Nordson DuraBlue D4L Reference guide

DuraBlue Adhesive Melters
Models D4L, D10L, and D16L
Customer Product Manual
Part 1032059B
Issued 07/03
NORDSON CORPORATION •DULUTH, GEORGIA •USA
www.nordson.com

Part 1032059B E2003 Nordson Corporation Manual 41-DURABLUE-MA-02
Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General information
about Nordson can be found on the Internet using the following address: http://www.nordson.com.
Address all correspondence to:
Nordson Corporation
Attn: Customer Service
11475 Lakefield Drive
Duluth, GA 30097
Notice
This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2002.
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.
2003 All rights reserved.
Trademarks
AccuJet, AeroCharge, AquaGuard, Asymtek, Automove, Autotech, Baitgun, Blue Box, CF, CanWorks, Century,
Clean Coat, CleanSleeve, CleanSpray, Control Coat, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, Durafiber,
Durasystem, Easy Coat, Easymove Plus, Econo-Coat, EFD, ETI, Excel 2000, Flex-O-Coat, FlexiCoat, Flexi-Spray,
Flow Sentry, Fluidmove, FoamMelt, FoamMix, Helix, Heli-flow, Horizon, Hot Shot, Isocoil, Isocore, Iso-Flo, JR, KB30,
Kinetix, Little Squirt, Magnastatic, MEG, Meltex, Microcoat, MicroSet, Millennium, Mini Squirt, Moist-Cure, Mountaingate,
MultiScan, Nordson, OmniScan, OptiMix, Package of Values, Patternview, Plasmod, PluraFoam, Porous Coat,
PowderGrid, Powderware, Prism, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, PRX, RBX, Rhino, S. design stylized, Saturn,
SC5, Seal Sentry, Select Charge, Select Coat, Select Cure, Slautterback, Smart-Coat, Solder Plus, Spectrum,
Spray Squirt, Spraymelt, Super Squirt, Sure Coat, Tela-Therm, Trends, Tribomatic, UniScan, UpTime, Veritec, Versa-Coat,
Versa-Screen, Versa-Spray, Walcom, Watermark, and When you expect more.
are registered trademarks of Nordson Corporation.
AeroDeck, AeroWash, Apogee, ATS, Auto-Flo, AutoScan, BetterBook, Chameleon, CanNeck, Check Mate, Colormax,
Control Weave, Controlled Fiberization, CoolWave, CPX, DuraBlue, Dura–Coat, Dura–Screen, Dry Cure, E-Nordson,
EasyClean, Eclipse, Equi=Bead, ESP, Fill Sentry, Fillmaster, Gluie, iControl, iFlow, Ink-Dot, Iso-Flex, iTrend, KVLP,
Lacquer Cure, Maxima, MicroFin, MicroMax, Minimeter, Multifil, Origin, PermaFlo, PluraMix, Powder Pilot, Powercure,
Primarc, ProBlue, Process Sentry, PurTech, Pulse Spray, Ready Coat, Select Series, Sensomatic, Shaftshield, SheetAire,
Spectral, Spectronic, Speed–Coat, Speedking, Spray Works, Summit, Sure Brand, Sure Clean, Sure Max, Swirl Coat,
Tempus, ThruWave, Tracking Plus, Trade Plus, Universal, VersaBlue, Vista, Web Cure, and 2 Rings (Design)
are trademarks of Nordson Corporation.

