Nordson DuraBlue D4L User manual

NORDSON CORPORATION •DULUTH, GEORGIA •USA
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.
DuraBluerAdhesive Melters
Models D4L, D10L, and D16L (Gerotor)
Customer Product Manual
Part 1073401_07
Issued 01/2021

Part 1073401_07 E2021 Nordson Corporation
All rights reserved
For CE Declaration, refer to equipment documentation.
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 2006.
Nopartofthisdocument may be photocopied, reproduced, or translated to another language without the prior written
consent of NordsonCorporation. Theinformationcontained in this publication is subject to change without notice.
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Table of Contents i
Part 1073401_07
E2021 Nordson Corporation
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 1-4..........................
Installation Practices 1-4.....................................
Operating Practices 1-4......................................
Maintenance and Repair Practices 1-5.........................
Equipment Safety Information 1-5................................
Equipment Shutdown 1-6.....................................
Relieving System Hydraulic Pressure 1-6.....................
De-energizing the System 1-6..............................
Disabling the Applicators 1-6...............................
General Safety Warnings and Cautions 1-7......................
Other Safety Precautions 1-10.................................
First Aid 1-10.................................................
Safety Labels and Tags 1-11.....................................
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 2-3.........................................
Intended Use 2-4............................................
Limitations of Use 2-4........................................
Modes of Operation 2-4......................................
Melter Identification 2-5......................................
Key Components 2-6...........................................
Optional Equipment 2-8.........................................

Table of Contents
ii
Part 1073401_07 E2021 Nordson Corporation
Installation 3-1................................................
Quick-Start 3-1................................................
Overview 3-1..................................................
Additional Information 3-2.....................................
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 Applicators 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.................
Setpoint Temperature of the Tank, Hoses, and Applicators 3-18.....
Review Parameter and Setpoint Temperature Changes 3-20.......
Installing Optional Equipment 3-22................................
Connecting a Applicator Driver, Pattern Controller, or Timer 3-22.......
Flushing the Melter 3-22.........................................
Adjusting the Pressure Control Valve 3-23..........................
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 4-12..................
How F4 Faults are Handled 4-13.............................
Adjusting Component Temperatures 4-18..........................
Enter the Melter Password 4-22..................................
Using Melter Function Keys 4-23..................................
Heater Key 4-23..............................................
Pump Key 4-23..............................................
Setup Key 4-24..............................................
Seven-day Clock Key 4-24.....................................
Standby Key 4-25............................................
Shutting Down the Melter 4-26....................................

Table of Contents iii
Part 1073401_07
E2021 Nordson Corporation
Maintenance 5-1..............................................
Relieving System Pressure 5-2..................................
Locking Out External Communications 5-2........................
Cleaning the Melter 5-4.........................................
Replacing the Filter 5-6.........................................
Cleaning the Tank 5-8..........................................
Troubleshooting 6-1...........................................
Safety 6-1.....................................................
Melter Faults 6-2..............................................
Pump Operating Variables 6-4...................................
Using the Troubleshooting Flow Chart 6-6.........................
Troubleshooting Quick-checks 6-6..............................
Returning the Melter Setup to Factory Settings 6-7...............
Identifying Electrical Components 6-7..........................
No hot melt output from one or more applicators 6-13.............
DuraBlue Troubleshooting Charts 6-13.............................
Parts 7-1......................................................
Using the Illustrated Parts List 7-1...............................
Front Panel Service Kits 7-2.....................................
Electrical Component Service Kits 7-4............................
Circuit Boards 7-4...........................................
Fuses 7-6..................................................
Thermostat 7-7.............................................
RTDs 7-7...................................................
Heaters 7-7.................................................
Cables and Harnesses 7-7....................................
Tank Strainer 7-8..............................................
Drive Assembly Service Kits 7-9.................................
Motor 7-10..................................................
Pump 7-12..................................................
Manifold 7-14................................................
Drive Assembly (Complete) 7-16...............................
Optional Equipment 7-18.........................................
Flow/Pressure Control and Pressure Indication 7-18..............
Expansion and Control Kits 7-18................................
General Melter Accessory Kits 7-18.............................
Technical Data 8-1.............................................
General Specifications 8-1......................................
Electrical Specifications 8-2.....................................
Heater Specifications 8-2.......................................
Motor and Pump Specifications 8-3..............................
Dimensions 8-4................................................
D4L Melter 8-4..............................................
D10L and D16L Melter 8-5....................................
Conduit Penetration Sizes 8-6...................................

