Nordson ProBlue 1028303 User manual

Copyright Notice
ProBlue Adhesive Melters
Instruction Sheets
TM
Issued 10/02

Instruction Sheet P/N 1029711A
Pump Service Kit - P/N 1028303
Use this service kit to replace the pump assembly in any ProBluet
adhesive melter. This kit contains two new O-rings that should be used to
replace the existing O-rings that are located between the pump and the
manifold.
WARNING: Risk of personal injury or equipment damage! Refer to
the safety information provided in the melter manual before servicing
the melter. Failure to comply with the safety information provided
can result in personal injury, including death.
Required Tools:
6-mm hex wrench
O-ring (bottom)
O-ring (top)
Parker lubricant
6-mm tube elbow
Pump assembly
Remove the Pump
1. Switch the melter off. 2. Relieve system hydraulic pressure. Refer to the
melter product manual for information on relieving
hydraulic pressure.
a. Rotate the isolation valve handle upward
until it is vertical.
3. Remove the pump as follows:
b. Remove the three pump-mounting bolts. c. While pulling the pump away from the
manifold, tilt the top of the pump toward the
front of the melter and then disconnect the air
line from the back of the pump.
Note: To gain leverage when removing the
pump, insert long M6 bolts into the two threaded
holes located on the front of the pump body.
d. Lift the pump clear of the melter.

Install the New Pump
2. Remove and discard the top and bottom
manifold O-rings. Lubricate the two new O-rings
with Parker lubricant, and then insert the O-rings
into the manifold.
CAUTION: When reinstalling the pump, ensure that the
RTD is fully seated in its slot and that the RTD wires are
not caught between the pump and the manifold.
1. Thread the 6-mm tube elbow into the air inlet port
on the back of the new pump. 3. Reinstall the pump by reversing the sequence illustrated in Removing the Pump, step 3.
4. Switch the melter on and allow it to reheat. Turn
the pump off if it automatically turns on when the melter
reaches ready status.
5. Place a waste container under the drain valve,
and then open the valve (counterclockwise).
6. Turn the pump on and allow hot melt to flow from
the drain valve until the flow is free of air.
7. Close the drain valve and wipe off the drain chute.
8. Continue normal operation of the melter.

Instruction Sheet P/N 1029713A
Pneumatic Panel Assembly Service Kit - P/N 1028307
Use this service kit to replace the pneumatic panel assembly on any
ProBlue adhesivemelter. WARNING: Risk of personal injury or equipment damage! Refer to the safety information provided in the melter manual before servicing
the melter. Failure to comply with the safety information provided
can result in personal injury, including death.
Required Tools:
Phillips-head screwdriver
4-mm hex wrench
Pneumatic panel assembly
M5 screws (Spare)
1. Disconnect the melter from the plant air supply.
3. Removethe front panel.
2. Switch the melter off.
4. Remove the two M5 screws that secure the
pneumatic assembly, and then carefully remove
the assembly from the chassis.
6. Reverse steps 1 through 4 to place
the melter back into operation.
7. Adjust the operating air pressure.
5. Disconnect the two 6-mm air lines and the
electrical quick-disconnect from the pneumatic
assembly, and then reconnect them to the new
assembly.

