Bulk Melters BM 200

with Gear Pump

- EASY Pneumatics -
Manual P/N 397189E
- English -

Issued 05/06

NORDSON ENGINEERING GMBH D LÜNEBURG D GERMANY

 Note
After approx. December 2003, this manual applies to the entire series.

Order number
P/N = Order number for Nordson products

Notice
This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2003.
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.

© 2006 All rights reserved.

Trademarks
AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Autotech, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, CleanSleeve,
CleanSpray, ColorMax, Control Coat, Coolwave, Cross‐Cut, Cyclo‐Kinetic, Dispensejet, DispenseMate, DuraBlue, Durafiber, Dura‐Screen, Durasystem,
Easy Coat, Easymove Plus, Ecodry, Econo‐Coat, e.dot, e.stylized, EFD, ETI, Excel 2000, Fillmaster, FlexiCoat, Flexi‐Spray, Flex‐O‐Coat, Flow Sentry,
Fluidmove, FoamMelt, FoamMix, Heli‐flow, Helix, Horizon, Hot Shot, iControl, iFlow, Isocoil, Isocore, Iso‐Flo, iTRAX, JR, KB30, Kinetix, Little Squirt,
LogiComm, Magnastatic, March, MEG, Meltex, Microcoat, Micromark, MicroSet, Millenium, Mini Squirt, Moist‐Cure, Mountaingate, MultiScan, Nordson,
OmniScan, OptiMix, Package of Values, PatternView, PermaFlo, Plasmod, PluraFoam, Porous Coat, PowderGrid, Powderware, Prism, Printplus,
ProBlue, Pro‐Flo, ProLink, Pro‐Meter, Pro‐Stream, RBX, Rhino, Saturn, Scoreguard, SC5, S. design stylized, Seal Sentry, Select Charge, Select Coat,
Select Cure, Slautterback, Smart‐Coat, Solder Plus, Spectrum, Speed‐Coat, Spraymelt, Spray Squirt, Super Squirt, SureBead, Sure Clean, Sure Coat,
Sure‐Max, Tela‐Therm, Tracking Plus, TRAK, Trends, Tribomatic, Ultra, Ultrasaver, UniScan, UpTime, Vantage, Veritec, VersaBlue, Versa‐Coat,
Versa‐Screen, Versa‐Spray, Walcom, Watermark, When you expect more. are registered trademarks - ® - of Nordson Corporation.

Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AquaCure, ATS, Auto‐Flo, AutoScan, Best Choice, BetterBook, Blue Series,
CanNeck, Celero, Chameleon, Check Mate, ClassicBlue, Color‐on‐Demand, Controlled Fiberization, Control Weave, CPX, DispensLink, Dry Cure,
DuraBraid, DuraCoat, DuraDrum, DuraPail, E‐Nordson, Easy Clean, EasyOn, Eclipse, Equi=Bead, ESP, Exchange Plus, Fill Sentry, Gluie, G‐Net, G‐Site,
HDLV, Ink‐Dot, iON, Iso‐Flex, iTrend, KVLP, Lacquer Cure, Lean Cell, Maverick, Maxima, MicroFin, MicroMax, MiniBlue, MiniEdge, Minimeter, Multifil,
Myritex, OptiStroke, Origin, PatternPro, PCI, PluraMix, Powder Pilot, Powercure, Primarc, Process Sentry, Prodigy, Pulse Spray, PurTech, Quad Cure,
Ready Coat, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit,
Sure Brand, SureMix, SureSeal, Sure Wrap, Swirl Coat, Tempus, ThruWave, Trade Plus, TrueBlue, Ultrasmart, Universal, Viper, Vista, VersaDrum,
VersaPail, WebCure, 2 Rings (Design) are trademarks - T - of Nordson Corporation.

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

P/N 397189E BM200_EASY_GEAR E 2006 Nordson Corporation

 Table of Contents I

Table of Contents
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐1
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐1
Unintended Use - Examples - . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐1
Area of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐2
Residual Risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐2
Definition of Term(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐2
Note on Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐3
Configuration Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐4
ID Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐5
Essential Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐6
Model Variations and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐7
Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐7
Exhaust Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐7
Changeover System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐7
High Drum Jacket for Cardboard Drums . . . . . . . . . . . . . . . . 2‐8
Divided Base Plate for Pallet Conveyance . . . . . . . . . . . . . . 2‐8
Electrical Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐9
Button Two‐hand Control and Pneumatic Switch . . . . . . . . . 2‐10
Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐10
Key Switch Remote / Local and Indication Lamp Remote . . 2‐10
Main Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐10
Electrical Cabinet Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐10
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐11
Week Timer (Accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐12
Door Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐12
Light Tower (Accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐12
Heating Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐13
Melting Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐13
Functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐14
Raising and Lowering Heating Punch . . . . . . . . . . . . . . . . . . . . . 2‐14
Deaerating Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐14
Aerating Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐14
Melting Process and Material Flow . . . . . . . . . . . . . . . . . . . . . . . 2‐15
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐15
Heating and Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . 2‐16
Undertemperature Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐16
Overtemperature Indication / Shutdown . . . . . . . . . . . . . . . . 2‐16
Temperature Setback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐16

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

II Table of Contents

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐1
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐1
Lifting (Unpacked System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐1
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐2
Setting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐2
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐3
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐3
Exhausting Material Vapors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐4
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐5
Laying Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐5
Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐5
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐5
Hose Receptacle(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐5
Operating with Assembly Handguns . . . . . . . . . . . . . . . . . . . 3‐5
Pilot Voltage / Tach Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐5
Interface XS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐6
Installing Heated Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐7
Laying Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐7
Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐7
Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐7
Relieving Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐7
Second Open‐jawed Wrench . . . . . . . . . . . . . . . . . . . . . . . . . 3‐7
Pneumatic Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐8
Preparing for Changeover System . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐8
Reducing Heating Punch Lifting Speed . . . . . . . . . . . . . . . . . . . . . . 3‐8
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐9
Light Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐9
Week Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐9
Tach Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐9
Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐9

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐1
Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐1
Adjusting Switch Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐2
Setting Values and Parameters - Notes - . . . . . . . . . . . . . . . . . . . . 4‐3
Speed, Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐3
Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐3
Recommended Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐3
Inserting and Replacing Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐4
Raising Heating Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐5
Lowering Heating Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐5
Switching System ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐6
Daily Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐6
Daily Switchoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐6
Switching Off in an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐7
Settings Record Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐8

P/N 397189E BM200_EASY_GEAR E 2006 Nordson Corporation

 Table of Contents III

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐1
Risk of Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐1
Relieving Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐1
Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐2
Regular Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐3
External Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐4
Visual Inspection for External Damage . . . . . . . . . . . . . . . . . . . . . . 5‐4
Electrical Cabinet Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐4
Compressed Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐5
Draining Condensate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐5
Cleaning Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐5
Pneumatic Pressure Restrictor Valves . . . . . . . . . . . . . . . . . . . . . . 5‐6
Function Testing of Pressure Restrictor Valve . . . . . . . . . . . . . . 5‐6
Cleaning Pressure Restrictor Valve . . . . . . . . . . . . . . . . . . . . . . . 5‐6
Changing Type of Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐7
Purging with Cleaning Agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐7
Cleaning Melting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐7
Maintenance Record Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐8

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐1
Some Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐1
Troubleshooting with Control System . . . . . . . . . . . . . . . . . . . . . . . 6‐2
Indication Lamps and Light Tower . . . . . . . . . . . . . . . . . . . . . . . . 6‐2
Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐3

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐1
General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐1
Replacing Sealing Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐2
Replacing O‐rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐3
Replacing Melting Plate Temperature Sensor and Thermostat . . 7‐4

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8‐1

General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8‐1
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8‐1
Motors / Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8‐2
Temperatures and Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8‐2
Air Cunsumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9‐2
Exhaust Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8‐2
Material Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8‐3
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8‐3
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8‐4
Processing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8‐4
Lubricating Heating Punch Sealing Rings . . . . . . . . . . . . . . . . . 8‐4
Inserting Thermostats and Temperature Sensors . . . . . . . . . . . 8‐4
Lubricating O‐rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8‐4
Screw Locking Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8‐4

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

IV Table of Contents

P/N 397189E BM200_EASY_GEAR E 2006 Nordson Corporation

 Safety 1‐1

Section 1
Safety

Observe and follow all safety instructions, the general safety instructions
included as a separate document,
as well as the specific safety instructions in all other related documentation.

