AltaBlue™ Plus Flow/Pressure
Control and Monitoring
Customer Product Manual
Part 1130505_01
Issued 12/21
This document contains important safety information.
Be sure to read and follow all safety information in this
document and any other related documentation.
NORDSON CORPORATION  DULUTH, GEORGIA  USA
www.nordson.com
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 2021.
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.
Trademarks
10‐Point Finger Grip, 2-RINGS (Design), 200 Barb Series, 400 Barb Series, 4800 INTEGRA, Allegro, Apogee, AspireFP, Assure,
Asymtek, Avex, BaitGun, BKG, Blue Box, Bowtie, Build‐A‐Part, Canvas, Cerno, CF, CleanSleeve, CleanSpray, ColorMax,
Color‐on‐Demand, Conexis, Contour, ControlCoat, Coolwave, Cross‐Cut, CrystallCut, C‐SAM, Dage, Dial‐A‐Dose, Dima, DispenseJet,
DispenseMate, DuraBlue, DuraDrum, DuraPail, e-stylized, e.DOT, EasyCoat, Ecodry, Econo‐Coat, EDI, EFD, Encore, EviroShield,
Excel 2000, Fibrijet, FILM‐PAK, FlexTRAK, Fluidmove, FoamMelt, FoamMelt - stylized, FoamMix, Forte, Freedom, Fulfill, Gensys,
GreenUV, HDLV, Heli‐flow, Helios, Horizon, iControl, iDry, iFlow, Integra, IntelliJet, Isocore, Iso‐Flo, iTrax, KISS, LeanCell, LogiComm,
March, Matrix, MatriX and design, Maverick, Measuring the Invisible, MEG, Meltex, MicroCoat, MicroMark, Micromedics, Micro‐Meter,
Microshot, Millennium, MiniBlue, Mini Squirt, Modcath, NexJet, nLighten, No-Drip, Nordson, Nordson - stylized, Nordson and Arc,
Nordson and Arc Select, Novo, NYTVision, Optima, OptiMix, OptiMixer, Optimum, Package of Values, Paragon, PermaFlo, PICO,
PICO Touch, PicoPulse, Polymer Solution Casting, PorousCoat, Posi‐Dose, PowderGrid, Precisecoat, PrintPlus, ProBlue, ProBlue
Liberty, Prodigy, Pro‐Flo, Program‐A‐Bead, Program‐A‐Shot, Program‐A‐Swirl, Pro‐Meter, Prospector, Prototools, Quadra, Quadra Nt,
Quantum, Ratio‐Pak, RBX, ReadiSet, Rhino, Saturn, Saturn with Rings, Scoreguard, Sealant Equipment & Engineering, Inc.,
SEE (and design), See‐Flo, SelectCharge, SelectCoat, Select Cure, Servo‐Flo, Shot‐A‐Matic, Signature - stylized, Slautterback,
Smart‐Coat, Smart-Gun, SolderPlus, Sonolab, Sonoscan, Spectrum, Speed‐Coat, StediFlo, Striped Hose, Sure Coat, SureBead,
SureWrap, Symphony, Tip-Seal, TRAK, Tribomatic, Trilogy, TrueBlue, Turbo, Ultra, u‐TAH, Value Plastics, Vantage, Vention Medical,
Vention Medical Advancing Your Innovations For Health, VersaBlue, VersaDrum, VersaPail, VersaPUR, Versa‐Spray, Versatility, Vortix,
VP Big 10pt - 3D Design, VP stylized, When you expect more., X-Plane, and YesTech are registered trademarks of Nordson Corporation.
Accubar, Active Nozzle, Advanced Plasma Systems, AeroDeck, AeroWash, AirShield, AltaBlue, AltaSlot, AltaSpray, ATS, Auto‐Flo,
Autoflex, AutoScan, Axiom, BBconn, Best Choice, Better Dispensing, Blue Series, Bravura, CanPro, Champion, Check Mate, Classic IX,
ClassicBlue, CleanCoat, Cobalt, Color Silver Hose, Concert, ContourCoat, Control Weave, Controlled Fiberization, CPX, cScan+,
cSelect, Cyclo‐Kinetic, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraPUR, e.dot+, Emerald, E‐Nordson, Easy Clean, EasyOn,
EasyPW, Eclipse, EcoBead, EdgeControl, Equalizer, EquiBead, ExoSPHERE, FasTRAK, FillEasy, FillSentry, FlexSeam, FlexVIA,
Flow Coat, FluxPlus, G‐Net, G‐Site, Get Green with Blue, Harmony, Inspire, iON, Iso‐Flex, iTrend, JetStream, Lacquer Cure, LightTite,
Liquidyn, LoadermoveTouch, Maxima, MaxVIA, MegaVIA, Melt‐on‐Demand, Mesa, MesoSPHERE, MicroDot, MicroFin, MicroMax,
MicroSpray, Mikros, MiniEdge, Minimeter, MiniPUR, ModVIA, Multifill, MultiScan, Myritex, Nordson Electronics Solutions, OmniScan,
OptiStroke, Optix, OsteoPrecision, Partnership+Plus, PatternJet, PCI, PharmaLok, PicoDot, Pinnacle, PowderPilot, Powder Port,
Powercure, Process Sentry, Progeny, ProVIA, Pulse Spray, PURBlue, PUReOne, PURJet, Qadence, Ready Coat, RediCoat, Rhythm,
RollVIA, Royal Blue, Seeing is Believing, SelectSeries, Sensomatic, Shaftshield, SheetAire, Smart, Smart Melt, Smart Tune, Smartfil,
SolidBlue, Spectral, SPHERE, Spray Works, Steadi‐Mix, StediTherm, StratoSPHERE, StrokeControl, Summit, SureFoam, SureMix,
SureSeal, SwirlCoat, SYRINGELok, TAH, TradePlus, ThruCoat, ThruCure, ThruWave, Trio, TruFlow, Ultraflex, Ultrasaver, Ultrasmart,
Uniflow, Unity, UNITYMotion, Universal, Ultra FoamMix, UltraMax, ValueMate, Veritas, VIA, Vista, VP Quick Fit, VP Quick‐Fit stylized,
WaferLock, Waterplume, Web Cure, Wisdom, and Wisdom & Design aretrademarks of NordsonCorporation.
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.
Part 1130505_01
E 2021 Nordson Corporation
All rights reserved
Table of Contents
i
Table of Contents
E 2021 Nordson Corporation
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Alert Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Responsibilities of the Equipment Owner . . . . . . . . . . . . . . . . . . . . . . .
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions, Requirements, and Standards . . . . . . . . . . . . . . . . . .
User Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applicable Industry Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . .
Intended Use of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions and Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Repair Practices . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relieving System Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . .
De‐energizing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disabling the Applicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Safety Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . .
Other Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1‐1
1‐1
1‐2
1‐2
1‐2
1‐3
1‐3
1‐3
1‐4
1‐4
1‐4
1‐5
1‐5
1‐6
1‐6
1‐6
1‐6
1‐7
1‐10
1‐10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limitations and Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Key Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow and Pressure Option Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow and Pressure Option Board Kits . . . . . . . . . . . . . . . . . . . . .
Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Transducer Applicator and Cable Kits . . . . . . . . . . . . .
Flow Meter/Transmitter (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Device and Cable Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow and Pressure Closed Loop Theory of Operation . . . . . . . . . . . . .
Gear-to-Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Build . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2-1
2-1
2-2
2-3
2-4
2-4
2-5
2-5
2-6
2-7
2-8
2-9
2-10
Hardware Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Experience of Installation Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Flow/Pressure Option Board and Terminal Block . . .
Installing Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Pressure Transducer Installation . . . . . . . . . . . . . . . . . .
About Internal Pressure Transducer Configuration . . . . . . . . . .
Installing Flow Meter/Encoders (Optional) . . . . . . . . . . . . . . . . . . . .
Flow Cable Wire Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mating Connector for the TruFlow Transmitter Box . . . . . . . . . . . .
3-1
3-1
3-2
3-3
3-5
3-5
3-8
3-13
3-16
3-16
Part 1130505_01
ii
Table of Contents
Part 1130505_01
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What's Next? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Pump Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuring and Modifying Pressure Control and Monitor . . . . . . .
Configuring and Modifying Flow Control and Flow Monitoring . . . .