Instruction Sheet P/N 1029714A
Pressure Discharge Valve Service Kit - P/N 1028308
Use this service kit to replace the pressure discharge valve in any
ProBluetadhesive melter. WARNING: Risk of personal injury or equipment damage! Refer to the safety information provided in the melter manual before servicing
the melter. Failure to comply with the safety information provided
can result in personal injury, including death.
Tools:
4-mm hex wrench
13-mm open-end wrench
Pressure discharge valve
6-mm Tee
M5 x 50 screws
3. Switch the melter off.
4. Open the filter access door, and then remove
the top panel, the air filter, and the back panel.
2.Relieve the system hydraulic pressure. Refer to
the melter product manual for information on relieving
hydraulic pressure.
1. Operate the melter and discharge hot
melt until the level of hot melt in the tank is
below the tank fill line.
9. Apply Never-Seez lubricant to the three
M5 x 50 screws, and then use each screw,
and an M5 washer, to secure the valve to the
manifold. Tighten each screw to
3–4 N•m (30–37 in./lb).
11. Reconnect both of the air lines to the
Tee, replace both panels and the air filter, and
then switch the melter on.
5. Disconnect both air lines from the top of the
pressure discharge valve.
7. Pull the valve out of the manifold.
8. Apply Parker lubricant to the O-rings on
the new valve, and then insert the valve into
the manifold.
10. Thread the new 6-mm Tee into the
valve and tighten the Tee securely.
6. Remove the three screws that secure
the valve to the manifold.

Instruction Sheet P/N 1029715A
Manifold Service Kit - P/N 1028309
Use this service kit to replace the manifold O-rings on any ProBluet
adhesive melter. WARNING: Risk of personal injury or equipment damage! Refer to the safety information provided in the melter manual before servicing
the melter. Failure to comply with the safety information provided
can result in personal injury, including death.
Required Tools:
4-mm hex wrench
6-mm hex wrench
5/16 in. open-end wrench (2 required)
P/N 942080
P/N 1019515 (Three)
Parker Lubricant
P/N 941161 (Two)
P/N 942111
3. Disconnect all hoses from the manifold.
2.Relieve the system hydraulic pressure. Refer to the
melter product manual for information on relieving hydraulic
pressure.
1. Operate the melter and discharge hot melt until the
tank is empty.
Note: Reducethe speed of the pump to
fully empty the tank.
6. Open the filter access door, and then
remove the top panel, the air filter, and the
back panel.
Prepare the Melter
WARNING: Risk of electrocution! The manifold heater terminals
carry high voltage. Before removing the back panel, ensure that
power to the melter is disconnected at the local power disconnect.
Failure to properly disconnect power from the melter can result in
personal injury, including death.
4. Switch the melter off.
5. Disconnectpower to the melter at the local power
disconnect switch.

Remove the Pump
a. Rotate the isolation valve handle upward
until it is vertical.
1. Remove the pump as follows:
b. Remove the three pump-mounting bolts. c. While pulling the pump away from the
manifold, tilt the top of the pump toward the
front of the melter and then remove the air line
from the back of the pump.
d. Lift the pump clear of the melter.
Note: To gain leverage when removing the
pump, thread long M6 bolts into the two threaded
holes located on the face of the pump body.
2. Remove RTD from the
back of the manifold.

Remove the Manifold
1. Disconnectthe air line from
the pressure discharge valve.
2. Disconnectthe leads from the
heater terminals and the thermostat.
CAUTION: Use two wrenches, one on
each terminal nut, when disconnecting the
heater terminals. Using only one wrench
can result in damage to the heater.
1
2
3. Remove the two M5 screws and lock
washers, and then remove the backup
and insulator plates.
4. Loosen,and then partially remove
the three M8 screws that attach the
manifold to the tank.
5. Pull the manifold away from the tank,
and then remove the manifold from the
back of the melter.
Note: Removethe tank-to-manifold
cross-over tube if it remains in the tank
outlet after removing the manifold.

Replace the Manifold O-Rings
1. Disassemblethe isolation valve.
2. Remove and discard the seven existing O-rings.
3.Lubricate each of the seven new O-rings with Parker
Lubricant, and then install each O-ring into the manifold.
See the illustration to the right.
4.Re-assemble the manifold.
5. Reinstall the manifold by reversing the sequence of
steps described in Remove the Manifold.
6.Reinstall the pump by reversing the sequence of steps
described in Remove the Pump.
7.Replace the back panel, the top panel, and the air filter;
restore power to the melter; and then switch the melter on.
P/N 1019515
P/N 942080
P/N 942111
P/N 941161

