Nordson Fulfill User's Product Manual
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Nordson Fulfill User's Product Manual

Nordson Fulfill User's Product Manual

Durablue/versablue 25l and 50l melters
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Fulfill
Retrofit Kit −
DuraBlue/VersaBlue 25L and 50L
Melters
Customer Product Manual
Part 1105309A
Issued 2/11
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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  • Page 1 DuraBlue/VersaBlue 25L and 50L Melters Customer Product Manual Part 1105309A Issued 2/11 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 Durasystem, Easy Coat, Easymove Plus, Ecodry, Econo-Coat, e.DOT, EFD, Emerald, Encore, ESP, e stylized, ETI - stylized, Excel 2000, 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, MicroSet,...

  • Page 3: Table Of Contents

    ........Part 1105309A E 2010 Nordson Corporation...
  • Page 4 ..........E 2010 Nordson Corporation...

  • Page 5: Safety

    CAUTION! Indicates a potentially hazardous situation that, if not avoided, can result in minor or moderate personal injury. CAUTION! (Used without the safety alert symbol) Indicates a potentially hazardous situation that, if not avoided, can result in damage to equipment or property. Part 1105309A E 2010 Nordson Corporation...

  • Page 6: Responsibilities Of The Equipment Owner

    Provide appropriate emergency and first aid equipment. Conduct safety inspections to ensure required practices are being followed. Re‐evaluate safety practices and procedures whenever changes are made to the process or equipment. E 2010 Nordson Corporation Part 1105309A...

  • Page 7: User Qualifications

    Do not modify the equipment. Do not use incompatible materials or unapproved auxiliary devices. Contact your Nordson representative if you have any questions on material compatibility or the use of non‐standard auxiliary devices. Part 1105309A E 2010 Nordson Corporation...

  • Page 8: Instructions And Safety Messages

    Familiarize yourself with the location and meaning of the safety warning labels and tags affixed to the equipment. Refer to Safety Labels and Tags at the end of this section. If you are unsure of how to use the equipment, contact your Nordson representative for assistance. Installation Practices Install the equipment in accordance with the instructions provided in this document and in the documentation provided with auxiliary devices.

  • Page 9: Maintenance And Repair Practices

    Read and comply with the manufacturer's instructions and the MSDS supplied with equipment cleaning compounds. NOTE: MSDSs for cleaning compounds that are sold by Nordson are available at www.nordson.com or by calling your Nordson representative. Confirm the correct operation of all safety devices before placing the equipment back into operation.

  • Page 10: Equipment Shutdown

    2. Disconnect the input signal wiring to the applicator solenoid valve(s). 3. Reduce the air pressure to the applicator solenoid valve(s) to zero; then relieve the residual air pressure between the regulator and the applicator. E 2010 Nordson Corporation Part 1105309A...

  • Page 11: General Safety Warnings And Cautions

    General Safety Warnings and Cautions Table 1 contains the general safety warnings and cautions that apply to Nordson hot melt and cold adhesive equipment. Review the table and carefully read all of the warnings or cautions that apply to the type of equipment described in this manual.
  • Page 12 Failure to properly isolate electrical power to auxiliary equipment before servicing the equipment can result in personal injury, including death. WARNING! Risk of fire or explosion! Nordson adhesive equipment is not rated for use in explosive environments and should not be used HM, CA, PC with solvent‐based adhesives that can create an explosive atmosphere...
  • Page 13 CAUTION! Nordson hot melt equipment is factory tested with Nordson Type R fluid that contains polyester adipate plasticizer. Certain hot melt materials can react with Type R fluid and form a solid gum that can clog the equipment.

  • Page 14: Other Safety Precautions

    3. Do NOT attempt to remove the solidified hot melt from your skin. 4. In case of severe burns, treat for shock. 5. Seek expert medical attention immediately. Give the MSDS for the hot melt to the medical personnel providing treatment. E 2010 Nordson Corporation Part 1105309A...

  • Page 15: Safety Labels And Tags

    Figure 1 Safety labels and tags Table 2 Safety Labels and Tags Item Part Description 1021984 WARNING! Hazardous voltage. Disconnect all power supply connections before servicing. Part 1105309A E 2010 Nordson Corporation...

  • Page 16: Description

    The retrofit kit adds adhesive to the sealed tank, reducing the possibility of char, contaminants, thermal shock and incorrect adhesive temperatures that result in poor adhesive bonding. The Fulfill system is shipped with the components illustrated in Figure 2. Figure 2 Fulfill system components 1.

