Page 1 FoamMelt Processor Customer Product Manual Part 321222_06 Issued 04/2015 NORDSON CORPORATION  DULUTH, GEORGIA  USA www.nordson.com...
Page 2 Shaftshield, SheetAire, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit, Sure Brand, SureSeal, Sure Wrap, Swirl Coat, Tempus, ThruWave, Trade Plus, Trak, TrueBlue, Ultra, Ultrasmart, Universal, Vantage, Vista, Web Cure, 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’...
Page 15: Operate Safely
Wear personal protective equipment and clothing such as safety goggles and gloves. Familiarize yourself with and follow all safety instructions prescribed by your company, general accident-prevention regulations, and government safety regulations. A1EN−02−[XX−SAFE]−1 E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 16: Safety Symbols
WARNING: System or material pressurized. Relieve pressure. Failure to observe may result in serious burns. CAUTION: Failure to observe may result in equipment damage. CAUTION: Hot surface. Failure to observe may result in burns. A1EN−02−[XX−SAFE]−1 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 17: Qualified Personnel
The following actions of the owner or operator of the unit are some, but not all, examples of unintended use which would permit Nordson to claim it is not responsible for personal injury or property damage arising from...
Page 18: Installation And Electrical Connections
Prior to start-up of the unit, check to make sure all safety guards and safety equipment are in place and functioning properly. A1EN−02−[XX−SAFE]−1 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 19: Less-Obvious Dangers
Action in the Event of Unit If the unit malfunctions, switch it off immediately. Malfunction Turn the circuit breaker or main power switch OFF. Have the unit repaired by qualified personnel only. A1EN−02−[XX−SAFE]−1 E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 20: Danger Of Burns
If the unit does not energize, proceed with maintenance or repair work. If the unit energizes, repeat the disconnect, lock out, and tag procedure. Re-test the unit. A1EN−02−[XX−SAFE]−1 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 21: Cleaning
Secure pneumatically- or hydraulically-operated equipment against uncontrolled movement. Only use parts which do not compromise the safety of the unit. Only use genuine Nordson parts. Always use tools with insulated handles when removing or installing components. NOTE: Always refer to the material manufacturer's Safety Data Sheet 8.
Page 22: Thermoplastic Hot Melt Material
Dispose of equipment and materials used in operation and cleaning 10. Equipment and Material according to local regulations. Disposal A1EN- 02- [XX- SAFE]- 1 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 25: Section A 2
Description Section A 2 Description NOTE: The FoamMelt 200 (FM 200) Series processor may be used only 1. Introduction to melt, transfer, and apply hot melt materials. The FM 200 processor is not intended for use other than that described in this manual.
Page 26: Compatible Equipment
Zero cavity and reduced cavity hot melt applicators are used for dispensing the foamed hot melt solution. These applicators reduce the drooling and stringing caused by expanding gas. Hoses Nordson conventional, automatic, and water wash hoses can be used with automatic applicators. Manual 321222_06...
Page 27: System Components
Gas Control Panel in this section for more information. Gas pressure panel Allows adjustment and monitoring of gas pressure 4020021A Fig. A 2 1 Control Components Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 28: Tank And Drive Assembly
FM-200 processor, refer to the Goodyear SilentSync Drive Belt Kit Instruction Sheet (P/N 1124462) for instructions on how to replace the previously used drive belt. For parts information refer to Parts, Section 10. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 29: Manifold Assembly
Filters foreign material before foamed hot melt material reaches the applicators; signals the system for gas as required Drain valve Allows the processor to be drained of hot melt material 4020011A Fig. A 2 3 Manifold Assembly Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 30: Operating Modes
NOTE: Because the controller stores data on a special chip that does not require a battery backup, a brownout or power failure has no negative impact on memory. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 31 Allows the displays to function 4130076 Fig. A 2 4 Control Assembly Components 1. Power board 4. Control end frame 2. Control board 5. Operator panel 3. Display board Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 32: Unit-Specific Boards
Allows switching of grid heater power 4020027A Fig. A 2 5 Unit Specific Boards and I/O Board 1. Contactor board 3. I/O board 2. 5/6 hose/gun board 4. Grid board Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 33: Optional Input/Output Board
Fig. A 2 6 Standard (A) and Enhanced (B) I/O Boards 1. TB10 terminal block 4. X2 terminal block 2. XP5 card edge connector 5. X1 terminal block 3. TB20 terminal block Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 34 Vista panel of the control end frame (1). 4130282 Fig. A 2 7 XP5 Card Edge Connector 1. Control end frame 3. XP5 card edge receptacle 2. Flange Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 36: Functional Areas
System Status (1) Displays (2) System Setup (3) System Controls (4) 4103925 Fig. A 2 8 Vista Control Panel 1. System Status 3. System Setup 2. Displays 4. System Controls Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 37: System Status Area
The green READY light turns on to indicate: all zones are +/ 3 C (+/ 5 F) of the setpoint temperatures system ready time delay has elapsed no faults exist Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 38: Displays Area
Saves the number shown on the multipurpose display Up/down arrow keys Increases or decreases value shown in the multipurpose display Up key Changes the value in the selector display 4130011 Fig. A 2 10 Displays Area Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 39: System Setup Area
See Figure A 2 11 and refer to Table A 2 7 for a description of the components in the system setup area. 4103928 Fig. A 2 11 System Setup Area Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 40 Allows you to program the system to turn heaters on or off or to place the system in standby or operating mode at a time that you select; each interval stores four settings: Standby enter and exit, and Heater on and Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 41: System Controls Area
(6). turn on or off main power to the processor (7). 4103929 Fig. A 2 12 System Controls Area Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 43 System Status area of the Vista control panel will turn off once the test is completed. If the problem was not corrected, the FAULT indicator will stay on. POWER switch Turns on or off power to the processor. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 44: Pump Speed/System Pressure Control Panel
When lit, indicates that gas is flowing into the pump LOW GAS SUPPLY When lit, indicates that the gas supply is low indicator GAS ON/OFF key Turns on and off the gas supply to the pump Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 45 A 2-21 Description ON/OFF PUMP SPEED GAS FLOW LOW GAS SUPPLY GAS CONTROL SYSTEM PRESSURE 4020010A Fig. A 2 13 Pump Speed/System Pressure and Gas Control Panels Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 46: Theory Of Operation
A series of slots cut into the plates above and below the second stage gear teeth also help mix the gas with molten hot melt material. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 47: Gas Modulation
If hydraulic pressure reaches 85 bar  7 bar (1250 psi  100 psi), the valve redirects the solution into the pump return passage. The hydraulic pressure is controlled through manual adjustments of the pressure control valve. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 48 PUMP VALVE PRESSURE REEDEX SWITCH VALVE TRANSDUCER PRESSURE GAUGE DRAIN PRESSURE VALVE RELIEF VALVE DENSITY CONTROLLER/FILTER MANIFOLD PRESSURE CONTROL VALVE GUNS 4020041A Fig. A 2 14 System Operation Diagram Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 51: Section A 3
Read the following paragraphs before installing your processor: 4. Installation Requirements Location Wiring Hose/Gun Power Other requirements and recommendations are provided in the installation procedures when they are needed. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 52: Location
Hose/Gun Power The power requirements of your hoses and guns must be determined to make sure that you do not overload the processor. If your Nordson representative has not already checked to see that your processor can support all of the hoses and guns you plan to install, or if you need to add new hoses,you must calculate your hose/gun power requirements now.