Table of Contents i
Part 1032059B
E2003 Nordson Corporation Manual 41-DURABLUE-MA-02
Table of Contents
Safety 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Alert Symbols 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Responsibilities of the Equipment Owner 1-2. . . . . . . . . . . . . . . . . . . . . .
Safety Information 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions, Requirements, and Standards 1-2. . . . . . . . . . . . . . . . . .
User Qualifications 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applicable Industry Safety Practices 1-3. . . . . . . . . . . . . . . . . . . . . . . . . .
Intended Use of the Equipment 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions and Safety Messages 1-3. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Practices 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Practices 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Repair Practices 1-5. . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Safety Information 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Shutdown 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relieving System Hydraulic Pressure 1-6. . . . . . . . . . . . . . . . . . . . .
De-energizing the System 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disabling the Guns 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Safety Warnings and Cautions 1-7. . . . . . . . . . . . . . . . . . . . .
Other Safety Precautions 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First Aid 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Labels and Tags 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other Sources of Information 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Guide 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
User’s Guide 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Resource CD 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Description 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intended Use 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limitations of Use 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modes of Operation 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Melter Identification 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Key Components 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Equipment 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents
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Part 1032059B E2003 Nordson Corporation
Manual 41-DURABLUE-MA-02
Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quick-Start 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Information 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Tasks 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Experience of Installation Personnel 3-2. . . . . . . . . . . . . . . . . . . . . . . .
Installation Requirements 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearances 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Power 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other Considerations 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unpacking the Melter 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents of the Installation Kit 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Customer-Supplied Materials 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting the Melter 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the Electrical Service 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Hoses and Guns 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Up the Melter 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quick Setup 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Parameters 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Operating Parameters 3-14. . . . . . . . . . . . . . . . . . . . . . . . . .
Reading or Editing Operating Parameters 3-14. . . . . . . . . . . . . . . . .
Set-point Temperature of the Tank, Hoses, and Guns 3-18. . . . . . . . . .
Review Parameter and Set-point Temperature Changes 3-20. . . . . . .
Installing Optional Equipment 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting a Gun Driver, Pattern Controller, or Timer 3-22. . . . . . . . . . . .
Flushing the Melter 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Pressure Control Valve 3-22. . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents iii
Part 1032059B
E2003 Nordson Corporation Manual 41-DURABLUE-MA-02
Operation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Information 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
More about Heated Components 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling the Tank 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Melter 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monitoring the Melter 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Confirm that the Melter is Operating Correctly 4-6. . . . . . . . . . . . . . .
Monitor Component Temperatures 4-7. . . . . . . . . . . . . . . . . . . . . . . . .
Monitor Melter Faults 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How F1, F2, and F3 Faults are handled 4-11. . . . . . . . . . . . . . . . . . .
How F4 Faults are Handled 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Component Temperatures 4-16. . . . . . . . . . . . . . . . . . . . . . . . . .
Using Melter Function Keys 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Key 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Key 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup Key 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seven-day Clock Key 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standby Key 4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutting Down the Melter 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relieving System Pressure 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the Melter 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Filter 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the Tank 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Melter Faults 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Operating Variables 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Troubleshooting Flow Chart 6-6. . . . . . . . . . . . . . . . . . . . . . . . .
Identifying Electrical Components 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Illustrated Parts List 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Service Kits 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Component Service Kits 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Boards 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuses 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat, Heaters, and RTDs 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Ribbon Cables 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tank Strainer 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Assembly Service Kits 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor 7-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Assembly (Complete) 7-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents
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Part 1032059B E2003 Nordson Corporation
Manual 41-DURABLUE-MA-02
Optional Equipment 7-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software 7-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Control Kit 7-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control Valve Knob 7-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Footswitch Kit 7-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Valve Kit 7-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose Support Kit 7-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Gage Kit 7-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handgun Support Kit 7-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Pressure Control 7-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Specifications 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor and Pump Specifications 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D4L Melter 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D10L and D16L Melter 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conduit Penetration Sizes 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calculating Melter Power Requirements A-1. . . . . . . . . . . . . . . . . . . . .
Operating Parameters B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seven-day Clock B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example 1 B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example 2 B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example 3 B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PID Selection B-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety 1-1
Part 1032059B
E2003 Nordson Corporation Manual 41-DURABLUE-MA-02
Section 1
Safety
Read this section before using the equipment. This section contains
recommendations and practices applicable to the safe installation,
operation, and maintenance (hereafter referred to as “use”) of the product
described in this document (hereafter referred to as “equipment”).
Additional safety information, in the form of task-specific safety alert
messages, appears as appropriate throughout this document.
WARNING: Failure to follow the safety messages, recommendations, and
hazard avoidance procedures provided in this document can result in
personal injury, including death, or damage to equipment or property.
Safety Alert Symbols
The following safety alert symbol and signal words are used throughout this
document to alert the reader to personal safety hazards or to identify
conditions that may result in damage to equipment or property. Comply with
all safety information that follows the signal word.
WARNING: Indicates a potentially hazardous situation that, if not avoided,
can result in serious personal injury, including death.
CAUTION: Indicates a potentially hazardous situation that, if not avoided,
can result in minor or moderate personal injury.
CAUTION: (Used without the safety alert symbol) Indicates a potentially
hazardous situation that, if not avoided, can result in damage to equipment
or property.