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

1‐2 Safety

P/N 397189E BM200_EASY_GEAR E 2006 Nordson Corporation

 Introduction 2‐1

Section 2
Introduction

Intended Use
Bulk melters in the series BM 200 with Gear Pumps - hereafter also referred
to as system - may be used only to melt and feed suitable materials. When in
doubt, seek permission from Nordson.

CAUTION: Only undamaged and suitable drums (Refer to Technical Data)

may be used.

CAUTION: PUR material may be processed only in models with exhaust

hood and manual drum aeration valve!

Any other use is considered to be unintended. Nordson will not be liable for
personal injury or property damage resulting from unintended use.
Intended use includes the observance of Nordson safety instructions.
Nordson recommends obtaining detailed information on the materials to be
used.

Unintended Use - Examples -

The systems may not be used under the following conditions:
S In defective condition
S With electrical cabinet door open
S In a potentially explosive atmosphere
S With unsuitable operating/processing materials
S When safety valves and pressure restrictor valves are not lead‐sealed
S When the values stated under Technical Data are not complied with.

The systems may not be used to process the following materials:

S Explosive and flammable materials
S Erosive and corrosive materials
S Food products.

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

2‐2 Introduction

Area of Use
The system is designed for use in industrial areas.
When using in industrial areas and in small businesses, the system may
cause interference in other electrical units, e.g. radios.

Residual Risks
In the design of the unit, every measure was taken to protect personnel from
potential danger. However, some residual risks can not be avoided.
Personnel should be aware of the following:
S Risk of burns from hot material
S Risk of burns from hot system components
S Risk of burns when conducting maintenance and repair work for which
the system must be heated up
S Risk of burns when attaching and removing heated hoses
S Material fumes can be hazardous. Avoid inhalation
S Pinching parts of the body between heating punch and drum
S The safety valve may malfunction due to hardened or charred material.

Definition of Term(s)
The safety valve is also referred to as bypass and bypass valve in Nordson
literature.

P/N 397189E BM200_EASY_GEAR E 2006 Nordson Corporation

 Introduction 2‐3

Note on Manual
S This manual applies to models with PLC‐controlled pneumatics (after
approx. December 2003)
S This manual is valid only in conjunction with all documents included in the
complete set of documentation (blue binder)
S When the system has special features, customer specifications and/or
supplements or a higher‐ranking system description may be added to this
manual
S The position numbers in the illustrations do not correspond to the position
numbers in the technical drawings and parts lists. Refer to separate
document Parts List for details.

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

2‐4 Introduction

Configuration Code
The configuration code is engraved on the ID plate.
NOTE: An X indicates that the function or component was not ordered,
meaning that it is unavailable. An S indicates that the model deviates from
the configuration code. Such deviations are described in a supplement or a
system description.

Box Code Key

1 BM200 Series or unit designation
2 Melting plate Drum aeration valve Exhaust hood
A Axial Automatic No
B Axial Automatic Yes
R Axial Manual No
C Axial Manual Yes
F Fine‐blade Automatic No
P Fine‐blade Manual No
G Smooth Automatic Yes
U Smooth Manual Yes
3 3 Operating voltage 400VAC, 3 Ph Y
4 400VAC, 3 Ph, Delta
5 480VAC, 3 Ph, Delta
4 K Hose connection 16 mm (5/8 in) installed
8 mm (5/16 in) included
Equipment

M 20 mm (3/4 in)
L 32 mm (11/4 in)
5 11 Pump type Gear, PR 6m1
12 Gear, PR 12m1
13 Gear, PR 12m2
14 Gear, PR 25m2
50 Gear, PU 15/85
51 Gear, PU 25/85
52 Gear, PU 35/85
53 Gear, PU 50/85
41 Piston pump, 42:1
42 Piston pump, 24:1
6 L Overtemperature 150 ° C / 300 ° F
M thermostat 176 ° C / 350 ° F
H 230 ° C / 450 ° F
7 1 Number of hose 1
2 connections 2
Continued...

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 Introduction 2‐5

Box Code Key

9 D Pressure‐controlled
10 P Profibus interface
Options

11 6 Six additional heating channels (three additional receptacles)

12 J High drum jacket (for cardboard drums)
13 W Divided base plate (for pallet conveyance)
14 S Special

NOTE: Models with a piston pump are not described in this manual.
CAUTION: PUR material may be processed only in models with exhaust
hood and manual drum aeration valve!

ID Plate

BM 1 2 ADHESIVE MELTER
3
Nordson Engineering GmbH
4 Lilienthalstr. 6
D 21337 Lüneburg - Germany

Serial No: 5 Year www.nordson.com

Fig. 2‐1

1 Melter designation
2 Order number
3 Configuration code
4 Electrical connection, operating voltage, line voltage frequency, melter fuse protection
5 Serial number

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2‐6 Introduction

Essential Components
Components - when they are relevant to installation, operation and
maintenance - are described in the appropriate sections of this manual or in
separate manuals.

1
15

14

13

12 3

11

10

9 8 7 6 5

Fig. 2‐2
1 Pressure controller 5 Safety valve* 11 Hose connection
2 Switch rod 6 Pump* 12 Exhaust hood (option)
3 Electrical cabinet 7 Drip pan 13 Drive
4 Automatic drum aeration valve 8 Drum deaeration valve 14 Hose holder
(option) mounted on heating 9 Heating punch 15 Hose receptacle
punch
or 10 Sensor Drum inserted (mounted
Manual drum aeration valve on base plate)
mounted on cross beam
Note: There are separate manuals available for components marked with an asterisk (*).

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 Introduction 2‐7

Model Variations and Options

Pressure Control
The material pressure beyond the pump is measured by a pressure sensor
and regulated by a control system to remain at a constant pressure (can be
adjusted). Refer to separate manual.

Exhaust Hood
If the bulk melter is used to process polyurethane hot melt adhesives (PUR),
fumes are created that should be suctioned off directly at the drum. An
exhaust hood is integrated into the bulk melter for this purpose.
The exhaust hood must be connected to the customer's exhaust device (Also
refer to Installation, Exhausting Material Vapors).

Changeover System
The changeover system allows uninterrupted operation of two bulk melters.
One of the systems is active (feeding material), and the other is in standby
mode (system switched on, heating punch heater not yet on).
If a drum is almost empty (in this case, in the system on the right), the heating
punch heater of the other system is automatically switched on. Now the
empty drum can be replaced while the other system is feeding material.
Refer to separate manual.

Fig. 2‐3 Principle drawing

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2‐8 Introduction

High Drum Jacket for Cardboard Drums

CAUTION: Do not use metal drums with this model! The drum jacket is
designed only for cardboard drums!

NOTE: Models for cardboard drums have only the lower sealing ring on the
heating punch (configuration code: box 12 = J).