Instruction Sheet P/N 1029719A
ProBluet10 Main Circuit Board Service Kit - P/N 1028323
Use this service kit to replace the main circuit board assembly in a model
P10 ProBlue adhesive melter. WARNING: Risk of personal injury or equipment damage! Refer to the safety information provided in the melter manual before servicing
the melter. Failure to comply with the safety information provided
can result in personal injury, including death.
Tools:
Philips-head screwdriver
Main Circuit Board Assembly
3. Disconnect the hose electrical cordset from each hose/gun
module, and then remove or partially disengage each hose/gun
module (or blank module) from the main circuit board.
WARNING: Risk of electrocution! The control switch does not remove
high-voltage power from the melter. Before opening the electrical
compartment door, ensure that the local power disconnect switch is in the
off position and locked. Failure to properly disconnect power from the
melter can result in personal injury, including death.
1. Switch the melter off.
2. Disconnectpower to the melter at the local power
disconnect switch.
5. Remove the Phillip-head screw and washers
that secure the main circuit board to the chassis.
Note: Begin with the top-most hose/gun module
when removing or partially disengaging the modules.
4. Open the electrical enclosure door, and then
disconnect the voltage plug (J1/J2) and all cables
from the main circuit board (TB1, TB2, J6, J7, and
J8).

11. Restore electrical power to the melter
and then switch the melter on. Verify that the
melter starts normally.
10. Connectthe voltage plug and all cables
(TB1, TB2, J6, J7, and J8) to the new circuit
board, and then close the electrical enclosure
door.
CAUTION: Before removing the new circuit board from its
anti-static bag, ground yourself by touching any bare-metal
part of the chassis or another grounded structure. Failure to
properly ground yourself can cause electrostatic discharge
resulting in damage to the board.
6. Slide the main circuit board assembly
out of the electrical enclosure. 9. Slide the new circuit board assembly into the electrical enclosure, and then secure the
assembly with the Phillips-head screw and
matching and washers.
7. (Optional)If the melter is configured for
six hoses/guns, disconnect the ribbon and
power cable that connect the main board and
the 6-hose extension board, and then remove
the extension board.
8. (Optional)Assemble the extension board
to the new main circuit board assembly, and
then reconnect the power cable (J10 to J2)
and the ribbon cable (J5 to J1).

Instruction Sheet P/N 1029720A
6-Hose Extension Board Kit - P/N 1028324
Use this service kit to expand the hose capacity of any model P10 ProBlue
adhesive melter from four hoses to six hoses. WARNING: Risk of personal injury or equipment damage! Refer to the safety information provided in the melter manual before servicing
the melter. Failure to comply with the safety information provided
can result in personal injury, including death.
Tools:
Philips-head screwdriver
Main Circuit Board Assembly
Ribbon Cable
Power Cable
M3 Screws (Spare) 3. Disconnect the hose electrical cordset from each hose/gun
module, and then remove or partially disengage each hose/gun
modules (or blank module) from the main circuit board.
WARNING: Risk of electrocution! The control switch does not remove
high-voltage power from the melter. Before opening the electrical
compartment door, ensure that the local power disconnect switch is in the
off position and locked. Failure to properly disconnect power from the
melter can result in personal injury, including death.
1. Switch the melter off.
2. Disconnectpower to the melter at the local power
disconnect switch.
5. Remove the Phillip-head screw and washers
that secure the main circuit board to the chassis.
Note: Begin with the top-most hose/gun module
when removing or partially disengaging the modules.
4. Open the electrical enclosure door and disconnect
all of the cables from the main circuit board (TB1, TB2,
J6, J7, and J8).

