Nordson BM 200 User manual

Bulk Melters BM 200
with Gear Pump
- EASY Pneumatics -
Manual P/N 397189E
- English -
Issued 05/06
NORDSON ENGINEERING GMBH DLÜNEBURG DGERMANY

P/N 397189E E2006 Nordson Corporation BM200_EASY_GEAR
Note
After approx. December 2003, this manual applies to the entire series.
Order number
P/N = Order number for Nordson products
Notice
This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2003.
No part of this document may be photocopied, reproduced, or translated to another language without the prior
written consent of Nordson Corporation. The information contained in this publication is subject to change
without notice.
©2006 All rights reserved.
Trademarks
AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Autotech, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, CleanSleeve,
CleanSpray, ColorMax, Control Coat, Coolwave, Cross‐Cut, Cyclo‐Kinetic, Dispensejet, DispenseMate, DuraBlue, Durafiber, Dura‐Screen, Durasystem,
Easy Coat, Easymove Plus, Ecodry, Econo‐Coat, e.dot, e.stylized, EFD, ETI, Excel 2000, Fillmaster, FlexiCoat, Flexi‐Spray, Flex‐O‐Coat, Flow Sentry,
Fluidmove, FoamMelt, FoamMix, Heli‐flow, Helix, Horizon, Hot Shot, iControl, iFlow, Isocoil, Isocore, Iso‐Flo, iTRAX, JR, KB30, Kinetix, Little Squirt,
LogiComm, Magnastatic, March, MEG, Meltex, Microcoat, Micromark, MicroSet, Millenium, Mini Squirt, Moist‐Cure, Mountaingate, MultiScan, Nordson,
OmniScan, OptiMix, Package of Values, PatternView, PermaFlo, Plasmod, PluraFoam, Porous Coat, PowderGrid, Powderware, Prism, Printplus,
ProBlue, Pro‐Flo, ProLink, Pro‐Meter, Pro‐Stream, RBX, Rhino, Saturn, Scoreguard, SC5, S. design stylized, Seal Sentry, Select Charge, Select Coat,
Select Cure, Slautterback, Smart‐Coat, Solder Plus, Spectrum, Speed‐Coat, Spraymelt, Spray Squirt, Super Squirt, SureBead, Sure Clean, Sure Coat,
Sure‐Max, Tela‐Therm, Tracking Plus, TRAK, Trends, Tribomatic, Ultra, Ultrasaver, UniScan, UpTime, Vantage, Veritec, VersaBlue, Versa‐Coat,
Versa‐Screen, Versa‐Spray, Walcom, Watermark, When you expect more. are registered trademarks - ®- of Nordson Corporation.
Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AquaCure, ATS, Auto‐Flo, AutoScan, Best Choice, BetterBook, Blue Series,
CanNeck, Celero, Chameleon, Check Mate, ClassicBlue, Color‐on‐Demand, Controlled Fiberization, Control Weave, CPX, DispensLink, Dry Cure,
DuraBraid, DuraCoat, DuraDrum, DuraPail, E‐Nordson, Easy Clean, EasyOn, Eclipse, Equi=Bead, ESP, Exchange Plus, Fill Sentry, Gluie, G‐Net, G‐Site,
HDLV, Ink‐Dot, iON, Iso‐Flex, iTrend, KVLP, Lacquer Cure, Lean Cell, Maverick, Maxima, MicroFin, MicroMax, MiniBlue, MiniEdge, Minimeter, Multifil,
Myritex, OptiStroke, Origin, PatternPro, PCI, PluraMix, Powder Pilot, Powercure, Primarc, Process Sentry, Prodigy, Pulse Spray, PurTech, Quad Cure,
Ready Coat, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit,
Sure Brand, SureMix, SureSeal, Sure Wrap, Swirl Coat, Tempus, ThruWave, Trade Plus, TrueBlue, Ultrasmart, Universal, Viper, Vista, VersaDrum,
VersaPail, WebCure, 2 Rings (Design) are trademarks - T- of Nordson Corporation.
Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes,
could lead to violation of the owners' rights.