Divided Base Plate for Pallet Conveyance

The bulk melter is set up on a divided base plate. This enables a drum to be
moved under the punch on a pallet.
CAUTION: Risk of damage! Do not operate equipment until it is screwed
securely to the floor. Otherwise the descending punch would lift the system
off of the floor.

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 Introduction 2‐9

Electrical Cabinet

10

1
2 11
1
12
3
4
5

Fig. 2‐4
1 Button Two‐hand control 6 Main switch 9 Light tower
2 Pneumatic switch 7 Electrical cabinet ventilation 10 Electrical connections
3 Control system* 8 Base 11 Door lock
4 Indication lamp Remote 12 Week timer* (accessory)
(only with option Profibus)
5 Key switch Remote / local
(only with option Profibus)
Note: There are separate manuals available for components marked with an asterisk (*).

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

2‐10 Introduction

Button Two‐hand Control and Pneumatic Switch

Used to manually control the heating punch when the drum is being
changed.
WARNING: The two‐hand control may only be operated by one person
using both hands!

The pneumatic switch lights up green when the drum is inserted.

Control System
On the control system, values and parameters are set, and operating modes
and faults are displayed.
Refer to manual for the Control System used.

Key Switch Remote / Local and Indication Lamp Remote

When set to Remote, the system is not controlled by the internal control
system but via the interface Profibus (Option).

Main Switch
The main switch is used to switch the system on and off.
Position 0/OFF = System is switched off.
Position I/ON = System is switched on.
Padlocks can be used to protect the main switch from unauthorized access.

Black Main Switch (Special Model)

Systems with a black main switch are normally supplied with power by a
higher‐ranking system; the higher‐ranking main switch is on that system. The
black main switch does not perform the EMERGENCY OFF function.
Connected components can still be switched on!

Electrical Cabinet Ventilation

Air Filter / Fan with Filter
Electrical cabinet ventilation reduces the temperature inside of the electrical
cabinet. It must be serviced regularly. Refer to Maintenance.

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 Introduction 2‐11

Electrical Connections
Also refer to section Installation and to the wiring diagram.

Fig. 2‐5
1 Additional receptacles (with option 3 Receptacle XS5, tach generator
Additional heating channels) 4 Interface XS2
2 Interface Profibus (Option)

Additional Receptacles
Depending on the model, up to three additional receptacles are available.
Two heating zones (usually for hose and application head) can be controlled
via each receptacle.
NOTE: Hose receptacles on the terminal box (Pos. 15, Fig. 2‐2) are for
hoses connected to the bulk melter heating punch.

Interface PROFIBUS (Option)

The PROFIBUS interface enables Remote operation by a higher‐ranking
control unit. Refer to separate manual.

Receptacle XS5
The receptacle is used to connect pilot voltage that regulates the system's
electrical motor synchronously to the speed of the parent machine. The pilot
voltage can be supplied e.g. by a tach generator (accessory) driven by the
parent machine. Refer to Installation.

Interface XS2
Serves as a connection between the system and external devices.

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2‐12 Introduction

Week Timer (Accessory)

The week timer is used to automatically switch the system on and off. The
main switch must be set to I/ON (switched on) when using the week timer.
Refer to separate manual.

Door Lock
The electrical cabinet can be opened for installation, maintenance and repair.
Store the included key such that it is accessible only to qualified and
authorized personnel. The system may not be operated when the electrical
cabinet is open.
WARNING: Risk of electrical shock. Failure to observe may result in
personal injury, death, or equipment damage.

WARNING: Disconnect equipment from the line voltage.

Light Tower (Accessory)

The light tower shows the system operating modes.
Refer to section Troubleshooting and manual Control System.

White Switched on
Green Ready for operation
Yellow Drum almost empty (flashing light) and drum empty (light on)
Red Collective fault

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 Introduction 2‐13

Heating Punch
The heating punch consists of the heating plate, the melting plate and
sealing rings.
NOTE: Models for cardboard drums have only the lower sealing ring on the
heating punch (configuration code: box 12 = J).

Fig. 2‐6
1 Heating plate 2 Sealing rings 3 Melting plate (if present)

Melting Plates
Depending on what the bulk melter is used for, one of these melting plates is
used. The melting plates are all release coated.

Smooth melting plate Fine‐blade melting plate Axial melting plate

Fig. 2‐7

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2‐14 Introduction

Functioning

Raising and Lowering Heating Punch

A pneumatic cylinder controls raising and lowering of the heating punch.
When lowering the heating punch, a two‐hand control must be operated for
safety reasons until the heating punch is in the drum.
The air pressure in the pneumatic cylinders is limited to 7.5 bar (0,75 MPa /
109 psi) by a pressure restrictor valve.

Deaerating Drum
The drum deaeration valve must be opened manually so that air can escape
(drum is deaerated) when the heating punch is lowered into the drum.

Aerating Drum
Air must be introduced into the drum (drum is aerated) to prevent a vacuum
from forming when the heating punch is raised. Depending on the model, this
is done with an automatic drum aeration valve or must be prepared manually
by screwing in an aeration pipe.
The air pressure in the drum is limited to 1 bar (0.1 MPA / 14.5 psi) by a
pressure restrictor valve.

Air

Heating punch Heating punch

Compressed air

Drum Drum

Deaerating Aerating
Fig. 2‐8

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 Introduction 2‐15

Melting Process and Material Flow

The material is melted only directly below the melting plate (4). A pump (1)
(gear pump) feeds the melted material to the hose connection (3). From
there it flows through a heated hose to an application head or an assembly
handgun, possibly to a melter, to fill that unit.
A safety valve (2) limits the material pressure generated by the pump and
keeps it constant.

1 2

Fig. 2‐9 Principle drawing

Drive
An electronically controlled electrical motor drives a gear pump. It standardly
runs in manual mode. Automatic mode is also possible.
S Manual mode: In manual mode the motor/pump speed is held steady at
the manually set value.
S Automatic mode: In automatic mode (key‐to‐line mode) the motor/pump
speed is regulated synchronously to the speed of the parent machine.
For this to occur, the system must receive pilot voltage from the parent
machine.
NOTE: With the option Pressure control, the speed is regulated such that
the material pressure behind the pump is kept steady.

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2‐16 Introduction

Heating and Temperature Control

The heating punch is heated by cast‐in heating elements.
Temperatures are measured by sensors and electronically controlled.

Undertemperature Interlock
The undertemperature interlock prevents the system from being started up
before the material has exceeded the temperature setpoint minus
undertemperature value. However, every time initial heating occurs, the
interlock is not released until the actual temperature is 3 ° C (5.4 ° F) below
the temperature setpoint.
The undertemperature interlock locks the motors, solenoid valves and, in
some cases, other components of the application system. Refer to the wiring
diagram to determine which components are locked.

Overtemperature Indication / Shutdown

The independently operating overtemperature shutdown mechanisms
protect the system and the material from overheating. For overtemperature
shutdown, the heating and motor are switched off. The red indication lamp
Collective fault lights up.
S Overtemperature indication through temperature controller: When the
temperature setpoint plus overtemperature value has been reached, the
relay output Collective fault is switched and the red indication lamp
Collective fault lights. The system remains ready for operation.
S Overtemperature shutdown by temperature controller: The
overtemperature shutdown value is set automatically 30 ° C (54 ° F)
higher than the highest temperature setpoint value.
S Overtemperature shutdown by thermostat(s): Serves as an emergency
switch OFF in case the overtemperature shutdown of the temperature
controller does not function properly. Refer to section Technical Data for
shutdown value.
WARNING: When the overtemperature shutdown is triggered, there is either
a fault in settings or system malfunction. Switch off the system and have the
fault remedied by qualified personnel.

