Nordson ProBlue Fulfill Reference guide

ProBlue

Fulfillt
tt
t
Integrated Fill System
Customer Product Manual
Part 1101094_02
Issued 01/2013
NORDSON CORPORATION •D L TH, GEORGIA •SA
www.nordson.com
This document contains important safety information
Be sure to read and follow all safety information in this
document and any other related documentation.

Part 1101094_02 E2012 Nordson Corporation
All rights reserved
For CE Declaration, refer to equipment documentation.
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Address all correspondence to:
Nordson Corporation
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Notice
This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2010.
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.
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Table of Contents i
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Table of Contents
Manual Coverage 1............................................
Safety 1......................................................
Getting Started 1...............................................
Restrictions to System Use 2....................................
Description 2.................................................
Intended Use 3................................................
Unintended Use 3..............................................
Melter Firmware Requirements 3.................................
Theory of Operation 3...........................................
Modes of Operation 4...........................................
Overview of Pneumatic and Mechanical Components 5..............
(A). Adhesive Transfer Hose 5.................................
(B). Adhesive Storage Bin 5...................................
(C). Filter Housing and Lid Assembly 6..........................
(D). Air Pressure Regulator/Solenoid Assembly 6.................
(E). Suction Lance 6.........................................
Overview of Electrical Components 7.............................
(F). Control Panel 7..........................................
Refill Board 8...............................................
Level Sensor 8..............................................
Installation 10.................................................
Installation Clearances 10........................................
Installation Components 12.......................................
Assemble the Lid Components 13.................................
Assemble the Transfer Hose, Air Line, and Suction Lance 14..........
Set Up the Fill System 16.........................................
Test the Fill System 18...........................................
Remove the Inlet Air Deflector (Optional) 19.........................
Operation 20...................................................
Monitoring Refill Operation 20.....................................
Clearing a Refill Alarm 21.........................................

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Troubleshooting 22............................................
Restoring ProBlue Fulfill Factory Settings 23........................
Level Sensor Adjustment and Calibration 24........................
Baseline Setting 25...........................................
Final Setting 25...............................................
Parts 27.......................................................
Using the Illustrated Parts Lists 27.................................
Melter Assembly Part Numbers 28.................................
Installation Kit Parts 28...........................................
Standard Installation Kit 28.....................................
Splash-Resistant Installation Kit 29..............................
Lid Assembly Parts 30...........................................
Regulator/Solenoid Assembly Parts 32.............................
Miscellaneous System Parts 34...................................
Optional Accessories 37.........................................
Service Kits and Recommended Spare Parts 37.....................
Technical Data 39..............................................
Fulfill System Specifications 39....................................
Dimensions 40..................................................
Wiring Diagram 42..............................................

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ProBlue Fulfill Integrated Fill System
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.
Manual Coverage
This manual provides information specific to the installation, operation, and
troubleshooting of the integrated fill sub-system (Fulfill) incorporated into
your ProBlue adhesive melter.
NOTE: For ProBlue Fulfill melters (generation 1) with fill system controls in
the sub-base, refer to manual P/N 1081444.
Safety
Before installing and operating the fill system, read the safety information
provided in the melter product manual in Section 1, Safety.
Getting Started
Step 1—Refer to the installation guide provided with the melter for
information about installing the melter (steps 1 through 5 in the installation
guide).
Step 2—Refer back to this manual for information about installing the fill
system.
Step 3—Refer to the operation section of both the melter manual and this
manual for information about operating your melter and the fill system.

