Operation 4-1

Section 4
Operation

WARNING! Allow only personnel with appropriate training and experience

to operate or service the equipment. The use of untrained or inexperienced
personnel to operate or service the equipment can result in injury, including
death, to themselves and others, and damage to the equipment.

This section provides information about the following operator-level tasks:

 Filling the melter tank

 Starting the melter
 Monitoring melter operation
 Adjusting the operating temperature of heated components
 Using the melter function keys
 Shutting the melter down
Most of the controls described in this section are located on the
control panel behind the keypad door. Refer to Section 2, Key Components,
for the location of the control panel.

Additional Information
This section presents operating procedures in their most commonly used
form. 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.

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4-2 Operation

More about Heated Components

The melter contains three groups of heated components. These are the
tank group, which contains the tank and the manifold, the hose group, and
the gun group. Component groups are represented on the control panel by
the component keys shown to the left.

Heated components within each group are identified by their position

number. The position of the tank and pump is fixed at 1. Hose and gun
position numbers are automatically assigned based on the hose/gun
receptacle they are connected to. For example, the position numbers of a
hose/gun pair that is connected to the second receptacle would be hose
Component keys position 2 and gun position 2.
(tank, hose, and gun)
The number of hose/gun receptacles available on each melter depends on
the configuration in which the melter was ordered. ProBlue adhesive
melters may have either two, four, or six hose/gun receptacles. An optional
expansion base may be ordered that adds receptacles for two additional
hoses/guns.

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 Operation 4-3

Filling the Tank

Before filling the tank, confirm that the hot melt material is compatible with
the melter. Refer to Section 2, Intended Use, for information about hot melt
materials that should not be used in ProBlue melters.

The tank is equipped with a low-level float switch. When the volume of
adhesive in the tank reaches approximately one-half of the tank’s rated
capacity, the float switch turns on the low-level LED located on the control
panel.
Low-level LED (yellow)

To fill the tank

WARNING! Hot! Risk of burns! Use a scoop to fill the tank with hot melt
Never use your bare hands. Using your bare hands to fill the tank may
result in personal injury.

1. Open the tank lid.

See Figure 4-1

2. Use a scoop to fill the tank with hot melt up to the tank fill line. The line is
marked on the screen that protects the tank float switch. Table 4-1 lists
the tank capacity of each ProBlue melter.
3. Close the tank lid when you are finished filling the tank.

Figure 4-1 Tank fill line

Table 4-1 Tank Capacity

Model Capacity
Liters Kilograms Pounds
P4 4 4 9
P7 7 7 15
P10 10 10 22
*Assumes a hot melt with a specific gravity of 1

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4-4 Operation

Starting the Melter

Before starting the melter for the first time, confirm that the

 melter is fully installed including any required inputs and outputs,

gun drivers, pattern controllers, and timers
 melter’s operating parameters are set up to support the
current manufacturing process
Refer to Section 3, Installation, if any of the items listed above are
not complete.

To start the melter

1. Switch the melter on.
The melter:
 Tests the control panel LEDs
Melter control switch (on/off)
 Turns on the heaters (the heaters LED turns green)
 Begins to automatically scan through and display the
actual temperature of the tank and each hose and gun that has a
set-point temperature that is greater than zero degrees. The
sequence of the automatic scan is: tank, each hose and gun pair,
and then back to the tank.
Heaters LED  Turns on the ready LED (green) when the tank and all of the
hoses and guns are within 3 C (5 F) of their assigned
set-point temperature.
NOTE: Appendix D contains a functional description of the pump.
2. Check the air pressure gauge on the front of the melter to confirm
that the operating air pressure is set correctly.
Automatic scan sequence
NOTE: The minimum operating air pressure is 0.7 bar (10 psi).
Operating the melter with the air pressure set to less than 0.7 bar (10
psi) may cause the pump to function erratically.

Ready LED

Air pressure gauge

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 Operation 4-5

If the melter is switched on when Appendix B, Parameter 4

the temperature of the tank is 27 C (50 F)
or greater below its assigned
set-point temperature (cold start condition), the
ready LED will not turn on until the ready delay
(defined when the melter was set up) has
elapsed.