Viewing Total Adhesive Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuring Gear-to-Line with Pressure/Flow Monitoring . . . . . . . .
About Testing and Fine-Tuning Configurations . . . . . . . . . . . . . . . .
More About PIDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fine-Tuning Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fine-Tuning Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuring Channel Alert/Fault Alarms . . . . . . . . . . . . . . . . . . . . . .
Configuring Pressure Channel Alert/Fault Alarms . . . . . . . . . . . . . .
Configuring Flow Channel Alert/Fault Alarms . . . . . . . . . . . . . . . . .
Monitoring and Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessing the SD Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessing the FTP Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stop Using / Disable a Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Default Flow and Pressure Settings and Ranges . . . . . . . . . . . . . . . . .
Flow Global Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
4-1
4-2
4-3
4-6
4-10
4-12
4-16
4-16
4-18
4-22
4-25
4-26
4-26
4-27
4-27
4-28
4-29
4-30
4-30
4-32
4-33
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relieving Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning Filter Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purging with Cleaning Agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning Complete Flow Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forcibly Actuating Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow General and Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Processing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Transducer Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5‐1
5‐2
5‐2
5‐3
5‐3
5‐3
5‐3
5‐4
5‐4
5‐4
5‐4
5‐5
5‐6
5‐6
5‐7
5‐7
5‐7
5‐7
5‐8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow and Pressure Alerts/Faults Pop-up Messages . . . . . . . . . . . .
Troubleshooting Flow Rate Issues . . . . . . . . . . . . . . . . . . . . . . . . . .
6‐1
6‐2
6‐3
E 2021 Nordson Corporation
Safety
1-1
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.
E 2021 Nordson Corporation
Issued 04-15
1-2
Safety
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
S Research 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.
S Make safety information available to equipment users in accordance with
governing regulations. Contact the authority having jurisdiction for
information.
S Maintain safety information, including the safety labels affixed to the
equipment, in readable condition.
Instructions, Requirements, and Standards
S Ensure that the equipment is used in accordance with the information
provided in this document, governing codes and regulations, and best
industry practices.
S If 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.
S Provide appropriate emergency and first aid equipment.
S Conduct safety inspections to ensure required practices are being
followed.
S Re‐evaluate safety practices and procedures whenever changes are
made to the process or equipment.
Issued 04−15
E 2021 Nordson Corporation
Safety
1-3
User Qualifications
Equipment owners are responsible for ensuring that users:
S receive safety training appropriate to their job function as directed by
governing regulations and best industry practices
S are familiar with the equipment owner's safety and accident
prevention policies and procedures
S receive 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
S possess industry‐ and trade‐specific skills and a level of experience
appropriate to their job function
S are 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
S Use the equipment only for the purposes described and within the limits
specified in this document.
S Do not modify the equipment.
S Do 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.
E 2021 Nordson Corporation
Issued 04-15
1-4
Safety
Instructions and Safety Messages
S Read and follow the instructions provided in this document and other
referenced documents.
S Familiarize 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.
S If you are unsure of how to use the equipment, contact your Nordson
representative for assistance.
Installation Practices
S Install the equipment in accordance with the instructions provided in this
document and in the documentation provided with auxiliary devices.
S Ensure 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.
S Ensure that the processing characteristics of the material will not create a
hazardous environment. Refer to the Safety Data Sheet (SDS) for the
material.
S If the required installation configuration does not match the installation
instructions, contact your Nordson representative for assistance.
S Position the equipment for safe operation. Observe the requirements for
clearance between the equipment and other objects.
S Install lockable power disconnects to isolate the equipment and all
independently powered auxiliary devices from their power sources.
S Properly ground all equipment. Contact your local building code
enforcement agency for specific requirements.
S Ensure that fuses of the correct type and rating are installed in fused
equipment.
S Contact the authority having jurisdiction to determine the requirement for
installation permits or inspections.
Operating Practices
S Familiarize yourself with the location and operation of all safety devices
and indicators.
S Confirm that the equipment, including all safety devices (guards,
interlocks, etc.), is in good working order and that the required
environmental conditions exist.
S Use 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.
S Do not use equipment that is malfunctioning or shows signs of a potential
malfunction.
Issued 04−15
E 2021 Nordson Corporation
Safety
1-5
Maintenance and Repair Practices
S Allow only personnel with appropriate training and experience to operate
or service the equipment.
S Perform scheduled maintenance activities at the intervals described in
this document.
S Relieve system hydraulic and pneumatic pressure before servicing the
equipment.
S De‐energize the equipment and all auxiliary devices before servicing the
equipment.
S Use only new Nordson‐authorized refurbished or replacement parts.
S Read 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.
S Confirm the correct operation of all safety devices before placing the
equipment back into operation.
S Dispose 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.
S Keep 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:
S hot melt and cold adhesive application equipment and all related
accessories
S pattern controllers, timers, detection and verification systems, and all
other optional process control devices
E 2021 Nordson Corporation
Issued 04-15
1-6
Safety
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.
Issued 04−15
E 2021 Nordson Corporation
Safety
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 1‐1General Safety Warnings and Cautions
Equipment
Type
HM
HM
HM, CA
Warning or Caution
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.
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.
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...
E 2021 Nordson Corporation
Issued 04-15
1-7
1-8
Safety
Table 1‐1General Safety Warnings and Cautions (contd)
Equipment
Type
HM
HM, PC
HM, CA, PC
HM, CA, PC
HM, CA, PC
Warning or Caution
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.
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.
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.
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.
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.
Issued 04−15
E 2021 Nordson Corporation
Safety
Equipment
Type
HM
Warning or Caution
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.
E 2021 Nordson Corporation
Issued 04-15
1-9
1-10 Safety
Other Safety Precautions
S Do not use an open flame to heat hot melt system components.
S Check high pressure hoses daily for signs of excessive wear, damage, or
leaks.
S Never point a dispensing handgun at yourself or others.
S Suspend dispensing handguns 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.
Issued 04−15
E 2021 Nordson Corporation
Description
2−1
Section 2
Description
The Flow and Pressure Option board mounts on top of an existing Motor
Control board and expands the available pump operation modes to:
S Flow Control and Monitor - Controls the accurate flow rate of adhesive
dispensing that is based on inline measurements of consumption, add­on
weights, and application pressure proportional to the line speed.
S Pressure Control and Monitor - Controls the delivery of consistent
adhesive output by varying pump speed to control system pressure
proportional to the line speed.
S Gear-to-Line with optional Flow and/or Pressure Monitoring - View
only flow rates and/or pressure information proportional to the line speed.
NOTE: Flow and Pressure control and monitoring is not available for manual
pump operation.
Limitations and Intended Use
Flow and Pressure Control/Monitor board is specifically designed to be used:
S With compatible equipment manufactured by Nordson Corporation
S In non-explosive environments
The Flow and Pressure Control/Monitor board is virtually complete, but is
intended to be incorporated into machinery and configured by an integrator.
The equipment must not be placed into use in a member state of the
European Union until the parent machinery or assemblies have been
declared by the integrator to be in conformity with the applicable directives
of the European Commission.
Key Components
The primary components are:
S The Flow and Pressure Option board
S An internal or external pressure transducer
S Flow meter and encoder (optional)
E 2021 Nordson Corporation
Part 1130505_01
2−2
Description
Flow and Pressure Option Board
The Flow and Pressure Option board mounts on top of an existing Motor
Control board, expanding the pump operation mode and options.
1
2
Figure 2‐1
Flow and Pressure Option board
1. Motor Control board
2. Flow and Pressure Option
board
The following lists the pump operation mode and options:
S You can install one Flow and Pressure Option board per Motor Control
board. Maximum is two per melter.
S Similar to the Motor Control board, one Flow and Pressure Option board
controls two pumps.
S When properly installed, and when the melter is switched On, the melter
automatically detects the Flow and Pressure Option board, as well as the
following:
‐
which pumps will have the additional pump operation modes and
options
‐
the type of Flow and Pressure Option board.
S There are two types of Flow and Pressure Option boards:
Monitor Only - Allows you to only monitor and log pump pressure
and/or flow rates.
Control and Monitor - Allows a pump to run at a variable speed to
maintain the desired pressure or flow rate based on setpoint values
and line speed. You can also monitor and log pump pressure and/or
flow rates as well.
