Nordson ProBlue Fulfill Customer Product Manual
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Nordson ProBlue Fulfill Customer Product Manual

Nordson ProBlue Fulfill Customer Product Manual

Adhesive dispenser feeding unit
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ProBlue
Fulfill
Integrated
Fill System
Customer Product Manual
Part 1123107_01
Issued 4/15
This document contains important safety information
Be sure to read and follow all safety information in this
document and any other related documentation.
NORDSON CORPORATION  DULUTH, GEORGIA  USA
www.nordson.com

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Summary of Contents for Nordson ProBlue Fulfill

  • Page 1 Fill System Customer Product Manual Part 1123107_01 Issued 4/15 This document contains important safety information Be sure to read and follow all safety information in this document and any other related documentation. NORDSON CORPORATION  DULUTH, GEORGIA  USA www.nordson.com...
  • Page 2 ContourCoat, CPX, cSelect, Cyclo Kinetic, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, e.dot+, E Nordson, Equalizer, EquiBead, FillEasy, Fill Sentry, Flow Coat, Fluxplus, Freedom, Get Green With Blue, G Net, Genius, G Site, IntelliJet, iON, Iso Flex,...

  • Page 3: Table Of Contents

    ......... . . Part 1123107_01 E 2015 Nordson Corporation...
  • Page 4 ....Restoring ProBlue Fulfill Factory Settings ......

  • Page 5: Problue) Fulfill) Integrated Fill System

    Safety Before installing and operating the fill system, read the safety information provided in the melter product manual in Section 1, Safety. Figure 1 shows the safety labels and tags specific to the ProBlue Fulfill integrated melter. Part 1123107_01 E 2015 Nordson Corporation...
  • Page 6 TAG, WARNING, HAZ VOLTS 1100253 1100254 TAG, CAUTION, HOT SURFACE 1100252 TAG, WARNING, HOT ADHESIVE, VERTICAL TAG, WARNING, DO NOT THROW TRASH 1122129 TAG, WARNING, DO NOT TIP OVER (multi feed bins only) 1122762 Part 1123107_01 E 2015 Nordson Corporation...

  • Page 7: Getting Started

    Before installing the fill system, ensure that your application DOES NOT require: The transfer of solid formed adhesive material greater than 12 mm across the largest dimension Adhesive temperatures exceeding 205 _C (400 _F) Part 1123107_01 E 2015 Nordson Corporation...

  • Page 8: Description

    Figures 2 and 3 show the components of a typical single melter or multi melter ProBlue Fulfill integrated fill system. Figure 2 Fulfill system components: melter with single feed adhesive storage bin (ProBlue 7 melter shown) 1.
  • Page 9 (connects to the transfer hose 3. Adhesive transfer hose connects to the bin) solenoid harness) 4. Transfer hose solenoid harness 9. Quick disconnect (optional, (connects to the melter solenoid not shown) harness and to the sequencer) Part 1123107_01 E 2015 Nordson Corporation...

  • Page 10: Theory Of Operation

    Nordson offers a 120 L single-feed adhesive storage bin or a 240 L multi-feed storage bin. For customers who prefer to use their own storage bin, Nordson offers a single feed or multi-feed pump box similar to what is found on the Nordson adhesive storage bin. A suction lance with a regulator and bracket is also available for those who choose that option.

  • Page 11: Modes Of Operation

    NOTE: If remote inputs are used for fill system operation (Remote Enable/Disable and Clear Refill Alarm), then the Fill System Enable key on the control panel will not function. Part 1123107_01 E 2015 Nordson Corporation...

  • Page 12: Mechanical Components

    A filter (3) that prevents adhesive fines and powder in the adhesive from being emitted into the ambient air. This is NOT a lift point! Figure 4 Melter lid assembly components 1. Fill tube 3. Filter 2. Adhesive transfer hose Part 1123107_01 E 2015 Nordson Corporation...

  • Page 13: Adhesive Storage Bin Options

    A plug is shipped with the multi-feed storage bin to prevent spillage from unused ports. Figure 5 Adhesive storage bins 1. Single feed 120 L bin 2. Multi feed 240 L bin Part 1123107_01 E 2015 Nordson Corporation...

