Page 1 Models D4L, D10L, and D16L (Gerotor) Customer Product Manual Part 1073401_07 Issued 01/2021 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 This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2006. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Nordson Corporation. The information contained in this publication is subject to change without notice. Trademarks 4800 INTEGRA, Allegro, Apogee, Artiste, Asymtek, Automove, Avex, BaitGun, BKG, Blue Box, BM-32, BM-58, BM-63, Bowtie, Build‐A‐Part, CF, Century, CleanSleeve, CleanSpray, Color‐on‐Demand, ColorMax, Conexis, Connections to Life, Contour, Control Coat,...
Page 3: Table Of Contents
......... Part 1073401_07 E 2021 Nordson Corporation...
Page 4 ........4-26 E 2021 Nordson Corporation Part 1073401_07...
Page 5 ........Part 1073401_07 E 2021 Nordson Corporation...
Page 6 ..........B-13 E 2021 Nordson Corporation Part 1073401_07...
Page 7 ## TABSHEET ##...
Page 8: 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. Issued 04-15 E 2021 Nordson Corporation...
Page 9: 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. Issued 04−15 E 2021 Nordson Corporation...
Page 10: 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. Issued 04-15 E 2021 Nordson Corporation...
Page 11: 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 12: Maintenance And Repair Practices
Read and comply with the manufacturer's instructions and the SDS supplied with equipment cleaning compounds. NOTE: SDSs 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 13: 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. Issued 04−15 E 2021 Nordson Corporation...
Page 14: General Safety Warnings And Cautions
General Safety Warnings and Cautions Table 1‐1 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 15 WARNING! Risk of fire or explosion! Nordson adhesive equipment is not rated for use in explosive environments and has not been certified for the ATEX directive or as nonincendive. In addition, this equipment HM, CA, PC should not be used with solvent‐based adhesives that can create an...
Page 16 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 17: 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 SDS for the hot melt to the medical personnel providing treatment. Issued 04−15 E 2021 Nordson Corporation...
Page 18: Safety Labels And Tags
If required by governing safety regulations, apply the appropriate overlay to the text portion of the labels shown in Figure 1‐1. Figure 1-1 Safety labels and tags Issued 04-15 E 2021 Nordson Corporation...
Page 19 Release pressure before servicing. Tag, hazardous votage [located inside the electrical cabinet on the main board—refer to Section 8, Parts, for an illustration that shows the location of the main board] NS: Not Shown Issued 04−15 E 2021 Nordson Corporation...
Page 20 ## TABSHEET ##...
Page 21: Introduction
DuraBlue 10 L (D10L), and DuraBlue 16 L (D16L) adhesive melters. When necessary, the reader is referred to the documentation supplied with other Nordson products or products supplied by third parties. With the exception of tank capacity, hose/applicator capacity, and exterior appearance, all DuraBlue melters are function identically.
Page 22: Other Sources Of Information
The resource CD, which is stored in the back of this manual, contains an electronic version of this manual, parts information, and other useful resources that are designed to assist you with using and servicing your melter. E 2021 Nordson Corporation Part 1073401_07...
Page 23: Product Description
Product Description See Figure 2‐1. Nordson DuraBlue adhesive melters are used in conjunction with Nordson hot melt hoses and applicators to create a hot melt application system. The melter liquifies solid‐form hot melt and maintains the hot melt at the desired temperature.
Page 24: Intended Use
230 _C (450 _F) for 240 VAC melters or below 200 _C (400 _F) for 120 VAC melters Be used with compatible hot melt hoses and applicators that are manufactured by Nordson Corporation Be used in non‐explosive environments Limitations of Use Use DuraBlue melters only for the purpose for which they are designed.
Page 25: Melter Identification
The model and part number are indicated on the equipment identification plate that is located on the front of the melter. Figure 2-2 Equipment identification plate Part 1073401_07 E 2021 Nordson Corporation...
Page 26: Key Components
9. Pressure control valve 2. Control panel (see Figure 2‐4) 6. Hose/applicator receptacles 10. Filter 3. Tank lid 7. Tank isolation valve 11. Pump (D10/D16 only) 4. Side panels 12. Mounting bracket 8. Manifold 13. Motor E 2021 Nordson Corporation Part 1073401_07...
Page 27 Introduction Figure 2-4 Control panel 1. Fault LED 4. Control switch 6. Left display and scroll key 2. Ready LED 5. Right display and scroll keys 7. Function keys 3. Component keys/LEDs Part 1073401_07 E 2021 Nordson Corporation...
Page 28: Optional Equipment
Pressure control valve knob that replaces the hex screw pressure adjustment with a hand knob. Refer to Section 7, Parts, for a complete list of optional equipment. E 2021 Nordson Corporation Part 1073401_07...
Page 29 ## TABSHEET ##...
Page 30: Installation
The illustrations accompanying the procedures in this section depict the D10L melter. Unless otherwise noted, the instructions also apply to the D4L and D16L melters. Part 1073401_07 E 2021 Nordson Corporation...
Page 31: Additional Information
The instructions provided in this section are intended to be used by personnel who have experience in the following subjects: Hot melt application processes Industrial power and control wiring Industrial mechanical installation practices Basic process control and instrumentation E 2021 Nordson Corporation Part 1073401_07...
