connection ¼‐in. NPT female ¼‐in. BSPP femaleG ¼ female

Pump type Venturi

Noise emission 76 dBA

Suction lance dimensions (L) 615 mm x (W) 105 mm maximum(24.21 in. x 4.14 in. maximum)

Adhesive storage bin capacity 60 Kg (132 lb)



Dimensions

A

B

C

D

Figure 18 Melter dimensions (refer to Table 4; P4 melter shown)

Note: For clearances, refer to Installation Clearances under Installation.

Table 4 Melter Dimensions

Parameter ProBlue 4 ProBlue 7 ProBlue 10

A 539.1 mm (21.22 in.) 603.2 mm (23.75 in.) 606.7 mm (23.89 in.)

B 567.4 mm (22.34 in.) 565.2 mm (22.25 in.) 654.3 mm (25.76 in.)

C 371.9 mm (14.64 in.) 369.9 mm (14.56 in.) 390.6 mm (15.38 in.)

D 348 mm (13.70 in.)



559 mm(22 in.)

940 mm(37 in.)

534 mm(21 in.)

559 mm(22 in.)

1397 mm

(55 in.)

Figure 19 Adhesive storage bin dimensions and clearances



Wiring Diagram

FUL

FIL

L A

DA

PTE

RB

OA

RD

J1J2

Figure 20 Wiring diagram

Integrated Refill System With Nordson Level Sensor A-1


Appendix A

Integrated Refill System With NordsonLevel Sensor

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

Sensor Features

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

Wide Sensing Area

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

Simplified Mechanical Mounting

The Nordson level sensor simply installs in the mounting location with noheight adjustments required.

Integrated Refill System With Nordson Level SensorA-2


Push Button Calibration

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

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

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

RTD Temperature Compensation

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

Sensor Diagnostics

The Nordson level sensor offers several diagnostic functions not present inthe previous level sensor. These new diagnostic functions are reported withLED flash codes. The flash codes are displayed on the membrane panel.

Low Tank Output

A low level output is generated when the adhesive level gets near the bottomof the probe. It provides a warning to the user if the tank level becomesabnormally low. For example, if the fill system is disabled while the pump isrunning, the low level output would warn the user that the tank level is lowbefore the unit runs out of adhesive.



Unit Features

The picture below shows the Retrofit system and its components.

Figure A‐1 Location of the PCA and power supply (power supply on back plate of PCA)

Delay Timer

The delay timer determines how long the Refill board waits when the sensorcalls for adhesive before the vacuum system is activated.



Overfill Fault Timer

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

Status Relay Contact Output

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

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

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

If a 24 VDC signal is desired instead of a potential free contact, connect 24VDC to the COM contact and then use the NC and NO contacts. Use the NCcontact for a signal that supplies 24 VDC when the fill system is workingnormally and the NO contact for a signal that supplies 24 VDC when aproblem with the fill system exists. See Figure A‐2.

TB3

Figure A‐2 Photo of TB3:



Configuration Switch

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

Melter Configuration Switch Settings

Switch 1 Switch 2 Switch 3 Switch 4

ProBlue 4 Integrated INTEGR INT TcA 150

ProBlue 7 Integrated INTEGR INT TcA 150

ProBlue 10 Integrated INTEGR INT TcB 150

ProBlue 4 Retrofit RETRO INT TcA 150

ProBlue 7 Retrofit RETRO INT TcA 150

ProBlue 10 Retrofit RETRO INT TcB 150

ProBlue 15, 30/50 RETRO INT TcB 150

Mesa 4 RETRO INT TcA 150

Mesa 6 RETRO INT TcA 150

Mesa 9 RETRO INT TcB 150

Mesa 14 RETRO INT TcB 150

Series 3100 RETRO INT TcA 150

Series 3400 RETRO INT TcA 150

Series 3500 RETRO INT TcB 150

Series 3700 RETRO INT TcB 150

Series 3860/3960 RETRO INT TcB 300

DuraBlue 10 RETRO INT TcB 150

DuraBlue 16 RETRO INT TcB 150

DuraBlue/VersaBlue 25 RETRO INT TcB 300



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

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



Configuration Switch(contd)

The figure below shows the features of the Refill PCA.