Part 1130505_01
E 2021 Nordson Corporation
Description
2−3
S You can combine different Flow and Pressure Option board types within
the melter.
S Table 2‐1 details the additional pump modes and options based on the
type of installed Flow and Pressure Option board.
Table 2‐1 Available Pump Modes and Options Based on Type of Installed Flow and Pressure Option Board
Flow and Pressure
Option Board Type
Available Pump Modes
Flow Control and Monitoring with
Pressure Build
Pressure Control and Monitoring
Control and Monitor
Gear-to-Line
Optional
S
S
S
S
S
S
S
S
Pressure Monitoring
Alert and Fault Alarms
Flow Monitoring
Pressure Build
Alert and Fault Alarms
Flow Monitoring
Pressure Monitoring
Alert and Fault Alarms
Manual
None
Gear-to-Line
S Flow Monitoring
S Pressure Monitoring
S Alert and Fault Alarms
Manual
None
Monitor Only
Flow and Pressure Option Board Kits
Table 2‐2 Flow and Pressure Option Board Kits for Pumps 1 & 2 or Pumps 3 & 4
Item
PCA Board
Description
Flow/Pressure Option Board (Control) for pumps 1 & 2 or pumps 3 & 4
Kit Part
Number
7415554
PCA, Pressure /Flow (Control)
Ribbon Cable, Assembly, 34 POS, 50 in.
Board, breakout, TB, 34POS, screw
SCR, PAN, SLT, M3X6, ZN
Washer, LK, M, INT, M3, STL, ZN
PCA Board
Flow/Pressure Option Board (Monitor only) for pumps 1 & 2 or pumps 3 & 4
7415555
PCA, Pressure /Flow (Monitor Only)
Ribbon Cable, Assembly, 34 POS, 50 in.
Cable Sensor, 6 PIN, E-Panel, M1/2, Touch
SCR, PAN, SLT, M3X6, ZN
Washer, LK, M, INT, M3, STL, ZN
E 2021 Nordson Corporation
Part 1130505_01
2−4
Description
Pressure Transducers
Pressure transducers can be installed either inside the melter and connected
to the output manifold port, or externally installed and connected directly to
the applicator.
Internal Pressure Transducer
−not replaceable
External Pressure Transducer
−order PN 7415031
Figure 2‐2
Pressure transducer
You can install up to four pressure transducers per pump.
NOTE: You must have at least one internal or external pressure transducer
installed and calibrated on a pump for either Flow or Pressure control and/or
monitoring.
Pressure Transducer Applicator and Cable Kits
Table 2‐3 Pressure Transducer Kits
Item
PRESSURE
TRANSDUCER
CABLE
Part 1130505_01
Description
Kit Part
Number
KIT,CABLE,0‐10V,16FT,PRESSURE
7403141
KIT,CABLE,0‐10V,24FT,PRESSURE
7403142
KIT,CABLE,0‐10V,30FT,PRESSURE
7403143
E 2021 Nordson Corporation
Description
2−5
Flow Meter/Transmitter (Optional)
The Flow meter and transmitter should be installed as close to the applicator
as possible.
NOTE: Although not required for Flow Monitoring, Flow Control does require
a pressure transducer installed and calibrated for Pressure Build.
1
2
Figure 2-3
Flow meter and transmitter
1. Flow meter
2. Transmitter
Flow Device and Cable Kits
Table 2‐4 Flow Meter kits
Part
Number
Description
Displacement
Resolution
Heater
Watts
1515087
FLOWMETER ASSY,1.8CC,NI,QUAD,TRUFLOW
1.8cc/rev
900 pulses/rev
(quadrature)
200
1511577
FLOWMETER ASSY,4.2CC,NI,QUAD,TRUFLOW
4.2cc/rev
840 pulses/rev
(quadrature)
200
1514980
FLOWMETER ASSY,13.5CC,NI,QUAD,TRUFLOW
13.5cc/rev
1890 pulses/rev
(quadrature)
200
1515333
FLOWMETER ASSY,38CC,NI,QUAD,TRUFLOW
38cc/rev
1900 pulses/rev
(quadrature)
275
1515334
FLOWMETER ASSY,133CC,NI,QUAD,TRUFLOW
133cc/rev
1862 pulses/rev
(quadrature)
400
E 2021 Nordson Corporation
Part 1130505_01
2−6
Description
Flow and Pressure Closed Loop Theory of
Operation
The following shows the work flow for both Flow Control and Pressure
Control.
1.
Receive line speed signal,
and compute desired flow
or pressure value.
2.
3.
Adjusts pump speed to
reduce flow or pressure
errors.
Figure 2‐4
Part 1130505_01
Software compares
desired set point with
actual value.
Flow and Pressure Closed Loop theory of operation
E 2021 Nordson Corporation
Description
2−7
Gear-to-Line
Gear-to-Line uses a single setpoint to control the pump.
NOTE: You can enter a minimum value on the pump speed to maintain a
minimum pump speed regardless of line speed.
Figure 2‐5 indicates the following:
S At 80% maximum line speed, the pump set point RPM speed is 60 RPM.
S A minimum pump speed of 15 RPM was used.
70
80%, 60 RPM
60
Motor Speed (RPM)
50
40
30
20
10
0
0%
20%
40%
60%
80%
100%
% Line Speed
Figure 2‐5
E 2021 Nordson Corporation
Gear-to-Line, single point on a curve
Part 1130505_01
2−8
Description
Pressure Control
Pressure Control uses two setpoints to control the pump.
NOTE: If you want a constant pressure, then enter the same pressure for
both setpoints.
Figure 2‐6 indicates the following:
S At 80% maximum line speed, the desired pressure is 600 PSI.
S At 20% minimum line speed, the desired pressure is 300 PSI.
700
80%, 600 PSI
600
Pressure (PSI)
500
400
300
20%, 300 PSI
200
100
0
0%
20%
40%
60%
80%
100%
% Line Speed
Figure 2‐6
Part 1130505_01
Pressure Control, double point on a curve
E 2021 Nordson Corporation
Description
2−9
Flow Control
Flow Control uses a single setpoint to control the pump.
NOTE: Flow Control requires a pressure transducer for Pressure Build.
NOTE: Desired flow is always at 0% line speed.
Figure 2‐7 indicates the following:
S At 70% line speed, the desired flow is 50 grams/minute.
70
60
Flow Rate, grams/minute
50
70%,
50 grams/minute
40
30
20
10
0%,
0 grams/minute
0
0%
20%
40%
60%
80%
100%
% Line Speed
Figure 2‐7
E 2021 Nordson Corporation
Flow Control, single point on a curve
Part 1130505_01
2−10 Description
Pressure Build
Pressure Build allows the system to maintain a minimal constant pressure if
the line speed drops below a specified line speed percentage.
Other benefits include:
S Decreases pressure response time online start-up.
S Decreases hammer-head effects when the line stops and the
adhesive is under high pressure.
S Relieves residual pressure when the line is stopped.
NOTE: If you do not use Pressure Build, the motor control switches to
Gear-to-Line mode when the line speed drops below the defined setpoint.
NOTE: Pressure Build can be used with Flow Control, Pressure Control, and
Gear-to-Line pump operation modes.
Figure 2‐8 indicates the following:
S The unit enters Pressure Build when the line speed drops below 10%. As
long as the line speed is below this threshold, the motor will be controlled
to maintain the Pressure Build setpoint pressure of 50 PSI.
Part 1130505_01
E 2021 Nordson Corporation
Description 2−11
700
100%, 600 PSI
600
Pressure (PSI)
500
400
300
10%, 300 PSI
200
100
10%, 50 PSI
0
0%
20%
40%
60%
80%
100%
% Line Speed
Figure 2‐8
E 2021 Nordson Corporation
Pressure Build
Part 1130505_01
2−12 Description
This page intentionally left blank.
Part 1130505_01
E 2021 Nordson Corporation
Hardware Installation
3−1
Section 3
Hardware Installation
WARNING! Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
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.
WARNING! Risk of electrocution! The control switch does not remove
high­voltage 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 the power from the melter
can result in personal injury, including death.
Experience of Installation Personnel
The instructions provided in this section are intended to be used by
personnel who have experience in the following areas:
S
S
S
S
E 2021 Nordson Corporation
Hot melt application processes
Industrial power and control wiring
Industrial mechanical installation practices
Basic process control and instrumentation
Part 1130505_01
3−2
Hardware Installation
Hardware Installation Overview
The following table indicates the required and optional installation steps.