  • Page 17: Theory Of Operation

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

  • Page 18: Pneumatic & Mechanical Components

    Refer to Figure 3 as you learn about the components of the DuraBlue/VersaBlue 25L and 50LL and 50L Fulfill retrofit assembly. Figure 3 Assembled DuraBlue/VersaBlue 25L and 50LL and 50L Fulfill retrofit assembly. (1). Adhesive Storage Bin Place adhesive in the adhesive storage bin. The bin contains a gasket that prevents debris from entering the bin.

  • Page 19: Air Pressure Regulator/Solenoid Assembly

    The deflector distributes adhesive evenly in the tank. A safety interlock switch detects whether the melter tank lid is in place. If the tank lid is not in place, the fill system will not operate. Part 1105309A E 2010 Nordson Corporation...

  • Page 20: Electrical Components

    Clear fault button - Press the clear fault button to reset fault and resume normal activity. Figure 4 Fill system controls and indicators 1. Enable On/Off 3. Fault symbol and red LED 2. Filling activated symbol and blue LED 4. Clear fault E 2010 Nordson Corporation Part 1105309A...
  • Page 21 60 seconds, but can be adjusted from 0 to 119 seconds. The factory sets the potentiometer at the 12 o'clock position, sufficient for the majority of applications. For reference, 9 o'clock is 20 seconds and 3 o'clock is 100 seconds. Part 1105309A E 2010 Nordson Corporation...

  • Page 22: Sensor

    (7). Sensor The level sensor detects the level of adhesive in the melter tank. When the adhesive falls below the set point, the level sensor sends a signal to the Fulfill control box. For optimal performance based on specific applications, see the Level Sensor Adjustment and Calibration detailed later in the manual.

  • Page 23: Installation

    Prepare the Melter 1. De‐energize the system as directed in the Maintenance section of the DuraBlue/VersaBlue 25L and 50LL and 50L melter manual. CAUTION! Remove dirt and debris from the melter before proceeding with these procedures. Part 1105309A E 2010 Nordson Corporation...

  • Page 24: Install The Tank Lid Components

    Fulfill Retrofit Kit − DuraBlue/VersaBlue 25L and 50L Melters Install the Tank Lid Components 1. See Figure 6. Remove the rear and right side panels from the melter. Figure 6 Installing the tank components E 2010 Nordson Corporation Part 1105309A...
  • Page 25 8. Set the lid assembly (1) onto the melter. Install the M6 screws and washers from the ship‐with kit through the slotted holes in the rear of the lid and into the threaded holes in the lid bracket (6). Do not tighten at this time. Part 1105309A E 2010 Nordson Corporation...
  • Page 26 (1) to the lid bracket (6). 11. See Figure 9. Open the lid and attach the folding brace to the underside of the lid with the M4 flathead screw and locknut from the ship‐with kit. E 2010 Nordson Corporation Part 1105309A...
  • Page 27 Attach the folding brace 12. Thread the level sensor probe through the slot in the lid into the holder. Set the level probe to the desired height and tighten the nut on the holder. Part 1105309A E 2010 Nordson Corporation...
  • Page 28 14. See Figure 8. Remove one screw from the underside of the tank flange and install the spade terminal from the ship‐with kit. 15. Route the groundwire from the lid assembly as shown and connect the spade terminal. 16. Replace the rear and right side panels. E 2010 Nordson Corporation Part 1105309A...

  • Page 29: Install The Control Box/Regulator Assembly

    Figure 11 Connect the customer-supplied power cord to the control box 1. L1-L2/N wire power cord connection 3. Power cord strain relief (interchangeable) 2. Ground wire power cord connection 3. Tighten the strain relief. Part 1105309A E 2010 Nordson Corporation...

  • Page 30: Assemble The Transfer Hose, Air Line, And Suction Lance

    6. Leaving enough air line to reach the outlet (F) of the air solenoid, cut the air line to length and then insert the end of the air line into the outlet. Connect plant air to the regulator. For best results, run the air piping from the main header. E 2010 Nordson Corporation Part 1105309A...
  • Page 31  Fulfill Retrofit Kit − DuraBlue/VersaBlue 25L and 50L Melters Figure 12 Assembling the transfer hose, air line, and suction lance Part 1105309A E 2010 Nordson Corporation...