Temperature Setback
Serves to protect the material and save energy during interruptions in
production or work stoppages. Setback value and setback period are
adjustable.

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 Installation 3‐1

Section 3
Installation
WARNING: Allow only qualified personnel to perform the following tasks.
Observe and follow the safety instructions in this document and all other
related documentation.

Unpacking
Unpack carefully and check for damage caused during transport. Save pallet
and fastening and packing material for later use, or dispose of properly
according to local regulations.

Lifting (Unpacked System)

Refer to Technical Data for weight. Lift only with a suitable floor conveyor (lift
truck or fork lift).

Transport
S For systems with divided base plate:
CAUTION: Risk of damage! Do not move system without attaching
transport protection to the base plate.

S Refer to Technical Data for weight. Use only suitable transport devices.
S If possible, use the pallet on which the system was delivered, and fasten
the system to the pallet.
S Protect from damage, moisture and dust with suitable packing material.
S Avoid jolts and vibrations.

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3‐2 Installation

Storage
Do not store system outside! Protect from humidity, dust and extreme
temperature fluctuations (formation of condensation).

Setting Up
S For systems with divided base plate:
CAUTION: Risk of damage! Do not operate equipment until it is
screwed securely to the floor. Otherwise the descending punch
would lift the system off of the floor.

S Set up only in an environment that corresponds to the stated Degree of

Protection (Refer to Technical Data). Do not set up in a potentially
explosive atmosphere!
S Protect from vibration. Remove transport protection (if present).
S Ensure that there is sufficient free space around the system, especially
above it. Refer to Technical Data for dimensions.

Fig. 3‐1

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 Installation 3‐3

Removing
1. Convey all material out of system and remove drum.
2. When system will not be used for longer periods of time, purge with
cleaning agent if necessary (Refer to Maintenance).
3. Wipe off sealing ring and clean melting plate (Refer to Maintenance).
4. Disconnect all lines to the system, and allow system to cool.

Disposal
When your Nordson product has exhausted its purpose and/or is no longer
needed, dispose of it properly according to local regulations.

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3‐4 Installation

Exhausting Material Vapors

Ensure that material vapors do not exceed the prescribed limits. Always
observe the safety data sheet (MSDS) for the material to be processed.
If necessary, exhaust material vapors and/or provide sufficient ventilation of
the location of the system. On systems with exhaust hoods, material vapors
are suctioned directly at the drum.
NOTE: The exhaust hood must be connected to the customer's exhaust
device. Refer to Technical Data.

Customer's

System without exhaust hood System with integrated exhaust hood

Fig. 3‐2

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 Installation 3‐5

Electrical Connections
WARNING: Risk of electrical shock. Failure to observe may result in
personal injury, death, or equipment damage.

Laying Cable
WARNING: Use only temperature resistant cable in the heating part of the
system. Ensure that cables do not touch rotating and/or hot parts. Do not
pinch cables and check regularly for damage. Replace damaged cables
immediately!

Line Voltage
WARNING: Operate only with the line voltage stated on the ID plate.

NOTE: Permitted deviation from the rated line voltage is +5% / ‐10%.
NOTE: The power connection cable must have a cross‐section matching the
power consumption Pmax. (Refer to ID Plate).

Power Supply
The mains terminals are located in the electrical cabinet. Refer to Wiring
Diagram for connecting arrangement.

Hose Receptacle(s)
For electrical connection values, refer to Technical Data.

Operating with Assembly Handguns

For applications with assembly handguns that switch the motor via the
heated hose, the bridge XLS1: 1 ‐ 2 (Refer to Wiring Diagram) must be
removed.

Pilot Voltage / Tach Generator

For automatic mode, pilot voltage must be connected to XS5. The pilot
voltage can be supplied e.g. by a tach generator (accessory) driven by the
parent machine.
CAUTION: The pilot voltage may not exceed 160 VDC. Failure to observe
will result in damage to succeeding components.

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3‐6 Installation

Interface XS2
The interface serves as a connection between the system and external
devices. The functions are described in detail in the manual Control System
CS 20 for Bulk Melters, section Central Module with Digital Input/Output.
NOTE: It is essential to bridge Pin 9 with Pin 1 (24 VDC) before initial startup.
Also refer to plug connection diagram Interface XS2 for BM 20 (wiring
diagram).
NOTE: To conform with a European standard regarding electro‐magnetic
compatibility, only shielded cable may be connected. The shield must be
connected to ground in compliance with the standard (PE connection in plug
connector).
NOTE: Inductive loads (e.g. solenoid valves) connected to the system must
be equipped with a protective device (e.g. recovery diode) that disables the
inductive voltage generated when an inductive load is switched off.

Pin Input Output Function

1 ‐ 24 VDC Internal switching voltage for activating inputs 2, 3, 4, 5, 7 and 9.
The switching voltage must be connected to the appropriate input.
2 24 VDC ‐ Unit release (main contactor)
3 24 VDC ‐ Release Drives
4 24 VDC ‐ Switch on/off Temperature setback
5 24 VDC ‐ Release Motor for application 1
6 - ‐ Not assigned
7 24 VDC ‐ Release Motor for application 2
8 ‐ ‐ Not assigned
9 ‐ ‐ Internal link
10 ‐ ‐ Internal link
11 ‐ ‐ Not assigned
12 ‐ ‐ Internal link
13‐16 ‐ ‐ Not assigned
17 24 VDC ‐ External potential for outputs 18, 19, 20, 21, 24 and 26
external 24 VDC +/‐ 10 %
18 ‐ 24 VDC max. 2 A Indication Ready for operation
19 ‐ 24 VDC max. 2 A Indication Collective fault
20 ‐ 24 VDC max. 2 A Indication Drum almost empty
21 ‐ 24 VDC max. 2 A Indication Drum empty
22 ‐ ‐ Internal link
23 ‐ ‐ Not assigned
24 ‐ 24 VDC max. 2 A Valve control application 1
25 ‐ ‐ Not assigned
26 ‐ 24 VDC max. 2 A Valve control application 2
27‐32 ‐ ‐ Not assigned
PE ‐ ‐ Shield

NOTE: Refer to Wiring Diagram for electrical connection.

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 Installation 3‐7

Installing Heated Hoses

WARNING: Hot! Risk of burns. Wear heat‐protective gloves.

Laying Hoses
Guide hose through the hose guide. The hose connection is located on the
heating punch.

Connecting
If cold material can be found in the hose connection (1) and/or hose fitting
1 2 3 (2), these components must be heated until the material softens (approx.
80 _C, 176 _F).
1. First connect the hose (3) electrically to the unit. For more than one hose:
Every hose connection is allocated to a corresponding receptacle. Do not
mistakenly exchange!
2. Heat the system and hose to approx. 80 _C (176 _F).
3. Screw the heated hose onto the unit.
NOTE: Close unused hose connections with Nordson port plugs.

Disconnecting
WARNING: System and material pressurized. Relieve system pressure
before disconnecting heated hoses. Failure to observe can result in serious
burns.

Relieving Pressure
1. Set motor speed to 0 min‐1 (rpm); switch off motor(s).
2. Place a container under the nozzle(s) of the application head/assembly
handgun.
3. Activate the application head / assembly handgun electrically or
manually. Repeat this procedure until no more material flows out.
4. Re‐use the material or dispose of properly according to local regulations.

Second Open‐jawed Wrench

Use a second open‐jawed wrench when connecting and disconnecting the
heated hose. This prevents the unit's hose connection from turning.