Table of Contents I
P/N 397189E
E2006 Nordson Corporation BM200_EASY_GEAR
Table of Contents
Safety 1‐1.................................................
Introduction 2‐1............................................
Intended Use 2‐1............................................
Unintended Use - Examples - 2‐1...........................
Area of Use 2‐2...........................................
Residual Risks 2‐2..........................................
Definition of Term(s) 2‐2......................................
Note on Manual 2‐3..........................................
Configuration Code 2‐4.......................................
ID Plate 2‐5..............................................
Essential Components 2‐6....................................
Model Variations and Options 2‐7...........................
Pressure Control 2‐7....................................
Exhaust Hood 2‐7......................................
Changeover System 2‐7.................................
High Drum Jacket for Cardboard Drums 2‐8................
Divided Base Plate for Pallet Conveyance 2‐8..............
Electrical Cabinet 2‐9......................................
Button Two‐hand Control and Pneumatic Switch 2‐10.........
Control System 2‐10.....................................
Key Switch Remote / Local and Indication Lamp Remote 2‐10..
Main Switch 2‐10........................................
Electrical Cabinet Ventilation 2‐10..........................
Electrical Connections 2‐11...............................
Week Timer (Accessory) 2‐12.............................
Door Lock 2‐12..........................................
Light Tower (Accessory) 2‐12.............................
Heating Punch 2‐13........................................
Melting Plates 2‐13......................................
Functioning 2‐14.............................................
Raising and Lowering Heating Punch 2‐14.....................
Deaerating Drum 2‐14....................................
Aerating Drum 2‐14......................................
Melting Process and Material Flow 2‐15.......................
Drive 2‐15.................................................
Heating and Temperature Control 2‐16........................
Undertemperature Interlock 2‐16...........................
Overtemperature Indication / Shutdown 2‐16................
Temperature Setback 2‐16................................

Table of Contents
II
P/N 397189E E2006 Nordson Corporation BM200_EASY_GEAR
Installation 3‐1.............................................
Unpacking 3‐1..............................................
Lifting (Unpacked System) 3‐1..............................
Transport 3‐1...............................................
Storage 3‐2.................................................
Setting Up 3‐2..............................................
Removing 3‐3...............................................
Disposal 3‐3................................................
Exhausting Material Vapors 3‐4...............................
Electrical Connections 3‐5....................................
Laying Cable 3‐5..........................................
Line Voltage 3‐5..........................................
Power Supply 3‐5.........................................
Hose Receptacle(s) 3‐5....................................
Operating with Assembly Handguns 3‐5...................
Pilot Voltage / Tach Generator 3‐5...........................
Interface XS2 3‐6.........................................
Installing Heated Hoses 3‐7...................................
Laying Hoses 3‐7.........................................
Connecting 3‐7...........................................
Disconnecting 3‐7.........................................
Relieving Pressure 3‐7..................................
Second Open‐jawed Wrench 3‐7.........................
Pneumatic Connection 3‐8....................................
Preparing for Changeover System 3‐8..........................
Reducing Heating Punch Lifting Speed 3‐8......................
Accessories 3‐9.............................................
Light Tower 3‐9...........................................
Week Timer 3‐9...........................................
Tach Generator 3‐9.......................................
Transformer 3‐9..........................................
Operation 4‐1..............................................
Initial Startup 4‐1............................................
Adjusting Switch Rod 4‐2.....................................
Setting Values and Parameters - Notes - 4‐3....................
Speed, Pressure 4‐3......................................
Temperatures 4‐3.........................................
Recommended Values 4‐3...............................
Inserting and Replacing Drum 4‐4.............................
Raising Heating Punch 4‐5.................................
Lowering Heating Punch 4‐5................................
Switching System ON/OFF 4‐6................................
Daily Startup 4‐6..........................................
Daily Switchoff 4‐6........................................
Switching Off in an Emergency 4‐7..........................
Settings Record Form 4‐8....................................