Page 32: Installation Requirements
(41.40 in.) (35.42 in.) door and tank lid are fully opened. Minimum vertical space required for the 878 mm 640 mm melter when the tank lid is at its highest point. (34.57 in.) (25.18 in.) Part 1073401_07 E 2021 Nordson Corporation...
Page 33: Electrical Power
The melter must be installed away from areas with strong drafts or where sudden temperature changes occur. The melter must be installed where it will be in conformance with the ventilation requirements specified in the Material Safety Data Sheet for the hot melt being used. E 2021 Nordson Corporation Part 1073401_07...
Page 34: Unpacking The Melter
Before starting the installation, remove the melter from the pallet, locate the installation kit, and inspect the melter for damaged and missing parts. Report any problems to your Nordson representative. Contents of the Installation Kit The installation kit provided with the melter contains the components shown in Figure 3‐2.
Page 35: Mounting The Melter
NOTE: The bolt mounting pattern of DuraBlue melters can be adapted to that of many other Nordson melters. Refer to Table 3‐2. 318 mm (12.50 in.)
Page 36 Installation Table 3-2 Comparison of DuraBlue Melter Dimensions with Other Melter Dimensions 3500 LS10 3100 3700 LS20 Dimension KB20 3400 3830 KB10 3930 • • • • • • • • Part 1073401_07 E 2021 Nordson Corporation...
Page 37: Connecting The Electrical Service
200-240 volts are shown in Table 3‐3. Table 3-3 Maximum Amperages for 200−240 Volt Melters Model Maximum Amperage D10L D16L NOTE: The ground conductor is the striped wire. Melter with attached power cable E 2021 Nordson Corporation Part 1073401_07...
Page 38 4. Connect the ground lead from the power cable to the ground lug that is located on the chassis. The ground lug is marked PE/G. Opening the electrical enclosure door Main Board-XT1 PE/G Figure 3-4 Connecting the power cable and grounding lead on the DuraBlue10/16L melter Part 1073401_07 E 2021 Nordson Corporation...
Page 39: Connecting Hoses And Applicators
Hose ports manifold. (Filtered and nonfiltered manifolds Refer to the user's guide provided with each Nordson hose. The guide shown) contains important information about routing and installing the hose. Save all of the plugs that were removed from the hose ports. A plug will need to be reinstalled into a hose port if a hose is later removed.
Page 40 To connect applicators Observe the following guidelines: For information about choosing the most appropriate Nordson hot melt applicator for your manufacturing process, refer to the latest edition of Nordson's hot melt dispensing equipment Replacement Parts Catalog or contact your Nordson representative. Refer to Appendix A, Calculating Melter Power Requirements, for information about how to calculate the power required by Nordson hot melt applicators.
Page 41: Setting Up The Melter
If you need to make changes to the factory setup or if you want to learn about other operating parameters, go to the next part in this section, Operating Parameters. E 2021 Nordson Corporation Part 1073401_07...
Page 42 A group of parameters that control the melter's clock. 50 to 77 Seven‐day Clock The clock is used to automatically turn the heaters on Disabled and off and to place the melter into the standby mode. Part 1073401_07 E 2021 Nordson Corporation...
Page 43: Operating Parameters
Table 3‐6. Reading or Editing Operating Parameters Regardless of whether a parameter's value is editable or not, the procedure for accessing each parameter in order to read or edit its current value is the same. E 2021 Nordson Corporation Part 1073401_07...
Page 44 (‐‐‐‐) for three seconds and then it will change back to the original value. 8. Repeat step 5 through step 7 to read or change the next sequential parameter number or press the Setup key to exit the setup mode. Part 1073401_07 E 2021 Nordson Corporation...
Page 45 Schedule 3 Exit Standby 0000 to 2359 —:— Schedule for Monday 0−7 Schedule for Tuesday 0−7 Schedule for Wednesday 0−7 Schedule for Thursday 0−7 Schedule for Friday 0−7 Schedule for Saturday 0−7 Schedule for Sunday 0−7 E 2021 Nordson Corporation Part 1073401_07...
Page 46 If password protection is enabled, the melter will Appendix B, Parameter 10 return to the password protected mode whenever you exit the setup mode. Part 1073401_07 E 2021 Nordson Corporation...
Page 47: Setpoint Temperature Of The Tank, Hoses, And Applicators
The right display indicates all dashes (‐‐‐‐) and the LEDs on the tank, hose, and applicator keys turn green. 3. Press a right‐display scroll key. The right display flashes. Left display and scroll key E 2021 Nordson Corporation Part 1073401_07...
Page 48 Each component begins to heat or cool to the new global setpoint temperature and the melter returns to the automatic scan mode. When all of the components reach the global setpoint temperature, the ready LED turns on (green). Ready LED Part 1073401_07 E 2021 Nordson Corporation...
Page 49: Review Parameter And Setpoint Temperature Changes
3. Press a right‐display scroll key to review each of the remaining nine log entries. Each press of a scroll key displays a progressively older log Component key LEDs entry. 4. Press the Setup key to return to the automatic scan mode. Scrolling through the log E 2021 Nordson Corporation Part 1073401_07...