Page 53: Mounting
5. For installation within the European Community, use the optional packet of adhesive backed, local language warning tags that are available from Nordson Corporation. Overlay the English language part of the tags already on this processor with the tags from the packet in your own language.
Page 54: Hoses
Î Î Î Î 4904007 Fig. A 3 2 Hose and Gun Configurations 1. 1 gun 3. 2 guns 5. 4 guns 2. 2 guns 4. 3 guns 6. Handgun Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 55 8. Repeat steps 2 through 7 if your processor requires an additional supply hose. 4020026A Fig. A 3 3 Attaching Supply Hose to the Processor 1. Electrical socket 4. Connector 2. Hose electrical plug 5. Supply port 3. Supply hose Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 56: Jumper Hoses Between Automatic Guns
4. Connect the hose electrical plug to one of the electrical sockets on the processor. 5. Repeat steps 1 through 4 if your processor requires an additional return hose. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 57: Gas Supply Connection
8. When the gas system is leak free, close the service valve on the cylinder until the processor is ready for use. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 58: Electrical Connections
4. Loosen the screws on the front (5) and back (1) of the enclosure cover. 5. Slide the electrical enclosure cover back away from the Vista control panel (2) and off of the processor. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 59 Installation 4020022A Fig. A 3 4 Opening the Electrical Enclosure 1. Screws 5. Screws 2. Vista control panel 6. Screws 3. Electrical enclosure door 7. Enclosure cover 4. Screws Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 60: Strain Relief Installation
VOLTS (ac) portion (1) of the identification plate. 4130689A Fig. A 3 5 Processor Identification Plate 1. VOLTS (ac) portion 2. AMPS (max.) portion Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 61 Loosen the captive screws that secure the base electrical panel (4) to the processor and remove the panel. 4. Install a strain relief in one of the knockout holes. Refer to Strain Relief Installation for more information. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 62 7. Connect the ground wire of your electrical service line to the ground terminal. 4020048A Fig. A 3 6 Gas and Electrical Connections 1. Gas connection 3. Power terminal block 2. Knockouts 4. Base electrical panel Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 63 L1 L2 L3 N 4020005A Fig. A 3 7 Electrical Service Connections at TB12 (with ground wire shown) 9. Tighten the strain relief and install the base electrical panel. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 64: Output Contact Connection (Optional)
1. If you have not already done so, open the electrical enclosure. Refer to Opening the Electrical Enclosure in this section. 2. Install a strain relief in one of the large knockout holes. Refer to Strain Relief Installation for more information. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 65 Use the proper length of wire and route the wires so they do not touch any of the printed circuit boards. 4020025A Fig. A 3 8 Connecting Output Contacts 1. TB1 3. Optional I/O board 2. TB2 Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 66 5, 6 (System Ready) (processor not (processor ready) ready) NOTE A: The output contacts are not polarity sensitive. It does not matter which wire is inserted into a position. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 67: Optional Input/Output Board
Make sure the wires reach the I/O board terminal blocks when the electrical enclosure is opened. Position the ferrites as close to the rear panel as possible. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 68 TB20 1, 2 POWER ON/OFF 5, 6 STANDBY ON/OFF STATUS STATUS 3, 4 PUMP ON/OFF 7, 8 WARNING CONDITION STATUS 4130935A Fig. A 3 9 Standard I/O Board Connections Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 69 DISABLE HOSE/GUN FOUR 1, 2 POWER ON/OFF STATUS 5, 6 STANDBY ON/OFF STATUS 3, 4 PUMP ON/OFF STATUS 7, 8 WARNING CONDITION 4130933A Fig. A 3 10 Enhanced I/O Board Connections Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 73: Section A 4
NOTE: The SYSTEM PRESSURE panel allows the user to change the unit of measure (bar/psi) at which the system pressure is displayed. Refer to System Pressure Adjustment in the Operation section for more information. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 74 1. Move up/down keys 3. Interval indicators 2. Move right key Refer to Table A 4 1. Configure the system to your application needs by completing the applicable procedures. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 76 4130012 Fig. A 4-2 Changing the Setting of a Selected Feature 1. Up key 4. Up and Down keys 2. Selector display 5. Enter key 3. Multipurpose display Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 77 6 _C (10 _F). C: Feature No. 6 = tank, Feature No. 7 = grid, Feature Nos. 8-13 = hoses 1-6, Feature Nos. 14-19 = guns 1-6. Continued on next page Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 78: System Settings
Refer to Checking the Warning or Fault recent) Log in the Operation section for a list of warning codes. NOTE E: Features 26-29 and 35-37 are always on. There is no default setting. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 79: I/O Board Features
If this feature is set to 1 or 2, patterns can (setting is off) be selected via inputs on the I/O board. This (Pattern feature is only available on the enhanced I/O control units board. only) Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 80: Temperature Controls
When you program TEMPERATURE settings, the number in the Selector display represents a particular zone number. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 81: Programming Guidelines
Refer to Table A 4-2, Feature No. 3. To reduce static power consumption and material degradation, set the grid temperature 14 _C (25 _F) less than the reservoir setting. 321222_06 E 2015 Nordson Corporation Manual All rights reserved Issued 04/2015...