Table of Contents III
P/N 397189E
E2006 Nordson Corporation BM200_EASY_GEAR
Maintenance 5‐1...........................................
Risk of Burns 5‐1............................................
Relieving Pressure 5‐1.......................................
Daily Maintenance 5‐2.......................................
Regular Maintenance 5‐3.....................................
External Cleaning 5‐4........................................
Visual Inspection for External Damage 5‐4......................
Electrical Cabinet Ventilation 5‐4..............................
Compressed Air Filter 5‐5....................................
Draining Condensate 5‐5...................................
Cleaning Filter Element 5‐5.................................
Pneumatic Pressure Restrictor Valves 5‐6......................
Function Testing of Pressure Restrictor Valve 5‐6..............
Cleaning Pressure Restrictor Valve 5‐6.......................
Changing Type of Material 5‐7................................
Purging with Cleaning Agent 5‐7...............................
Cleaning Melting Plate 5‐7....................................
Maintenance Record Form 5‐8................................
Troubleshooting 6‐1........................................
Some Tips 6‐1..............................................
Troubleshooting with Control System 6‐2.......................
Indication Lamps and Light Tower 6‐2........................
Troubleshooting Tables 6‐3...................................
Repair 7‐1.................................................
General Notes 7‐1...........................................
Replacing Sealing Ring 7‐2...................................
Replacing O‐rings 7‐3........................................
Replacing Melting Plate Temperature Sensor and Thermostat 7‐4..
Technical Data 8‐1.........................................
General Data 8‐1............................................
Electrical Specifications 8‐1...................................
Motors / Speeds 8‐2.........................................
Temperatures and Thermostats 8‐2............................
Air Cunsumption 9‐2.........................................
Exhaust Hood 8‐2...........................................
Material Pressures 8‐3.......................................
Dimensions 8‐3.............................................
Weight 8‐4.................................................
Processing Materials 8‐4.....................................
Lubricating Heating Punch Sealing Rings 8‐4.................
Inserting Thermostats and Temperature Sensors 8‐4...........
Lubricating O‐rings 8‐4....................................
Screw Locking Device 8‐4..................................

Table of Contents
IV
P/N 397189E E2006 Nordson Corporation BM200_EASY_GEAR

Safety 1‐1
P/N 397189E
E2006 Nordson Corporation BM200_EASY_GEAR
Section 1
Safety
Observe and follow all safety instructions, the general safety instructions
included as a separate document,
as well as the specific safety instructions in all other related documentation.

Safety
1‐2
P/N 397189E E2006 Nordson Corporation
BM200_EASY_GEAR

Introduction 2‐1
P/N 397189E
E2006 Nordson Corporation BM200_EASY_GEAR
Section 2
Introduction
Intended Use
Bulk melters in the series BM 200 with Gear Pumps - hereafter also referred
to as system - may be used only to melt and feed suitable materials. When in
doubt, seek permission from Nordson.
CAUTION: Only undamaged and suitable drums (Refer to Technical Data)
may be used.
CAUTION: PUR material may be processed only in models with exhaust
hood and manual drum aeration valve!
Any other use is considered to be unintended. Nordson will not be liable for
personal injury or property damage resulting from unintended use.
Intended use includes the observance of Nordson safety instructions.
Nordson recommends obtaining detailed information on the materials to be
used.
Unintended Use - Examples -
The systems may not be used under the following conditions:
SIn defective condition
SWith electrical cabinet door open
SIn a potentially explosive atmosphere
SWith unsuitable operating/processing materials
SWhen safety valves and pressure restrictor valves are not lead‐sealed
SWhen the values stated under Technical Data are not complied with.
The systems may not be used to process the following materials:
SExplosive and flammable materials
SErosive and corrosive materials
SFood products.

Introduction
2‐2
P/N 397189E E2006 Nordson Corporation
BM200_EASY_GEAR
Area of Use
The system is designed for use in industrial areas.
When using in industrial areas and in small businesses, the system may
cause interference in other electrical units, e.g. radios.
Residual Risks
In the design of the unit, every measure was taken to protect personnel from
potential danger. However, some residual risks can not be avoided.
Personnel should be aware of the following:
SRisk of burns from hot material
SRisk of burns from hot system components
SRisk of burns when conducting maintenance and repair work for which
the system must be heated up
SRisk of burns when attaching and removing heated hoses
SMaterial fumes can be hazardous. Avoid inhalation
SPinching parts of the body between heating punch and drum
SThe safety valve may malfunction due to hardened or charred material.
Definition of Term(s)
The safety valve is also referred to as bypass and bypass valve in Nordson
literature.

Introduction 2‐3
P/N 397189E
E2006 Nordson Corporation BM200_EASY_GEAR
Note on Manual
SThis manual applies to models with PLC‐controlled pneumatics (after
approx. December 2003)
SThis manual is valid only in conjunction with all documents included in the
complete set of documentation (blue binder)
SWhen the system has special features, customer specifications and/or
supplements or a higher‐ranking system description may be added to this
manual
SThe position numbers in the illustrations do not correspond to the position
numbers in the technical drawings and parts lists. Refer to separate
document Parts List for details.