Installation
Description
S Install the Flow and Pressure Option Board on top
of a Motor Control board, and install the 34‐pin RDI
terminal block on the panel din rail.
Required
S Install at least one pressure transducer for Pressure
Control.
NOTE: You can install up to four pressure transducers
per pump or eight per Flow and Pressure Option board.
Refer to the documentation that came with the pressure
transducer for installation and calibration procedures.
Optional
S Assemble and install a Flow Meter/Encoder for
Flow Control.
You can install up to two Flow Encoders per pump or
four per Flow and Pressure Option board.
NOTE: Flow Control requires a pressure transducer for
Pressure Build.
Part 1130505_01
E 2021 Nordson Corporation
Hardware Installation
3−3
Installing the Flow/Pressure Option Board and Terminal Block
A Flow and Pressure Option board mounts on top of an existing Motor
Control board, expanding the pump operation modes to include flow and/or
pressure control and monitoring.
Required Tools
The required tools needed:
S 5/32 in. socket head wrench
S 5/16 in. socket head wrench
S 2.5 mm socket head wrench
S 18 mm socket wrench
S 3 mm flat blade screwdriver
Items and Kit Numbers
Table 3‐1 Flow and Pressure Option Boards Items
Description
E 2021 Nordson Corporation
Kit Number
Flow/Pressure Option board (Control) for pumps 1 & 2
or pumps 3 & 4
7415554
Flow/Pressure Option board (Monitor only) for pumps
1 & 2 or pumps 3 & 4
7415555
Part 1130505_01
3−4
Hardware Installation
Installing the Flow/Pressure Option Board and Terminal Block (contd)
Step 1
Step 2
34-pin connector for
external
pressure transducers,
channels 5-8 and
flow channels 1-4
Step 3
Step 4
Figure 3‐0
Graphical instructions for installing the Flow and Pressure Option board and terminal block
1. Disconnect and lock out power to the melter. Remove the front panel,
and then open the electrical enclosure door.
2. Install and secure the Flow and Pressure Option board on top of an
existing Motor Control board with four screws. Make sure the long-end of
the pins connect from the Option board to the Motor Control board.
3. Connect the 34-pin ribbon cable to the Flow and Pressure Option board
34-pin connector.
4. Install the 34‐pin RDI terminal block on the right panel din rail, securing it
with the end stop. When done, connect the other end of the 34-pin ribbon
cable to the appropriate terminal block.
NOTE: You do not have to remove the Motor Control board.
Part 1130505_01
E 2021 Nordson Corporation
Hardware Installation
3−5
Installing Pressure Transducers
You can install a pressure transducer in the following locations:
S Internally - Connected to the pump manifold output.
S Externally - Connected directly to most any applicator that has an
available port.
Prerequisites
S The Flow/Pressure Option board and terminal block is already
installed.
S Disconnect and lock out power to the melter. Remove the front panel,
and then open the electrical enclosure door.
S Refer to the following sections for Internal and External pressure
transducer installation instructions.
NOTE: Refer to the documentation that came with the pressure transducer
for calibration, maintenance, and troubleshooting information.
Required Tools
The required tools needed:
S 5/32 in. socket head wrench
S 5/16 in. socket head wrench
S 2.5 mm socket head wrench
S 18 mm socket wrench
S 3 mm flat blade screwdriver
External Pressure Transducer Installation
Items and Kit Numbers
Table 3‐2 Pressure Transducer Items
Description
KIT,PRESSURE SENSOR,1450PSI,0-10VDC,
APPLICATOR
E 2021 Nordson Corporation
Kit Number
7415031
Part 1130505_01
3−6
Hardware Installation
External Pressure Transducer Installation(contd)
Step 2
Step 1
Step 3
Step 4
Figure 3-1
Cable
pass-through
hole
Graphical instructions for installing an external pressure transducer
NOTE: A multi module AltaSpray applicator was used for illustration
purposes. Most any applicator with an additional port is supported.
1. Remove the plug from the applicator.
2. Install the adapter, and then connect the pressure transducer and cable.
3. Run the transducer cable into the melter using the cable pass‐through
holes.
4. Connect the other end of the transducer cable to the appropriate terminal
block and pin number. Refer to Table 3‐3 for more information.
5. Write down the pressure transducer type and full‐scale output. You will
need this information when using the software to configure the channel.
Part 1130505_01
E 2021 Nordson Corporation
Hardware Installation
3−7
Table 3‐3 External Pressure Transducer RDI Terminal Block PIN Assignments
Channel
RDI
Number Terminal
Block
PIN
Number
Description
Channel
RDI
Number Terminal
Block
Pump 1
5
6
-10X11
8
1
Signal +
2
Signal -
3
24VDC +
4
24VDC -
13
14
-10X51
E 2021 Nordson Corporation
1
Signal +
2
Signal -
3
24VDC +
4
24VDC -
5
Signal +
5
Signal +
6
Signal -
6
Signal -
7
24VDC +
7
24VDC +
8
24VDC -
8
24VDC -
9
-10X11
Description
Pump 3
Pump 2
7
PIN
Number
Pump 4
Signal +
15
9
Signal +
10
Signal -
10
Signal -
11
24VDC +
11
24VDC +
12
24VDC -
12
24VDC -
13
Signal +
13
Signal +
14
Signal -
14
Signal -
15
24VDC +
15
24VDC +
16
24VDC -
16
24VDC -
16
-10X51
Part 1130505_01
3−8
Hardware Installation
About Internal Pressure Transducer Configuration
Internal pressure transducers are typically installed at the factory. Refer to
the following figures for maintenance and troubleshooting purposes.
Melter Type
Refer to page
AltaBlue Plus 2D
3-9
AltaBlue Plus 4D
3-10
Flow and Option Board Internal Transducer
Cable Assignments
3-12
CAUTION! As a result of the system heating, regardless of pump state or
status, thermal expansion within the pump manifold can cause pressure to
exceed 20.68 bar (300 PSI or 2068.42kPa).
Part 1130505_01
E 2021 Nordson Corporation
3−9
Hardware Installation
AltaBlue Plus 2D Configuration
Refer to Figure 3‐2 and Table 3‐4 for more information.
4
3
2
2D Unit
Figure 3‐3
1
AltaBlue Plus 2D internal pressure transducer configuration
Table 3‐4 AltaBlue Plus 2D
Transducer Location
1
1SS
2SS
1DS
1DS/1SS
1SS/1DS
2DS
D
D
D
D
D
D
D
D
D
D
D
D
2
3
4
D
D
D
SS=Single Stream
DS=Dual Stream
E 2021 Nordson Corporation
Part 1130505_01
3−10 Hardware Installation
AltaBlue Plus 4D Configuration
Refer to Figure 3‐4 and Table 3‐5 for more information.
PUMP 1
PUMP 4
8
Figure 3-4
7
6
5
4
3
2
1
AltaBlue Plus 4D internal pressure transducer configuration
Part 1130505_01
E 2021 Nordson Corporation
Hardware Installation 3−11
Table 3‐5 AltaBlue Plus 4D
Transducer Location
1
1SS/
1SS
1SS/
1DS
1DS/
1SS
1DS/
1DS
2SS/
1SS
2SS/
2SS
2DS/
1SS
2DS/
2SS
2SS/
2DS
2DS/
2DS
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
2
3
4
5
6
7
8
D
D
D
D
D
D
D
D
D
D
D
D
D
SS=Single Stream
DS=Dual Stream
E 2021 Nordson Corporation
Part 1130505_01
3−12 Hardware Installation
Flow and Option Board Internal Transducer Cable Assignments
Figure 3‐5
Connecting internal pressure transducer channels directly to the Flow and Pressure Option board
Part 1130505_01
E 2021 Nordson Corporation
Hardware Installation 3−13
Installing Flow Meter/Encoders (Optional)
In addition to the Flow meter and encoder, you must also install a pressure
transducer, which is required for Pressure Build.
Pressure Build allows the system to maintain a minimal constant pressure if
the line speed drops below a specified line speed value, as well as relieves
residual pressure when the line is stopped.
Prerequisites
S The Flow/Pressure Option board and terminal block have already
been installed.