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Restrictions to System Use
Before installing the fill system, ensure that your application DOES NOT
require:
Sthe transfer of solid-formed adhesive material greater than 12 mm
across the largest dimension.
Sadhesive temperatures exceeding 205 _C (400 _F).
Description
The Fulfill system extends proven ProBlue adhesive melter technology by
providing automatic delivery of solid-formed adhesive to the melter tank.
For a complete ProBlue Fulfill integrated fill system, both the melter and an
installation kit must be ordered.
Figure 1 ProBlue Fulfill melter (installation kit not shown)

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Intended Use
SSame as the melter. Refer to the melter manual.
Unintended Use
SSame as the melter. Refer to the melter manual.
Melter Firmware Requirements
Operation of the fill system requires that melter firmware version 2.076 or
later be installed in the melter. Firmware updates are available from
www.enordson.com/support.
Theory of Operation
The fill system adds small quantities of adhesive to the sealed melter tank at
regular intervals, reducing the possibility of adhesive char, contaminants,
thermal shock, and incorrect adhesive temperatures that result in poor
bonding.
A capacitance sensor located in the melter detects a low adhesive level and
then sends a signal to the system control. A delay timer prevents the fill
system from frequently cycling on and off.
At the end of the delay, the control activates the vacuum via a solenoid valve.
Air pressure flows to a suction lance that is placed in the supplied bulk
adhesive container. Using vacuum, the system conveys adhesive from the
bulk container to the adhesive melter tank.
The controller activates the suction lance for a limited amount of time to
prevent overfill conditions. If the maximum fill time is exceeded, the controller
generates a refill alarm that stops the system from filling but does not disable
the melter heaters or take the melter out of ready status. If used, a refill alarm
output is generated when the maximum fill time is exceeded. A refill alarm
can be cleared via the control panel or the Clear Refill Alarm input, if used.
NOTE: The low level LED present on a standard ProBlue melter is not
present on a Fulfill integrated melter.

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Modes of Operation
The default mode of operation is the automatic mode. When the melter is
operating in the automatic mode, the fill system tracks the melter ready
signal. When the melter is ready, the fill system is enabled. If the melter
status changes to not ready, then the fill system is disabled.
When the melter is operating in the manual mode, the fill system must be
manually enabled via the control panel or a remote input. The fill system can
only be enabled when the melter is ready. If the melter is placed into standby
when the system is operating in the manual mode, the fill system will be
disabled. The fill system will remain disabled until the melter is again ready
and the fill system is manually enabled via control panel or remote input.
NOTE: If remote inputs are used for fill system operation (Remote
Enable/Disable and Clear Refill Alarm), then the Fill System Enable key on
the control panel will not function.

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Overview of Pneumatic and Mechanical Components
C
B
E
A
D
F
Figure 2 Overview of Fulfill system components
(A). Adhesive Transfer Hose
The adhesive transfer hose connects the suction lance to the lid assembly.
Thetransferhoseconveysadhesivefromtheadhesivestoragebintothe
melter tank.
(B). Adhesive Storage Bin
Place adhesive in the adhesive storage bin. The bin contains a gasket that
prevents debris from entering the bin. For best results, break up the adhesive
as much as possible when emptying into the bin. Do not get the adhesive
wet.

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(C). Filter Housing and Lid Assembly
The Fulfil lid assembly includes the filter stack, lid, fill tube, baffle, and
deflector:
SThe filter stack contains a replaceable filter sock to prevent adhesive
fines and powder in the adhesive from being emitted into the ambient
air.
SThe fill tube attaches to the adhesive transfer hose.
SThe baffle prevents adhesive from entering the filter sock.
SThe deflector distributes adhesive evenly in the tank.
A safety interlock switch detects whether the removable melter tank lid is in
place. If the tank lid is not in place, the fill system will not operate.
(D). Air Pressure Regulator/Solenoid Assembly
The supplied air pressure regulator is permanently set at 65 psig, the optimal
setting for most adhesives.
The solenoid valve turns on after the sensor indicates level state and the time
delay has been reached. The solenoid directs compressed air to flow to the
suction lance.
(E). Suction Lance
Thesuctionlancedrawsadhesivefromtheadhesivestoragebin.The
suction lance includes:
SA venturi pump to draw in and transport the adhesive.
SA vibrator to keep the adhesive in loose condition. The vibrator is
active as long as compressed air is supplied to the suction lance.
Airlinetubingandtheadhesivetransferhoseareconnectedtothesuction
lance. The lance is placed in the PVC pipe located in the adhesive storage
bin.