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3‐8 Installation

Pneumatic Connection
Connect dry, clean and non‐lubricated compressed air (2). Set air pressure
for pneumatic cylinder to approx. 5 bar (0.5 MPa / 72.5 psi) on the pressure
controller (1). The setting can be modified according to the material
processed (max. 7.5 bar / 0.75 MPa / 109 ps).
The air pressure in the pneumatic cylinders is limited to 7.5 bar (0.75 MPa /
109 psi) by a pressure restrictor valve.
1

Preparing for Changeover System

The DIP switches S 8.1 and S 8.2 of the CS 20 control system's temperature
control panel board must be set to OFF (no leading channel) in changeover
systems. Refer to separate manual for control system.

Reducing Heating Punch Lifting Speed

NOTE: The lifting speed need only be reduced if the heating punch often lifts
the drum as it moves up.
1. Remove protective plate (1) from pneumatics.
2. Turn throttle screw (2) clockwise slightly with a screwdriver. The correct
setting must be determined by trial and error.
3. Attach protective plate again.
1
2

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 Installation 3‐9

Accessories
The following components can also be installed later as accessories:

Light Tower
The light tower must be screwed onto the electrical cabinet. It must be
connected to terminal XLWT according to the Wiring Diagram.

Week Timer
The week timer must be installed in the electrical cabinet. To do this, remove
clamp XLWZ and install the week timer in its place. Wire according to Wiring
Diagram.

Tach Generator
It is connected to receptacle XS 5.
Also refer to Wiring Diagram and manual Tach Generator.
NOTE: The pilot voltage produced by the tach generator must be adjusted
(Refer to manual for the control system used).
CAUTION: The pilot voltage may not exceed 160 VDC. Failure to observe
will result in damage to succeeding components.

Transformer
Systems designed for operating voltage of 400VAC, 3 Ph Y can be operated
at 200 or 240 VAC with the transformer.

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

3‐10 Installation

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 Operation 4‐1

Section 4
Operation
WARNING: Allow only qualified personnel to perform the following tasks.
Observe and follow the safety instructions in this document and all other
related documentation.

Initial Startup
NOTE: Some of the following tasks are described in detail in the subsequent
text.
1. Ensure that the switch rod is set to the drum height.
2. Set pneumatic switch to 0.
3. Set main switch to I/ON.
4. Control system: Set values and parameters.
5. Set week timer, if present.
6. Insert drum.
7. Pre‐select motor and switch on.
8. Set motor speed on control system to achieve desired output quantity.
With option Pressure Control: Set the setpoint pressure instead of the
motor speed.
NOTE: To prevent excessive wear, the motor/pump speed should not
continuously fall below 5 min‐1 (rpm) or continuously exceed 80 min‐1
(rpm).
9. Optimize settings and record in settings record form.

NOTE: All system functions were tested before the system left the factory.
Special test material was used. There may be residue from this material on
the melting plate, in the pump, etc. To remove such residue, melt and feed
several kilograms of material before starting production.

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

4‐2 Operation

Adjusting Switch Rod

Set the switch rod (2) such that it activates switch 4 when the upper sealing
1 ring (3) is completely submerged in the drum. To do this, release hexagonal
socket screw (1).
NOTE: Models for cardboard drums have only the lower sealing ring on the
2
heating punch (configuration code: box 12 = J).
3
Setting the switch rod adjusts the system to the drum height used. The switch
4 rod activates the switches (4, 5 and 6) one after the other and thus triggers
the following switching functions:

Switching Functions when Lowering

S Switches from two‐hand lowering mode to normal lowering mode when
the sealing ring (3) is completely submerged in the drum (switch 4).
5
S Triggers the drum almost empty indication (switch 5).
6 S Triggers the drum empty indication (switch 6).

Switching Functions when Raising

S Switches off the automatic drum aeration (switch 4).

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 Operation 4‐3

Setting Values and Parameters - Notes -

Many values and parameters are set on the control system.
For additional information, refer to control system used.

Speed, Pressure
With the option Pressure control, the speed is not regulated to a preset value;
the pressure at the material outlet is regulated.
In automatic mode, the speed and thus the output quantity is determined by a
pilot voltage. The pilot voltage is supplied e.g. by a tach generator driven by
the parent machine.

Temperatures
CAUTION: The temperature setting is determined by the processing
temperature prescribed by the adhesive supplier. The maximum operating
temperature for the product and heated components described here may not
be exceeded.

Nordson will grant no warranty and assume no liability for damage resulting
from incorrect temperature settings.

Recommended Values
The values stated in the tables are general values determined by experience;
deviation may prove necessary.

Heating zone / temperature / time Setting

Heating punch 10 ° C (18 ° F) below prescribed processing temperature
Undertemperature value 10 ° C (18 ° F) (deviation from setpoint)
Overtemperature value 10 to 30 ° C (18 to 54 ° F) (deviation from setpoint)
Temperature setback value (standby) As needed
Setback period As needed
Application head (accessory) Prescribed processing temperature
Heated hose (accessory) Prescribed processing temperature

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

4‐4 Operation

Inserting and Replacing Drum

CAUTION: Place only undamaged, suitable drums in the system; otherwise
the heating punch sealing ring will be damaged. Always keep the base plate
of the system clean so that the drum is positioned straight.

WARNING: Risk of burns! Hot material can splash out when the heating
punch exits the drum. Hot material may flow out of the deaeration valve.
Wear suitable protective clothing!

NOTE: Some of the following tasks are described in detail in the subsequent
text.
1. Raise heating punch.
2. Set pneumatic switch to 0/Stop.
3. Insert or replace drum. The pneumatic switch lights up green when the
drum is inserted.
4. Lubricate sealing ring. Refer to Processing Materials in the section
Technical Data.
5. Lower heating punch.
6. Properly dispose of empty drum according to local regulations.

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 Operation 4‐5

Raising Heating Punch

If the heating punch is inside of the drum, the drum must be aerated to
support raising. Aerating means that compressed air is forced under the
heating punch.

1 1. Aeration must be done manually for models without automatic aeration

valve:
2 a. Screw out rod (1).
b. In place of the rod, screw in the aeration pipe (2, stored in the holder
a on the electrical cabinet).
c. Attach aeration connection (3, stored on the cross beam) to aeration
pipe.
2. Set pneumatic switch to Raise.
Automatic drum aeration begins when the pneumatic switch is moved to
2 Raise and ceases when the punch leaves the drum. In case the heating
b punch lifts the drum:
S Quick fix: Set pneumatic switch to 0 and press two‐hand control to
increase air pressure in drum.
S Long term solution: Reduce heating punch lifting speed (Refer to
Installation).

3 The air pressure in the drum is limited to 1 bar (0.1 MPA / 14.5 psi) by a
pressure restrictor valve.
c

Lowering Heating Punch

The drum must always be deaerated when the heating punch is moved into
the drum. When the drum is deaerated, the air that is under the heating
punch escapes.
1. Set pneumatic switch to Lower.
2. Place the drip pan (3) in front of the deaearation valve (2).
3. Open deaeration valve on lever (1).
1
4. Press both buttons on the two‐hand control at the same time
(within 0.5 seconds) until the heating punch is inside of the drum.
2 The downward movement continues on its own.
5. Close deaeration valve when material flows out free of bubbles.
3
6. Properly dispose of material according to local regulations.

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4‐6 Operation

Switching System ON/OFF

NOTE: Before initial startup, read and observe the instructions in Initial
Startup. Start up only as described under Initial Startup.
NOTE: The main switch must be set to I/ON (switched on) when using the
week timer (accessory). Additional information on the week timer can be
found in the manual Week Timer.
NOTE: When external system release via interface XS2 is used, the main
switch must be set to I/ON (switched on).