Introduction
2‐4
P/N 397189E E2006 Nordson Corporation
BM200_EASY_GEAR
Configuration Code
The configuration code is engraved on the ID plate.
NOTE: An X indicates that the function or component was not ordered,
meaning that it is unavailable. An S indicates that the model deviates from
the configuration code. Such deviations are described in a supplement or a
system description.
Box Code Key
1BM200 Series or unit designation
Equipment
2Melting plate Drum aeration valve Exhaust hood
A Axial Automatic No
B Axial Automatic Yes
R Axial Manual No
C Axial Manual Yes
F Fine‐blade Automatic No
P Fine‐blade Manual No
G Smooth Automatic Yes
U Smooth Manual Yes
33Operating voltage 400VAC, 3 Ph Y
4400VAC, 3 Ph, Delta
5480VAC, 3 Ph, Delta
4KHose connection 16 mm (5/8in) installed
8 mm (5/16 in) included
M20 mm (3/4in)
L32 mm (11/4in)
511 Pump type Gear, PR 6m1
12 Gear, PR 12m1
13 Gear, PR 12m2
14 Gear, PR 25m2
50 Gear, PU 15/85
51 Gear, PU 25/85
52 Gear, PU 35/85
53 Gear, PU 50/85
41 Piston pump, 42:1
42 Piston pump, 24:1
6LOvertemperature
thermostat
150 °C / 300 °F
M176 °C / 350 °F
H230 °C / 450 °F
71Number of hose
connections
1
2 2
Continued...

Introduction 2‐5
P/N 397189E
E2006 Nordson Corporation BM200_EASY_GEAR
KeyCodeBox
Options
9D Pressure‐controlled
10 PProfibus interface
11 6Six additional heating channels (three additional receptacles)
12 JHigh drum jacket (for cardboard drums)
13 WDivided base plate (for pallet conveyance)
14 S Special
NOTE: Models with a piston pump are not described in this manual.
CAUTION: PUR material may be processed only in models with exhaust
hood and manual drum aeration valve!
ID Plate
ADHESIVE MELTER
BM
Nordson Engineering GmbH
Lilienthalstr. 6
D 21337 Lüneburg - Germany
www.nordson.com
Serial No:
3
4
5
12
Year
Fig. 2‐1
1Melter designation
2Order number
3Configuration code
4Electrical connection, operating voltage, line voltage frequency, melter fuse protection
5Serial number

Introduction
2‐6
P/N 397189E E2006 Nordson Corporation
BM200_EASY_GEAR
Essential Components
Components - when they are relevant to installation, operation and
maintenance - are described in the appropriate sections of this manual or in
separate manuals.
1
4
6
3
2
15
12
14
13
10
11
87
95
Fig. 2‐2
1 Pressure controller
2 Switch rod
3 Electrical cabinet
4 Automatic drum aeration valve
(option) mounted on heating
punch
or
Manual drum aeration valve
mounted on cross beam
5 Safety valve*
6 Pump*
7 Drip pan
8 Drum deaeration valve
9 Heating punch
10 Sensor Drum inserted (mounted
on base plate)
11 Hose connection
12 Exhaust hood (option)
13 Drive
14 Hose holder
15 Hose receptacle
Note: There are separate manuals available for components marked with an asterisk (*).

Introduction 2‐7
P/N 397189E
E2006 Nordson Corporation BM200_EASY_GEAR
Model Variations and Options
Pressure Control
The material pressure beyond the pump is measured by a pressure sensor
and regulated by a control system to remain at a constant pressure (can be
adjusted). Refer to separate manual.
Exhaust Hood
If the bulk melter is used to process polyurethane hot melt adhesives (PUR),
fumes are created that should be suctioned off directly at the drum. An
exhaust hood is integrated into the bulk melter for this purpose.
The exhaust hood must be connected to the customer's exhaust device (Also
refer to Installation, Exhausting Material Vapors).
Changeover System
The changeover system allows uninterrupted operation of two bulk melters.
One of the systems is active (feeding material), and the other is in standby
mode (system switched on, heating punch heater not yet on).
If a drum is almost empty (in this case, in the system on the right), the heating
punch heater of the other system is automatically switched on. Now the
empty drum can be replaced while the other system is feeding material.
Refer to separate manual.
Fig. 2‐3 Principle drawing

Introduction
2‐8
P/N 397189E E2006 Nordson Corporation
BM200_EASY_GEAR
High Drum Jacket for Cardboard Drums
CAUTION: Do not use metal drums with this model! The drum jacket is
designed only for cardboard drums!
NOTE: Models for cardboard drums have only the lower sealing ring on the
heating punch (configuration code: box 12 = J).
Divided Base Plate for Pallet Conveyance
The bulk melter is set up on a divided base plate. This enables a drum to be
moved under the punch on a pallet.
CAUTION: Risk of damage! Do not operate equipment until it is screwed
securely to the floor. Otherwise the descending punch would lift the system
off of the floor.