  • Page 32: Level Sensor Adjustment And Calibration

    The level sensor should be recalibrated any time the level probe's height is changed or the type of adhesive being used changes. E 2010 Nordson Corporation Part 1105309A...

  • Page 33: Baseline Setting

    Wait 10 minutes and check the adhesive again. If the adhesive level is still too low, repeat this process until the adhesive level is satisfactory. When finished, re‐install the plug over the calibration pot to discourage tampering. Part 1105309A E 2010 Nordson Corporation...

  • Page 34: Operation

    NOTE: During warm‐up, the melter's ready-delay time may need to be increased for the Fulfill to operate properly. The proper ready-delay time depends on the tank size and shape, adhesive type, and application temperature.
  • Page 35 Retrofit Kit − DuraBlue/VersaBlue 25L and 50L Melters Figure 14 PCA timer settings (located inside the control box) Use a flat head screwdriver to turn the timers clockwise to increase the time settings, counterclockwise to decrease the timer settings. Part 1105309A E 2010 Nordson Corporation...

  • Page 36: Monitoring Refill Operation

    Inspect the system daily to ensure that hose fittings are secure and that the unit is free from dirt and debris. Inspect the filter sock weekly to ensure that it's not clogged; replace as needed. E 2010 Nordson Corporation Part 1105309A...

  • Page 37: Troubleshooting

    Clogged filter sock Replace if needed. No/low air pressure Verify that sufficient air pressure and flowrate is supplied to the Fulfill unit from your factory. Static pressure should be 65 psi min.; operating pressure should be 45 psi min. Replace the regulator if defective.

  • Page 38: Refill Pca Troubleshooting Diagnostic Instructions

    ”FILL” measured to any ”COM” pin). Verify with the level sensor is NOT calling for adhesive that the fill control output is 0 to 0.5V. If the problem has not be isolated to this point, replace the Refill PCA and/or membrane panel. E 2010 Nordson Corporation Part 1105309A...
  • Page 39  Fulfill Retrofit Kit − DuraBlue/VersaBlue 25L and 50L Melters This page intentionally left blank. Part 1105309A E 2010 Nordson Corporation...

  • Page 40: Parts

    Refer to the melter manual for information about all other melter components. Using the Illustrated Parts Lists To order parts, call the Nordson Customer Service Center or your local Nordson representative. Use these five‐column parts lists, and the accompanying illustrations, to describe and locate parts correctly. The following chart provides guidance for reading the parts lists.

  • Page 41: Durablue/Versablue 25L And 50L Retrofit Kit Assemblies

    S Lid assembly, DuraBlue 25, Fulfill retrofit 1103806 S Plate, level probe, DuraBlue 25 Fulfill 1103802 S Holder assy, level probe 1099250 S Clamp assy w/ actuator, DB 25 Fulfill retrofit 1103805 S Clamp assy, Fulfill retro 1103804 S Bracket, lid, Fulfill retro, DuraBlue 25 1103796...

  • Page 42: Durablue/Versablue 25L Lid Assembly Parts

    S Clip, cable tie, M5. mounting, aluminum 1101305 S Cabletie, 3.9 in, 185F/85C, nylon, natural 939110 S Harness, ground, lid 1104273 S Kit, srvc., 300 mm lg. lev. sensor, Fulfill 1104650 S Scr, skt, M4 x 8, bl 982059 S Ctl box, Fulfill retrofit 1104883...
  • Page 43  Fulfill Retrofit Kit − DuraBlue/VersaBlue 25L and 50L Melters Figure 16 25L Lid assembly parts Part 1105309A E 2010 Nordson Corporation...
  • Page 44  Fulfill Retrofit Kit − DuraBlue/VersaBlue 25L and 50L Melters DuraBlue/VersaBlue 25L Lid Assembly Parts (contd) Figure 17 25L Lid assembly parts E 2010 Nordson Corporation Part 1105309A...
  • Page 45  Fulfill Retrofit Kit − DuraBlue/VersaBlue 25L and 50L Melters This page intentionally left blank. Part 1105309A E 2010 Nordson Corporation...