Unit Low LED

Configuration switches

Power LED

Fill low

LEDStatus LED

Full calibration button

Empty calibration button

Delay timer

potentiometer

Overfill fault

potentiometer

Fault LED Siren LED

Vibrator LED

Fill enabled LED

Fill active LED

Figure A‐3 PCA board



Sensor Calibration

Calibration Summary

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

Order toPerform

TypeCalibration

ButtonsUsed

DataPoints

Affected

Notes

1 BasicCalibration

(EmptyLevel)

BlueButton(SW3)

Emptyand Full

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

2(optional)

PrecisionCalibration

(Full Level)

WhiteButton(SW2)

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

Basic (Empty Level) Calibration

CAUTION! Do not calibrate a full unit under empty level calibration.

1. Allow tank to reach application temperature.

2. Adhesive level should be near the bottom of the probe.

3. Close lid.

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

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

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

3. Close lid.

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



Troubleshooting

Fault LED/Red Status LED

The diagnostic fault messages (red flashes) for the STATUS LED (DS3,located on Refill PCA) are listed below. These flash codes are alsoperformed on the FAULT LED located on the membrane panel.

Number ofRed Flashes

(DS3) andPanel Fault

LED

Diagnostic Action Required

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

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

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

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

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

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

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

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

5 RTD shorted. The temperature compensationRTD is electrically shorted.

Replace sensor

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

Replace Refill board if fault persists



Fill Enable LED/Yellow PCA LED/Yellow Light Tower

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

Number ofYellow

Flashes(DS3) and

PanelEnable LED

Diagnostic Action Required

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

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

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

Replace sensor

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

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

6 Unstable sensor readings Check sensor cable connection. If theproblem persists, replace the sensorand/or the refill PCA.

7 Probe temperature under 80 �C (175 �F) andfilling is prevented

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



Service Parts Part Description

1121798 Kit, service, siren, MKIII, ProBlue FF

1121800 Kit, service, power supply, Fulfill

1121802 Kit, service, Nordson sensor, 150 mm, Fulfill integrated

1121804 Kit, service, PCA, MKIII Fulfill

1121491 Harness, 24 VDC

1121493 Harness, low level

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

1121773 Harness, siren, Fulfill, ProBlue

1121774 Harness, AC input, Fulfill, ProBlue

1121806 Kit, light tower






EC Declaration of Conformity

for Adhesive and Sealant Application Equipment conforming to European Council Directives

PRODUCTS:

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

AltaBlue� TT Melters, Models A4, A10, A16

Cobalt� GR Series Bulk Material Unloaders

DuraBlue��Melters

FoamMelt� FM‐200 Melter

Fulfill� Retrofit Kit

Mesa� Melters

MiniPUR� Melters

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

ProBlue� Fulfill�, Models P4F, P7F, P10F

PURBlue� Melters

Series 3000V Melters

SureFoam� Foam Dispensing System

APPLICABLE DIRECTIVES:

Machinery Directive: 2006/42/EC

Electromagnetic Compatibility Directive: 2004/108/EC

STANDARDS USED TO VERIFY COMPLIANCE:

EN ISO 12100 EN 60204‐1

EN ISO 13732‐1 EN 61000‐6‐2

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

other environments may pose potential difficulty ensuring

electromagnetic compatibility due to conducted as well as

radiated disturbances.)

PRINCIPLES:

This product has been manufactured according to good engineering practice.

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

Technical File Contact:

Dieter Ziesmer

Nordson Engineering GmbH

Lilienthalstrasse 6

21337 Lueneburg

GERMANYDate: 14 December 2012

Peter Lambert, Senior Vice PresidentAdhesives Dispensing Systems

1105311A03

DOC074R4

Nordson Corporation � 28601 Clemens Road ��Westlake, Ohio

Model Number_________________________

Serial Number______________________________________

Documents

ProBlue Fulfill Integrated Fill System - Welcome to …emanuals.nordson.com/adhesives/English_Manuals/1121787.pdfTable of Contents i 2013 Nordson Corporation Part 1121787_02 ProBlue