The time remaining on the ready delay (in Appendix B, Parameter 4

minutes) appears in right display at the end of
every scan cycle. When only one minute remains
in the ready delay time, the right display counts
down in seconds.

You can by-pass the ready delay time by

pressing the Heaters key twice.

The appearance of F4 in the right Section 4, Monitor Melter Faults

display immediately after the melter is switched
on indicates a problem with the
melter’s processor or main board.

The appearance of F1 in the right Section 6, Troubleshooting

display immediately after starting the
melter indicates that a hose or gun cordset may
be loose or disconnected.

If the melter is set up for manual Appendix B, Parameter 8

pump activation, the pump LED will not turn
on when the melter is ready.

The condition of one or more inputs, Section 3, Installing Inputs

may prevent the heaters from turning on.

If the seven-day clock feature was set up and Section 4, Using Melter Function Keys
turned on when the melter was last switched off,
the clock will automatically turn on the next time
the melter is switched on.

It is normal for the pump to slowly cycle when no

hot melt is being dispensed from the guns.

If a power failure occurs, the melter will restart in

its normal heat-up cycle, even if the heaters
were off or the melter was in standby prior to the
power failure. 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.

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4-6 Operation

Monitoring the Melter

The melter provides indicators that allow you to:

 Quickly confirm that the melter is operating correctly

 Monitor the actual temperature of the manifold and each hose
and gun
 Identify melter faults
 Identify when the level of hot melt in the tank is low
 Check the operating air pressure
 Determine when service is required
The melter automatically determines the number and location of all
hoses and guns that are connected to it. Refer to More About
Heated Components, earlier in this section, for information about hose/gun
capacity and the identification of heated components.

You can also use a personal computer to monitor the melter. Refer to
Appendix C, Melter Communications, for information about connecting a
personal computer to the melter and installing the required software.

Confirm that the Melter is Operating Correctly

The ready LED turns on (green) when all of the heated components
are within 3 C (5 F) of their set-point temperature.

The ready LED will not turn on, or will turn off, if any of the following events
occur:

Ready LED  The ready delay is still counting down.

 The operator or a remote input places the melter in the standby
mode.
 The seven-day clock places the melter in the standby mode.
 There is a fault (the fault LED will turn on).
Refer to Monitoring 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.

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 Operation 4-7

Heated components with a set-point temperature

of zero degrees are skipped during the automatic
scan cycle.

The set-point temperature of the tank and

the manifold cannot be set independently.

The time remaining on the ready delay appears Appendix B, Parameter 4

in the right display at the end of each scan
cycle.

You can override the seven-day clock at Section 4, Using Melter Function Keys
any time. If the clock has turned the heaters
off, pressing the heaters key will turn the heaters
back on. If the clock has placed the melter into
the standby mode, pressing the standby key will
return the heated components to their assigned
set-point temperature.

Monitor Component Temperatures

You can check the actual temperature of each heated component—the tank
and each hose and gun—using the automatic scan mode or by manually
selecting and checking each component.

By default, the melter remains in the automatic scan mode except when:

 The melter is placed into the setup mode

 The set-point temperature of all hoses and guns is set to zero
degrees
 A fault occurs

To check component temperatures using the automatic scan mode

1. When the ready LED is on, observe the LEDs on the component keys.
2. When the LED on the key that represents the desired component
group (tank, hose, or gun) turns on, observe the left display until it
indicates the position number of the specific component you want to
check.
3. When the position number of the desired component appears in the
LEDs on component keys
left display, observe the right display to determine the component’s
actual temperature.

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4-8 Operation

Monitor Component Temperatures (contd)

To manually check a component’s temperature

1. Press the key (tank, hose, or gun) that represents the component
group you want to check.
The automatic scan stops and the left display indicates the number
of the first sequential component in the selected component group. The
right display indicates the component’s actual temperature.

NOTE: When the tank key is pressed, the left display does not
indicate a component number (blank display).
Left display and scroll key
2. If the first sequential component is not the component you want
to check, use the left-display scroll key to change to the correct
component number.
The right display indicates the actual temperature of the
selected component.

Component temperature display 3. Press the Setup key twice to return to the automatic scan mode.

When you scroll the left display past

the number of the last sequential component
in a component group, the number of the
first sequential component in the next
component group appears in the left display.