  • Page 46: Durablue/Versablue 50L Lid Assembly Parts

    S Spacer, lid, Fulfull retrofit 1097663 S Baffle, Fulfill retrofit 1099398 S Scr, skt, M4X8, bl 982059 S Kit, srvc., 300 mm lg. lev. sensor, Fulfill 1104650 S Bracket, pneumatic & level controls 1103794 S Lug, 45, double, .250, .438 271221 S Cabletie, 3.9 in,185f/85c, nylon, natural...
  • Page 47  Fulfill Retrofit Kit − DuraBlue/VersaBlue 25L and 50L Melters Figure 18 50L Lid assembly parts Part 1105309A E 2010 Nordson Corporation...
  • Page 48  Fulfill Retrofit Kit − DuraBlue/VersaBlue 25L and 50L Melters DuraBlue/VersaBlue 50L Lid Assembly Parts (contd) Figure 19 50L Lid assembly parts E 2010 Nordson Corporation Part 1105309A...

  • Page 49: Lid Switch Assembly For 25L Melters

    Lid Switch Assembly for 25L Melters See Figure 20. Item Part Description Quantity — 1103807 Switch assembly, lid, Fulfill Retrofit — S Bracket, lid switch 1103797 S Switch assembly 1104086 S Terminal block, 380V 225337 S Scr, skt, hd, M3x20 mm...

  • Page 50: Lid Switch Assembly For 50L Melters

    Lid Switch Assembly for 50L Melters See Figure 21. Item Part Description Quantity — 1105713 Switch assembly, lid, Fulfill Retrofit — S Bracket, lid switch 1105712 S Switch assembly 1104086 S Terminal block, 380V 225337 S Scr, skt, hd, M3x20 mm...

  • Page 51: Clamp Assembly With Actuator

    25L Clamp Assembly With Actuator See Figure 22. Item Part Description Quantity — 1103805 Clamp assy w/ actuator, Fulfill retrofit S Body, clamp, Fulfill retrofit 1103792 S Scr, set, cup, M6X12, bl 982514 S Actuator,switch,magnetic 1093724 S Mach scrm, pan, rec, M3X8, sems...

  • Page 52: Clamp Assembly With Actuator

    50L Clamp Assembly With Actuator See Figure 23. Item Part Description Quantity — 1104669 Clamp assy w/ actuator, Fulfill retrofit S Body, clamp, Fulfill retrofit 1103792 S Scr, set, cup, M6X12, bl 982514 S Actuator,switch,magnetic 1093724 S Mach scrm, pan, rec, M3X8, sems...

  • Page 53: Level Probe Holder Assembly

    Quantity — 1099250 Holder assy, level probe S Holder, level probe, 16mm 1099251 S Nut, holder, level probe, 16mm 1099252 S O ring,Viton, .625 X .813 X .094 941144 Figure 24 Level probe holder Part 1105309A E 2010 Nordson Corporation...

  • Page 54: Pneumatic Control Assembly

    Retrofit Kit − DuraBlue/VersaBlue 25L and 50L Melters Pneumatic Control Assembly See Figure 25. Item Part Description Quantity Note — 1095728 Control unit, pneumatic Fulfill ------ S Valve, solenoid, 3-way, 24V, 1093650 S Elbow, male, 233785 S Regulator/filter, 40 mic, 1096668 NPT, 65 psig S Muffler polyethylene...

  • Page 55: Control Box Assembly

    Quantity Note — 1104883 Ctl.box assy,Fulfill retrofit — S Domeplug,.500”D,.250”pnl.thk.,nylon, blac 1098483 S Membrane panel,Fulfill retrofit kit ‐ ‐ ‐ ‐ ‐ ‐ S PCA, refill controller ‐ ‐ ‐ ‐ ‐ ‐ S Domeplug,.750”D,.250”pnl.thk.,nylon, blac 1098484 S Connector,strain‐relief,pg7,nylon 1046998 S Connector,strain relief,pg‐11...

  • Page 56: Container/Wand Kit

    S Clamp, hose, worm dr, 1.06-2 in., ss 231362 Service Kits Part Description 1099525 Kit, membrane panel 1104650 Kit, srvc., 300mm lg. lev. sensor, Fulfill 1096221 Kit, service, PCA 1082942 Kit, service, sock filter, 5 pc Accessories Part Description 1098962...

  • Page 57: Specifications

    Pump Type Venturi Noise Emission 76 dBA Suction Lance Dimensions (L) 615 mm x max (W) 105 mm (24.21 in. x max 4.14 in.) Storage Bin Capacity 60 Kg (132 lb) Enclosure rating IP54 Part 1105309A E 2010 Nordson Corporation...

  • Page 58: Wiring Diagram

     Fulfill Retrofit Kit − DuraBlue/VersaBlue 25L and 50L Melters Wiring Diagram E 2010 Nordson Corporation Part 1105309A...

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