Daily Startup
NOTE: Do not operate Nordson pumps without material. Before switching on
motor, ensure that a drum that is not empty is in the system and that the
heating punch has contact with the material.
NOTE: To prevent excessive wear, the motor/pump speed should not
continuously fall below 5 min‐1 (rpm) or continuously exceed 80 min‐1 (rpm).
1. Set main switch to I/ON.
2. Set pneumatic switch to Lower.
3. Wait until system is ready.
4. Pre‐select motor.
5. Switch on motor.

Daily Switchoff
1. Set main switch to 0/OFF and protect from unauthorized access with
padlocks if necessary.
2. Set pneumatic switch to Stop.
3. Perform daily maintenance.

P/N 397189E BM200_EASY_GEAR E 2006 Nordson Corporation

 Operation 4‐7

Switching Off in an Emergency

WARNING: Immediately switch off the system in any emergency situation.

1. Set main switch to 0/OFF or - when available - press EMERGENCY OFF

button (special feature).
2. Set pneumatic switch to 0/Stop.
3. After standstill and before switching the system back on, have the fault
remedied by qualified personnel.

Black Main Switch (Special Model)

Systems with a black main switch are normally supplied with power by a
higher‐ranking system; the higher‐ranking main switch is on that system. The
black main switch does not perform the EMERGENCY OFF function.
Connected components can still be switched on!

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

4‐8 Operation

Settings Record Form

Production information:

Application material Manufacturer

Processing temperature
Viscosity

Cleaning agent: Manufacturer

Flash point

Leading channel: Factory‐set

Processing temperatures (Setpoint temperatures):

Heating punch
Heated hose (accessory) 1) 2) 3) 4)
Application head (accessory) 1) 2) 3) 4)
Assembly handgun (accessory) 1) 2) 3) 4)

Motor/pump speeds:
Motor/pump

Air pressure: bar MPa psi

Operating pressure

Notes:

Name Date

P/N 397189E BM200_EASY_GEAR E 2006 Nordson Corporation

 Maintenance 5‐1

Section 5
Maintenance
WARNING: Allow only qualified personnel to perform the following tasks.
Observe and follow the safety instructions in this document and all other
related documentation.

NOTE: Maintenance is an important preventive measure for maintaining

operating safety and extending the lifetime of the unit. It should not be
neglected under any circumstances.

Risk of Burns
WARNING: Hot! Risk of burns. Wear appropriate protective
clothing/equipment. Some maintenance work can only be done when the
system is heated up.

Relieving Pressure
WARNING: System and material pressurized. Relieve system of pressure
before disconnecting heated hoses, application heads and assembly
handguns. Failure to observe can result in serious burns.

1. Set motor speed to 0 min‐1 (rpm); switch off motor(s).

2. Place a container under the nozzle(s) of the application head/assembly
handgun.
3. Activate the application head / assembly handgun electrically or
manually. Repeat this procedure until no more material flows out.
4. Re‐use the material or dispose of properly according to local regulations.

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

5‐2 Maintenance

Daily Maintenance
The maintenance intervals are general guidelines based on experience.
Depending on the location of the system, production conditions and
operating time of the system, other maintenance intervals may prove
necessary.

Unit part Activity Interval Refer to

Complete system External cleaning Daily Page 5‐4
Inspect for external damage Page 5‐4
Power cable Inspect for damage -
Air hoses Inspect for damage -
Displays and lamps Function check (test) Manual
Control System
Electrical cabinet ventilation Clean fan screens, clean or Daily, if dust Page 5‐4
replace filter accumulation is
severe
Melting plate Check melting plate for Every time the Page 5‐7
charred material, clean if drum is changed
necessary
Sensor Drum inserted Check sensor for material -
residue or other impurities,
clean if necessary
Base plate Check base plate for material -
residue or other impurities,
clean if necessary
Electrical motor Clean fan cover Daily, if dust Manual Motor
accumulation is
severe

P/N 397189E BM200_EASY_GEAR E 2006 Nordson Corporation

 Maintenance 5‐3

Regular Maintenance
The maintenance intervals are general guidelines based on experience.
Depending on the location of the system, production conditions and
operating time of the system, other maintenance intervals may prove
necessary.

Unit part Activity Interval Refer to

Compressed air filter Drain condensate Weekly Page 5‐5
Clean filter element Every three
months
Clean condensate collector When cleaning
filter element
Pneumatic pressure restrictor Function test Every six months Page 5‐6
valve Clean When not
functioning
correctly
Safety valve Refer to separate manual
Pump
Electrical motor

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

5‐4 Maintenance

External Cleaning
External cleaning prevents pollution created by production from causing
system malfunctions.
CAUTION: Observe the unit's Degree of Protection when cleaning (Refer to
section Technical Data).

CAUTION: Do not damage or remove warning signs. Damaged or removed

warning signs must be replaced by new ones.

Remove material residue only with a cleaning agent recommended by the

material supplier. Heat with an air heater if necessary.
Remove dust, flakes etc. with a vacuum cleaner or a soft cloth.

Visual Inspection for External Damage

WARNING: When damaged parts endanger the operating safety and/or the
safety of personnel, switch off the system and have the damaged parts
replaced by qualified personnel. Use only original Nordson spare parts.

Electrical Cabinet Ventilation

The electrical cabinet fans require no maintenance. The filters must be
cleaned or replaced, depending on dust accumulation.

ÂÂÂ
ÂÂÂ
ÂÂ
A dirty filter can be recognized by its dark color. It is cleaned by shaking the
filter out.

ÂÂÂ
ÂÂÂ
ÂÂÂÂÂ
ÂÂÂ
Â
ÂÂÂ
ÂÂ
ÂÂÂ
Â
ÂÂÂ
Â

P/N 397189E BM200_EASY_GEAR E 2006 Nordson Corporation

 Maintenance 5‐5

Compressed Air Filter

The compressed air filter dehydrates and cleans the compressed air.

Draining Condensate
Drain condensate before it reaches a level approx. 10 mm below the filter
disk.
To do this, open the condensate drain valve (7).

7
10 mm

Cleaning Filter Element

Under normal conditions, clean filter element (5) approx. every three months.
Clean sooner if compressed air filter outlet pressure falls.
1
1. Stop compressed air supply and release residual pressure by opening
the condensate drain valve (7).
2 2. Unscrew condensate collector (6).
3 3. Unscrew filter element (5) by turning to the left.
4. Rinse filter element (5) with suitable cleaning agent. Then blow out from
4 the inside. The condensate collector (6) may not come into contact with
the cleaning agent!
5. Clean condensate collector (6) if necessary. Use only water!
5 6. Reassemble compressed air filter.

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

5‐6 Maintenance

Pneumatic Pressure Restrictor Valves

The factory‐set, lead‐sealed pressure restrictor valves prevent unpermissibly
high pressurization of subsequent pneumatic components. When the values
set at the factory are exceeded, the compressed air is audibly discharged.
NOTE: There are pressure restrictor valves
S on the drum aeration valve (4, Fig. 2‐2)
S in the pneumatic box (1).
1

Function Testing of Pressure Restrictor Valve

Functioning of the pressure restrictor valve should be checked approx. every
six months. Do this by turning the knurled screw until the compressed air is
audibly released. When functioning is not correct, the pressure restrictor
valve should be cleaned. If it is still not working as it should, it must be
replaced.
NOTE: A defective pressure restrictor valve may be replaced only with an
original spare valve. Repairs to the pressure restrictor valve may be made
only by the manufacturer!