Page 50 Unused log entries in the change history log are indicated by “P-_” in the right display. To view how many heater hours have elapsed since a specific change (displayed) was made, simultaneously press both of the right-display scroll keys. Part 1073401_07 E 2021 Nordson Corporation...
Page 51: Installing Optional Equipment
Flushing the melter is accomplished by processing a minimum of one tank volume of hot melt through the melter, hoses, and applicators. Refer to Section 4, Operation, for information about filling the tank and operating the melter. E 2021 Nordson Corporation Part 1073401_07...
Page 52: Adjusting The Pressure Control Valve
Adjusting the pressure control valve Part 1073401_07 E 2021 Nordson Corporation...
Page 53 3-24 Installation E 2021 Nordson Corporation Part 1073401_07...
Page 54 ## TABSHEET ##...
Page 55: Operation
Procedural variations or special considerations are explained in the additional information table that follows most procedures. Where applicable, some table entries also contain cross‐reference information. Additional information tables are indicated by the symbol shown to the left. Part 1073401_07 E 2021 Nordson Corporation...
Page 56: More About Heated Components
(or otherwise identify) the auxiliary device as to the hose or applicator position number that represents the device. The control panel will identify such devices as a hose or applicator, regardless of what the device actually is. E 2021 Nordson Corporation Part 1073401_07...
Page 57: Filling The Tank
2. Use a scoop to fill the tank with hot melt. Table 4‐1 lists the tank capacity of each DuraBlue melter. NOTE: Nordson Corporation recommends that the tank be kept at least one‐half full while the melter is operating. 3. Close the tank lid when you are finished filling the tank.
Page 58: Starting The Melter
Ready LED NOTE: You can change the way the pump key operates by changing parameter 8 (automatic pump on). Refer to Appendix B, Operating Parameters. Pump key E 2021 Nordson Corporation Part 1073401_07...
Page 59 If the seven-day clock was on prior to the power failure, the melter will restart in the mode dictated by the clock schedule at the time the melter restarts. Part 1073401_07 E 2021 Nordson Corporation...
Page 60: Monitoring The Melter
Refer to Monitor Melter Faults and Using Melter Function Keys later in this section for information about melter faults and using the seven‐day clock and standby functions. Refer to Appendix B, parameter 4, for information about the ready delay. E 2021 Nordson Corporation Part 1073401_07...
Page 61: Monitor Component Temperatures
3. When the position number of the desired component appears in the left display, observe the right display to determine the component's actual temperature. LEDs on component keys Part 1073401_07 E 2021 Nordson Corporation...
Page 62 UP scroll key. Holding down the scroll key while the melter is in the automatic scan mode reveals the setpoint of each component that is scanned. E 2021 Nordson Corporation Part 1073401_07...
Page 63 Operation This page intentionally left blank. Part 1073401_07 E 2021 Nordson Corporation...
Page 64: Monitor Melter Faults
Internal clock Heaters remain on, Battery‐backed RAM Replace CPU F4/4 battery backed but fault condition failure persists Heaters remain on, Battery‐backed RAM Replace CPU Internal clock F4/5 but fault condition battery dead battery persists Continued... E 2021 Nordson Corporation Part 1073401_07...
Page 65 CPU and the card persists optional I/O card Alert output (if output Fieldbus card failure. Replace the Fieldbus Fieldbus option 6 is selected) card F4/E communications Melter continues to failure operate normally. Part 1073401_07 E 2021 Nordson Corporation...
Page 66: How F1, F2, And F3 Faults Are Handled
LED will turn off, the red fault LED will turn on, the Fault LED (red) heaters turn off, and the melter records the fault in the fault log. Refer to To review the fault log later in this section. E 2021 Nordson Corporation Part 1073401_07...
Page 67: How F4 Faults Are Handled
I/Os. Refer to Section 6, Troubleshooting, for information about diagnosing F4 faults. 5. The melter records the fault in the fault log. Refer to To review the fault log later in this section. Part 1073401_07 E 2021 Nordson Corporation...
Page 68 235 _C (458 _F), an immediate F3 fault will occur (no two‐minute monitoring period). If F4 appears in the right display when you press the clock key, the internal clock function has failed. E 2021 Nordson Corporation Part 1073401_07...
Page 69 4-15 Operation This page intentionally left blank. Part 1073401_07 E 2021 Nordson Corporation...
Page 70 ‐ F temperature 4 = Hose 4 or applicator 4 3 = Component over temperature 5 = Hose 5 or applicator 5 4 = Processor or electrical failure 6 = Hose 6 or applicator 6 E 2021 Nordson Corporation Part 1073401_07...
Page 71 When an F1 fault is the result of a hose/applicator pair being disconnected from the melter, two fault log entries are created. The first entry is for the applicator and the second entry is for the hose. Part 1073401_07 E 2021 Nordson Corporation...
Page 72: Adjusting Component Temperatures
5. Press the Tank key. All components begin to heat or cool to the new global setpoint temperature. When all of the components reach their setpoint temperature, the ready LED turns on (green). Ready LED E 2021 Nordson Corporation Part 1073401_07...