Page 82: Temperature Programming Shortcuts
Pressing and holding the key changes the number in increments of five. 5. Press the Enter key (5) to save the setting. The Multipurpose display stops flashing. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 83 7. Press the Up key to select the next zone number for the zone that you wish to customize, and repeat this procedure until you have set temperatures for all zones. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 84: All Zones
NOTE: When you exit the Set All feature, it always returns to the default setting of 177 _C (350 _F). 5. Record your setting in the forms provided at the end of this section. Refer to Configuration Charts. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 85: Clock Controls
NOTE: If you have enabled the password feature, you must change the number in the Multipurpose display (500) to the password (321) and press the Enter key before the system will allow you to change the clock settings. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 86 If the code is correct, press the Enter key (4) to save the setting. If the code is not correct, press the Up key (6) until the correct code appears on the display. Press the Enter key to save the correct setting. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 87: Standby And Heater Times
Each interval can store these time settings: enter standby exit standby turn on the heaters turn off the heaters Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 88: Setting Standby And Heater Times
10. To set a second time for the same day, press the Move Right key until the INTERVAL 2 light turns on. Press the Enter key to save the day and repeat steps 5 through 9. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 89: Deleting Standby And Heater Times
To delete times for an entire day, follow the Deleting procedure and turn off the clock for each feature: entering standby, exiting standby, turning on heaters, turning off heaters. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 90: Example Of Seven-Day Clock Use
Turn off the heaters (HEATERS OFF) Monday through Friday at the end of the second shift (INTERVAL 1). NOTE: The clock is not set for Saturday or Sunday when the company is closed. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 91: Configuration Charts
) show that the heaters for this zone have not been programmed. B: For a zone to be on, the operating temperature must be set at or above 38 C (100 F). Manual E 2015 Nordson Corporation 321222_06 All rights reserved...
Page 92: Standby Temperatures
) show that the heaters for this zone have not been programmed. C: For a zone to be on, the operating temperature must be set at or above 38 C (100 F). Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 93: Heaters On/Off Times
- - - - and 00:01 to 24:00 (Sunday) NOTE A: Four dashes ( ) show that the heaters on feature has not been programmed for the indicated day of the week. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 94: Standby Enter/Exit Times
- - - - and 00:01 to 24:00 (Sunday) NOTE A: Four dashes ( ) show that the standby feature has not been programmed for the indicated day of the week. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 95: Customized System Settings
Auto Energize Heaters On (1) On (1) or Off (0) Auto Standby Timeout 0 minutes From 0 to 1440 minutes In Standby Timeout 0 minutes From 0 to 1440 minutes Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 96: System Fault Log
Fault Code 3 = RTD is shorted. Fault Code 4 = Zone is overtemperature. Fault Code 5 = Control board is bad. Fault Code 6 = Brownout has occurred. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 97: System Warning Log
Warning Code 2 = RTD is open. Warning Code 3 = RTD is shorted. Warning Code 4 = Temperature out of band. Warning Code 5 = Not used. Warning Code 6 = Not used. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 101: Section A 5
Entering and exiting standby mode Refer to System Monitoring in this section for procedures on checking the zone temperatures, checking the programmed settings, checking the fault log, and running a system test. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 102: Seven-Day Clock
Press the CLOCK key to turn on and off the seven day clock. The CLOCK indicator turns on when the clock is on. If the clock is not turned on, the processor's automatic, clock related functions will not operate. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 103: Standby Mode
You can also program the processor to automatically exit the standby mode at a specified time. Refer to CLOCK Controls in the Configuration section. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 104: Startup
5. See Figure A 5 2. Press the GAS ON/OFF key. The GAS ON/OFF indicator will light. NOTE: If the LOW GAS SUPPLY indicator lights, check the gas supply in the cylinder. Install a new gas cylinder if necessary. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 105 Pump Speed Adjustment and Pump Charts in this section for more information. ON/OFF GAS FLOW LOW GAS SUPPLY GAS CONTROL 4020009A Fig. A 5 2 Gas Control Panel Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 106: Pump Speed Adjustment
Refer to Density Determination and Adjustment in this section. PUMP SPEED SYSTEM PRESSURE 4020013A Fig. A 5 3 Changing Pump Speed 1. Pump speed display 2. Up and down keys Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 107: Pump Charts
Fig. A 5 4 Pump Chart Pump Speed The motor controller is programmed for a maximum pump speed of 900 rpm. The minimum recommended pump speed is 300 rpm. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 108: Viscosity
Nordson Corporation recommends a ratio of 3:1 to maintain optimum pressure and density control. Reduction of the ratio to below 2:1 will result in erratic pressure and density control.
Page 109: Density Control Adjustment
Make sure that the material does not have any bubbles in it. 7. Weigh the hot melt sample. 8. Press the PUMP key again to stop the pump. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 110: Taking A Foam Sample
10. Manually trigger a gun to obtain a measured sample of foam in a shallow heat proof container. NOTE: Make sure that the hot melt and foam samples fill the containers to the same level. 11. Weigh the foam sample. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 111: Density Determination And Reduction
NOTE: Turn the density control knob a maximum of two turns at a time to adjust the density reduction gradually. This practice may prevent you from over-adjusting at a given time. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 112 8. Make sure the processor is running at its normal output for your application needs. 9. Adjust the gas pressure setting until the GAS FLOW indicator turns on and off intermittently. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 113: System Pressure Adjustment
Take a timed weight sample to determine the actual output rate. Make sure that the circulation to deposit ratio is at least 2:1. Refer to Pump Charts or Pump Speed Adjustment in this section. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 114: System Monitoring
3. Check the Multipurpose display to determine the setting for the feature. 4. To change the setting for the feature, refer to System Settings Controls in the Configuration section of this manual. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 115: Fault Log
The control board is bad. A brownout has occurred. NOTE: Refer to the Troubleshooting section of this manual for additional troubleshooting information. 4. To clear the fault log, press the CLEAR FAULTS key. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 116: Running A System Test
4. Clean each gun as needed. Refer to the gun manual for information on gun disassembly, cleaning, and rebuilding. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 117 Overtemperature setpoint Refer to System Settings Controls in the Configuration section of this manual. SETPOINT or STANDBY Refer to Temperature Controls in temperature setpoint the Configuration section of this manual. 321222_06 Manual E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 118: System Flush
3. Fill the hopper with clean hot melt material to a maximum of 2.5 cm (1 in.) below the top of the hopper. 4. Press the HEATERS key. 5. Wait for the SYSTEM READY indicator to turn on. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 119 10. Press the PUMP key to stop the pump. 11. Connect the return hoses to the manifold ports. 12. Loosen the pressure control valve until the adjustment screw is loose. 13. Return to system operation. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 120: Shutdown
Air operated guns: Turn off the operating air. Electric guns: Turn off the gun driver. Hand operated guns: Lock the trigger. 4. Press the HEATERS key. The HEATERS indicator will turn off. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 123: Section A 6
The following procedures describe how to prepare the system for 2. System Preparation maintenance and for normal operation after maintenance. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 124 3. Turn the pressure control valve counter clockwise until there is no tension. 4. Press the GAS ON/OFF key to turn off the gas. 5. Press the PUMP key and reduce the pump speed to 100 rpm. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 125 11. See Figure A 6 2. Use a flat blade screwdriver to open the drain valve as a final safety check before breaking any hydraulic connection. Make sure that the SYSTEM PRESSURE display reads zero. 4020029A Fig. A 6 2 Opening the Drain Valve Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 126 Refer to Pump Charts in the Description section. 5. Press the GAS ON/OFF key to turn on the gas. 6. Allow the system to stabilize 3-5 minutes before resuming normal operation. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 127 In cases where component degradation affects the safety or performance of the processor, and quick troubleshooting may be difficult, Nordson Corporation recommends replacing components as preventive maintenance. Table A 6 1 Recommended Maintenance Schedule...