Table of Contents
iv
Part 1073401_07 E2021 Nordson Corporation
Calculating Melter Power Requirements A-1.....................
Operating Parameters B-1......................................
Standard B-2..................................................
Pressure Control B-7...........................................
Temperature Control B-8........................................
Seven-day Clock B-12...........................................
Example 1 B-13............................................
Example 2 B-13............................................
Example 3 B-13............................................

## TABSHEET ##
Safety

Safety 1-1
E2021 Nordson Corporation Issued 04-15
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
E2021 Nordson Corporation
Issued 04−15
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
E2021 Nordson Corporation Issued 04-15
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.

Safety
1-4
E2021 Nordson Corporation
Issued 04−15
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.
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. This equipment has not been certified for compliance with the
ATEX directive nor as nonincendive and should not be installed in
potentially explosive environments.
SEnsure that the processing characteristics of the material will not create a
hazardous environment. Refer to the Safety Data Sheet (SDS) 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 SDS for PPE requirements.
SDo not use equipment that is malfunctioning or shows signs of a potential
malfunction.

Safety 1-5
E2021 Nordson Corporation Issued 04-15
Maintenance and Repair Practices
SAllow only personnel with appropriate training and experience to operate
or service the equipment.
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 Nordson‐authorized refurbished or replacement parts.
SRead and comply with the manufacturer's instructions and the SDS
supplied with equipment cleaning compounds.
NOTE: SDSs 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 SDS or
contact the authority having jurisdiction for information.
SKeep equipment safety warning labels clean. Replace worn or damaged
labels.
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

Safety
1-6
E2021 Nordson Corporation
Issued 04−15
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, applicators, 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.
Disabling the Applicators
NOTE: Adhesive dispensing applicators are referred to as “guns” in some
previous publications.
All electrical or mechanical devices that provide an activation signal to the
applicators, applicator solenoid valve(s), or the melter pump must be
disabled before work can be performed on or around an applicator that is
connected to a pressurized system.
1. Turn off or disconnect the applicator triggering device (pattern controller,
timer, PLC, etc.).
2. Disconnect the input signal wiring to the applicator solenoid valve(s).
3. Reduce the air pressure to the applicator solenoid valve(s) to zero; then
relieve the residual air pressure between the regulator and the applicator.

Safety 1-7
E2021 Nordson Corporation Issued 04-15
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, applicators, etc.)
PC = Process control
CA = Cold adhesive (dispensing pumps, pressurized container, and
applicators)
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 SDS. 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
SDS 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 applicators 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.
Continued...

Safety
1-8
E2021 Nordson Corporation
Issued 04−15
Table 1‐1General Safety Warnings and Cautions (contd)
Equipment
Type Warning or Caution
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 applicators. Before working on
or near an operating applicator, disable the applicator's triggering
device and remove the air supply to the applicator's solenoid valve(s).
Failure to disable the applicator'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.
HM, CA, PC
WARNING! Risk of fire or explosion! Nordson adhesive equipment is
not rated for use in explosive environments and has not been certified
for the ATEX directive or as nonincendive. In addition, this equipment
should not be used with solvent‐based adhesives that can create an
explosive atmosphere when processed. Refer to the SDS 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.

Safety 1-9
E2021 Nordson Corporation Issued 04-15
Warning or Caution
Equipment
Type
HM
CAUTION! Hot surfaces! Avoid contact with the hot metal surfaces of
applicators, 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 SDS 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.

Safety
1-10
E2021 Nordson Corporation
Issued 04−15
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 hand‐held applicator at yourself or others.
SSuspend dispensing hand‐held applicators by their proper suspension
point.
First Aid
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 SDS for the hot melt
to the medical personnel providing treatment.

Safety 1-11
E2021 Nordson Corporation Issued 04-15
Safety Labels and Tags
Figure 1‐1 illustrates the location of the product safety labels and tags affixed
to the equipment. Table 1‐2 provides an illustration of the hazard
identification symbols that appear on each safety label and tag, the meaning
of the symbol, or the exact wording of 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.
5
Figure 1-1 Safety labels and tags

Safety
1-12
E2021 Nordson Corporation
Issued 04−15
Table 1-2 Safety Labels and Tags
Item Description
1
WARNING:
Hazardous voltage.
Disconnect all power supply
connections before servicing.
2CAUTION:
Burn hazard. Hot surfaces.
3
WARNING:
Hazardous voltage.
Disconnect all power supply
connections before servicing.
4CAUTION:
Burn hazard. Hot surfaces.
5
WARNING:
Burn hazard.
Hot adhesive.
Release pressure
before servicing.
NS
Tag, hazardous votage [located inside the
electrical cabinet on the main board—refer to
Section 8, Parts, for an illustration that shows the
location of the main board]
NS: Not Shown

## TABSHEET ##
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