Page 73 Refer to Entering the Melter Password later in this section. 5. Press the left‐display scroll key. The hoses or the applicators begin to heat or cool to their new setpoint temperature. Part 1073401_07 E 2021 Nordson Corporation...
Page 74 To register the new setpoint temperature and return to the automatic scan mode, go to step 6. 6. Press any component key (tank, hose, or applicator). The selected component begins to heat or cool to its new setpoint temperature. E 2021 Nordson Corporation Part 1073401_07...
Page 75 The melter stores a record of the last Section 3, Installation, Review ten changes made to the setpoint Parameter and Setpoint Temperature temperatures (and operating parameters) in Changes the change history log. Part 1073401_07 E 2021 Nordson Corporation...
Page 76: Enter The Melter Password
Setup key twice. The melter password is created and Setting Up the Melter in Section 3, enabled/disabled during system setup. Installation E 2021 Nordson Corporation Part 1073401_07...
Page 77: Using Melter Function Keys
When the pump is running, the LED is green. If the automatic pump on feature (parameter 8) is disabled, then the pump key must be used to start the pump when the melter is ready. Part 1073401_07 E 2021 Nordson Corporation...
Page 78: Setup Key
The clock will still operate when the melter is faulting or is in the setup mode. If F4 appears in the right display when you press Section 7, Troubleshooting the clock key, the internal clock function has failed. E 2021 Nordson Corporation Part 1073401_07...
Page 79: Standby Key
The melter may also be set up to automatically Appendix B, Parameters 25, 26, 57, 62, enter the standby mode using a variety of and 67 operating parameters. Whenever manual standby is enabled, the Appendix B, Parameter 26 standby LED blinks. Part 1073401_07 E 2021 Nordson Corporation...
Page 80: Shutting Down The Melter
1. Switch the melter off. 2. Disable the applicators as follows: Air‐operated applicators: Turn off the air supply to the applicators. Electric applicators: Turn off the applicator driver, pattern controller, or timer. Melter control switch (on/off) E 2021 Nordson Corporation Part 1073401_07...
Page 81 ## TABSHEET ##...
Page 82: Maintenance
DuraBlue melters operating within their specified limits and to prevent equipment malfunctions. For information about maintaining optional equipment that was supplied by Nordson, refer to the instructions provided with the equipment. If the melter stops operating or is operating incorrectly, refer to Section 6, Troubleshooting, for information about diagnosing common problems and performing corrective maintenance.
Page 83: Relieving System Pressure
To lockout external communications with the melter Set the control option for operating parameter 14 to 1 (enabled). Refer to Section 3, Setting Up the Melter, for information about changing operating parameters. E 2021 Nordson Corporation Part 1073401_07...
Page 84 Maintenance This page intentionally left blank. Part 1073401_07 E 2021 Nordson Corporation...
Page 85: Cleaning The Melter
‐inch) hex‐head wrench to turn the ‐turn fastener located in the center of each side panel counterclockwise. 3. Lift the panel out of the melter's frame. 4. Reverse steps 2 and 3 to reinstall each panel. E 2021 Nordson Corporation Part 1073401_07...
Page 86 Maintenance Figure 5-1 Removing the exterior panels Part 1073401_07 E 2021 Nordson Corporation...
Page 87: Replacing The Filter
Hot melt flow path E 2021 Nordson Corporation Part 1073401_07...
Page 88 NOTE: 50‐ and 150‐mesh filters are also available (P/Ns 1021941 and 1034720). 5. Screw the filter into the pump body and then tighten the filter to 4.5 N•m (40 in.‐lb). 6. Resume normal operation. Loosening the filter Part 1073401_07 E 2021 Nordson Corporation...
Page 89: Cleaning The Tank
7. Pump all of the flushing material from the tank and through the hoses and applicators. 8. Return the melter to normal operation and pump a minimum of one tank volume of fresh hot melt through the tank, hoses, and applicators. E 2021 Nordson Corporation Part 1073401_07...
Page 90 Closing the pressure control valve 11. Fill the tank with fresh hot melt and then purge all of the hoses and applicators with the fresh hot melt. 12. Restore the system to normal operation. Part 1073401_07 E 2021 Nordson Corporation...
Page 91 5-10 Maintenance E 2021 Nordson Corporation Part 1073401_07...
Page 92 ## TABSHEET ##...
Page 93: Troubleshooting
If you cannot resolve the problem using the troubleshooting flowchart, contact your Nordson representative for technical assistance. Safety Never disconnect cables from, or reconnect cables to, any circuit board while the melter is energized.
Page 94: Melter Faults
Internal clock Heaters remain on, Battery‐backed RAM Replace CPU F4/4 battery backed but fault condition failure persists Heaters remain on, Battery‐backed RAM Replace CPU Internal clock F4/5 but fault condition battery dead battery persists Continued... E 2021 Nordson Corporation Part 1073401_07...
Page 95 CPU and the card persists optional I/O card Alert output (if output Fieldbus card failure. Replace the Fieldbus Fieldbus option 6 is selected) card F4/E communications Melter continues to failure operate normally. Part 1073401_07 E 2021 Nordson Corporation...