Cleaning Pressure Restrictor Valve

Pollution that has penetrated seat surfaces and conical nipples can be
removed by unscrewing the entire top piece - without changing the minimum
operating pressure. Use a sickle wrench to unscrew.

ÂÂ
Â
Â

Function test Unscrewing top

Fig. 5‐3
Note: The illustration shows the old model with locking wire instead of a lead sealing disk.

P/N 397189E BM200_EASY_GEAR E 2006 Nordson Corporation

 Maintenance 5‐7

Changing Type of Material

CAUTION: PUR material may be processed only in models with exhaust
hood and manual drum aeration valve!

NOTE: Before changing the material type, determine whether the old and
new material can be mixed.
S May be mixed: Remaining old material can be flushed out using the new
material.
S May not be mixed: Purge thoroughly and clean melting plate with a
cleaning agent recommended by the material manufacturer (Refer to
Cleaning Melting Plate).
NOTE: Properly dispose of the old material according to local regulations.

Purging with Cleaning Agent

CAUTION: Use only a cleaning agent recommended by the hot melt
material manufacturer. Observe the Material Safety Data Sheet for the
cleaning agent.

Before starting production again, flush out residue of the cleaning agent
using the new material.
NOTE: Properly dispose of cleaning agent according to local regulations.

Cleaning Melting Plate

The melting plate is standardly release‐coated. This makes it easy to clean.
Cooled material can usually be pulled off of the melting plate; if necessary,
first heat to 60 _C / 140 _C.
CAUTION: Do not use hard or metallic tools to clean. Do not use wire
brushes! This could damage the release coating. Use only soft aids (wooden
or PTFE- spatula or soft brush).

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

5‐8 Maintenance

Maintenance Record Form

Unit part Date / name Date / name Date / name
Electrical cabinet ventilation

Compressed air filter

Pneumatic pressure restrictor

valve

Safety valve

Pump

Electrical motor

P/N 397189E BM200_EASY_GEAR E 2006 Nordson Corporation

 Troubleshooting 6‐1

Section 6
Troubleshooting
WARNING: Allow only qualified personnel to perform the following tasks.
Observe and follow the safety instructions in this document and all other
related documentation.

WARNING: Troubleshooting activities may sometimes have to be carried

out when the system is energized. Observe all safety instructions and
regulations concerning energized unit components (active parts). Failure to
observe may result in an electric shock.

Some Tips
Before systematic troubleshooting is begun, the following should be
checked:
S Are all parameters set correctly?
S Is the XS 2 interface connected correctly?
S For automatic mode: Is pilot voltage present?
S Do all plug connections have sufficient contact?
S Have circuit breakers/fuses been activated?
S Could the fault have been caused by an external PLC?
S Are external, inductive loads (e.g. solenoid valves) equipped with
recovery diodes? The recovery diodes must be directly allocated to the
inductive load, e.g. through luminous sealings.

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

6‐2 Troubleshooting

Troubleshooting with Control System

The control system offers the following troubleshooting aids, described in the
manual Control System:
S Indication lamps and light tower
S Diagnosis program in the temperature section
S Automatic fault display in the temperature section
S Service display Error in the motor section
S LEDs on the modules and boards.

Indication Lamps and Light Tower

With the exception of the yellow light on the light tower, the indication lamps
and the light tower indicate the same modes as the control system:
S Red = Collective fault. The red lamp indicates that the control system has
recognized a fault.
S White = Switched ON. After switching on and during the heatup phase, at
first only the white indication lamp is lit (normal condition). A fault has only
occurred when the temperature does not increase (observe temperature
display) and when the green indication lamp is not lit after the heatup
phase has ended (1 hour and longer).
S Green = Ready for operation. The green indication lamp lights when all
channels have reached their setpoint temperatures.
S Yellow = Lower tank level, as set by customer.

17 Red

1 2 3 4 5 6 7 8 9 10 11 12

18 White
1 2 3 4 5 6 7 8 9 10 11 12

1 1 2 2 3 3 4 4 1 2

M1 min-1 bar
psi
C
F 19 Green

Fig. 6‐1 (Refer to manual Control System for position numbers)

P/N 397189E BM200_EASY_GEAR E 2006 Nordson Corporation

 Troubleshooting 6‐3

Troubleshooting Tables
The troubleshooting tables serve as an orientation for qualified personnel.
They cannot, however, replace targeted fault location with the help of wiring
diagrams and measuring instruments. They also do not include all possible
problems, only those which most typically occur.

Problem Possible Cause Corrective Action

System has no Main switch is set to 0 Set main switch to 1
electrical function Fuses are defective Check fuses in electrical cabinet
No line voltage supplied Check whether there is line voltage at
the line voltage terminals in the electrical
cabinet
Week timer programmed incorrectly Program differently
System has no There is no compressed air Connect compressed air
pneumatic Pressure controller set incorrectly Set pressure controller to max. 7.5 bar
function (0.75 MPa / 109 psi)
System does not Temperatures not set correctly on Check temperature settings for all
reach Ready temperature controller channels
Only the white Fuses for individual channels defective Check fuses for individual channels
indication lamp is Temperature setback switched on Switch off or wait until the setback period
lit has expired
Automatic temperature setback after Stop temperature setback
motor standstill activated
Channel is switched off Switch on
Channel is switched to measuring mode Switch to control mode
Channel/Heating zone defective Activate diagnosis program of the
temperature section
Continued...

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

6‐4 Troubleshooting

Problem Possible Cause Corrective Action

Too little or no System, hose and application head / Check all temperature settings.
material comes assembly handgun are cold or have not Consider heating phase
out the right temperature
Material viscosity too high Observe temperature instructions of
material manufacturer
Increase operating air pressure of bulk
melter (max. 7.5 bar / 0.75 MPa /
109 psi)
Motor does not turn Undertemperature interlock has not yet
released
Check position of motor switch
Check speed setting
Are fuses on motor controller functional?
Is motor controller functional? Is motor
functional?
Have motor controller or motor checked
- and, if necessary, replaced - by
qualified personnel
Pump turns, but feeds no or too little Check that pump functions correctly
material
Nozzle on application head or assembly Unscrew warm nozzle and clean
handgun blocked
Filter - if present on application head - is Replace filter cartridge
blocked
Heating punch can Sensor Drum inserted transmits no Clean sensor, check position
not be lowered signal The pneumatic switch lights up green
when the drum is inserted
Is the pneumatic switch set to Lower? Set pneumatic switch to Lower
Is the drum deaerated? Deaerating drum
Heating punch Set pneumatic switch to 0 If air continuously escapes from the
moves irregularly switch in this position, the switch is
or not at all defective and must be replaced
Set pneumatic switch to Raise If air continuously escapes from the
valve drain hole in this position, the
seals in the air cylinders are probably
defective and must be replaced
Pneumatic cylinder seals leak Replace seals
Heating punch lifts Lifting speed too high Reduce heating punch lifting speed
drum (Refer to Installation)

P/N 397189E BM200_EASY_GEAR E 2006 Nordson Corporation

 Repair 7‐1

Section 7
Repair
WARNING: Allow only qualified personnel to perform the following tasks.
Observe and follow the safety instructions in this document and all other
related documentation.

WARNING: Hot! Risk of burns. Wear appropriate protective

clothing/equipment. Some maintenance work can only be done when the
system is heated up.

WARNING: System and material pressurized. Relieve system of pressure

before disconnecting heated hoses, application heads and assembly
handguns. Failure to observe can result in serious burns.