The melter will return to the automatic

scan mode two minutes after the last key
is pressed.

When you press the Tank key, it is the

manifold temperature that is
actually indicated in the right display. To
check the actual temperature of the
tank, simultaneously press the Tank key and
the left-display scroll key.

The default unit for temperature display Appendix B, Parameter 20

is degrees Celsius (C). This may be
changed to degrees Fahrenheit using
operating parameter 20.

The LEDs on each component key

will change from green to yellow if
any component in the component group
drops more than 3 C (5 F) below its
assigned set-point temperature.

You can check the set-point temperature of a

component at any time, by pressing the
right-display UP scroll key. Holding down the
scroll key while the melter is in the automatic
scan mode reveals the set-point of each
component that is scanned.

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 Operation 4-9

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4-10 Operation

Monitor Melter Faults

The melter alerts the operator to the faults listed in Table 4-2. Faults affect
the melter in one of three ways: the heaters turn off; the heaters remain on,
but the fault condition persists; or the melter stops functioning.

When a fault occurs, you must diagnose and correct the fault condition and
then place the melter back into operation. You can use the fault log to
determine the type, order, and relative time of the last ten faults.

Table 4-2 Melter Faults

Display
Name Affect on Melter Cause
Code/Sub-code
The RTD for the component indicated has
F1/None RTD Heaters turn off failed or the component was disconnected
from the melter.
The actual temperature of the component
indicated has dropped below the under
F2/None Under temperature Heaters turn off
temperature delta, which was set using
parameter 22.

The actual temperature of the component

indicated has increased beyond the over
F3/None Over temperature Heaters turn off
temperature delta, which was set using
parameter 21.

Melter stops Internal RAM failure

F4/1 RAM test
functioning

Heaters remain on, Internal clock failure

F4/2 Internal Clock time but fault condition
persists
Heaters remain on, Battery-backed RAM failure
Internal clock battery
F4/4 but fault condition
backed RAM
persists
Heaters remain on, Battery-backed RAM battery dead
F4/5 Internal clock battery but fault condition
persists
Melter stops RTD analog-to-digital converter failed
F4/6 Analog-to-digital
functioning

RTD analog-to-digital converter could not be

Analog-to-digital Melter stops calibrated
F4/7
calibration functioning
Faulty hose or gun.
Melter stops Communication failure between main board
F4/8 Main board feedback
functioning and CPU

Melter stops Tank or manifold thermostat is open

F4/A Thermostat
functioning

Communications Heaters remain on, Communication failure between CPU and

F4/d with optional I/O but fault condition the optional I/O card
card persists
Alert output (if output Fieldbus card failure.
Fieldbus
option 6 is selected)
F4/E communications
Melter continues to
failure
operate normally.

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 Operation 4-11

How F1, F2, and F3 Faults are Handled

When the melter detects an F1, F2, or an F3 fault:

1. The automatic scan stops and the melter begins to monitor the potential
fault for up to two minutes. The ready and heater LEDs remain on during
the two-minute time period. If, at any time during the two-minute period,
the melter detects that the fault condition no longer exists, the melter will
return to the automatic scan mode.

2. The LED on the affected component key (tank, hose, or gun) turns on to
indicate the type of component that has, or is, failing.

3. The right display indicates the type of fault (F1, F2, or F3).

4. The left display indicates, as follows, the component that has, or is,
failing.

 If the LED on the tank key is on, the left display will indicate either 1
for the tank or 2 for the manifold.
 If the LED on the hose or gun key is on, the left display will indicate
the number of the affected hose or gun.
5. If the fault condition still exists at the end of the two-minute monitoring
period, the ready 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 part.

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4-12 Operation

Monitor Melter Faults (contd)

How F4 Faults are Handled

When the melter detects an F4 fault:

1. The ready LED turns off and the red fault LED turns on.

2. All of the component key LEDs (tank, hose, and gun) turn off.

3. The right display indicates F4.

4. The left display indicates a sub-code. Sub-codes classify the fault as

being fatal or nonfatal. The affect on the melter of each of these two
classes of F4 faults is:

Fatal—The fault LED turns on and stays on and the melter stops
functioning completely.
Nonfatal—The fault LED turns on for five seconds, but the heaters and
pump continue to operate normally. Nonfatal faults affect the internal
clock and the optional 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 part.