Page 96: Pump Operating Variables
Ready status of the melter Activation of a switched input (hand‐held applicator or footswitch) Activation of the pump key Table 6‐2 provides the status of the pump LED for each combination of the pump operating variables. E 2021 Nordson Corporation Part 1073401_07...
Page 97 C: Manual mode is for hand‐held applicator and footswitch applications. D: “On” means the pump key was pressed and the unit accepted the key press. “ ” means that the Ignored pump key will not respond to a key press. Part 1073401_07 E 2021 Nordson Corporation...
Page 98: Using The Troubleshooting Flow Chart
(if not required or expected at the current time). E 2021 Nordson Corporation Part 1073401_07...
Page 99: Returning The Melter Setup To Factory Settings
Hose/applicator 1 heaters (6.3 A, 250 V, 5 x 20 mm) F9/F10 −− Hose/applicator 2 heaters (6.3 A, 250 V, 5 x 20 mm) F11/F12 −− Motor power (6.3 A, 250 V, 5 x 20 mm) Continued... Part 1073401_07 E 2021 Nordson Corporation...
Page 100 High-voltage and control voltage out to hose/applicator 1 Input/output High-voltage and control voltage out to hose/applicator 2 Input Switch closure from melter control switch Test Points Contact +5 VDC out of low-voltage power supply Contact Circuit common of low-voltage power supply E 2021 Nordson Corporation Part 1073401_07...
Page 101 (HAND‐HELD back panel APPLICATOR TRIG INPUT) on main board Ribbon cable J1 on CPU board J1 on main board 1026662 NOTE A: Refer to Heaters in Section 7, Parts, for heater kit part numbers. Part 1073401_07 E 2021 Nordson Corporation...
Page 102 6-10 Troubleshooting This page intentionally left blank. E 2021 Nordson Corporation Part 1073401_07...
Page 103 Tank Heater (Left and Right) Thermostat (Center) Tank RTD (Bottom Right) Back Panel (Not Used) Pump RTD (Top) Pump Heater (Bottom) CPU Power CPU Failure (green) (red) Motor Control Switch TP2 (+) TP4 (−) 4.75−5.25 VDC CPU Board (B2) Main Board (B1) Gun Solenoid 1 Gun Solenoid 2 Figure 6-1...
Page 104 This page intentionally left blank.
Page 105: No Hot Melt Output From One Or More Applicators
No hot melt output from one or more applicators DuraBlue Troubleshooting Is the control panel illuminated? Charts − Go to Start Do dashes appear in both Do the words UP LOAD Is the fault LED Is the ready LED the left and right display? appear across the illuminated? illuminated?
Page 107 Is the power on the plant Check/repair the plant side of the disconnect wiring. − switch that is serving the Control panel is not illuminated melter? Is the power disconnect Turn the disconnect switch switch that is serving the − melter turned on? Is there power at terminal Check the plant wiring...
Page 109 P/N 1031179 − board between 4.75 and P/N 1026662 5.25 VDC? See Figure 6‐1. Is the green power LED on Does changing the main Contact Nordson for the CPU board board correct the problem? technical assistance. − − illuminated? P/N 1122064 See Figure 6‐1.
Page 111 Record the fault codes Go to Go to indicated in both the left T.2.1 T.2.2 and right displays and then contact Nordson for technical assistance. Is the tank key LED Are all of the Secure the electrical illuminated? applicator‐to‐hose and connectors and then press −...
Page 113 T.2.1 Reset the melter and turn the heaters back on Fault LED is illuminated > F2 fault exists Is the tank key LED Is the affected applicator or Are the hose or applicator Does the fault reoccur if illuminated? hose cordset loose? (The cordset pins bent, loose, or you move the faulting −...
Page 115: Reset The Melter And Turn The Heaters Back On
Reset the melter and turn the heaters back on T.2.2 Is more than one Is the tank LED Was the setpoint Fault LED is illuminated > component overheating? illuminated? temperature of the faulting F3 fault exists − − − Go to (Check the actual hose/applicator just T.2.4...
Page 117: Is The Power Indicator For The Affected Hose/Applicator Illuminated
No hot melt was recently added to the TRIACS functioning P/N 1122064 − tank properly? Are the tank and manifold Replace the malfunctioning Contact Nordson for RTDs functioning properly? RTD. technical assistance. − Tank ‐ P/N 1031234 Pump ‐ P/N 1031233...
Page 119: Main Board P/N 1122064
T.2.4 Does the fault clear if you Does the fault clear if you Have LEDs D1S/DS2 or switch the faulting hose/ replace just the hose or just DS3/DS4 on the affected − − − applicator pair to a known Fault LED is illuminated > the applicator RTD and hose/applicator module good hose/applicator...
Page 121 Heaters key to manually turn the heaters on. Does the right display Is the ready delay counting Is the standby LED on? Contact Nordson for indicate that components down? technical assistance. − − −...
Page 123: Go To
Is the motor running? Is the pump key LED Is the pump key LED Press the pump key to flashing yellow? illuminated yellow, but not enable the pump. − − − flashing? Is the applicator trigger The melter is waiting for an Does the motor start if you cordset or foot switch Go to...