Safety
1-2
Part 1032059B E2003 Nordson Corporation
Manual 41-DURABLUE-MA-02
Responsibilities of the Equipment Owner
Equipment owners are responsible for managing safety information,
ensuring that all instructions and regulatory requirements for use of the
equipment are met, and for qualifying all potential users.
Safety Information
SResearch and evaluate safety information from all applicable sources,
including the owner-specific safety policy, best industry practices,
governing regulations, material manufacturer’s product information, and
this document.
SMake safety information available to equipment users in accordance
with governing regulations. Contact the authority having jurisdiction for
information.
SMaintain safety information, including the safety labels affixed to the
equipment, in readable condition.
Instructions, Requirements, and Standards
SEnsure that the equipment is used in accordance with the information
provided in this document, governing codes and regulations, and best
industry practices.
SIf applicable, receive approval from your facility’s engineering or safety
department, or other similar function within your organization, before
installing or operating the equipment for the first time.
SProvide appropriate emergency and first aid equipment.
SConduct safety inspections to ensure required practices are being
followed.
SRe-evaluate safety practices and procedures whenever changes are
made to the process or equipment.

Safety 1-3
Part 1032059B
E2003 Nordson Corporation Manual 41-DURABLUE-MA-02
User Qualifications
Equipment owners are responsible for ensuring that users:
SReceive safety training appropriate to their job function as directed
by governing regulations and best industry practices
SAre familiar with the equipment owner’s safety and accident
prevention policies and procedures
SReceive, equipment- and task-specific training from another qualified
individual
NOTE: Nordson can provide equipment-specific installation,
operation, and maintenance training. Contact your Nordson
representative for information
SPossess industry- and trade-specific skills and a level of experience
appropriate to their job function
SAre physically capable of performing their job function and are not
under the influence of any substance that degrades their mental
capacity or physical capabilities
Applicable Industry Safety Practices
The following safety practices apply to the use of the equipment in the
manner described in this document. The information provided here is not
meant to include all possible safety practices, but represents the best safety
practices for equipment of similar hazard potential used in similar industries.
Intended Use of the Equipment
SUse the equipment only for the purposes described and within the limits
specified in this document.
SDo not modify the equipment.
SDo not use incompatible materials or unapproved auxiliary devices.
Contact your Nordson representative if you have any questions on
material compatibility or the use of non-standard auxiliary devices.
Instructions and Safety Messages
SRead and follow the instructions provided in this document and other
referenced documents.
SFamiliarize yourself with the location and meaning of the safety warning
labels and tags affixed to the equipment. Refer to Safety Labels and
Tags at the end of this section.
SIf you are unsure of how to use the equipment, contact your Nordson
representative for assistance.

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Installation Practices
SInstall the equipment in accordance with the instructions provided in this
document and in the documentation provided with auxiliary devices.
SEnsure that the equipment is rated for the environment in which it will be
used and that the processing characteristics of the material will not
create a hazardous environment. Refer to the Material Safety Data
Sheet (MSDS) for the material.
SIf the required installation configuration does not match the installation
instructions, contact your Nordson representative for assistance.
SPosition the equipment for safe operation. Observe the requirements for
clearance between the equipment and other objects.
SInstall lockable power disconnects to isolate the equipment and all
independently powered auxiliary devices from their power sources.
SProperly ground all equipment. Contact your local building code
enforcement agency for specific requirements.
SEnsure that fuses of the correct type and rating are installed in fused
equipment.
SContact the authority having jurisdiction to determine the requirement for
installation permits or inspections.
Operating Practices
SFamiliarize yourself with the location and operation of all safety devices
and indicators.
SConfirm that the equipment, including all safety devices (guards,
interlocks, etc.), is in good working order and that the required
environmental conditions exist.
SUse the personal protective equipment (PPE) specified for each task.
Refer to Equipment Safety Information or the material manufacturer’s
instructions and MSDS for PPE requirements.
SDo not use equipment that is malfunctioning or shows signs of a
potential malfunction.

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Maintenance and Repair Practices
SPerform scheduled maintenance activities at the intervals described in
this document.
SRelieve system hydraulic and pneumatic pressure before servicing the
equipment.
SDe-energize the equipment and all auxiliary devices before servicing the
equipment.
SUse only new or factory-authorized refurbished replacement parts.
SRead and comply with the manufacturer’s instructions and the MSDS
supplied with equipment cleaning compounds.
NOTE: MSDSs for cleaning compounds that are sold by Nordson are
available at www.nordson.com or by calling your Nordson
representative.
SConfirm the correct operation of all safety devices before placing the
equipment back into operation.
SDispose of waste cleaning compounds and residual process materials
according to governing regulations. Refer to the applicable MSDS or
contact the authority having jurisdiction for information.
SKeep equipment safety warning labels clean. Replace worn or
damaged labels.