To put the melter back into operation

1. Diagnose and correct the fault condition. Refer to Section 6,

Troubleshooting, for information about diagnosing and correcting fault
conditions.

NOTE: When a fatal F4 fault exists, the control switch will not function.
Remove power to the melter at the local disconnect switch.

2. Return the melter to the automatic scan mode by pressing the Setup
key twice.

3. Press the Clear/Reset key.

Clear/Reset key

4. Press the Heater key to turn on the heaters.

Heater key

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 Operation 4-13

To view the temperature of a heated component

when an F2 or F3 fault exists, simultaneously
press and hold both of the right-display scroll
keys.

You can temporarily dismiss an F1 fault (RTD)

and return to the automatic scan mode by
pressing the Clear/Reset key. The heaters will,
however, remain off. If the fault condition still
exists two minutes after pressing the clear/reset
key, the fault LED will turn back on.

When an F1 fault code appears, you

can determine whether the fault was caused
by an open or a shorted RTD by
simultaneously pressing both of the right-display
scroll keys. If the right display indicates OP,
the RTD is open, if it indicates SH, the RTD
has shorted.

If, for any reason, a component reaches

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.

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4-14 Operation

Monitor Melter Faults (contd)

To review the fault log

1. Press and hold the Setup key.
The automatic scan stops and operating parameter 1 appears in the
left display.
2. Scroll the left display to parameter 2 (the fault log).
The right display indicates the last fault that occurred as follows:

Setup Key  If the last fault was an F1, F2, or F3 fault, then the LED on
the affected component key turns yellow.
 If the last fault to occur was an F4 fault, then the LEDs on all of
the component keys turn off.
 The right display indicates the log entry for the last fault to
occur. Table 4-3 provides the meaning of each digit in the log
entry. Following the table are two example fault log entries.
3. Press the right-display scroll key to review each of the remaining
nine log entries. Each press of the scroll key displays a progressively
Left display and scroll key older log entry.
NOTE: The fault log only stores the last ten faults. After ten faults
occur, the existing log entries are overwritten, beginning with the oldest
entry, by the eleventh and following log entries.

4. Press the Setup key to return to the automatic scan mode.

Scrolling through the fault log

Table 4-3 Fault Log
First Digit Second and Third Digits Fourth Digit
Component: Type of fault:

1 = Tank or hose/gun 1 0 = Unused log entry

2 = Manifold or hose/gun 2 1 = RTD (open or short)
3 = Hose 3 or gun 3 -F 2 = Component under temperature
4 = Hose 4 or gun 4 3 = Component over temperature
5 = Hose 5 or gun 5 4 = Processor or electrical failure
6 = Hose 6 or gun 6

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 Operation 4-15

Fault Log Examples

Example 1:

An unused log entry.

Example 2:

If the LED on the tank key were on, this log entry
would indicate that the tank is under temperature. If the LED on the hose
key were on, this log entry would indicate that hose 1 is under temperature.

To view the number of heater hours that have

elapsed since a log entry was created,
simultaneously press both of the right-display
scroll keys. The hours are indicated in the right
display.

The melter will return to the automatic

scan mode if the fault log is left open for a period
of two minutes without any key being pressed.

When an F1 fault is the result of a hose/gun pair

being disconnected from the melter, two fault log
entries are created. The first entry is for the gun
and the second entry is for the hose.

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4-16 Operation

Monitor the Level of Hot Melt in the Tank

The tank contains a low-level float switch. When the volume of hot melt
in the tank drops below one-half of the tank’s rated capacity, the float
switch turns on the low-level LED located inside the tank key.

Nordson recommends that the tank be kept at least one-half full while
the melter is operating.

NOTE: The melter is also equipped with a low-level output that can
be connected to a customer-supplied signaling device or process control
Low-level LED (yellow)
system. Refer to Section 3, Installing Melter Outputs, for information about
using the low-level output.

Monitor and Adjust the Operating Air Pressure

The air pressure gauge located on the front of the melter indicates the
air pressure that is supplied to the melter’s pump. The air pressure must
be adjusted to meet the requirements of your manufacturing process.