Page 125: Main Board Illuminated
T.4.1 No faults > Is indicator DS7 on the Replace fuses F11 and main board illuminated? F12. Ready LED is illuminated > − P/N 1031203 No hot melt output from all applicators > Motor is not turning > All motor start conditions are correct > Tank setpoint temperature is correct Is the electrical harness Connect the harness.
Page 127 T.4.2 No faults > Is the tank empty? Is the pump input shaft Replace the turning? motor‐to‐pump coupling or Ready LED is illuminated > − − replace the shaft key. Not hot melt output from all applicators > Motor is turning Fill the tank.
Page 128 This page intentionally left blank.
Page 129: Replace The Applicator
Is the setpoint temperature of Adjust the setpoint the affected hose/applicator temperature. − below the temperature No faults > recommended by the hot Ready LED is illuminated > melt manufacturer? Hot melt output from some applicato Is the melter set up for a Are you using a switched Repair/replace the affected Are the applicator, applicator...
Page 130 This page intentionally left blank.
Page 131 6-39 Troubleshooting Figure 6-2 Opening the tank isolation valve (D10L/D16L only) 1. Open 2. Closed Part 1073401_07 E 2021 Nordson Corporation...
Page 132 6-40 Troubleshooting E 2021 Nordson Corporation Part 1073401_07...
Page 133 ## TABSHEET ##...
Page 134: Parts
Item—Identifies illustrated parts that are available from Nordson Corporation. Part—Provides the Nordson Corporation part number for each saleable part shown in the illustration. A series of dashes in the parts column (‐ ‐ ‐ ‐ ‐ ‐) means the part cannot be ordered separately.
Page 135: Front Panel Service Kits
S Panel, front ‐ ‐ ‐ ‐ ‐ ‐ Service kit, panel, front, D10L/D16L, with tags — 1031177 — S Panel, front ‐ ‐ ‐ ‐ ‐ ‐ Switch, rocker, SPsT, 250 V, 16 A 1017947 E 2021 Nordson Corporation Part 1073401_07...
Page 136 Parts This page intentionally left blank. Part 1073401_07 E 2021 Nordson Corporation...
Page 137: Electrical Component Service Kits
Parts Electrical Component Service Kits Electrical components include circuit boards, fuses, thermostats, heaters, RTDs, and ribbon cables. Circuit Boards Figure 7-2 Circuit board service kit parts E 2021 Nordson Corporation Part 1073401_07...
Page 138 B: For fuses, see Figure 7-3. C: A capacitor is provided in each motor service kit Refer to Motor in Drive Assembly Service Kits later in this section. D: Available only for 120-volt melters. Part 1073401_07 E 2021 Nordson Corporation...
Page 139: Fuses
S Fuse, slow, 2 A, 250 VAC, 5 x 20 mm, F3−F4 939955 S Fuse, fast, 5 A, 250 VAC, 5 x 20 mm, F5−F6 ‐ ‐ ‐ ‐ ‐ ‐ S Fuse, 6.3 A, 250 VAC, 5 x 20 mm, F7−F12 939683 E 2021 Nordson Corporation Part 1073401_07...
Page 140: Thermostat
NOTE A: All heater service kits include thermal compound. NS: Not Shown Cables and Harnesses Refer to Identifying Electrical Components in Section 6, Troubleshooting, for an illustration and part numbers for cables and harnesses. Part 1073401_07 E 2021 Nordson Corporation...
Page 141: Tank Strainer
Parts Tank Strainer Figure 7-4 Tank strainer Item Part Description Quantity Note Strainer, tank, D4L 1028330 Strainer, tank, D10L 1028334 Strainer, tank, D16L 1028336 E 2021 Nordson Corporation Part 1073401_07...
Page 142: Drive Assembly Service Kits
1067875 1069148 — — 1069734 1056358 1067875 1071716 — — 1069735 1056358 1067875 1069148 — — 1069736 1031213 1067875 1071503 — 240V 1069737 1031212 1067875 1069148 — 240V 1069738 1031213 1067875 1071503 — 240V Part 1073401_07 E 2021 Nordson Corporation...
Page 143: Motor
7-10 Parts Motor Figure 7-5 120V and 240V motor service kit parts E 2021 Nordson Corporation Part 1073401_07...
Page 144 NOTE A: For the location of the capacitor, see Figure 7‐2. B: Used for 4L DuraBlue melter. If B is used, C is not necessary. C: Used for 10/16L DuraBlue melter. If C is used, B is not necessary. NS: Not Shown Part 1073401_07 E 2021 Nordson Corporation...
Page 145: Pump
7-12 Parts Pump Figure 7-6 Pump service kit parts E 2021 Nordson Corporation Part 1073401_07...
Page 146 A: Parts designated as “PA” are recommended for use in product assembly applications with operating temperatures greater than 191 _C (375 _F). PA-type O-rings provide exceptionally high chemical and temperature resistance. B: Refer to Drive Assembly (Complete). NS: Not Shown Part 1073401_07 E 2021 Nordson Corporation...
Page 147: Manifold
7-14 Parts Manifold Figure 7-7 Manifold service kit parts (filtered manifold shown) E 2021 Nordson Corporation Part 1073401_07...