Page 128 4. Allow hot melt material to flow from the drain valve until the material is free of debris. 5. Press the PUMP key. The motor turns off. 6. Close the drain valve. 7. Return the processor to normal operation. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 129: Removal
3. See Figure A 6 3. Note the index number position of the density controller knob. 4. Remove the screw in the center of the knob and remove the knob. 5. Remove the wire retainer clip (1). Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 130 Failure to observe may result in equipment damage. 7. See Figure A 6 4. Use a wrench to turn the density controller and filter assembly counterclockwise to remove it from the manifold. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 131 A 6-9 Maintenance Î Î Î Î Î Î Î Î Î Î Î Î 4020034A Fig. A 6 4 Removing the Density Controller and Filter Assembly Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 132 2. Place a new O ring onto the filter assembly. Filter screen is clogged or Proceed with Filter Screen damaged Cleaning and Replacement. Filter screen is clean and Proceed with Density Controller undamaged and Filter Installation. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 133 4. Slide the new or cleaned filter screen onto the filter core. 5. Place the support on the end of the filter assembly. 6. Replace and tighten the bolt into the end of the filter assembly. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 134: Installation
System before resuming normal operation. 10. Resume normal operation as described in Resuming Normal Operation in this section. 11. Check for leaks at the filter assembly O ring and drain valve. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 136 9. Fill the hopper with fresh hot melt material. 10. Wait for the material to melt. 11. Resume normal operation as described in Resuming Normal Operation in this section. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 137 If the belt is not damaged, install the drive belt cover. 6. Check the drive belt for proper tension. The tension should be approximately 14.5 kg (32 lb) to deflect the belt 1 in. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 138 Name Date Name Date Clean and inspect processor Flush filter assembly Check connections Change filter element Flush the system Check drive belt Install new density controller and filter assembly Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 141 1. Introduction cover only the most common problems that you may encounter. If you cannot solve the problem with the information given here, contact your local Nordson representative for help. The following table provides general troubleshooting information for 2. Mechanical mechanical problems.
Page 142 2000 hours of operation S moderate increase in pump speed causes the GAS FLOW indicator to light S moderate decrease in pump speed causes the GAS FLOW indicator to go out Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 143 Replace the transducer. Pressure display value Pressure transducer is disconnected Check and connect the transducer. is fixed and does not from the monitor board vary Faulty transducer Replace the transducer. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 144 I/O board and at the remote devices. Tighten any loose connections. Defective I/O board Replace the I/O board. Refer to I/O Board Replacement in the Repair section. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 147 GO TO AP8- J2C OVERTEMPERATURE PRESENT PG2,ZONE A- 6 116B 116C THERMOSTAT HEATER 4020069A Fig. A 8-1 FoamMelt 200 Processor Wiring Diagram: 200- 240 Volt (page 1 of 2) 321222_06 Manual E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 149 1.) PARTS IN DASHED LINE ARE OPTIONAL. 4020070A 2.) PARTS IN DASH DOT DASH ARE EXTERNAL CONNECTIONS. Fig. A 8-2 FoamMelt 200 Processor Wiring Diagram: 200- 240 Volt (page 2 of 2) 321222_06 Manual E 2015 Nordson Corporation All rights reserved...
Page 151 GO TO AP8- J2C OVERTEMPERATURE 116B 116C THERMOSTAT PG2,ZONE A- 6 GRID BD HEATER 4020071A Fig. A 8-3 FoamMelt 200 Processor Wiring Diagram: 400 Volt (page 1 of 2) 321222_06 Manual E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 153 1.) PARTS IN DASHED LINE ARE OPTIONAL. 4020072A 2.) PARTS IN DASH DOT DASH ARE EXTERNAL CONNECTIONS. Fig. A 8-4 FoamMelt 200 Processor Wiring Diagram: 400 Volt (page 2 of 2) 321222_06 Manual E 2015 Nordson Corporation All rights reserved...
Page 157: Repair
Otherwise, use a heat gun or other flameless heating device to melt solidified hot melt material on system components. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 158 Use the following procedures to replace the drive belt. 1. See Figure A 9 1. Remove the belt cover (1) by loosening the four screws (6). 2. Loosen the four motor bolts (4). Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 159 8. Secure the belt cover to the processor using the four screws. 4020037A Fig. A 9-1 Replacing the Drive Belt 1. Belt cover 4. Motor bolts 2. Belt 5. Motor 3. Pulleys 6. Screws Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 160: Removal
Removing the Pulley 1. Cap screw 3. Pulley hub 2. Key 4. Bushing Motor 1. Loosen the set screw on the pulley. 2. Remove the pulley from the motor. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 161 3. Remove the motor plate by removing the two bolts (5) and spacers (4). NOTE: Do not remove the alignment plate unless instructed to do so by a Nordson service representative. The alignment plate was carefully positioned at the factory and does not need to be removed for normal service.