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Overview of Electrical Components
The integrated Fulfill system includes a Fulfill-specific control panel. A refill
board located inside the electrical enclosure and a level sensor located
inside the tank control fill system operation.
(F). Control Panel
The Fulfill control panel shown in Figure 3 provides the following controls and
indicators:
S(1) Refill alarm symbol and LED (red light)—Activates if the system
exceeds the user defined fill time limit. The system will not resume
operation until the fault is cleared by pressing the Clear Fault key.
S(2) Adhesive transfer LED (blue light)—Indicates adhesive delivery is
active. When a low level is detected, the indicator notes that adhesive
is being transferred from the adhesive storage bin into the melter tank
through the transfer hose.
S(3) Fill system enable key and LED (green light)—Pressing the fill
system enable key turns the fill system on or off. The LED turns green
when the system is enabled.
3
2
1
Figure 3 Fulfill system controls and indicators
1. Refill alarm symbol and LED
2. Adhesive transfer LED
3. Fill system enable key
(on/off) and LED

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Refill Board
See Figure 4. The refill board is located inside the electrical enclosure. Note
that:
SThe FAULT, DELAY, and AIR potentiometer functions are controlled
through parameters. Refer to Set Up the Fill System under Installation
for parameter descriptions.
SA dip switch labeled SW1 is preset at the factory. Positions M1 and
M2 should always be ON.
SW1
XT1
XT2
M1
M2
ON
Figure 4 Refill board (located inside the electrical enclosure)
Level Sensor
The level sensor detects the level of adhesive in the melter tank. When the
adhesive falls below the set point, the level sensor sends a signal to the refill
board.
The sensor comes preset from the factory for an average application in which
the adhesive in the tank is typically molten. To adjust the level sensor
settings, refer to Level Sensor Adjustment and Calibration under
Troubleshooting.

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Installation
Before installing the fill system, familiarize yourself with Section 3,
Installation, in the melter manual.
Installation Clearances
Figure 5 Minimum installation clearances (top and side views shown; refer to Table 1)

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Table 1 Installation Clearances (see Figure 5)
Item Description Required Clearance
A
Thedistancefromtheoutsideedgeofa5/16-in. Nordson hose
to the front face of the melter when a short 90-degree hose
fitting is used to connect the hose to the melter
P4 = 370 mm (14.5 in.)
P7 = 370 mm (14.5 in.)
P10 = 391 mm (15.4 in.)
B
The clearance required to open the pump enclosure door P4 = 243 mm (9.6 in.)
P7 = 243 mm (9.6 in.)
P10 = 268 mm (10.55 in.)
C
Thedistancefromthemelterbasetothetopsurfaceofthetank
lid when it is closed.
P4 = 567.4 mm (22.34 in.)
P7 = 565.2 mm (22.25 in.)
P10 = 654.3 mm (25.76 in.)
D
The clearance required on the left side of the melter to open the
electrical enclosure door or remove a hose/gun module.
P4 = 648 mm (25.5 in.)
P7 = 711 mm (28.0 in.)
P10 = 714 mm (28.1 in.)
EThe clearance required to access the fill system filter. All = 50.8 mm (2.00 in.)
F
The clearance required to open the tank lid. P4 = 895.9 mm (35.27 in.)
P7 = 977.7 mm (38.49 in.)
P10 = 974 mm (38.35 in.)
559 mm
(22 in.)
940 mm
(37 in.)
534 mm
(21 in.)
559 mm
(22 in.)
1397 mm
(55 in.)
Figure 6 Adhesive storage bin clearances

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Installation Components
In addition to the components contained in the melter installation kit, the
Fulfill system is shipped with the components shown in Figure 7.
NOTE: These components are shipped inside the adhesive storage bin.
Refer to Installation Kit Parts under Parts for component part numbers.
12 34
56
789
Figure 7 Fulfill system components shipped inside the adhesive storage bin
1. Adhesive storage bin (tote)
2. Transfer hose (standard)
3. Suction lance
4. Airline(4m)
5. Inlet tube
6. Hose clamp (2)
7. Wire tie (5)
8. Filter housing
9. Filter sock
Note: Extension kits are available if longer hose/air line lengths are needed. Refer to Parts for the extension kit part
numbers.