Page 148 B: The 2-port manifold service kits include one hose connector. The 4-port manifold service kit includes two hose connectors. C: This hose connector is included only in the 4-port manifold service kit. D: Present only on filtered manifolds. NS: Not Shown Part 1073401_07 E 2021 Nordson Corporation...
Page 149: Drive Assembly (Complete)
7-16 Parts Drive Assembly (Complete) 13.5-16.3 NSm (10-12 ft‐lb) 6 1 6 8 NSm (54 60 in lb) Figure 7-8 hp drive assembly E 2021 Nordson Corporation Part 1073401_07...
Page 150 A: Provided in pump service kit. Refer to Pump earlier in this section for kit part numbers. B: Refer to Manifold earlier in this section. C: Refer to Motor earlier in this section. D: Provided in the motor coupling service kit. NS: Not Shown Part 1073401_07 E 2021 Nordson Corporation...
Page 151: Optional Equipment
1030542 Kit, footswitch — — 1047093 Kit, remote trigger General Melter Accessory Kits Part Description Quantity 1050595 Kit, support, hose, double — 1030530 Kit, hand‐held applicator hanger — — 1043074 Kit, return feed, D10/D10L/D16/D16L E 2021 Nordson Corporation Part 1073401_07...
Page 152 ## TABSHEET ##...
Page 153: Technical Data
18, 29, or 42 kg/hr (40, 64, or 92 lb/hr) at 50 Hz NOTE A: The noise level is measured at a distance of 1 m (3.3 ft.) from the surface of the melter. Part 1073401_07 E 2021 Nordson Corporation...
Page 154: Electrical Specifications
2 x 650 80.2-93.5 ohms each Tank, D16L 240 V 2 x 900 57.9-67.6 ohms each NOTE A: Nominal wattage at 177-204 _C (350-400 _F). B: Measured at room temperature for a previously heated element. E 2021 Nordson Corporation Part 1073401_07...
Page 155: Motor And Pump Specifications
7.8 cc/rev Motor speed 54.6 rpm at 60 Hz or 45 rpm at 50 Hz 86.25 or 138 rpm at 60 Hz 71.25 or 114 rpm at 50 Hz NOTE Depends on gear reducer used Part 1073401_07 E 2021 Nordson Corporation...
Page 156: Dimensions
(12.0 in.) 235 mm 281 mm (9.24 in.) (11.05 in.) 614 mm (24.19 in.) 640 mm (25.18 in.) 509 mm (20.05 in.) 334 mm 600 mm (23.8 in.) (13.14 in.) Figure 8-1 D4L melter dimensions E 2021 Nordson Corporation Part 1073401_07...
Page 157: D10L And D16L Melter
(12.07 in.) (12.99 in.) 851 mm (33.50) 878 mm (34.57 in.) 584 mm (23.00 in,) 393 mm 605 mm (23.8 in.) (15.48 in.) Figure 8-2 D10L/D16L melter dimensions Figure 8-3 B900N mounting dimensions (from manifold) Part 1073401_07 E 2021 Nordson Corporation...
Page 158: Conduit Penetration Sizes
Technical Data Conduit Penetration Sizes D10/D16 Figure 8-4 Electrical enclosure conduit penetrations E 2021 Nordson Corporation Part 1073401_07...
Page 159 ## TABSHEET ##...
Page 160: Calculating Melter Power Requirements
Two hose/applicator pair maximum—The combined wattage of hose/applicator pairs 1 and 2 If your Nordson representative has already calculated the hose/applicator power requirements and confirmed that the maximum allowable wattages will not be exceeded, then no further calculation is necessary. However, you should re‐evaluate the hose and applicator power requirements before you:...
Page 161 Tables A‐2 and A‐3, then the configuration or position of the hose/applicator pairs must be rearranged, shorter hoses must be used, or lower power applicators must be used in order to reduce the power requirement. E 2021 Nordson Corporation Part 1073401_07...
Page 162 Sum of hose/applicator pairs 1 and 2 on a... 1045 W D4L with hp motor* 1045 W D10L with hp motor* 985 W D10L with hp motor* 985 W D16L with hp motor* *Refer to the motor identification plate. Part 1073401_07 E 2021 Nordson Corporation...
Page 163 Calculating Melter Power Requirements E 2021 Nordson Corporation Part 1073401_07...
Page 164 ## TABSHEET ##...
Page 165: Operating Parameters
0 to 8 and Standard Frequently used parameters 10 to 14 Pressure Control 15 to 17 Configure pressure settings Temperature Control 20 to 26 Control heater function Seven-day Clock 50 to 77 Configure the clock feature Part 1073401_07 E 2021 Nordson Corporation...
Page 166: Standard
F1, F2, F3, and F4 Use: Use the right-display scroll keys to review the log entries for the last ten faults. Empty log entries are indicated by “_-F0.” Refer to Monitor the Melter in Section 4, Operation. E 2021 Nordson Corporation Part 1073401_07...
Page 167 The service LED will turn on after the pre-set time elapses. With the melter in the scan mode, press the Clear/Reset key to turn off the service LED and reset the time. Part 1073401_07 E 2021 Nordson Corporation...