Page 162 4904136 Fig. A 9-4 Removing the Face Seal 1. Drive coupling 2. Pan Screw 3. Retaining sleeve 4. Face seal 5. External retaining ring 6. Flat washer Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 163 2. Face seal seat (orient groove as shown) 3. Ceramic face seal ring 4. Viton shaft seal 5. Shaft seal housing 6. Shaft seal retainer 7. Compression spring 8. Spring retainer Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 164: Drive Assembly Installation
5. Tighten the bolts. 6. Make sure that the alignment tool rotates freely in the alignment plate. If the tool is difficult to rotate, loosen the bolts and tighten them again. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 165: Installing The Drive Assembly
Figure A 9 4, (1)) lines up with the pump drive shaft. 2. Insert the bolts and washers (10) to secure the drive assembly to the alignment plate and tighten them evenly. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 166: Motor And Motor Plate Installation
2. Install the pulleys, belt, and belt cover. Refer to Pulley Installation and Alignment in this section. 3. Connect power and restore the unit to normal operation (refer to Routine Operation in the Operation section). Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 167: Pulley Installation And Alignment
6. NOTE: Check the torque of the screws after operating the processor for the first time with the new belt. Repeat steps 4-8 if the screws have loosened. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 168: Pressure Control Valve
3. See Figure A 9 7. Open the manifold cover. 4. Turn the hex nut (1) nearest the manifold counterclockwise to thread the pressure control valve (2) out of the manifold. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 169 6. Install the new valve in the manifold and tighten firmly. Do not overtighten. 7. Reconnect power and restore the unit to normal operation. Refer to the Operation section. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 170: Rebuilding The Pressure Control Valve
1. See Figure A 9 8. Unscrew the valve actuator assembly (1) from the valve body (4). 2. Carefully remove and discard the external O rings (2) from the actuator assembly. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 171 É É É É É É É Ì Ì Ì Î Î É É É É É É É 4904141 Fig. A 9-9 Removing the Valve Spring 1. Ball carrier 2. Spring 3. Stop ring Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 172: Cleaning And Inspection
WARNING: Risk of explosion or fire. Fire, open lights and smoking prohibited. 2. Place the valve components in a container of Nordson Type R fluid or other recommended cleaning agent. 3. Heat the fluid slightly above the application temperature of the hot melt material on a regulated hot plate or similar device.
Page 173: Density Controller Rebuild
NOTE: Check the density reduction. Refer to Density Determination and Reduction in the Operation section for instructions. 4904190A Fig. A 9-10 Disassembling the Density Controller 1. Bung 2. Slug 3. Spring 4. Core Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 174: Pressure Relief Valve Replacement
7. Use a socket wrench to tighten the valve. 8. Install the access plug into the grid. 9. Install the round insulation plug. 10. Secure the cover to the processor using the two screws. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 175 A 9-19 Repair 4020023A Fig. A 9-11 Replacing the Pressure Relief Valve 1. Insulation plug 3. Pressure relief valve 5. Screws 2. Access plug 4. Cover Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 176: Drain Valve Replacement
4. Screw the new drain valve into the manifold until it is secure; then adjust it as necessary to install and tighten the alignment screw and washer. 5. Resume operation. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 177: Hose Connector O-Ring Replacement
4. Remove the O ring from the connector or plug. 4020026A Fig. A 9-13 Hose Connector O-ring Replacement 1. Electrical socket 4. Connector 2. Hose electrical plug 5. Manifold port 3. Hose Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 178 A 9-22 Repair NOTE: Use only Nordson O rings. Using other O rings may result in Hose Connector O-ring leakage. Replacement (contd) 5. Make sure that the new O ring and its groove are free of debris, then lubricate the O ring with Never Seez.
Page 179: Gas Repair
WARNING: Risk of electrical shock. Failure to disconnect and lock out power can result in personal injury, death, or equipment damage. 3. Disconnect and lock out input power from the unit. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 180: Gas Pressure Control Panel
4. Connect the gas supply tube to the bulkhead fittings. 5. Carefully push the gas pressure control panel assembly into the base of the cabinet and tighten the four pan head screws (11). Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 181: Gas Pressure Regulator Replacement
4. Loosen the set screw in the pressure regulator knob (4), then remove the knob. 5. Remove the knurled trim nut and the locknut that secure the regulator, then remove the regulator from the rear of the panel assembly. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 182: Gas Pressure Gauge Replacement
6. Reconnect the tubing to the fitting on the back of the gauge. 7. Install the gas control panel. Refer to Gas Control Panel Installation for instructions. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 183: Reedex Valve Replacement
6. Reconnect gas lines and restore power. Be sure to check for leaks on pressurized gas lines. Refer to Connecting the Gas Supply in the Installation section for details. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 184: Gas Pressure Check Valve Replacement
One diaphragm is located on Assembly Replacement the reservoir near the thermostat. The transducer assembly converts hydraulic pressure into electrical signals that display the pump outlet pressure on the SYSTEM PRESSURE display. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 185: Removal
8. Loosen the screw that secures the control panel to the center frame divider. 9. Remove both ends of the transducer valve assembly and the metal conduit pick up wire from the unit. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 186: Installation
Loosen the screws on the front (5) and back (1) of the enclosure cover. e. Slide the electrical enclosure cover back away from the Vista control panel (2) and off of the processor. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 187 XP5 card edge connector. 5. Remove the new board from its static safe container, making sure to handle the board by its edges without touching pins, wires, or circuitry. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 188 Tighten the screw to 2.03-2.26 NSm (18-20 in. lb). 7. Connect wires to the new I/O board. 8. Close and secure the electrical enclosure. 9. Restore power to the unit and resume normal operation. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 191 A dash ( ) is used when the part number applies to all parts in the illustration. The number in the Part column is the Nordson Corporation part number. A series of dashes in this column ( ) means the part cannot be ordered separately.