NOTE: The minimum operating air pressure is 0.7 bar (10 psi). Operating
the melter with the air pressure set to less than 0.7 bar (10 psi) may cause
the pump to function erratically.

Use the adjustment screw located to the right of the pressure gauge
to adjust the operating air pressure.
Pressure regulator and
adjustment screw Typically, adjustments to the operating air pressure are made in order
to change the volume of hot melt dispensed by the guns. Other factors
such as the temperature of the hot melt, the speed of the
manufacturing line, and the type and size of the nozzles used on the guns
also impact the volume of hot melt that is dispensed.

CAUTION! Do not force the air pressure adjustment screw beyond its
normal range of adjustment. Forcing the adjustment screw beyond its
normal range of adjustment will damage the pneumatic assembly.

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 Operation 4-17

Monitor the Service Interval

The melter can be set up so that the service LED located on the left side
of the control panel turns on after a customer-defined time period elapses.
The service LED may be used to signal the need to change the hot melt
filter or to complete any other customer-specified maintenance
activity. Once the specified maintenance is performed, the service LED must
be reset.

To reset the service LED

With the melter in the scan mode, press the Clear/Reset key to turn off the
service LED and reset the service interval time.
Service LED (yellow)

Clear/Reset key

The default setting for the service interval time is Appendix B, Parameter 5
500 hours.

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4-18 Operation

Adjusting Component Temperatures

You can adjust the the set-point temperature of heated components using
the following methods:

 Global—The tank and all hoses and guns are set to the same
set-point temperature.
 Global-by-component group—All of the hoses or all of the guns
are set to the same set-point temperature.
 Individual Component—The set-point temperature of the tank
and each hose and gun is adjusted independently.
Before adjusting set-point temperatures, confirm that each hose/gun pair
is connected to the correct hose/gun module. For example, hose/gun pair 1
should be connected to the first receptacle (lowest) on hose/gun module 1
(lowest module). Refer to More About Heated Components, earlier in this
section for information about hose/gun modules.

To adjust set-point temperatures using the global method

1. Press and hold the Tank key for three seconds.
The left display flashes 1.
Tank key
2. Scroll the left display to 0 (flashing).
The right display indicates all dashes (- - - -) and the LEDs on all of
the component keys turn green.
3. Press the Enter key.
The right display flashes.
4. Use the keypad to enter the set-point temperature recommended by
the manufacturer of the hot melt. Refer to the technical data
sheet provided by the manufacturer of the hot melt to determine the
optimal set-point temperature.
Left display and scroll key
NOTE: If the keypad or the right-display scroll keys have no affect
on the right display, the melter is password protected. You must enter
a valid password before you can change set-point temperatures. Refer
to Enter the Melter Password, later in this section.

5. Press the Tank key.

All components begin to heat or cool to the new global
set-point temperature. When all of the components reach their
Enter key set-point temperature, the ready LED turns on (green).

Ready LED

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 Operation 4-19

To adjust the set-point temperature using the global-by-component

method
1. Press and hold the Hose or Gun key for three seconds.

The left display indicates the number of the first sequential hose or
gun. The right display indicates the current set-point temperature of the
hose or the gun.
2. Scroll the left display to 0.

The right display indicates all dashes (- - - -).

Tank, hose, and gun keys
3. Press the Enter key.

The right display flashes.

4. Use the keypad to enter the set-point temperature recommended by
the manufacturer of the hot melt. Refer to the technical data
sheet provided by the manufacturer of the hot melt to determine the
optimal set-point temperature.
NOTE: If the keypad or the right-display scroll keys have no affect
on the right display, the melter is password protected. You must enter
a valid password before you can change set-point temperatures. Refer
to Enter the Melter Password, later in this section.

5. Press the Enter key.

The hoses or the guns begin to heat or cool to their new
set-point temperature.

To adjust the set-point temperature of an individual component

1. Press and hold the Tank, Hose, or Gun key for three seconds.

If the tank key was pressed, the left display indicates 1 (Flashing). If a
hose or gun key was pressed, the left display indicates the number of
the first sequential hose or gun (Flashing). The right display indicates
the current set-point temperature of the component indicated in the left
display.
2. Scroll the left display to the number of the desired component.