Page 168 If Automatic Pump On is enabled, the pump will turn on automatically when the melter is ready. NOTE: If Automatic Pump On is disabled (0) while the pump is running, the pump will remain on until the pump key is pressed. E 2021 Nordson Corporation Part 1073401_07...
Page 169 0 (disabled) Format: — Use: Use only when a Nordson manifold-mounted electric applicator is installed and a switching device is connected to the melter’s switch receptacle. Refer to the electric applicator manual for information on mounting and using the applicator.
Page 170 0 (disabled) Format: — Use: Use only when a Nordson manifold-mounted electric applicator is installed and a switching device is connected to the melter’s switch receptacle. Refer to the electric applicator manual for information on mounting and using the applicator.
Page 171: Pressure Control
— Default Value: Format: — Use: This parameter is available only when the optional analog I/O board is installed on the melter. Refer to Section 7, Parts, for the I/O board kit part number. Part 1073401_07 E 2021 Nordson Corporation...
Page 172: Temperature Control
The number of degrees that the temperature of any component can decrease from its setpoint temperature before an under temperature fault (F2) occurs. Value: 5 _C (10 _F) to 60 _C (110 _F) Resolution: Default Value: 25 _C (50 _F) Format: — Use: — E 2021 Nordson Corporation Part 1073401_07...
Page 173 (parameter 24) before the heaters turn off. Value: 0 to 1440 minutes (24 hours) Resolution: 1 minute Default Value: 0 (disabled) Format: — Use: Set parameter 24 (automatic standby timeout) to the desired value before setting parameter 25. Part 1073401_07 E 2021 Nordson Corporation...
Page 174 Set the standby delta (parameter 23) to the desired value before setting parameter 26. Note: When a time value equal to or greater than 1 minute is entered, the standby LED will flash to indicate that the manual standby timer is counting down. E 2021 Nordson Corporation Part 1073401_07...
Page 175 B-11 Operating Parameters This page intentionally left blank. Part 1073401_07 E 2021 Nordson Corporation...
Page 176: Seven-Day Clock
71 through 77 is schedule 0, which has no time values assigned to it. With the default set to sched- ule 0, unintentionally pressing the clock key will have no affect on the melter. E 2021 Nordson Corporation Part 1073401_07...
Page 177 1600 at the end of the day, every day of the week: Par 55 = 0600 Par 56 = 1600 Par 57 = 1130 Par 58 = 1230 Par 71 through 75 = 1 Par 71 and 77 = 1 Part 1073401_07 E 2021 Nordson Corporation...
Page 178 Resolution: 1 minute Default Value: 1700 Format: Hours, Hour: Minute, Minute Use: To disable this parameter, set the parameter’s value to “- - - -” by simultaneously pressing both of the right-display scroll keys. E 2021 Nordson Corporation Part 1073401_07...
Page 179 Hours, Hour: Minute, Minute Use: Set the desired time for the heaters to turn on. To disable this parameter, set the parameter’s value to “- - - -” by simultaneously pressing both of the right-display scroll keys. Part 1073401_07 E 2021 Nordson Corporation...
Page 180 Note: Do not set an exit standby time that is outside of the time period defined by the schedule’s heater on and off time. The melter cannot enter the standby mode when the heaters are off. E 2021 Nordson Corporation Part 1073401_07...
Page 181 Note: Do not set an enter standby time that is outside of the time period defined by the schedule’s heater on and off time. The melter cannot enter the standby mode when the heaters are off. Part 1073401_07 E 2021 Nordson Corporation...
Page 182 Default Value: Format: — Use: Selects the active schedule(s) for the day. NOTES: If the 0 schedule option is used, the heaters will not turn on again until the next scheduled heaters on time arrives. E 2021 Nordson Corporation Part 1073401_07...
Page 183 Default Value: Format: — Use: Selects the active schedule(s) for the day. NOTES: If the 0 schedule option is used, the heaters will not turn on again until the next scheduled heaters on time arrives. Part 1073401_07 E 2021 Nordson Corporation...
Page 184 Default Value: Format: — Use: Selects the active schedule(s) for the day. NOTES: If the 0 schedule option is used, the heaters will not turn on again until the next scheduled heaters on time arrives. E 2021 Nordson Corporation Part 1073401_07...
Page 185 Default Value: Format: — Use: Selects the active schedule(s) for the day. NOTES: If the 0 schedule option is used, the heaters will not turn on again until the next scheduled heaters on time arrives. Part 1073401_07 E 2021 Nordson Corporation...
Page 186 B-22 Operating Parameters E 2021 Nordson Corporation Part 1073401_07...
Page 187 ## TABSHEET ##...
Page 190 DuraBluer Adhesive Melters DuraBluer Adhesive Melters Models D4L, D10L, D16L (Gerotor) Models D4L, D10L, D16L (Gerotor) Customer Product Manual Customer Product Manual P/N 1073401_06 P/N 1073401_06 DuraBluer Adhesive Melters DuraBluer Adhesive Melters Models D4L, D10L, D16L (Gerotor) Models D4L, D10L, D16L (Gerotor) Customer Product Manual Customer Product Manual P/N 1073401_06...

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