General Notes
S Material hoses can not be repaired. However, defective hoses can be
exchanged for overhauled hoses with full guarantee through Nordson's
AT program (replacement program).
S The processed material must be soft for disassembly of some
components. Heat the system to softening temperature. Use a hot air fan
if necessary.
S Use only original Nordson spare parts. Refer to separate document Parts
List for details.
S Also refer to separate manuals for the individual components.

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

7‐2 Repair

Replacing Sealing Ring

WARNING: Hot! Risk of burns. Wear heat‐protective gloves.

NOTE: Models for cardboard drums have only the lower sealing ring on the
heating punch (configuration code: box 12 = J).
1. Heat heating punch to operating temperature.
2. Aerate drum.
3. Set pneumatic switch to Raise until the heating punch exits the drum.
4. Set pneumatic switch to 0/Stop.
5. Place a clean, hard, heat‐resistant surface (e.g. metal plate) on the drum
under the melting plate.
6. Set pneumatic switch to Lower until the melting plate reaches the resting
surface.
7. Set pneumatic switch to 0/Stop.
8. Cut old sealing rings with a knife and dispose of properly.
CAUTION: Do not damage release coating.

9. Heat solid rubber or PTFE‐coated sealing rings in an oven.

10. Clean and lubricate grooves. Refer to Processing Materials in section
Technical Data for lubricant.
11. Put heated sealing rings into place on heated punch with two people.

180 ‐ 200 ° C
(356 ‐ 392 °F)

Fig. 7‐1

P/N 397189E BM200_EASY_GEAR E 2006 Nordson Corporation

 Repair 7‐3

Replacing O‐rings
When leakage occurs, e.g. at the hose connections, the O‐rings must be
replaced. Observe the following:
S Clean and lubricate O‐ring groove. Nordson recommends
high‐temperature grease; refer to Processing Materials in section
Technical Data.
S Also lubricate O‐ring.
S Do not use removed O‐rings again.
S Tighten hose connections and blind covers with a torque wrench to
9.5 Nm.

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

7‐4 Repair

Replacing Melting Plate Temperature Sensor and

Thermostat
WARNING: Hot! Risk of burns. Wear heat‐protective gloves.

1. Heat heating punch to operating temperature.

2. Aerate drum.
3. Set pneumatic switch to Raise until the heating punch exits the drum.
4. Set pneumatic switch to 0/Stop.
5. Place a clean, hard, heat‐resistant surface (e.g. metal plate) on the drum
under the melting plate.
6. Set pneumatic switch to Lower until the melting plate reaches the resting
surface.
7. Set pneumatic switch to 0/Stop.

WARNING: Risk of electrical shock. Failure to observe may result in

personal injury, death, or equipment damage.

8. Disconnect the system from the line voltage.

9. Remove cover (1).

3 2

Fig. 7‐2

P/N 397189E BM200_EASY_GEAR E 2006 Nordson Corporation

 Repair 7‐5

NOTE: If the temperature sensor is defective: Continue with Step 16.

10. Remove thermostat (2) along with fastening screws and spring washers.
11. Extract connecting cable from porcelain terminals.
12. Apply heat transfer compound to contact surfaces of the new thermostat
(Refer to Processing Materials in section Technical Data), then install the
thermostat with spring washers and screws.
13. Connect thermostat wires to porcelain terminals.
14. Screw on cover.
15. Start up system.

Replacing Temperature Sensor

First perform steps 1 to 9.
16. Release nipple (4) on temperature sensor (3), then remove temperature
sensor.
17. Apply heat transfer compound to the new temperature sensor, then press
it into the nipple. Then fasten the nipple.
18. Install cover (1) again.
19. Start up system.

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

7‐6 Repair

P/N 397189E BM200_EASY_GEAR E 2006 Nordson Corporation

 Technical Data 8‐1

Section 8
Technical Data

General Data
Type of heating Cast‐in electrical resistance heating elements
Temperature sensor Ni 120
Degree of protection IP 54
Heatup time 30 to 60 minutes, depending on system, material
used and ambient temperature
Noise emission < 72 dBA

Electrical Specifications
WARNING: Operate only at the operating voltage shown on the ID plate.

Operating voltage Refer to ID plate

Operating voltage frequency 50/60 Hz
Fuse rating Refer to ID plate
Power consumption P Refer to ID plate
Power consumption Pmax Refer to ID plate
Load per hose receptacle (2 channels) Max. 1800 Watt
Max. pilot voltage (input voltage) 160 VDC
The pilot voltage may not exceed 160 VDC. Failure
to observe will result in damage to succeeding
components.
or 0 ‐ 10 V
The pilot voltage must be adjusted (Refer to manual
Control System).

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

8‐2 Technical Data

Motors / Speeds
Motor Motor / gear pump speed setting range
3‐phase AC motor with helical gear 1 to 100 min‐1
To prevent excessive wear, the motor/pump speed
should not continuously fall below 5 min‐1 (rpm) or
continuously exceed 80 min‐1 (rpm).

Temperatures and Thermostats

Temperatures System / components °C °F
Min. ambient temperature - 10 50
Max. ambient temperature - 40 104
Min. operating temperature - 50 122
Adjustable operating temperatures Depending on the heating channel max. . . . 230 446
CAUTION: When setting the
temperature, the temperature
prescribed by the hot melt adhesive
manufacturer is decisive. The
maximum operating temperature for the
product and heated components
described here may not be exceeded.
Overtemperature shutdown by Permissible thermostats
thermostat 230 ° C 450 ° F
177 ° C 350 ° F
150 ° C 300 ° F
Replacing thermostat: refer to Repair

Air Consumption
Per cycle (melting plate down and up) Approx. 600 l

Exhaust Hood
Nominal air quantity (recommendation) 510 m3/h
Pressure loss at nominal air quantity Approx. 180 Pa
Connecting sleeve ∅ 150 mm

P/N 397189E BM200_EASY_GEAR E 2006 Nordson Corporation

 Technical Data 8‐3

Material Pressures
Motor/pump model (standard) bar MPa psi
Three‐phase AC motor with gear pump 5 to 100 0.5 to 10 72.5 to 1450
Note: Safety valve setting is decisive for maximum 35 3.5 507.5
outlet pressure. Factory setting:

Dimensions
System Drum diameter Min. drum height* Max. drum height*
BM 200 571 mm 830 930
* The switch rod must be adapted to the max. drum height (Refer to section Operation)

2720
1730

1270*

B 800

953*

Fig. 8‐1
Note: Dimensions with an asterisk (*) apply to models with an exhaust hood.

E 2006 Nordson Corporation BM200_EASY_GEAR P/N 397189E

8‐4 Technical Data

Weight
System Weight
BM 200 Approx. 730 kg

Processing Materials
Before using, read the included EU safety data sheet.

Lubricating Heating Punch Sealing Rings

Lubricant Centoplex H0
Chemical characterization Mineraloil, lithium soap
Manufacturer Klüber Lubrication, D‐81379 München
Nordson order number P/N 285600

Inserting Thermostats and Temperature Sensors

Type Heat transfer compound
Nordson order number P/N 257326

Lubricating O‐rings
High temperature grease Caution: Do not mix this
lubricant with other lubricants!
Tube 250 g P/N 783959
Cartridge 400 g P/N 402238

Screw Locking Device

Screw locking device Warning: Observe
Thread seal Loctite 241, P/N 789772 manufacturer's safety
50 ml bottle instructions

Activator Loctite 7471, P/N 219186

500 ml bottle

P/N 397189E BM200_EASY_GEAR E 2006 Nordson Corporation