Page 192 SCREW, 20, TRUSS HEAD 340925 COVER, MANIFOLD, ASSEMBLY 340880 COVER, FRONT, ASSEMBLY NUT, SPRING, TYPE U BRACKET, FRONT COVER SCREW, HIGH LOW, PAN, RECESSED, CUT Continued on next page Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 193 SCREW, PAN, RECESSED, M5 X 16 983551 WASHER, 0.250 ID X 0.500 OD X 0.06 106433 SPACER, 0.218 ID, 0.375 OD X 0.31 4020042A Fig. A 10 1 Enclosure Parts Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 194 SVC KIT, DRIVE, FM200, NRG BELT AND SPROCKETS 1124463 S BELT, HELICAL OFFSET, 8MM, 90T 1124464 S SPROCKET, HELICAL, 26T DRIVE, 2.607 PITCH 1124465 S BUSHING,PULLEY,48T,SPROCKET 1124466 S SPROCKET, HELICAL, 48T DRIVE, 4.812 PITCH Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 195 A 10-5 Parts Motor Components (contd) Fig. A 10-2 Motor Components ® A. Previously used drive belt components B. New Goodyear SilentSync drive belt components 321222_06 E 2015 Nordson Corporation Manual All rights reserved Issued 04/2015...
Page 196 B: Refer to Control Panel Assembly in this section for a breakdown of the parts in this assembly. C: Refer to Electrical Panel Assembly in this section for a breakdown of the parts in this assembly. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 198 C: Refer to Density Controller/Filter Assembly in this section for a breakdown of the parts in this assembly. D: Refer to Pressure Control Valve in this section for a breakdown of the parts in this assembly. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 200 S O RING, VITON, 0.489 ID X 0.070 WIDE S PISTON 942111 S O RING, VITON, 0.812 X 1.062 X 0.125 IN. S SCREW, SET, LOCK, 20 X 4020054A Fig. A 10 5 Pressure Control Valve Parts Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 201 S WASHER, LOCK, E, SPLIT, #8, STEEL S SCREW, SOCKET, 8 32 X 1.000 S WASHER, LOCK, E, SPLIT, #6, STEEL S SCREW, SOCKET SET, 6 32 X 0.50, CUP, BLACK Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 203 S WASHER, LOCK, E, SPLIT, #10 271221 S LUG, 45, DOUBLE, 0.250 X 0.032 IN. 984129 S NUT, HEX, MACHINE, #10 32, BRASS 1004029 S WIRE GROUP, GROUND, BASE MODULE NS: Not Shown Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 205 S FUSE BLOCK, BUSS 341365 S COVER, FUSE 939491 S FUSE, 25 AMP 1004027 S HARNESS, FILTER, FM 200 1004020 S HARNESS, CONTROL PANEL, FM 200 Continued on next page Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 206 S HARNESS, POWER, 200/240 V, FM 200 1004102 S HARNESS, POWER, 400/230 V, FM 200 NOTE Use these parts with 200/240 V processors. B: Use these parts with 400/230 V processors. NS: Not Shown Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 209 S PANEL, CONTROL, MOTOR, FM 200 320291 S PANEL, CONTROL, GAS, FM 200 1002097 S PANEL, MEMBRANE, BLANK, FM 200 4020064A Fig. A 10 10 Control Panel Assembly Parts Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 210 S TEE, PIPE, HYDRAULIC, NPT FEMALE 971291 S CONNECTOR, MALE, TUBE X 939561 S SWITCH, PRESSURE, NORMALLY CLOSED, 30 PSI 310444 S TUBING, NYLON, 0.12 IN. OD NS: Not Shown Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 212 FILTER ELEMENT, 0.028 IN. (0.71 MM) 24 MESH 271598 FILTER ELEMENT, 0.011 IN. (0.28 MM) 50 MESH 271599 FILTER ELEMENT, 0.006 IN. (0.15 MM) 100 MESH 271600 FILTER ELEMENT, 0.003 IN. (0.008 MM) 200 MESH Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 213 Standard pump Hose/Gun Test Plugs Nordson offers two test plugs that simplify the troubleshooting of RTD faults. These test plugs help you quickly and easily determine whether the problem is a gun, hose, or tank RTD problem or a Vista controller problem.
Page 214 S SLEEVE, COUPLING, 1.25 OD X 1.00 IN. 982091 S SCREW, PAN HEAD, SLOT, M3 X, ZINC 900200 S ADHESIVE THREADLOCKING 985267 S PIN, DOWEL, 0.250 X 1.00 IN. H&G Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 215 S PIN, DOWEL, 0.250 X 1.00 IN. H&G Vista Controller Service Kits Part Description Quantity 1008524 KIT, SERVICE, FM200, VISTA ASM, 400/230V 1008525 KIT, SERVICE, FM200, VISTA ASM, 400/240V Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 216 S HEATSINK, MANIFOLD, FM200 982027 S SCREW, SOCKET HEAD, M5 X 14, BLACK 900298 S COMPOUND, HEATSINK, 1 OZ TUBE NOTE Apply heatsink compound, part 900 298, to this item. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 217 S LUBRICANT, NEVER SEEZ, TUBE, 1 OZ RTD and Thermostat Kits Use the following list to order RTD or thermostat service kits. Part Description Note 108907 SERVICE KIT, RTD 249800 SERVICE KIT, THERMOSTAT Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 218 RETAINING RING, EXTERNAL, 0.625 IN. 986311 RETAINING RING, INTERNAL 206 BASIC 1009989 POWER SUPPLY 341251 MOTOR, AC, 3HP 1004240 MODULE, RESERVOIR/GRID/HOPPER 1005759 VALVE, PRESSURE RELIEF, 1250 PSI 275224 VALVE, ASSY, DRAIN, TANK Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 219 ADHESIVE, CYLINDRICAL RETAINING (FOR NON REMOVABLE WASHERS AND SCREWS) 900341 LUBRICANT, NEVER SEEZ (FOR REMOVABLE WASHERS AND SCREWS) 902514 GLOVES, PROTECTIVE 901915 KIT, NOZZLE CLEANING 270755 FLUID, TYPE R 143958 WRIST STRAP, ANTI STATIC GROUND Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 220 Description Quantity 719042 IN. AUTOMATIC HOSE INSTALLATION KIT 719023 IN. HOSE TO MANIFOLD FITTING 719024 IN. HOSE TO GUN FITTING (STRAIGHT) 719047 IN. HOSE TO GUN FITTING (45_ VERSION) Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 223 (2 input, 2 output) Temperature control method Exterior dimensions: Height 81 cm (32 in.) Depth 71 cm (28 in.) Width 107 cm (42 in.) Weight 129.5 kg (285 lb) Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 224 A weighted at SPL @ 76 dB(A) Display Digital temperature, pressure, and pump speed readout. Keyed lockout of temperature setpoints. Operator Interface Pressure sensitive membrane panel for system control. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 225 3. Clearance needed to remove electrical enclosure cover 4. Clearance to remove the pump/hopper enclosure 5. Size of tank opening = 22.9 cm x 25.4 cm (9.00 in. x 10.00 in.) Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 227 4020073A Fig. A 11-2 Pump Chart Pump Speed The motor controller is programmed for a maximum pump speed of 900 rpm. The minimum recommended pump speed is 300 rpm. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 228 Nordson Corporation recommends a ratio of 3:1 to maintain optimum pressure and density control. Reduction of the ratio to below 2:1 will result in erratic pressure and density control.