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Equipment Safety Information
This equipment safety information is applicable to the following types of
Nordson equipment.
SHot melt and cold adhesive application equipment and all related
accessories
SPattern controllers, timers, detection and verification systems, and all
other optional process control devices
Equipment Shutdown
To safely complete many of the procedures described in this document, the
equipment must first be shut down. The level of shut down required varies
by the type of equipment in use and the procedure being completed.
If required, shut down instructions are specified at the start of the
procedure. The levels of shut down are:
Relieving System Hydraulic Pressure
Completely relieve system hydraulic pressure before breaking any hydraulic
connection or seal. Refer to the melter-specific product manual for
instructions on relieving system hydraulic pressure.
De-energizing the System
Isolate the system (melter, hoses, guns, and optional devices) from all
power sources before accessing any unprotected high-voltage wiring or
connection point.
1. Turn off the equipment and all auxiliary devices connected to the
equipment (system).
2. To prevent the equipment from being accidentally energized, lock and
tag the disconnect switch(es) or circuit breaker(s) that provide input
electrical power to the equipment and optional devices.
NOTE: Government regulations and industry standards dictate specific
requirements for the isolation of hazardous energy sources. Refer to
the appropriate regulation or standard.

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Disabling the Guns
All electrical or mechanical devices that provide an activation signal to the
guns, gun solenoid valve(s), or the melter pump must be disabled before
work can be performed on or around a gun that is connected to a
pressurized system.
1. Turn off or disconnect the gun triggering device (pattern controller, timer,
PLC, etc.).
2. Disconnect the input signal wiring to the gun solenoid valve(s).
3. Reduce the air pressure to the gun solenoid valve(s) to zero; then
relieve the residual air pressure between the regulator and the gun.
General Safety Warnings and Cautions
Table 1-1 contains the general safety warnings and cautions that apply to
Nordson hot melt and cold adhesive equipment. Review the table and
carefully read all of the warnings or cautions that apply to the type of
equipment described in this manual.
Equipment types are designated in Table 1-1 as follows:
HM = Hot melt (melters, hoses, guns, etc.)
PC = Process control
CA = Cold adhesive (dispensing pumps, pressurized container, and
guns)

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Table 1-1 General Safety Warnings and Cautions
Equipment
Type Warning or Caution
HM
WARNING: Hazardous vapors! Before processing any polyurethane
reactive (PUR) hot melt or solvent-based material through a
compatible Nordson melter, read and comply with the material’s
MSDS. Ensure that the material’s processing temperature and
flashpoints will not be exceeded and that all requirements for safe
handling, ventilation, first aid, and personal protective equipment are
met. Failure to comply with MSDS requirements can cause personal
injury, including death.
HM
WARNING: Reactive material! Never clean any aluminum component
or flush Nordson equipment with halogenated hydrocarbon fluids.
Nordson melters and guns contain aluminum components that may
react violently with halogenated hydrocarbons. The use of
halogenated hydrocarbon compounds in Nordson equipment can
cause personal injury, including death.
HM, CA WARNING: System pressurized! Relieve system hydraulic pressure
before breaking any hydraulic connection or seal. Failure to relieve
the system hydraulic pressure can result in the uncontrolled release of
hot melt or cold adhesive, causing personal injury.
HM
WARNING: Molten material! Wear eye or face protection, clothing
that protects exposed skin, and heat-protective gloves when servicing
equipment that contains molten hot melt. Even when solidified, hot
melt can still cause burns. Failure to wear appropriate personal
protective equipment can result in personal injury.
HM, PC
WARNING: Equipment starts automatically! Remote triggering
devices are used to control automatic hot melt guns. Before working
on or near an operating gun, disable the gun’s triggering device and
remove the air supply to the gun’s solenoid valve(s). Failure to
disable the gun’s triggering device and remove the supply of air to the
solenoid valve(s) can result in personal injury.
HM, CA, PC
WARNING: Risk of electrocution! Even when switched off and
electrically isolated at the disconnect switch or circuit breaker, the
equipment may still be connected to energized auxiliary devices.
De-energize and electrically isolate all auxiliary devices before
servicing the equipment. Failure to properly isolate electrical power to
auxiliary equipment before servicing the equipment can result in
personal injury, including death.