11. Restore electrical power to the melter
and switch the melter on. Verify that the melter
starts normally.
10. Reconnectall of the cables (TB1, TB2, J6,
J7, and J8) to the new circuit board, and then
close the electrical enclosure door.
CAUTION: Before removing the new circuit board from its
anti-static bag, ground yourself by touching any bare-metal
part of the chassis or another grounded structure. Failure to
properly ground yourself can cause electrostatic discharge
resulting in damage to the board.
6. Slide the main circuit board assembly
out of the electrical enclosure. 7. Connectthe ribbon cable between the main board (J5) and the extension board (J1).
9. Slide the circuit board assembly back into
the electrical enclosure, and then secure the
assembly with the Phillips-head screw and
matching washers.
7. Attach the extension board to the main
board using the four M3 screws.
8. Connectthe power cable between the
main board (J10) and the extension board (J2).

Instruction Sheet P/N 1029721A
CPU Board Service Kit - P/N 1028325
Use this service kit to replace the CPU (central processor unit) on any
ProBlue adhesivemelter. WARNING: Risk of personal injury or equipment damage! Refer to the safety information provided in the melter manual before servicing
the melter. Failure to comply with the safety information provided
can result in personal injury, including death.
Required Tools:
Phillips-head screwdriver
6-mm open-end wrench
CPU board
Threaded spacers and
lock washers (Spare)
WARNING: Risk of electrocution! The control switch does not remove
high-voltage power from the melter. Before opening the electrical
compartment door, ensure that the local power disconnect switch is in
the off position and locked. Failure to properly disconnect power from
the melter can result in personal injury, including death.
1. Switch the melter off.
2. Disconnectelectrical power to the melter at the
local power disconnect switch.
3. Open the electrical enclosure door .
4. Disconnect the main board and serial
port ribbon cables from the CPU board.
5. Remove the six threaded
spacers and lock washers.
6. Disconnect the two ribbon cables that join the CPU
board and the control panel.
7. Install the new CPU board by reversing steps 3 through 6.
CAUTION: Before removing the new CPU board from its
anti-static bag, ground yourself by touching any bare-metal
part of the chassis or another grounded structure. Failure to
properly ground yourself can cause electrostatic discharge
resulting in damage to the board.
J1
8. Restore electrical power to the melter, and then
switch the melter on. Verify that the melter starts normally.

Instruction Sheet P/N 1029722A
Operator’s Panel/Enclosure Service Kit - P/N 1028326
Use this service kit to replace the operator’s panel on a model P4 or P7
ProBlue adhesivemelter. WARNING: Risk of personal injury or equipment damage! Refer to the safety information provided in the melter manual before servicing
the melter. Failure to comply with the safety information provided
can result in personal injury, including death.
Required Tools:
6-mm open-end wrench
Phillips-head screwdriver
4-mm hex wrench
Operator’s Panel
WARNING: Risk of electrocution! The control switch does not remove
high-voltage power from the melter. Before opening the electrical
compartment door, ensure that the local power disconnect switch is in
the off position and that it is locked. Failure to properly disconnect power
from the melter can result in personal injury, including death.
1. Switch the melter off.
2. Disconnectelectrical power to the melter at the
local power disconnect switch.
3. Open the electrical compartment door.
4. Disconnect the main board and serial port
ribbon cables from the CPU board.
5. Detach the CPU board by removing
the six threaded spacers and lock washers.
6. Disconnect the two ribbon cables that join the CPU
board and the control panel.
CAUTION: Before handling electrical components, ground
yourself by touching any bare-metal part of the chassis or
another grounded structure. Failure to properly ground yourself
can cause electrostatic discharge resulting in damage to the
CPU board.
J1
CPU Board

7. Detach the electrical enclosure door by removing
the four M5 screws and matching washers.
8. Detach the operator’s panel from both hinges
by removing the four locknuts.
9. Assemble the new operator’s panel to the
hinges, and then re-attach the electrical enclosure
door.
10. Reinstall the CPU board by reversing steps 3 through 6.
11. Restore electrical power to the melter, and then
switch the melter on. Verify that the melter starts normally.