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Assemble the Lid Components
See Figure 8. Install the filter enclosure, filter sock and inlet tube on the tank
lid of the Fulfill melter.
1. Remove the three M4 socket-head screws (5) and spacers (6) from the
tank lid assembly (7).
2. Insert the inlet tube (4) and rotate it to the desired position.
3. Reinstall the spacers (5) and socket-head screws (6).
4. Remove the tag from the filter sock (3).
5. Insert the filter sock (3) into the filter enclosure (1).
6. Set the filter enclosure on top of the tank lid and snap the filter enclosure
locks (2) onto the lid.
5
4
1
2
3
6
7
Figure 8 Fulfill lid assembly components
1. Filter enclosure
2. Filter enclosure locks
3. Filter sock
4. Inlet tube
5. M4 socket-head screw
6. Spacer
7. Melter tank lid

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AssembletheTransferHose,AirLine,andSuctionLance
SeeFigure9.
1. Using one hose clamp, attach the transfer hose (A) to the end of the
suction lance (B).
2. Use the remaining hose clamp to attach the transfer hose to the feed
system inlet tube (C).
NOTE: If necessary, loosen the inlet tube retaining screws and
reposition the inlet tube.
3. Connect the air line (D) to the suction lance air inlet (E).
NOTE: Extension kits are available if longer hose/air line lengths are
needed. Refer to Parts for the extension kit part numbers.
4. Route the air line along the transfer hose, securing it with cable ties as
you go.
5. Leaving enough air line to reach the outlet (G) of the air solenoid, cut the
air line to length and then insert the end of the air line into the outlet.
CAUTION! Risk of equipment damage. To keep the suction lance from
clogging, do not
Sput adhesive in the white PCV tube that houses the suction lance,
and
Sdo not apply excessive force to the suction lance when inserting it in
the tube.
6. Insert the suction lance into the adhesive storage bin.
7. Connect a regulated, clean, dry air supply to the regulator inlet (F). The
air supply must be capable of supplying 3.45-5.51 bar (50-80 psi) at
24 scfm.

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G
B
E
D
A
C
F
F
G
Figure 9 Assembling the transfer hose, air line, and suction lance

1
2
3
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Set Up the Fill System
Fulfill system setup involves connecting inputs/outputs and adjusting system
parameters as desired. If no changes are needed, skip to the next
procedure, Test the Fill System.
1. Refer to the Fulfill system parameters shown in Table 2 and make
changes to the parameters as desired. Refer to To change a Fulfill
system parameter as needed.
2. Connect inputs/outputs as desired for your operation. Refer to Table 3 for
available inputs/outputs. Refer to the installation section of the melter
manual for the procedures for connecting and setting up inputs/outputs.
NOTE: For ProBlue Fulfill melters (generation 1) with fill system controls in
the sub-base, refer to manual P/N 1081444.
To change a Fulfill system parameter
SeeFigure10.
1. Press the Setup key.
The left display flashes parameter 1.
2. Using the numeric keypad, enter (or scroll to) the desired parameter.
Refer to Table 2 For Fulfill system parameters or to Table 3 for
parameters that need to be changed for any inputs/outputs.
NOTE: If you incorrectly enter the parameter number, press the
Clear/Reset key to return to parameter 1 and then re-enter the correct
parameter.
3. Press the Enter key.
4. Using the numeric keypad, enter the new value for parameter.
5. Press the Enter key.
6. Press the Setup key to exit the setup mode.
7. Test the system.
8. When you are satisfied that the fill system is operating correctly, save all
of the current melter setting into memory by simultaneously pressing the
number 1key and the Setup key.
Figure 10 Keys used for
parameter setup
1. Setup key
2. Clear/reset key
3. Enter key