S At least one pressure transducer has been installed and calibrated.
S Disconnect and lock out power to the melter. Remove the front panel,
and then open the electrical enclosure door.
Required Tools
The required tools needed:
S
S
S
S
S
E 2021 Nordson Corporation
5/ in. socket head wrench
32
5 mm socket head wrench
6 mm socket head wrench
18 mm socket wrench
3 mm flat blade screwdriver
Part 1130505_01
3−14 Hardware Installation
Installing Flow Meter/Encoders (Optional)(contd)
Step 2
Step 1
Step 3
Step 4
Figure 3‐6
Cable
pass-through
hole
Graphical instructions for installing the Flow meter and Encoder
1. Mount the assembled Flow device directly to the applicator.
2. Connect the incoming/outgoing hoses supplying the glue through the
Flow meter.
3. Run the Flow cable into the melter using the cable pass‐through holes.
4.
Part 1130505_01
Connect the flow channel to the Flow and Pressure Option board using
the RDI Terminal 34-pin block. Refer to Table 3‐6 for PIN number
assignments.
E 2021 Nordson Corporation
Hardware Installation 3−15
Table 3‐6 Flow RDI Terminal Block PIN Assignments
Channel
RDI
Number Terminal
Block
PIN
Number
Description
Channel
RDI
Number Terminal
Block
Pump 1
1
2
-10X11
24VDC -
18
Signal
19
24VDC +
24VDC -
5
6
-10X51
4
-10X11
E 2021 Nordson Corporation
17
24VDC -
18
Signal
19
24VDC +
20
24VDC -
21
Signal
21
Signal
22
24VDC +
22
24VDC +
Pump 2
3
Description
Pump 3
17
20
PIN
Number
Pump 4
23
24VDC -
24
Signal
25
24VDC +
7
8
-10X51
23
24VDC -
24
Signal
25
24VDC +
26
24VDC -
26
24VDC -
27
Signal
27
Signal
28
24VDC +
28
24VDC +
Part 1130505_01
3−16 Hardware Installation
Flow Cable Wire Definition
The following figure shows the wire definition for the flow cable.
Figure 3‐7
Cable pin out - Front view of connector
Mating Connector for the TruFlow Transmitter Box
Connection
Pin Number
Missing Cable Wire Color
DC+
1
Brown
DC-
4
Black
Phase A
2
White
Phase B (Quadrature only)
5
Gray
Ground
3
Blue
Part 1130505_01
E 2021 Nordson Corporation
Operation
4−1
Section 4
Operation
WARNING! Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
Overview
The melter automatically detects whether a Flow and Pressure Option board
is installed, its type, and which pumps have the expanded pump operation
modes.
Table 4‐1 Flow and Pressure Control Option Board Types and Available Pump Modes and Options
Flow and Pressure
Option Board Type
Pump Modes
Flow and/or
Pressure
Monitoring and
Data Logging
Alert and Fault
Alarms
Pressure Build
Control
Manual
No
No
No
Yes
Available
Available
Gear-to-Line
Pressure Control
Flow Control
Monitor Only
Required
Manual
No
No
Gear-to-Line
Yes
Available
No
What's Next?
The following sections detail how to configure and operate the expanded
pump modes and options using the touch screen software.
Make sure you have already completed the following tasks:
S Installed the Flow and Pressure Option board and the 34‐pin terminal
block.
S Installed and calibrated at least one pressure transducer.
S Installed a Flow meter/encoder. (Optional)
NOTE: Refer to the AltaBlue™ Plus Adhesive Melter manual for instructions
on how to operate pumps.
E 2021 Nordson Corporation
Part 1130505_01
4−2
Operation
Changing Pump Operation Modes
Before changing to a different pump operation mode:
S You must have already installed the required flow and/or pressure
hardware.
S The Master Pump Control switch is OFF.
S You have sufficient adhesive in the hopper.
S The Master Heater Control switch is ON.
NOTE: It does not matter if the pump is enabled or disabled.
Figure 4‐1
Changing Pump Operation modes
1. From the Operator Display, touch the pump for which you want to
change its operation mode.
2. Touch Pump Settings and select the operation mode you want for this
pump.
Part 1130505_01
E 2021 Nordson Corporation
Operation
4−3
Configuring and Modifying Pressure Control and Monitor
Pressure Control delivers consistent adhesive output by varying pump speed
to control system pressure proportional to the line speed.
Tip: Rather than guessing or using the trial‐and‐error method to determine
the correct minimum and maximum pressure setpoint values, do the
following while in Gear-to-Line mode:
S Run at maximum production speed. Access the Monitor screen (refer
to Monitoring and Data Logging on page 4-27) and write down the
observed pressure (PSI, Bar or kPa) value. When configuring a
pressure input channel, use that value as the Maximum Setpoint
Pressure.
When done, run at minimum production speed. Access the Monitor
screen and write down the observed pressure (PSI, Bar or kPa) value.
When configuring a pressure input channel, use that value as the
Minimum Setpoint Pressure.
The following chart shows the sequence of tasks associated with configuring
Pressure Control and Pressure Monitoring.
Pressure Monitoring
Pressure Control
Configure a pressure input
channel with Control
Pressure Build (optional)
Test
configuration
Configure a pressure
input channel
(optional)
Configure additional pressure
and/or flow monitor only
input channels
Configure channel alert and
fault alarm settings
Figure 4‐2
E 2021 Nordson Corporation
Configuring Pressure Control and Pressure Monitoring tasks
Part 1130505_01
4−4
Operation
Configuring and Modifying Pressure Control and Monitor (contd)
NOTE:
S Pressure control requires at least one pressure input channel
configured with Control.
S The Pressure Build option is only available on the same pressure
input channel configured with Control.
S You can configure other pressure and flow input channels as Monitor
Only.
S You can only configure one pressure input channel with Control.
Figure 4‐3
Configuring and modifying Pressure Control and Monitor
1. From the Operator Display, touch the pump for which you want to
change its operation mode.
2. Touch Pump Settings and select Pressure.
3. Touch
.
4. Decide what you want to do:
S To configure or modify a Control pressure input channel, proceed to
step 5.
S To configure or modify a Monitor Only pressure or flow input channel,
proceed to step 6.
NOTE: If you plan to configure a Flow Monitor Only input channel, touch
Flow Settings and provide the required information. Refer to Tables 4‐2 and
4‐3 for more information.
Part 1130505_01
E 2021 Nordson Corporation
Operation
4−5
5. Configure a Control pressure channel. Refer to Table 4‐4 for more
information.
Touch
Description
To designate the pressure channel you want to
control the pump.
To configure or modify the corresponding Control
pressure channel. Provide the required information.
Since this channel has Control capabilities, you can
decide whether or not you want to make use of the
Pressure Build option.
Pressure Build allows the system to maintain a
minimal constant pressure if the line speed drops
below a specified line speed percentage.
Other benefits include:
S Decreases pressure response time online
start-up.
S Decreases hammer-head effects when the
line stops and the adhesive is under high
pressure.
S Relieves residual pressure when the line is
stopped.
NOTE: If you do not use Pressure Build, the
motor control switches to Gear-to-Line mode
when the line speed drops below the defined set
point.
S Proceed to step 6 to configure or modify monitor
only pressure and/or flow channels.
6. Configure a Monitor Only pressure or flow channel. Refer to Table 4‐4 for
more information.
Touch
Description
To configure or modify Monitor Only pressure or
flow channel. Provide the required information.
S Repeat this step for each available pressure
and/or flow input channel.
S Refer to Table 4‐4 for flow specific information.
7. Decide what you want to do next.
Touch…
To ….
Refer to
page…
Test Configuration
(Control only)
Test and if necessary fine-tune the pressure control settings with
your manufacturing process.
4-14
Manage Channel
Alert/Fault Alarms
(optional)
Configure and enable/disable alert and fault pressure and/or flow
alarms.
NOTE: You must first configure the flow or pressure input channel
before configuring its alarms.
4-22
E 2021 Nordson Corporation
Part 1130505_01
4−6
Operation
Configuring and Modifying Flow Control and Flow Monitoring
Flow Control dispenses an accurate flow rate of adhesive, based on inline
measurements of consumption, add-on weights, and application pressure
proportional to the line speed.