The right display indicates the current set-point temperature of the

component that you selected in the left display.
3. Press the Enter key.

The right display flashes.

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4-20 Operation

To adjust the set-point temperature of an individual component

(contd)
4. Use the keypad to enter the set-point temperature recommended by
the manufacturer of the hot melt. Refer to the technical data
sheet provided by the manufacturer of the hot melt to determine the
optimal set-point temperature.

NOTE: If the keypad or the right-display scroll keys have no affect

on the right display, the melter is password protected. You must enter
a valid password before you can change set-point temperatures. Refer
to Enter the Melter Password, later in this section.

5. Do one of the following:

 To register the new set-point temperature and then move on to

change the set-point temperature of the next sequential component,
press the Enter key and then repeat steps 4 and 5.

 To register the new set-point temperature and return to the automatic

scan mode, go to step 6.

6. Press any component key (tank, hose, or gun).

The selected component begins to heat or cool to its new

set-point temperature.

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 Operation 4-21

If you enter a valid set-point temperature for a

hose/gun that is not connected to the melter or if
you enter a set-point temperature that is out of
range, the right display will indicate dashes (----) for
three seconds and then change back to the original
set-point temperature.

When the right display is flashing, you can quickly

change the current set-point temperature to 0
degrees (off) by simultaneously pressing both of
right-display scroll keys.

After removing a hose or a gun, use the individual

component method of set-point temperature
adjustment to set the component’s temperature to
zero degrees (off). This will avoid causing an F1
fault when a hose or gun is added.

The factory set-point temperature of the tank is

175 C (350 F). The factory set-point temperature
of all others components is zero degrees (off).

When the units of temperature is set to degrees

Celsius, the minimum and maximum set-point
temperatures are 40 C and 230 C. When the units
of temperature are set to degrees Fahrenheit, the
minimum and maximum set-point temperatures are
100 F and 450 F.

When using the right-display scroll keys to adjust a

set-point temperature, the right display
automatically increments between 0, 175, and 230
C or between 0, 350, and 450 F.

If you make a mistake while you are changing a

set-point temperature, but you have not yet pressed
the enter key, press the Clear/Reset key to
reset the right display to the original temperature.

The melter will exit the setup mode and return to the
automatic scan mode two minutes after the last key
is pressed.

A global set-point temperature of zero degrees

(Celsius or Fahrenheit) turns all components off.

When scrolling through component numbers in the

left display, component numbers that are associated
with unused hose/gun receptacles are skipped.

The melter stores a record of the last ten changes Section 3, Installation, Review
made to the set-point temperatures (and operating Parameter and Set-point
parameters) in the change history log. Temperature Changes

You can save set-point temperature changes by Section 3, Operation, Save and
simultaneously pressing the 1 key and the Setup Restore Melter Setting
key.

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4-22 Operation

Enter the Melter Password

If the melter is password protected, a valid password must be
entered before any set-point temperature or melter parameter can be
changed.

To enter a melter password

1. Press the Setup key.
The left display indicates parameter 0 (flashing) and the right
display indicates 4000.
2. Press the Enter key.
The right display begins flashing.
3. Use the keypad to enter the melter password.
4. Press the Enter key.
One of the following occurs:
 If the password is correct, the left display indicates parameter 1.
 If the password is incorrect, the left display remains at 0 and the
right display momentarily indicates dashes (----) and then returns to
4000.
If the password is incorrect, re-enter it and then press the Enter key.

The melter will automatically revert back to the

password-protected mode two minutes after the
last key press (any key). To force the melter
back into the password protected mode before
two minutes has elapsed, press the Setup key
twice.

The melter password is created and Section 3, Setting Up the Melter

enabled/disabled during system setup.

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 Operation 4-23

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4-24 Operation

Using Melter Function Keys

The control panel provides the following standard and special function keys.

Standard function keys

 Heater
 Pump
 Setup
Special function keys
 Seven-day clock
 Standby

CAUTION: Unintentionally activating function keys can, under the

correct circumstances, have undesirable effects on the melter or the
manufacturing process. Only personnel who are familiar with the melter’s
setup and its connection with the manufacturing process should use the
function keys. Improper use of the function keys can result in erratic process
behavior or personal injury.