Page 231 These procedures cover only the most common problems that you may encounter. If you cannot solve the problem with the information given here, contact your local Nordson representative for help. The FM 200 processor was designed and tested to for resistance to EMI that is typically present in heavy industrial applications.
Page 232 Defective microprocessor chip Replace the control board. Refer to Control Assembly Board Replacement in the Temperature Control Repair section. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 233 The pins from the control board should extend through XP1 on the power board. Defective power board or control Replace the control assembly. Refer to board Control Assembly Replacement in the Temperature Control Repair section. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 234 R2 R3 XS2GR MOV1 XS1GR 4020028A Fig. B 1-1 Location of Connectors on Boards 1. Power board 3. 5/6 hose/gun board 5. Contactor board 2. Control board 4. Grid board Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 235 Hose 6 Gun 6 NOTE A: For example, if the Selector display shows the number 3 and the GUN light is on, then the affected zone is gun 3. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 236 RTD problem still exists after the 2 minute countdown ends, the control system logs a fault in the fault log, opens the fault output contact, and shuts the the melter down. Nordson offers two test plugs that simplifies troubleshooting the RTD faults. These test plugs help you quickly determine whether there is a component RTD problem or a control system problem.
Page 237 However, if the clock is not turned on and the clock battery dies, the melter will not indicate a fault. When the clock battery is dead, the melter will continue to operate normally except for any automatic functions. Manual E 2015 Nordson Corporation 321222_06 All rights reserved...
Page 238 J4 positions 2 and 5 on the power board. Voltage does not measure 230 VAC: Replace the POWER switch and harness. Voltage measures 230 VAC: Return to the Processor Not Powering On troubleshooting table. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 239 5. If your processor has a contactor board, make sure the correct contactor board harness is installed. See Figure B 1 1 for the location of the contactor board harness. Refer to the Parts section for part numbers. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 240 Refer to Table B 1 3. If you measure infinite or zero resistance at the tank or grid heater connectors, you must install a new tank or grid. Refer to the Tank Repair section. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 241 Gun 6 5/6 hose/gun board X1H: 1 and X2H: 2 600-100 ohms Tank Power board XS1 and XS2 10-30 ohms Grid Grid and contactor XS2GR and XS2A 10-30 ohms board Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 242 Return to the appropriate troubleshooting table. Short circuit or low resistance at high temperature: (defective thermostat) Replace the thermostat. Refer to RTD or Thermostat Installation in the Temperature Control Repair section. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 243 If the warning disappears, replace the defective hose or gun. If the warning still appears, continue to the next step. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 244 Assembly Board Replacement in the Temperature Control Repair section. 5. Check the heater or heater circuit of the affected zone. Refer to Checking a Heater or Heater Circuit in this section. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 245 1 F. If the temperature continues to rise during proportioning, then something other than the control system is closing the triacs on the power board and causing the heaters to heat. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 246 RTD and replacing the gun RTD. WARNING: Risk of equipment damage, personal injury, or death. Disconnect and lock out electrical power to the unit, including input/output (I/O) lines. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 247 33 and 34 of the harness attached to connector XP2 on the control board. For a grid RTD, measure the resistance at pins 21 and 22 of the harness attached to connector XP2 on the control board. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 248 Hose 6 (Note A) 5 and 8 31 and 32 Tank 33 and 34 Grid 21 and 22 NOTE A: Some units can accept only four hoses and four guns. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 249 B 1-19 Temperature Control Troubleshooting (250 (130 (170 (210 (290 (330 (370 (410 (450 5940833 Fig. B 1-3 RTD Resistance vs. Temperature Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 250 Check the tightness of the connections at the I/O board and at the remote devices. Tighten any loose connections. Defective I/O board Replace the I/O board. Refer to I/O Board Replacement. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 253 I/O wiring. 2. Open the electrical enclosure. Refer to Opening the Electrical Enclosure in the Installation section. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 254 [400 Vac/230 Vac (with neutral) 3 units] Grid Motor control fuses Motor control F30, F31 24V power supply Gas control board Pump speed/system pressure board Gas circuit Optional level control Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 255 B 2-3 Temperature Control Repair F11 F12 4130374A Fig. B 2-1 Location of Fuses on Boards 1. Power board 3. 5/6 hose/gun board 4. FM-200 electrical panel 2. Contactor board Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 256 B 2-4 Temperature Control Repair 2. Replacing a Fuse (contd) FU30 FU31 FIL1 FU32 4020008A Fig. B 2-2 Power Supply and Motor Control Fuses Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 258 Label or note all power board (5) connections for later reference. NOTE: Refer to the wiring diagrams in the Troubleshooting section. 3. Disconnect the voltage plug (8) from X3, and X4 if applicable, on the power board. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 259 NOTE: If the optional I/O board is connected to the control board on your unit, take care not to damage the I/O board as you remove the power board. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 260 6. Connect the voltage plug (8) you kept from your old board to X3 (and X4 if applicable) on the power board. 7. Connect all other harnesses, ribbon cables, and other connections to the power board. 8. Perform the System Restoration procedure. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 261 6. Carefully separate the control board from the display board. Take care not to bend the XP4A connector pins that join the control and display boards. Keep the connector for later use. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 262 Refer to the Installation section for instructions on I/O board installation. 5. Install the power board (5). Go to step 2 in Power Board Installation. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 263 12. Screws with nylon patches 3. Display board 8. Voltage plug 13. Screws with nylon patches 4. Control board 9. Triac clamp 5. Power board 10. Screws with lock washers Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 264 Installation section. 3. Close and secure the electrical enclosure. 4. If you replaced the control board, re enter your customized system settings, if any. Refer to the Configuration section. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 265: Removal
7. Use a citrus industrial cleaner to remove any adhesive that remains on the control end frame; then use denatured alcohol to thoroughly clean the residue left by the citrus industrial cleaner. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 266: Installation
XP1 on the control board. 7. Install the power board, connect the electrical service, and close and secure the electrical enclosure. Refer to Power Board Installation and System Restoration in this section. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 267: Removal
9. Label or note all power board connections for later reference. NOTE: Refer to the wiring diagrams in the Troubleshooting section. 10. Disconnect all harnesses, ribbon cables, and other connections from the power board. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 268: Installation
11. Connect the ground wire. 12. Close and secure the electrical enclosure. 13. Enter customized system settings, if any. Refer to the Configuration section. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 269 5. Taking care not to cut any electrical wires, cut the cable ties that bind the harness. WARNING: Hot! Risk of burns. Wear heat protective clothing, safety goggles, and heat protective gloves. Failure to observe this warning may result in personal injury. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 270 Remove the thermostat and protective rubber boot. b. Pull the RTD out of the slot in the tank wall. c. Discard the thermostat. c. Discard the RTD. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 271: Installation
4. Connect the RTD or thermostat plug. 5. Fold the insulation cut away back into place. 6. Install the front cover. 7. Close and secure the electrical enclosure. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 275 B: Your unit may have either a grid board or a 400 Vac tank board in this location. C: Present only on units with an I/O board. Refer to I/O Board in this section. Manual E 2015 Nordson Corporation 321222_06 All rights reserved...