Introduction 2‐9
P/N 397189E
E2006 Nordson Corporation BM200_EASY_GEAR
Electrical Cabinet
2
4
5
6
7
11
12
3
9
1
1
7
8
10
Fig. 2‐4
1 Button Two‐hand control
2 Pneumatic switch
3 Control system*
4 Indication lamp Remote
(only with option Profibus)
5 Key switch Remote / local
(only with option Profibus)
6 Main switch
7 Electrical cabinet ventilation
8 Base
9 Light tower
10 Electrical connections
11 Door lock
12 Week timer* (accessory)
Note: There are separate manuals available for components marked with an asterisk (*).

Introduction
2‐10
P/N 397189E E2006 Nordson Corporation
BM200_EASY_GEAR
Button Two‐hand Control and Pneumatic Switch
Used to manually control the heating punch when the drum is being
changed.
WARNING: The two‐hand control may only be operated by one person
using both hands!
The pneumatic switch lights up green when the drum is inserted.
Control System
On the control system, values and parameters are set, and operating modes
and faults are displayed.
Refer to manual for the Control System used.
Key Switch Remote / Local and Indication Lamp Remote
When set to Remote, the system is not controlled by the internal control
system but via the interface Profibus (Option).
Main Switch
The main switch is used to switch the system on and off.
Position 0/OFF = System is switched off.
Position I/ON = System is switched on.
Padlocks can be used to protect the main switch from unauthorized access.
Black Main Switch (Special Model)
Systems with a black main switch are normally supplied with power by a
higher‐ranking system; the higher‐ranking main switch is on that system. The
black main switch does not perform the EMERGENCY OFF function.
Connected components can still be switched on!
Electrical Cabinet Ventilation
Air Filter / Fan with Filter
Electrical cabinet ventilation reduces the temperature inside of the electrical
cabinet. It must be serviced regularly. Refer to Maintenance.

Introduction 2‐11
P/N 397189E
E2006 Nordson Corporation BM200_EASY_GEAR
Electrical Connections
Also refer to section Installation and to the wiring diagram.
1
2
3
4
Fig. 2‐5
1 Additional receptacles (with option
Additional heating channels)
2 Interface Profibus (Option)
3 Receptacle XS5, tach generator
4 Interface XS2
Additional Receptacles
Depending on the model, up to three additional receptacles are available.
Two heating zones (usually for hose and application head) can be controlled
via each receptacle.
NOTE: Hose receptacles on the terminal box (Pos. 15, Fig. 2‐2) are for
hoses connected to the bulk melter heating punch.
Interface PROFIBUS (Option)
The PROFIBUS interface enables Remote operation by a higher‐ranking
control unit. Refer to separate manual.
Receptacle XS5
The receptacle is used to connect pilot voltage that regulates the system's
electrical motor synchronously to the speed of the parent machine. The pilot
voltage can be supplied e.g. by a tach generator (accessory) driven by the
parent machine. Refer to Installation.
Interface XS2
Serves as a connection between the system and external devices.

Introduction
2‐12
P/N 397189E E2006 Nordson Corporation
BM200_EASY_GEAR
Week Timer (Accessory)
The week timer is used to automatically switch the system on and off. The
main switch must be set to I/ON (switched on) when using the week timer.
Refer to separate manual.
Door Lock
The electrical cabinet can be opened for installation, maintenance and repair.
Store the included key such that it is accessible only to qualified and
authorized personnel. The system may not be operated when the electrical
cabinet is open.
WARNING: Risk of electrical shock. Failure to observe may result in
personal injury, death, or equipment damage.
WARNING: Disconnect equipment from the line voltage.
Light Tower (Accessory)
The light tower shows the system operating modes.
Refer to section Troubleshooting and manual Control System.
White Switched on
Green Ready for operation
Yellow Drum almost empty (flashing light) and drum empty (light on)
Red Collective fault