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Warning or Caution
Equipment
Type
CA
WARNING: Risk of fire or explosion! Nordson cold adhesive
equipment is not rated for use in explosive environments and should
not be used with solvent-based adhesives that can create an
explosive atmosphere when processed. Refer to the MSDS for the
adhesive to determine its processing characteristics and limitations.
The use of incompatible solvent-based adhesives or the improper
processing of solvent-based adhesives can result in personal injury,
including death.
HM, CA, PC
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 can
damage to the equipment.
HM
CAUTION: Hot surfaces! Avoid contact with the hot metal surfaces
of guns, hoses, and certain components of the melter. If contact can
not be avoided, wear heat-protective gloves and clothing when
working around heated equipment. Failure to avoid contact with hot
metal surfaces can result in personal injury.
HM
CAUTION: Some Nordson melters are specifically designed to
process polyurethane reactive (PUR) hot melt. Attempting to process
PUR in equipment not specifically designed for this purpose can
damage the equipment and cause premature reaction of the hot melt.
If you are unsure of the equipment’s ability to process PUR, contact
your Nordson representative for assistance.
HM, CA
CAUTION: Before using any cleaning or flushing compound on or in
the equipment, read and comply with the manufacturer’s instructions
and the MSDS supplied with the compound. Some cleaning
compounds can react unpredictably with hot melt or cold adhesive,
resulting in damage to the equipment.
HM
CAUTION: Nordson hot melt equipment is factory tested with
Nordson Type R fluid that contains polyester adipate plasticizer.
Certain hot melt materials can react with Type R fluid and form a solid
gum that can clog the equipment. Before using the equipment,
confirm that the hot melt is compatible with Type R fluid.

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Other Safety Precautions
SDo not use an open flame to heat hot melt system components.
SCheck high pressure hoses daily for signs of excessive wear, damage,
or leaks.
SNever point a dispensing handgun at yourself or others.
SSuspend dispensing handguns by their proper suspension point.
First Aid
Do the following if molten hot melt comes in contact with your skin.
1. Do NOT attempt to remove the molten hot melt from your skin.
2. Immediately soak the affected area in clean, cold water until the hot melt
has cooled.
3. Do NOT attempt to remove the solidified hot melt from your skin.
4. In case of severe burns, treat for shock.
5. Seek expert medical attention immediately. Give the MSDS for the hot
melt to the medical personnel providing treatment.
Safety Labels and Tags
Figure 1-1 illustrates the location of the product safety labels or tags that are
affixed to the equipment. Table 1-2 provides the text of any safety message
that appears on each tag or the meaning of symbols that appear without
any safety message.
The installation kit provided with the melter may contain label overlays that
are printed in a variety of languages. If required by governing safety
regulations, apply the appropriate overlay to the text portion of the labels
shown in Figure 1-1.

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Figure 1-1 Location of safety labels and tags
Table 1-2 Safety Labels and Tags
Item Description
1WARNING:
Hazardous voltage.
Disconnect all power supply
connections before servicing.
2CAUTION:
Burn hazard. Hot surfaces.
3WARNING:
Hazardous voltage.
Disconnect all power supply
connections before servicing.
4CAUTION:
Burn hazard. Hot surfaces.

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Introduction 2-1
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Section 2
Introduction
This manual describes the installation and use of the DuraBlue 4 L (D4L),
DuraBlue 10 L (D10L), and DuraBlue 16 L (D16L) adhesive melters. When
necessary, the reader is referred to the documentation supplied with other
Nordson products or products supplied by third parties.
With the exception of tank capacity, hose/gun capacity, and exterior
appearance, all DuraBlue melters are function identically. To simplify the
presentation of information in this manual, depictions of the model D10L are
used generically throughout this manual to represent all DuraBlue melters.

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Other Sources of Information
Refer to the following additional resources for quick-reference information,
technical support, and information about getting the most out of your
DuraBlue melter.
Installation Guide
The installation guide shipped with the melter provides a visual
quick-reference for installing the melter.
User’s Guide
The user’s guide shipped with the melter provides a visual quick-reference
to the most common operator-level tasks. The guide is appropriately sized
and laminated so that it can be kept with the melter on the production floor.
Product Resource CD
The resource CD, which is stored in the back of this manual, contains an
electronic version of this manual, parts information, and other useful
resources that are designed to assist you with using and servicing your
melter.
Product Description
See Figure 2-1. Nordson DuraBlue adhesive melters are used in
conjunction with Nordson hot melt hoses and guns to create a hot melt
application system.
The melter liquifies solid-form hot melt and maintains the hot melt at the
desired temperature. When the guns are activated, the melter pumps the
liquified hot melt through the hoses and out the gun nozzles, where it is
commonly applied to the surface of a product.