Instruction Sheet P/N 1029723A
Operator’s Panel/Enclosure Service Kit - P/N 1028327
Use this service kit to replace the operator’s panel on a model P10
ProBlue adhesivemelter. WARNING: Risk of personal injury or equipment damage! Refer to the safety information provided in the melter manual before servicing
the melter. Failure to comply with the safety information provided
can result in personal injury, including death.
Required Tools:
6-mm open-end wrench
Phillips-head screwdriver
4-mm hex wrench
Operator’s Panel
WARNING: Risk of electrocution! The control switch does not remove
high-voltage power from the melter. Before opening the electrical
compartment door, ensure that the local power disconnect switch is in
the off position and that it is locked. Failure to properly disconnect power
from the melter can result in personal injury, including death.
1. Switch the melter off.
2. Disconnectelectrical power to the melter at the
local power disconnect switch.
3. Open the electrical compartment door.
4. Disconnect the main board and serial port
ribbon cables from the CPU board.
5. Detach the CPU board by removing
the six threaded spacers and lock washers.
6. Disconnect the two ribbon cables that join the CPU
board and the control panel.
CAUTION: Before handling electrical components, ground
yourself by touching any bare-metal part of the chassis or
another grounded structure. Failure to properly ground yourself
can cause electrostatic discharge resulting in damage to the
CPU board.
J1
CPU Board

7. Detach the electrical enclosure door by removing
the four M5 screws and matching washers.
9. Assemble the new operator’s panel to the
hinges, and then re-attach the electrical enclosure
door.
10. Reinstall the CPU board by reversing steps 3 through 6.
11. Restore electrical power to the melter, and then
switch the melter on. Verify that the melter starts normally.
8. Detach the operator’s panel from both
hinges by removing the four locknuts.

Instruction Sheet P/N 1029716A
RTD Service Kit - P/N 1028320
Use this service kit to replace either the tank or the manifold RTD. The kit
contains a ceramic terminal block that must be installed the first time you
replace either RTD.
WARNING: Risk of personal injury or equipment damage! Refer to
the safety information provided in the melter manual before servicing
the melter. Failure to comply with the safety information provided
can result in personal injury, including death.
Tools:
Wire cutters
Small flat-tip screwdriver
2.5-mm hex wrench
6-mm hex wrench (For manifold RTD only)
Terminal Block
RTD
Thermal Compound
O-ring
O-ring
1. Switch the melter off.
4. Strip the ends of the existing
RTD wires and then connect the
wires to the top terminals on the
terminal block. Tighten the terminal
screws.
5. Coat the new RTD with
thermal compound and then insert the RTD into
the slot until it stops.
Replacing the Tank RTD
2. Cut the wires on the failed
RTD just behind the RTD and then
pull out the RTD.
6. Trim the new RTD wires
approximately 100 mm (4 in.) from
the RTD, strip the ends of the wires,
and then connect both wires to the
bottom terminals on the terminal
block. Tighten the terminal screws.
3. Attach the terminal block to the bracket
using the 3-mm hex-head screw and
matching lock washer.

Replacing the Manifold RTD
a. While pressing both the Setup and the Tank
key, cycle the control switch off and then on
again. The left display will flash to indicate that
the melter is heating in the override mode. The
melter will continue to reheat for 20 minutes and
then automatically switch off.
b. To continue reheating the melter, repeat step a.
until the melter reaches 120 °C (250 °F).
2. Switch the melter off.
a. Rotate the isolation valve handle upward
until it is vertical.
4. Remove the pump as follows:
3. Relieve system hydraulic pressure. Refer to the
melter manual for information on relieving hydraulic
pressure.
b. Remove the three pump-mounting bolts. c. While pulling the pump away from the
manifold, tilt the top of the pump toward the
front of the melter and then remove the air line
from the back of the pump.
d. Lift the pump clear of the melter.
Note: To gain leverage when removing the
pump, thread long M6 bolts into the two holes
located on the face of the pump body.
1. To replace the manifold RTD you must first remove the pump.
If the temperature of the tank is below 120 °C (250 °F) it may not be
possible to remove the pump until the melter is reheated.
To reheat the melter: