Maintenance 5-1
Section 5
Maintenance
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.
Table 5-1 describes the preventive maintenance tasks required to keep
DuraBlue melters operating within their specified limits and to prevent
equipment malfunctions. For information about maintaining optional
equipment that was supplied by Nordson, refer to the instructions provided
with the equipment.
If the melter stops operating or is operating incorrectly, refer to Section 6,
Troubleshooting, for information about diagnosing common problems and
performing corrective maintenance.
Table 5-1 Preventive Maintenance Tasks
Task Frequency Reference
Relieving system pressure Before performing any maintenance Relieving System Pressure
task that requires opening a
hydraulic connection or port
Cleaning the exterior of the melter, Daily Cleaning the Melter
hoses, and guns
Replacing the filter S As needed Replacing the Filter
S When changing the type or grade of Instruction sheet provided with
hot melt replacement filter
Cleaning the tank S When changing the type or grade of Cleaning the Tank
hot melt
S When excessive charring occurs
E 2010 Nordson Corporation Part 1073400A03
5-2 Maintenance
Relieving System Pressure
Before disconnecting any hydraulic fitting or opening any pressurized port,
always complete the following procedure to safely relieve hydraulic pressure
that may be trapped inside the melter, hoses, and guns.
To relieve system pressure
1. Press the Pump key to stop the pump.
2. Trigger the guns until hot melt no longer flows from the guns.
Pump key
Locking Out External Communications
WARNING: Disable external inputs and fieldbus communcations with the
melter before performing maintenance. Failure to disable external inputs or
fieldbus communications with the melter can result in personal injury due to
unexpected operation of the melter while performing maintenance.
To lockout external communications with the melter
S Set the control option for operating parameter 14 to 1 (enabled).
Refer to Section 3, Setting Up the Melter, for information about changing
operating parameters.
Part 1073400A03 E 2010 Nordson Corporation
Maintenance 5-3
This page intentionally left blank.
E 2010 Nordson Corporation Part 1073400A03
5-4 Maintenance
Cleaning the Melter
To prevent components from overheating due to heat build-up or loss of air
circulation, regularly remove any hot melt that collects on the exterior of the
melter, hoses, and guns.
If hot melt inadvertently spills inside the melter’s interior spaces, the side
panels can be removed in order to clean out the spilled hot melt.
WARNING: Risk of electricution and fire! Do not clean the melter with a
direct stream of water or steam. Use only water or an appropriate,
non-flammable cleaning solution that is applied using a clean cloth.
Cleaning the melter using a direct stream of water or steam or a flammable
solvent can result in property damage and personal injury, including death.
To clean the exterior of the melter
S Use only cleaning compounds that are compatible with polyester.
S Apply cleaning compounds using a soft cloth.
S Do not use pointed or sharp tools to clean the exterior surface.
To remove and replace the exterior panels
See Figure 5-1.
1. De-energize the melter. Refer to Section 1, Safety.
2. Use a 4 mm (5/32-inch) hex-head wrench to turn the 1/2-turn fastener
located in the center of each side panel counterclockwise.
3. Lift the panel out of the melter’s frame.
4. Reverse steps 2 and 3 to reinstall each panel.
Part 1073400A03 E 2010 Nordson Corporation
Maintenance 5-5
Figure 5-1 Removing the exterior panels
E 2010 Nordson Corporation Part 1073400A03
5-6 Maintenance
Replacing the Filter
Some DuraBlue melters are equipped with a 100-mesh (0.15-mm)
disposable hot melt filter. The filter removes debris and char from the hot
melt as it flows from the tank. Hot melt flows from the inside to the outside
of the filter, trapping contaminants inside the filter. There is no need to
back-flush or clean the filter.
When the filter reaches the end of its service life, it should be replaced. The
factors that determine the service life of the filter are:
S the type, grade, and purity of the solid-form hot melt
S the set point temperature of the tank
S the period of time that the hot melt remains in the tank
The filter should also be replaced when making the change to a different
type or grade of hot melt.