Tip: Rather than guessing or using the trial and error method to determine
the correct flow rate (gr/min) setpoint value to use for Flow control and/or
monitoring, do the following while in Gear-to-Line mode:
S Run at production speed. Access the Monitor screen (refer to
Monitoring and Data Logging on page 4-27) and write down the
observed flow (mg/min) value. When configuring a flow input channel,
use that value as the Setpoint Flow Rate (gr/min).
The following chart shows sequence of tasks associated with configuring
Flow Control and Flow Monitoring Only channels.
Flow Control
Flow Monitoring
Configure Global
Flow Settings
Configure a Flow input
channel with Control
Configure a Pressure input
channel with Control
Configure Global
Flow Settings
Test
Configuration
Configure a Flow input
channel with Control
(optional)
Configure additional flow and/or
pressure monitor only channels
Configure channel alert and
fault alarm settings
Figure 4‐4
Configuring and modifying Flow Control and Flow Monitoring tasks
Part 1130505_01
E 2021 Nordson Corporation
Operation
4−7
NOTE:
S Flow control requires at least one flow and one pressure input
channel, each configured with Control. The pressure input channel
requires Pressure Build.
S You can configure other pressure and flow input channels as
Monitor Only.
S You can only configure one flow input channel with Control.
Figure 4‐5
Configuring and modifying Flow Control and Flow Monitoring
1. From the Operator Display, touch the pump for which you want to
change its operation mode.
2. Touch Pump Setting and then select Flow.
3. Touch
.
4. Touch Flow # and provide the required information. Refer to Table 4‐2 for
more information.
5. Decide what you want to do:
S To configure or modify a Control flow input channel, proceed to
step 6.
S To configure or modify a Control pressure input channel for pressure
build, a requirement for flow control, proceed to step 7.
S To configure or modify a Monitor Only flow and/or pressure input
channel, proceed to step 8.
E 2021 Nordson Corporation
Part 1130505_01
4−8
Operation
Configuring and Modifying Flow Control and Flow Monitoring (contd)
6. Configure a Control flow channel.
Touch
Description
To designate the flow channel you want to control
the pump.
To configure or modify the corresponding Control
flow channel. Provide the required information.
S Refer to Tables 4‐2 and 4‐3 for more
information.
S Proceed to step 7 to configure or modify Control
Pressure input channel with Pressure Build.
7. Touch
Pressure Build.
Touch
to Configure a Control pressure channel for
Description
To designate the pressure input channel you want
to control the pump (Pressure Build) when the line
speed drops below the user‐defined percentage
line speed.
To configure or modify the corresponding Control
pressure channel for Pressure Build. Provide the
required information.
S Refer to Table 4‐4 for more information.
S Proceed to step 8 to configure or modify Monitor
Only pressure and/or flow channels.
8. Configure a Monitor Only pressure or flow input channel.
Touch
Description
To configure or modify a Monitor Only pressure or
flow channel. Provide the required information.
S Repeat this step for each available pressure
and/or flow input channel.
S Refer to Tables 4‐2 and 4‐3 for more information
about flow settings.
S Refer to Table 4‐4 for more information about
pressure settings.
Part 1130505_01
E 2021 Nordson Corporation
Operation
4−9
9. Decide what you want to do next.
Touch
To
Refer to
page…
Test Configuration
(Control only)
Test and if necessary fine-tune the Pressure Control
settings with your manufacturing process.
4-14
Manage Channel
Alert/Fault Alarms
(optional)
Configure and enable/disable alert and fault pressure
or flow alarms.
NOTE: You must first configure the flow or pressure
input channel before configuring its alarms.
4-22
E 2021 Nordson Corporation
Part 1130505_01
4−10 Operation
Viewing Total Adhesive Used
You can view and reset the amount of adhesive used for each configured
Flow channel.
Figure 4‐6
Viewing total adhesive use
1. From the Operator Display, touch the pump with Flow input channels
configured.
2. Touch All Flow Curve, and then touch Adhesive Usage to view how
much adhesive has been used since the last time you touched the Reset
Adhesive Usage option.
Part 1130505_01
E 2021 Nordson Corporation
Operation 4−11
This page intentionally left blank.
E 2021 Nordson Corporation
Part 1130505_01
4−12 Operation
Configuring Gear-to-Line with Pressure/Flow Monitoring
Gear-to-Line delivers adhesive output at a rate proportional to the line speed.
Depending on the type of configured channels, you can also monitor flow
rates and/or pressure information as well.
Tip: Rather than guessing or using the trial and error method to determine
the correct flow rate or pressure set point value to use for flow/pressure
control and/or monitoring, do the following while in Gear-to-Line mode:
S For flow monitoring – Run at production speed. Access the Monitor
screen (refer to Monitoring and Data Logging on page 4-27), and then
write down the observed flow (mg/min) value. When configuring a
flow input channel, use that value as the Setpoint Flow Rate (gr/min).
S For pressure monitoring – Run at maximum production speed.
Access the Monitor screen (refer to Monitoring and Data Logging on
page 4-27) then write down the observed pressure (PSI, Bar or kPa)
value. When configuring a pressure input channel, use that value as
the Maximum Setpoint Pressure.
When done, run at minimum production speed. Access the Monitor
screen and write down the observed pressure (PSI, Bar or kPa) value.
When configuring a pressure input channel, use that value as the
Minimum Setpoint Pressure.
Part 1130505_01
E 2021 Nordson Corporation
Operation 4−13
The following chart shows sequence of steps associated with configuring
Pressure Control and Pressure Monitoring Only channels.
Gear-to-Line
Flow Monitoring
(optional)
Pressure Monitoring
(optional)
Configure Global
Flow Settings
Configure a Flow
input channel
Configure a Pressure
input channel
(optional)
Configure additional flow and/or
pressure monitor only channels
Configure channel alert and
fault alarm settings
Figure 4‐7
Configuring Gear-to-Line with Pressure/Flow Monitoring tasks
NOTE:
S The pressure and/or flow input channels are for monitoring purposes
only. Control of the pump is Gear-to-Line.
S If the type of Flow and Pressure Option board is Control, then you can
also configure a pressure input channel for Pressure Build.
E 2021 Nordson Corporation
Part 1130505_01
4−14 Operation
Configuring Gear-to-Line with Pressure/Flow Monitoring (contd)
Figure 4‐8
Part 1130505_01
Configuring Gear-to-Line with Pressure/Flow monitoring
E 2021 Nordson Corporation
Operation 4−15
1. From the Operator Display, touch the pump for which you want to
change its operation mode.
2. Touch Pump Settings and then select Pressure or Flow.
3. Touch
.
4. Configure Flow/Pressure monitoring.
I want to
configure…
Then…
Flow Monitoring
Make sure the pump is in Flow mode, touch Flow
Settings, and then touch the Flow channel button to
configure it for flow monitoring purposes. Refer to Tables
4‐2 and 4‐3 for more information.
When done, proceed to step 5.
Pressure
Monitoring
Make sure the pump is in Pressure mode, touch
Pressure Settings, and then touch the Pressure
channel button to configure it for pressure monitoring
purposes.
Refer to Table 4‐4 for more information.
NOTE: If the type of Flow and Pressure Option board is
Control, then you can also configure a pressure input
channel for Pressure Build. Refer to
Configuring and Modifying Pressure Control and Monitor
for more information.
5. Decide if you want to configure alert/fault alarms for Monitor Only
channels you just configured. Refer to page 4-22 for more information.
E 2021 Nordson Corporation
Part 1130505_01
4−16 Operation
About Testing and Fine-Tuning Configurations
Although you may have configured many input channels, you are only testing
and fine-tuning the configuration flow and/or pressure input channel that you
designated with Control.
The other input channels are for monitoring purposes only, and do not affect
or control the pump. When you are done testing the configuration, you can
enable and configure channel alert/fault alarms to maintain optimum
efficiency.
More About PIDs
PID is an acronym for Proportional, Integral, Derivative, which is a continuous
feedback loop that ensures the desired amount of adhesive. The system
takes appropriate corrective action when there is a deviation from either the
flow rate or pressure setpoint. These deviations could be caused by anything
from a slight change in line speed, ambient temperature, or a blockage in a
filter or applicator.
PID loops can be tuned manually or automatically using various techniques.
Tuning techniques that compute PID constants only get you close to the
optimal system response. Manual adjustments are typically required for
fine-tuning the system response.