  • Page 14: Pump Box

    A plug is shipped with the multi-feed pump box to prevent spillage from unused ports. Figure 6 Pump boxes 1. Single feed pump box 2. Multi feed pump box Part 1123107_01 E 2015 Nordson Corporation...

  • Page 15: Hose/Pump Assembly

    4 m clear hose with standard flow pump 9 m clear hose with standard flow pump 18 m clear hose with high flow pump Figure 7 Hose/pump assembly components 1. Venturi pump 3. Transfer hose solenoid harness 2. Adhesive transfer hose Part 1123107_01 E 2015 Nordson Corporation...

  • Page 16: Suction Lance Kit

    Figure 8 Suction lance kit components 1. Pneumatic control assembly 3. Transfer hose with solenoid harness 2. Suction lance 4. Worm clamp Part 1123107_01 E 2015 Nordson Corporation...

  • Page 17: Grate (Optional)

    Integrated Fill System Grate (Optional) See Figure 9. Optional grates are available for order to be used with Nordson 120 L and 240 L adhesive storage bins. Specify the type of adhesive (chiclets or pellets) to be used. Packaged adhesive can be poured through the grates, which will sift the adhesive and separate clumps that developed during the adhesive packaging process.

  • Page 18: Quick Disconnect (Optional)

    QD fitting on the top of the pump box/storage bin for easy removal and relocation. Figure 10 Quick disconnect assembly 1. Quick disconnect (connect a QD solenoid harness or sequencer harness) Part 1123107_01 E 2015 Nordson Corporation...

  • Page 19: Pump Inlet Screen (Problue 4, 7 And 10 Only)

    The pump inlet screen is specifically designed for use with the fill system. It easily snaps in place and blocks any adhesive from flowing on to the sensor from the return port in the melter tank. Figure 11 Location of the pump inlet screen Part 1123107_01 E 2015 Nordson Corporation...

  • Page 20: Electrical Components

    Sequencers are available in two-pump or four-pump options, and can be ordered with or without a quick-disconnect option. Output 4 Input 4 Output 3 Input 3 Output 2 Input 2 Output 1 Input 1 Figure 12 Sequencer Part 1123107_01 E 2015 Nordson Corporation...

  • Page 21: Fulfill Integrated System Control Panel

    The LED turns green when the system is enabled. Figure 13 Fulfill system controls and indicators 1. Refill alarm symbol and LED 3. Fill system enable key (on/off) and LED 2. Adhesive transfer LED Part 1123107_01 E 2015 Nordson Corporation...

  • Page 22: Refill Pca

    If the level sensor is not satisfied before the overfill fault timer expires, an overfill fault is generated. The overfill fault timer parameter is adjustable from 5 to 300 seconds. Part 1123107_01 E 2015 Nordson Corporation...
  • Page 23 Full calibration button Empty calibration button Overfill fault Delay timer Unit Low LED Vibrator LED Siren LED Fault LED Fill enabled LED Fill active LED Low level sensor harness Figure 15 Refill PCA components Part 1123107_01 E 2015 Nordson Corporation...

  • Page 24: Level Sensor

    Fulfill Integrated Fill System Level Sensor The Nordson level sensor features include a wide sensing area, simplified mechanical mounting, push button calibration, RTD temperature compensation, diagnostics to help identify sensor problems, and a separate low level output. The fill control point can be adjusted electronically without the need to mechanically move the sensor.
  • Page 25   ProBlue Fulfill Integrated Fill System This page intentionally left blank. Part 1123107_01 E 2015 Nordson Corporation...

  • Page 26: Connecting The Fill System

    Connect the bin end of the transfer hose solenoid harness to the Standard transfer hose solenoid harness solenoid valve connector (4) on the bin pneumatic assembly. c. Secure the ground wire to the ground screw (9) located on the back plate of the pump box. Part 1123107_01 E 2015 Nordson Corporation...

  • Page 27: To Convert From A Standard Harness To A Qd Harness

    (6). 2. Use customer supplied 12 mm OD air tubing to connect an air supply to the ¼ NPT air input fitting (7) on the storage bin. Part 1123107_01 E 2015 Nordson Corporation...
  • Page 28 6. Venturi pump air inlet 10. U shaped bracket 3. Melter solenoid harness 7. Main air supply inlet 11. Strain relief 4. Transfer hose solenoid harness connection on the bin (standard) 8. Quick disconnect adapter harness Part 1123107_01 E 2015 Nordson Corporation...

  • Page 29: Connect To A Multi-Feed Adhesive Storage Bin

    L1, L2/N, and PE/G terminals (3). d. Reinstall the sequencer touch guard and cover. Figure 17 Connecting a power supply to the sequencer 1. Cover 4. Power supply cable strain relief 2. Touch guard 3. Power supply terminals Part 1123107_01 E 2015 Nordson Corporation...

  • Page 30: Connect The Adhesive Transfer Hose To A Melter And The Sequencer

    5. Secure the ground wire on the bin end of the harness to the ground stud on the sequencer box bracket. Output 4 Input 4 Output 3 Input 3 Output 2 Input 2 Output 1 Input 1 Figure 18 Sequencer inputs and outputs Part 1123107_01 E 2015 Nordson Corporation...

  • Page 31: Connect The Adhesive Transfer Hose To The Sequencer And Bin

    Applying a numbered label to a melter and the sequencer and To connect the adhesive transfer hose cuff hose to the sequencer and bin for all melters and adhesive storage bins in your system. Part 1123107_01 E 2015 Nordson Corporation...

  • Page 32: Connect The Air Supply

    3. Melter solenoid harness 13. Solenoid connector on bin 8. Venturi pump air input pneumatic assembly 4. Sequencer and bracket 9. Quick disconnect bin harness 5. Sequencer solenoid harness (standard) 10. Ground screw on pump box Part 1123107_01 E 2015 Nordson Corporation...

  • Page 33: Connect To A Single Suction Lance

    NOTE: Nordson provides 8 feet of air tubing to connect the pneumatic controls to the suction lance. 8. Connect the Nordson supplied 8 ft x 10 mm OD air tubing from the outlet of the pneumatic controls kit to the inlet of the suction lance.

  • Page 34: Connect To Multiple Suction Lances

    NOTE: Nordson provides 8 feet of air tubing to connect the pneumatic controls to the suction lance. 10. Connect the Nordson supplied 8 ft x 10 mm OD air tubing from the outlet of the pneumatic controls kit to the inlet of the suction lance.

  • Page 35: Set Up The Fill System

    Refer to the installation section of the melter manual for the procedures for connecting and setting up inputs/outputs. NOTE: For ProBlue Fulfill melters (generation 1) with fill system controls in the sub base, refer to manual P/N 1081444.
  • Page 36 The F9 indication will be cleared on a change­of­state (on to off, or off to on). The Remote Enable/Disable input should be used in conjunction with the Clear Refill Alarm input to restore the FulFill system to normal operation after a fill fault. Part 1123107_01 E 2015 Nordson Corporation...

  • Page 37: Refill Pca Settings

    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 sensor such as the level sensor used on previous Fulfill units. Part 1123107_01 E 2015 Nordson Corporation...

  • Page 38: Status Relay Output Contact

    24 VDC when the fill system is working normally and the NO contact for a signal that supplies 24 VDC when a problem with the fill system exists. Photo of TB3 Figure 21 Part 1123107_01 E 2015 Nordson Corporation...

  • Page 39: Level Sensor Calibration

    2. Hand fill the adhesive level so that the pellets are at the desired level of capacity. 3. Close lid. 4. Within 30 seconds, press SW2 (white button) AND SW3 (blue button) on the PCA at the same time until all LEDs stop changing color (approximately 5 seconds). Part 1123107_01 E 2015 Nordson Corporation...

  • Page 40: Test The Fill System

    8. When you are satisfied that the fill system is operating correctly, save all Saving current settings of the current melter settings into memory by simultaneously pressing the number 1 key and the Setup key. Part 1123107_01 E 2015 Nordson Corporation...

  • Page 41: Operation

    NOTE: If the lid is open, the fill system will not operate. An open lid condition is indicated by a flashing fill system enable key LED. NOTE: If the air supply is shut off by the parent machine, a fault condition will occur. Part 1123107_01 E 2015 Nordson Corporation...

  • Page 42: Clearing A Refill Alarm

    2. Adjust to desired pressure, and then tighten with spanner tool. 3. Tighten the screw to 2.5~5.0 lb­in (0.3~0.6 Nm). 4. Close the hinged top to snap it shut. Regulator adjustment knob Part 1123107_01 E 2015 Nordson Corporation...

  • Page 43: Troubleshooting

    PCA. Refer to Table 4. RTD shorted. The temperature compensation Replace sensor RTD is electrically shorted. Internal memory failure. Unit was not able to Replace refill PCA if fault persists store calibration settings. Part 1123107_01 E 2015 Nordson Corporation...

  • Page 44: Fill Enable Led/Yellow Pca Led/Yellow Light Tower

    If melter ready signal not used, check jumper. Unstable sensor readings Check sensor cable connection. If the problem persists, replace the sensor and/or the refill PCA. Part 1123107_01 E 2015 Nordson Corporation...

  • Page 45: Restoring Problue Fulfill Factory Settings

    Fulfill Integrated Fill System Restoring ProBlue Fulfill Factory Settings There are two methods for restoring the melter to the ProBlue Fulfill factory settings: using the restore saved settings feature or re entering the fill system operating parameters. To restore saved settings If you previously saved the melter settings, you can restore them by simultaneously pressing the number 2 key and the Setup key.

  • Page 46: Parts

    A dash in this column indicates that the item is an assembly. The number in the Part column is the Nordson part number you can use to order the part. A series of dashes indicates that the part is not saleable.

  • Page 47: Melter Assembly Part Numbers

    Integrated Fill System Melter Assembly Part Numbers ProBlue Fulfill Integrated Melters Part Description Note 1122843 MELTER, PROBLUE FULFILL 4, 2H/G, 200/240V 1122844 MELTER, PROBLUE FULFILL 4, 4H/G, 200/240V 1122849 MELTER, PROBLUE FULFILL 7, 2H/G, 200/240V 1122850 MELTER, PROBLUE FULFILL 7, 4H/G, 200/240V...

  • Page 48: Lid Assembly Parts

    NOTE A: Refer to Service Kits and Recommended Spare Parts for the service kit part number. B: Used with P4 melters. C: Used with P7/P10 melters. D: This part is included in service kit 1100174. Part 1123107_01 E 2015 Nordson Corporation...
  • Page 49 OF TORQUE TIGHTEN TO 15-20 IN LBS TIGHTEN TO OF TORQUE 15-20 IN LBS OF TORQUE TIGHTEN TO 15-20 IN LBS TIGHTEN TO OF TORQUE 15-20 IN LBS OF TORQUE Figure 22 Lid assembly parts Part 1123107_01 E 2015 Nordson Corporation...

  • Page 50: Circuit Board And Membrane Panel Service Kits

    KIT,SVCE,FULFILL,CPU (display/CPU board) 1121804 SERVICE KIT,REFILL CONT.,PROBLUE (refill PCA) 1023675 FUSE, TR5, FA, WA, 250V, RAD, PC-MNT 1120837 KIT,SERVICE,FULFILL ADAPTER BOAD 1120411 S CABLE, FULFILL ADAPTER NS: Not Shown Figure 23 Circuit boards and membrane panel Part 1123107_01 E 2015 Nordson Corporation...
  • Page 51   ProBlue Fulfill Integrated Fill System This page intentionally left blank. Part 1123107_01 E 2015 Nordson Corporation...

  • Page 52: Single Feed Adhesive Storage Bin

    S S GROMMET,.438 ID X .75 OD,RUBBER NOTE A: Pump box assemblies are available as a kit. For a multi feed pump box kit, order part 1123015. B: To replace the solenoid, order service kit 1121549. Part 1123107_01 E 2015 Nordson Corporation...
  • Page 53   ProBlue Fulfill Integrated Fill System Figure 24 Single feed adhesive storage bin parts Part 1123107_01 E 2015 Nordson Corporation...

  • Page 54: Multi Feed Adhesive Storage Bin

    S S SCREW, 5/16-18-1.5", HEX HEAD, SS 1085340 S S LOCKNUT, NYLON INSERT, 5/16-18 1121880 S S BRACKET, SOLENOID SUPPORT NOTE A: Pump box assemblies are available as a kit. For a multi feed pump box kit, order part 1123101. Part 1123107_01 E 2015 Nordson Corporation...
  • Page 55   ProBlue Fulfill Integrated Fill System Figure 25 Multi feed adhesive storage bin parts Part 1123107_01 E 2015 Nordson Corporation...

  • Page 56: Sequencer

    S S SCR,HEX,WASHHD,TF,M5X12,BLK 983604 S S SCR,PANHD,THD FORM,M4X12,BL 939411 S S MARKER,NO. 1 939412 S S MARKER,NO. 2 939413 S S MARKER,NO. 3 939414 MARKER,NO. 4 984447 S S NUT,HEX,JAM,M5,STL,ZN 983401 S S WASHER,LK,M,SPT,M5,STL,ZN Continued... Part 1123107_01 E 2015 Nordson Corporation...
  • Page 57 S S WASHER, FLAT, REG, , ZN 1123477 S S SPCLSCR,HEXHEADCAP, -20,.75, NYLON, SLOTTED 1123478 S S SPCLSCR,HEXHEADCAP, -16,.75, NYLON, SLOTTED NOTE A: Double the quantity shown for a 4-melter sequencer. B: Used only with the 4-melter sequencer Part 1123107_01 E 2015 Nordson Corporation...
  • Page 58   ProBlue Fulfill Integrated Fill System INCLUDED WITH BOX TYP 4 PLACES TERMINAL BLOCK FROM WIRE HARNESS (WIRES NOT SHOWN) Figure 26 Sequencer parts (1 of 2) Part 1123107_01 E 2015 Nordson Corporation...
  • Page 59   ProBlue Fulfill Integrated Fill System Sequencer (contd) Figure 27 Sequencer parts (2 of 2) Part 1123107_01 E 2015 Nordson Corporation...

  • Page 60: Adhesive Transfer Hose Parts

    E: Refer to Adhesive Bin Pump Parts later in this section. The 18 m hose (part 1121956) includes a high flow pump. All other hoses include a standard flow pump. F: Present only on the high flow hose (part 1121956). Part 1123107_01 E 2015 Nordson Corporation...
  • Page 61   ProBlue Fulfill Integrated Fill System BIN END OF MELTER END OF HOSE ASSEMBLY HOSE ASSEMBLY EXPLODED VIEW, HOSE CUFF Figure 28 Adhesive transfer hose parts Part 1123107_01 E 2015 Nordson Corporation...

  • Page 62: Adhesive Bin Pump Parts

    NOTE A: To replace this item, order service kit 1121546 for a standard flow pump or service kit 1121947 for a high flow pump. B: Service kit 1121550 contains these O rings. NS: Not Shown TIGHTEN AIR FITTING TO 1.1-1.4 NSM (10-12 IN. LB) Figure 29 Adhesive bin pump parts Part 1123107_01 E 2015 Nordson Corporation...
  • Page 63   ProBlue Fulfill Integrated Fill System This page intentionally left blank. Part 1123107_01 E 2015 Nordson Corporation...

  • Page 64: Suction Lance Kit

    S CONN, MALE, ELBOW, 10MM X 3/8 900613 S TUBING, 12MM OD, BLUE 7408012 S SUCTION WAND W/BOX 1122131 S BRACKET, SOLENOID MOUNT, FF2 NOTE A: Gray transfer hose B: Clear transfer hose NS: Not Shown Part 1123107_01 E 2015 Nordson Corporation...
  • Page 65   ProBlue Fulfill Integrated Fill System Figure 30 Suction lance kit parts Part 1123107_01 E 2015 Nordson Corporation...

  • Page 66: Transfer Hose Solenoid Harnesses

    (if applicable) or to the adhesive storage bin. Item Part Description Quantity Note 1123391 CABLE,4M,PRO­FF­FREE BIN,SOL CONN 1123392 CABLE,9M,PRO­FF­FREE BIN,SOL CONN 1123393 CABLE,18M,PRO­FF­FREE BIN,SOL CONN MELTER Figure 31 Transfer hose solenoid harness Part 1123107_01 E 2015 Nordson Corporation...

  • Page 67: Quick Disconnect Kits (Optional)

    KIT, CABLE, FF2 QUICK DISC, 4M 1123395 KIT, CABLE, FF2 QUICK DISC, 9M 1123396 KIT, CABLE, FF2 QUICK DISC, 18M S HARNESS,BIN,FREEDOM S CABLE,PRO-FF-FREE BIN,QUICK DISC SOL CONN MELTER Figure 32 Quick disconnect kit parts Part 1123107_01 E 2015 Nordson Corporation...

  • Page 68: Service Kits

    KIT, SRVC, POWER SUPPLY, Fulfill MK III 1123146 KIT,SEQUENCER, PCA BOARD,FF2 FUSE,TR5,FA,2A,250V,RAD,PC-MNT 1023675 1100171 KIT,SVCE,FULFILL,CONTROLS MEMBRANE,P4/P7 (control panel membrane assembly) 1100172 KIT,SVCE,FULFILL,CONTROLS MEMBRANE,P10 (control panel membrane assembly) 1120837 KIT,SERVICE,FULFILL ADAPTER BOAD 1121798 KIT,SERVICE,SIREN mk iii,PROBLUE FF Part 1123107_01 E 2015 Nordson Corporation...

  • Page 69: Adhesive Storage And Transfer

    ASSY, CABLE, FF2 QUICK DISC, 9M 1123396 ASSY, CABLE, FF2 QUICK DISC, 18M 1121126 HARNESS,BIN,FREEDOM 1123391 CABLE,4m, PRO­FF­FREE BIN,SOL CONN 1123392 CABLE,9m, PRO­FF­FREE BIN,SOL CONN 1123393 CABLE,18m, PRO­FF­FREE BIN,SOL CONN 1121550 SERVICE KIT,O­RINGS,FILL PUMP 7408012 SUCTION WAND, Fulfill Part 1123107_01 E 2015 Nordson Corporation...

  • Page 70: Technical Data

    Suction lance dimensions (L) 615 mm x (W) 105 mm maximum (optional) (24.21 in. x 4.14 in. maximum) Adhesive storage bin capacity 120 L (264 lb) or 240 L (528 lb) Enclosure rating IP54 Part 1123107_01 E 2015 Nordson Corporation...

  • Page 71: Dimensions

    603.2 mm (23.75 in.) 606.7 mm (23.89 in.) 485.9 mm (19.13 in.) 489.7 mm (19.28 in.) 571.5 mm (22.50 in.) 371.9 mm (14.64 in.) 369.9 mm (14.56 in.) 390.6 mm (15.38 in.) 348 mm (13.70 in.) Part 1123107_01 E 2015 Nordson Corporation...
  • Page 72  ProBlue Fulfill Integrated Fill System Dimensions (contd) 554 mm (21.8 in.) 480 mm (18.9 in.) 1400 mm (55.1 in.) 917 mm (36.1 in.) Figure 34 Single feed adhesive storage bin dimensions and clearances Part 1123107_01 E 2015 Nordson Corporation...
  • Page 73   ProBlue Fulfill Integrated Fill System 667 mm (26.3 in.) 620 mm (25 in.) 1656 mm (65.2 in.) 688 mm (27 in.) Figure 35 Multi feed adhesive storage bin dimensions and clearances Part 1123107_01 E 2015 Nordson Corporation...

  • Page 74: Wiring Diagrams

      ProBlue Fulfill Integrated Fill System Wiring Diagrams Figure 36 Refill PCA wiring diagram Part 1123107_01 E 2015 Nordson Corporation...
  • Page 75   ProBlue Fulfill Integrated Fill System Figure 37 Sequencer wiring diagram Part 1123107_01 E 2015 Nordson Corporation...
  • Page 76   ProBlue Fulfill Integrated Fill System This page intentionally left blank. Part 1123107_01 E 2015 Nordson Corporation...

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