Heater Key
Use the heater key to manually turn the component heaters on and
off. Pressing the heater key overrides the control (on or off) of the heaters
by either the seven-day clock feature or a remote input. The LED on the
heater key turns on when the heaters are on.

When a fault occurs (Refer to Monitor Melter Faults, earlier in this

section) the heaters automatically turn off. The heater key is used to turn the
heaters back on after correcting a fault condition.
Heater key

Pump Key
Use the pump key to start or stop the pump. The LED on the pump key
turns on (green) when the pump is running.

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.

If any of the inputs are set up to use the pump enable/disable control option
Pump key (option 3), the pump will not start until the pump key is pressed (LED on)
and the correct voltage is applied to the input contacts. If the pump is
enabled, but the input voltage is not present, the pump LED will flash green.

Part 1024496D04  2010 Nordson Corporation

 Operation 4-25

Setup Key
Use the setup key to place the melter into and take the melter out of
the setup mode. When the melter is placed into the setup mode, the
automatic scan stops and the left and right displays are used to select and
read or edit operating parameters.

Setup key

Seven-day Clock Key

Use the seven-day clock key to turn the melter’s clock feature on and off.
When the clock is on, the temperature of each heated component is
automatically regulated based on a set of user-defined schedules.

To accommodate daily shift work and non-working days, four

clock schedules are available. Schedules 1, 2, and 3 are used to specify
when the heaters should turn on and off or when the melter should enter
and exit the standby mode. Schedule 0 is used to keep the melter in the last
Seven-day clock key condition dictated by the clock (heaters on or off, or standby).

When a clock schedule calls for the heaters to be on, the heaters
are regulated at their pre-assigned set-point temperatures. When the
clock activates the standby mode, the set-point temperature of each
component is temporarily reduced by a pre-set standby delta.

Refer to Appendix B, Operating Parameters, Seven-day Clock, for

information about setting up the seven-day clock and the standby delta.

If the melter is switched off while the clock is on,

the clock will automatically turn back on the next
time the melter is switched back on.

If the heaters are manually turned off at the time

that a clock schedule calls for the heaters to be
on, the heaters will not turn back on until the next
clock schedule calls for them to be on.

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.

 2010 Nordson Corporation Part 1024496D04

4-26 Operation

Using Melter Function Keys (contd)

Standby Key
Use the standby key to manually place the melter into, and take it out of, the
standby mode. Using the standby mode during periods of time when
the melter is inactive helps to conserve energy and allows heated
components to quickly return to their set-point temperatures when the
melter is once again needed.

When the melter is placed into the standby mode, the temperatures of
all components are reduced down from their set-point temperature by a
Standby key pre-set standby delta. The melter will remain in the standby mode until the
standby key is pressed or the function of one of the operating parameters
takes the melter out of the standby mode.

If the melter was set up to use the manual standby timer

(parameter 26), pressing the standby key will place the melter in the
standby mode for the period of time specified by the timer. After the manual
standby time has elapsed, the melter will once again begin heating all of the
components to their assigned set-point temperature.

Using the standby key overrides the control of the melter (on or off) by
the seven-day clock or a remote input.

Refer to Section 3, Operation Setting Up the Melter, and to Appendix B,

Operating Parameters, for information about setting the standby delta and
the standby timer.

The melter may also be set up to enter the Appendix B, Parameters 23, 24, 25,
standby mode using a variety of operating 26, 30–33, 57, 62, and 67
parameters.

Whenever manual standby is enabled, the Appendix B, Parameter 26

standby LED blinks.

Part 1024496D04  2010 Nordson Corporation

 Operation 4-27

Shutting Down the Melter

Shut down the melter when it will not be used for an extended period of
time.

To shut the melter down

1. Switch the melter off.
The automatic pressure discharge (APD) valve relieves the hydraulic
pressure in the manifold back to the tank.
2. Disable the guns as follows:
 Air-operated guns: Turn off the air supply to the guns.
Melter control switch (on/off)  Electric guns: Turn off the gun driver, pattern controller, or timer.

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4-28 Operation

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Part 1024496D04  2010 Nordson Corporation