Term
Description
P
Controls how fast the system responds to changes.
I
Controls the offset error between the setpoint and the actual.
D
Used to optimize the system response – but only if the
feedback signal is stable.
Note: Always leave the Derivative constant set to 0 (zero)
unless the feedback signal is very stable and noise free;
otherwise, you may experience unstable system response.
Although default PID values are provided, they should be used as a starting
point from which you can fine-tune to best suit your manufacturing process.
NOTE: Refer to textbooks or the Internet for proportional integral derivative
or PID Control for additional information.
Part 1130505_01
E 2021 Nordson Corporation
Operation 4−17
About the Test Configuration Graph
You can modify the following PIDs.
Operation Mode
Flow Control
Pressure Control
What you can Modify
S
S
S
S
S
Run PID
Ramp PID
Specific Density
Build PID
Control PID
Before Testing:
S Verify the hardware was installed properly. Refer to the documentation
that came with the pressure transducer for calibration procedures.
S
S
S
S
S
E 2021 Nordson Corporation
Verify the software settings you entered are correct.
The pump should be Enabled.
Make sure the Pump Control and Heater Control switch is On.
Make sure you have sufficient adhesive in the hopper.
Make sure the system status indicates green, Ready/OK.
Part 1130505_01
4−18 Operation
Fine-Tuning Pressure Control
You can fine-tune Pressure Build and Pressure Control PIDs.
Keep in mind the following:
S The default screen display is 60 seconds.
S The screen displays one sampling per second.
S You can change PID values while a test is in progress. The results
appear within a second of viewing the test configuration screen.
NOTE: It is not recommended enabling flow alert/fault alarms in
Pressure Control mode.
Figure 4‐9
Part 1130505_01
Fine-tuning pressure control
E 2021 Nordson Corporation
Operation 4−19
1. Access the Test Configuration curve.
From the Operator
Display
Touch the pump that you want to test the control
settings (the Pump Running mode should be
Pressure mode). The pressure test configuration
curve displays on the pump screen.
From the Pump
Display
Touch Start to view the performance of the pump
with the current settings. Touch the button again
to stop the test.
2. Do the following to continue.
Touch
Description
To modify the P, I, and D term values.
S Set both the I and D constants to 0 (zero).
S Increase the P constant until you see overshoot
with a minimal under shoot. Refer to Figure
4‐10.
Record this gain setting (Kpgg). Use small
changes in line speed step for best accuracy,
because you don’t want the motor speed to go
to 100%.
S Measure the time (Tou) in seconds between the
overshoot peak and the undershoot valley.
Compute PID constants with the following
equations:
S Kp = 0.7 * Kpgg
S Ki = 0.2 * Kpgg / Tou
S Kd = 0.29 * Kpgg * Tou
To zoom the curve X/Y axis.
E 2021 Nordson Corporation
Part 1130505_01
4−20 Operation
Fine-Tuning Pressure Control (contd)
3. When you are satisfied with the results of testing, do one of the following:
S Configure Monitor Only pressure and/or flow channels. (Optional)
S Configure flow and/or pressure alert and fault alarms. (Optional)
When you are satisfied with the test configuration results, take note of
the pressure at two different line speeds, and then set up the
appropriate alert/fault pressure set points using the observed
pressure values at the appropriate line speed.
*
Pressure Control
setpoint
Tou
Actual Pressure
Figure 4‐10
Testing and fine-tuning the Pressure Control configuration
Part 1130505_01
E 2021 Nordson Corporation
Operation 4−21
This page intentionally left blank.
E 2021 Nordson Corporation
Part 1130505_01
4−22 Operation
Fine-Tuning Flow Control
You can fine-tune Run and Ramp PIDs, as well as the specific gravity of the
adhesive.
Keep in mind the following:
S Some flow meters have an oscillation in their signal that makes using
the D constant impractical. Each application should examine the flow
signal before deciding whether a D term should be used in the PID.
S Use Ramp PIDs when the line speed change is typically very fast.
S RAMP mode PID constants can be the same as the RUN mode
constants, but the P constant is normally increased for faster
response under ramp conditions.
NOTE: Make sure the Drive Displacement (cc/rev) value is correct. If you
are not sure, use the default value. Refer to Tables 4‐2 and 4‐3 for more
information.
P Sensor 1
Figure 4‐11
Fine-tuning flow control
Part 1130505_01
E 2021 Nordson Corporation
Operation 4−23
1. Access the Test Configuration graph.
From the Operator
Display
Touch the pump that you want to test the control
settings (the pump running mode should be
Pressure mode). The flow test configuration
curve displays on the pump screen.
2. Touch Start to view the performance of the pump with the current
settings. Touch the button again to stop the test.
3. Get a baseline reading. Touch Start Test to view the performance of the
pump with the current settings. Touch the button again to stop the test.
4. Verify the Drive Displacement (cc/rev) value is correct. Refer to
Configuring and Modifying Flow Control and Flow Monitoring.
S Set the P, I, and D constants to 0 (zero) for Run and Ramp.
Increase the line speed and verify the actual flow rate graph is on top
of the setpoint graph. If not, adjust the drive pump displacement
parameter until the setpoint and actual graphs overlay each other.
They do not have to overlay perfectly for the system to work well.
NOTE: The stability of the actual flow rate signal on the graph with all
PID constants set to 0 (zero). If it is a flat line, you can use derivative
terms to help tune the PID. If oscillation is present, keep the D term set to
0 (zero) in the PID section to avoid system instability.
5. Do the following to fine-tune flow control. Refer to
Fine-Tuning Pressure Control to tweak the pressure build PIDs.
Touch
Description
To modify the P, I, and D term values. If the flow
signal contains significant jitter or oscillations, then
do the following:
S With the I and D RUN and RAMP constants set
to 0 (zero), increase the RUN and RAMP P
constants (both set to the same value) until fast
enough response is seen as the line speed is
varied.
S Running at a high, constant speed, increase the
RUN I constant until the error goes to 0 (zero).
Use the smallest I constant that eliminates the
error for the fastest response.
S Leave the D constant set to 0 (zero).
NOTE: If the flow feedback signal is stable, other
standard tuning methods may be used (Good Gain,
Ziegler-Nichols, Cohen-Coon, software tools, etc).
To zoom the curve X/Y axis.
E 2021 Nordson Corporation
Part 1130505_01
4−24 Operation
Fine-Tuning Flow Control (contd)
6. When you are satisfied with the results of testing, do one of the following:
S Configure Monitor Only pressure and/or flow channels. (Optional)
S Configure flow and/or pressure alert and fault alarms. (Optional)
Pressure can be monitored while operating in Flow Control mode.
When you are satisfied with the test configuration results, take note of
the pressure at two different line speeds, and then set up the
appropriate alert/fault pressure set points using the observed
pressure values at the appropriate line speed.
NOTE: It is not recommended to enable flow alert/fault alarms in
Pressure Control mode.
Part 1130505_01
E 2021 Nordson Corporation
Operation 4−25
Configuring Channel Alert/Fault Alarms
Alert and fault channel alarms enable the system to monitor deviations in
system performance. These deviations typically indicate an issue with the
system and therefore production. A channel alert allows you to deal with the
issue before it becomes a fault and stops production.
Deviations are calculated as follows:
(actual * setpoint)
setpoint
100 + %Deviation
Additional Information
S It is not recommended to enable flow alert/fault alarms in Pressure
Control mode, although pressure can be monitored while operating in
Flow Control mode.
S Deviations are represented in terms of a percentage (%).
S You can configure alert/fault alarms on a per pressure and/or flow
input channel basis.
S The system lets you define upper‐and‐lower alert and fault
thresholds.
S Whether the channel is configured for Control or not, if the system
detects a channel fault, the Master Pump Control automatically
switches Off, thereby stopping production. The Heater Control switch
remains On.
S To prevent erroneous alarm messages, you can indicate at what
percentage line speed AND how long to wait (in seconds) for the
system to stabilize before the system starts monitoring the available
channels.
Figure 4‐12
E 2021 Nordson Corporation
Configuring Channel Alert/Fault alarms
Part 1130505_01
4−26 Operation
Configuring Pressure Channel Alert/Fault Alarms
Figure 4‐13
Configuring Pressure Channel Alert/Fault alarms
1. From the Operator display, touch the pump for which you want to test the
Control settings (the pump running mode should be Pressure mode).