To determine the optimal service life for the filter, monitor and compare the
total number of hours that the heaters are on with observations of:
S the purity of the dispensed hot melt
S increases in operating pressure
S the frequency of gun nozzle replacement or cleaning
As an aid to ensuring that the filter is replaced at the end of its service life,
the melter is equipped with a service LED that turns on at the end of a
Hot melt flow path
customer-defined time period. Refer to Setting Up the Melter in Section 3,
Installation, for information about the service interval time.
Part 1073400A03 E 2010 Nordson Corporation
Maintenance 5-7
To replace the filter
1. Relieve the system pressure. Refer to Relieving System Pressure at the
beginning of this section.
2. Use an 8 mm (5/16-inch) hex-head wrench or an adjustable wrench to
Pump key loosen (counterclockwise) and then remove the filter.
3. Properly dispose of the old filter.
4. Confirm that the O-ring on the new filter is in good condition (100-mesh
filter is P/N 1028305).
NOTE: 50- and 150-mesh filters are also available (P/Ns 1021941 and
1034720).
5. Screw the filter into the pump body and then tighten the filter to
4.5 N•m (40 in.-lb).
6. Resume normal operation.
Loosening the filter
E 2010 Nordson Corporation Part 1073400A03
5-8 Maintenance
Cleaning the Tank
To avoid the problems that can occur when different hot melt materials are
mixed or when hot melt char forms in the tank, clean the tank when:
S changing to a different type of hot melt
S excessive char builds up inside the tank
NOTE: The tank cleaning procedures provided in this section require that
an appropriate flushing material be used. The flushing material should be
compatible with both the previous adhesive and the new adhesive, if
applicable.
To clean the tank when changing hot melt
1. Operate the melter normally until the tank is empty.
2. Press the Pump key to stop the pump.
3. Allow the melter to heat or cool to the temperature recommended by the
manufacturer of the flushing material.
Pump key 4. While wearing the appropriate protective equipment, wipe any residual
hot melt from the inside of the tank.
5. Add the appropriate type and quantity of flushing material to the tank.
6. Press the Pump key to start the pump.
7. Pump all of the flushing material from the tank and through the hoses
and guns.
8. Return the melter to normal operation and pump a minimum of one tank
volume of fresh hot melt through the tank, hoses, and guns.
Part 1073400A03 E 2010 Nordson Corporation
Maintenance 5-9
To clean the tank of excessive char
1. Remove the old hot melt and loose char as follows:
a. Operate the melter normally until the tank is empty.
b. Press the Pump key to stop the pump.
c. Allow the melter to heat or cool to the temperature recommended by
Pump key the manufacturer of the flushing material.
d. While wearing the appropriate protective equipment, wipe any
residual hot melt and loose char from the inside of the tank.
e. Remove the tank strainer, clean it with an appropriate flushing
material, and then reinstall it.
2. Add the appropriate type and quantity of hot melt solvent to the tank.
3. Disconnect a hose from a gun and direct the hose into a waste
container.
4. Close the pressure control valve by turning the valve all the way
clockwise.
Tank strainer
WARNING: Risk of burns! Wear protective equipment and use caution
when pumping hot material into a waste container.
5. Press the Pump key to start the pump.
6. When the tank is empty, stop the pump.
7. Fill the tank with fresh hot melt.
8. Repeat steps 5 and 6 to pump all of the hot melt out of the tank.
9. Reconnect the disconnected hose to its gun.
10. Replace the filter. Refer to Replacing the Filter earlier in this section.
11. Fill the tank with fresh hot melt and then purge all of the hoses and guns
Closing the pressure control valve with the fresh hot melt.
12. Restore the system to normal operation.
E 2010 Nordson Corporation Part 1073400A03
5-10 Maintenance
Part 1073400A03 E 2010 Nordson Corporation