Page 277 S WASHER, LOCK, SPLIT, M3 983411 S WASHER, FLAT, NARROW, M3 185071 S INDUCTOR, BEAD, 1.41 IN. DIAMETER (FERRITE) NS: Not Shown 4020059A Fig. B 3 2 I/O Board Parts Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 278 Fuse, 25 Amp (2 required) 939992 Fuse, 30 Amp (1 required) 5/6 Hose/Gun Board Fuse 939683 Fuse, 6.3 Amp (4 required) 4. Software Upgrades Part Description Quantity 234424 SERVICE KIT,SOFTWARE,VISTA STD Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 281 5. Turn off the POWER switch and lock out electrical power to the processor. 6. Remove all hoses and hookups. 7. Remove the manifold and pump from the processor. Refer to Manifold and Pump Removal in this section. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 282 3. Pressure control valve 5. Screws 2. Density controller 4. Drip trough 6. Manifold panel 6. See Figure C 1 2. Disconnect the gas line from the gas pressure check valve (8). Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 283 Pump O-ring Replacment 1. Hex nuts 6. Manifold O-rings 2. Lock washers 7. Studs 3. Special flat washers 8. Gas pressure check valve 4. Pump 9. Manifold block 5. Pump O-ring Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 284 4. Install the manifold/pump assembly into the processor using the following steps: a. Position the manifold/pump assembly in the processor. b. While holding the assembly against the reservoir, hand tighten the six screws and washers into the manifold. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 285 10. Secure the end panel (6) to the processor using the four screws (5). 11. Connect the hoses to the manifold ports. Refer to Hoses in the Installation section for instructions. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 286 6. Loosen the captive screws and pull the front (8) and back (9) panels off of the processor. 7. Remove the screws (6) securing the center support bracket (7) to the processor. Remove the center support bracket. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 287 Fig. C 1-4 Removing Enclosures 1. Hopper lid 6. Screws 2. Hopper cover 7. Center support bracket 3. Lid hardware 8. Front panel 4. Screws 9. Back panel 5. Hopper enclosure Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 288 Carefully remove the insulation (1, 2, 3) from around the hopper, grid, and reservoir. 4020047A Fig. C 1-5 Removing the Insulation 1. Hopper insulation 3. Grid insulation 4. Heater contacts 2. Reservoir insulation Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 289 If they do not, remove them by hand and set them aside. 5. See Figure C 1 5. Disconnect the heater wires from the tank heater contacts (4). Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 290 Removing the Tank Assembly 1. Grid RTD 5. Reservoir thermostat 2. Grid thermostat 6. Reservoir RTD 3. Spacers 7. Bolt, washer, and hex nut 4. Bolts 8. Gas control panel Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 291 Refer to the Tank Parts section for the O ring part number. 4130701A Fig. C 1-7 Removing the Hopper from the Grid 1. Hopper 3. Grid 2. O-ring Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 292 3. Remove the grid insulator (2) from the reservoir and set it aside. 4020051A Fig. C 1-8 Removing the Grid from the Reservoir 1. Grid 5. Bolt 2. Grid insulator 6. Beveled washers 3. Reservoir 7. Flat washer 4. Hex nut Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 293 8. Apply thermal compound to the RTD (6) and thermostat (5) and install them on the side of the reservoir. 9. Connect the ground wire (if present) to the reservoir. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 294 8. Make sure the air line adapter is securely inserted in the recessed area on the inside of the hose end panel. Secure the adapter with the screws you removed earlier. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 295 5. Attach the ground wire to the rear panel (9). Slide the panel into place and secure it with the captive screws. Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 296 (5). 9. Install the drain valve (1), density controller (2), and pressure control valve (3). 10. Connect the hoses to the manifold. Refer to Hoses in the Installation section. Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 299 S HARNESS, TANK, LONG, 230 V S ASSEMBLY, MANIFOLD, FM 200 NOTE A: Refer to Manifold Assembly in this section for a breakdown of the parts in this assembly. Continued on next page Manual E 2015 Nordson Corporation 321222_06 All rights reserved Issued 04/2015...
Page 300 S ROD END, BALL, M8 340864 S ROD, SUPPORT, RESERVOIR NOTE B: Refer to Drive Assembly in this section for a breakdown of the parts in this assembly. NS: Not Shown Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 302 S CONNECTOR, TUBE FITTING, 37_, 4 x 4 MM NOTE A: Use these parts with standard output manifolds. B: Use these parts with high output manifolds. NS: Not Shown Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...
Page 304 S S PIN, DOWEL, 0.019 X 1.00 IN. 982091 S SCREW, PAN HEAD, M3 X 6 940342 S O RING, 034, VITON S PIN, DOWEL, 0.250 X 1.00 IN Manual 321222_06 E 2015 Nordson Corporation All rights reserved Issued 04/2015...

Nordson foammelt 200 Product Manual

Section a 2

Description

Section a 2

Description (Contd)

Section a 3

Installation

Section a 4

Configuration

Section a 5

Operation

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