2. Touch Pressure Settings, and then select the pressure channel.
3. Decide if you want to enable or disable alert/fault alarms for the available
pressure input channels.
Configuring Flow Channel Alert/Fault Alarms
1. From the Operator display, touch the pump for which you want to test the
Control settings (the pump running mode should be Flow mode).
2. Touch Flow Settings, and then select the flow channel.
3. Decide if you want to enable or disable alert/fault alarms for the available
pressure input channels.
Part 1130505_01
E 2021 Nordson Corporation
Operation 4−27
Monitoring and Data Logging
Use monitoring and data logging to:
S View, in real-time, the performance of a flow or pressure channel.
S Capture data auto‐saved at HMI and auto‐copy to the internal SD card
within the next day.
S Copy the date file from the SD card directly or copy the date from the HMI
ftp server for troubleshooting purposes (optional).
Accessing the SD Card
The HMI includes one SD card (optional).
Figure 4‐14
Location of the customer and internal SD cards
1. Turn off the melter and disconnect the electrical power to the melter at
the local power source.
2. Disassemble the front of the melter to access the HMI.
3. Remove the SD card. Use a PC to copy the Flow and Pressure folders,
and replace the SD card when done.
4. Reassemble the front of the melter.
5. Reconnect the electrical power to the melter, and then turn it back on.
E 2021 Nordson Corporation
Part 1130505_01
4−28 Operation
Accessing the FTP Server
Figure 4‐15
Connecting to the FTP server
1. Turn on the melter.
2. Connect the melter to a computer by ethernet cable.
3. Disassemble the front of the melter to access the HMI.
4. Enter the FTP address in Microsoft® Windows® Explorer or a
Web browser. The FTP address is the HMI IP address.
For example, if the HMI IP address is 192.168.1.45, then enter the FTP
address as ftp://192.168.1.45.
5. Enter the FTP user name and password, as follows:
User name: ftp
Password: 111111
6. Copy the flow and pressure data from database folder.
Part 1130505_01
E 2021 Nordson Corporation
Operation 4−29
Stop Using / Disable a Channel
Read the following to determine which applies to you:
If you …
Then…
Want to replace the channel with
the exact same hardware and
specifications
You do not have to do anything.
The channel software configuration
retains its previous settings.
Want to replace the channel with
different hardware and
specifications
Refer to the appropriate pump
operation mode section in this
chapter that you want to use and
follow the instructions.
No longer want to make use of a
channel and you do not want to
physically remove or disconnect
anything
Continue with the following
instructions.
1. From the Operator Display, touch the pump that makes use of the flow
or pressure channel you no longer want to use. Touch Pressure
Settings on the Pressure mode or touch Flow Settings on the Flow
mode, and then touch Pressure Channels or Flow Channels. Verify
whether the channel is configured with Control.
2. Do one of the following to continue:
S Select another channel to use for Control. Touch the button to verify
or modify its settings.
S Change the pump operation mode to Manual or Gear-to-Line.
S Disable the pump. Refer to the AltaBlue™ Plus Adhesive Melter
manual for more information.
3. Verify the Alarms option for the channel you no longer want to use is not
enabled.
E 2021 Nordson Corporation
Part 1130505_01
4−30 Operation
Default Flow and Pressure Settings and Ranges
The following information contains details default settings and ranges for flow
and pressure settings.
Flow Global Settings
Table 4‐2 About Global Flow Input Channel Settings
Item
Default
Setting
Range
Notes
Adhesive Density
(g/cc)
0.960
Minimum: 0.001
Maximum: 2.000
The adhesive density setting is used to convert the flow
sensor readings from CC (volume) to grams (mass). You can
find the adhesive density in the MDS.
Melter Pump
Displacement
(cc/rev)
1.7
Minimum: 0.01
Maximum: 20.0
The actual output may differ due to age or worn gear sets.
You can compensate by lowering the displacement value.
Because this is a closed‐loop control, you can also fine-tune
the PID values when testing the configuration.
You can visually inspect the settings by watching the control
graph while the P, I, and D terms are set to 0 (zero). The
setpoint and actual graphs should be on top of each other.
Continued …
Part 1130505_01
E 2021 Nordson Corporation
Operation 4−31
Item
Flow Control
Stop Speed (%)
Default
Setting
10
Range
Notes
Minimum: 0
Maximum: 100
Flow control makes use of Run and Ramp operational
modes, each with their own unique PID constants.
You can determine when the unit switches from Run to
Ramp by entering the Minimum Acceleration - % Line
Speed/Sec. You can then fine-tune the Run and Ramp PIDs
from the Test Configuration screen. Refer to page 4-17 for
more information.
Use the following formula:
1000 * (Delta%LS - 10)/ Delta Time
Where:
S Delta%LS - The change in line speed during the
ramp.
S Delta Time - The time of the ramp.
S -10 - Makes sure the threshold set is lower than the
actual acceleration
Minimum
Acceleration
10000
Delta % LS
S * 1000 - Makes for better resolution.
Minimum: 1
Maximum: 10000
NOTE: If the Flow controller/monitor is used in an
intermittent application, use the following formula to
calculate the minimum speed:
MLS = 0.6*GL
Where:
S MLS = minimum line speed (m/min)
S GL = gap length (mm)
E 2021 Nordson Corporation
Part 1130505_01
4−32 Operation
Flow Settings
Table 4‐3 About Flow Input Channel Settings
Item
Default
Setting
Ranges/
Options
Maximum Line Speed
100
Minimum: 1
Maximum:100
Maximum Flow Rate
200
Minimum: 1
Maximum: 500
Encoder Resolution
1500
Minimum: 100
Maximum:10000
Number of Streams
(per Flow meter)
2
1‐2
Meter Displacement
(cc/Revolution)
3.72
Minimum: 0.01
Maximum: 20.0
Alarm Enable
Off
Off
On
Flow Alert Alarms
High: 10%
Low: 10%
Minimum: 1%
Maximum: 500%
Flow Fault Alarms
High: 25%
Low: 25%
Minimum: 1%
Maximum: 500%
Alarm Enable LS
30
Minimum: 0%
Maximum: 100%
Alarm Delay
10
Minimum: 1
Maximum: 600
Run Mode PIDs
P: 311
I: 623
D: 0
Ramp Mode PIDs
Part 1130505_01
P: 5000
I: 300
D: 0
Notes
At maximum line speed, the desired flow rate
is the maximum flow rate. The desired flow
rate is always at 0% line speed.
P: 0‐50000
I: 0‐50000
D: 0‐50000
E 2021 Nordson Corporation
Operation 4−33
Pressure Settings
Table 4‐4 About Pressure Input Channel Settings
Item
Default Setting
Ranges/
Options
Maximum/Minimum % Line Speed
100%
Minimum: 0%
Maximum: 100%
Maximum/Minimum Setpoint Pressure
500 - PSI
34.5 - Bar
3448.3 - kPa
0 - 1000 PSI
0 - 69 Bar
0 - 6896.6 kPa
Alarm Enable
Off
Off
On
Pressure Alert Alarms
High: 20%
Low: 20%
Minimum: 1%
Maximum: 500%
Flow Fault Alarms
High: 50%
Low: 50%
Minimum: 1%
Maximum: 500%
Alarm Enable LS
30
Minimum: 0%
Maximum: 100%
Alarm Delay
10
Minimum: 1
Maximum: 600
(Pressure) Build and Control PIDs
P: 2100
I: 585
D: 806
P: 0 - 50000
I: 0 - 50000
D: 0 - 50000
E 2021 Nordson Corporation
Notes
Part 1130505_01
4−34 Operation
This page intentionally left blank.
Part 1130505_01
E 2021 Nordson Corporation
Maintenance
5-1
Section 5
Maintenance
WARNING! Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
NOTE: Maintenance is an important preventive measure for maintaining
operating safety and extending the service life of the Flow applicator. It
should never be neglected.
E 2021 Nordson Corporation
Part 1130505_01
5-2
Maintenance
Relieving Pressure
WARNING: System and material pressurized. Relieve system pressure
before disconnecting heated hoses. Failure to observe can result in serious
burns.
WARNING: Hot! Risk of burns. Wear safety goggles and heat‐protective
gloves.
1. Set the motor speed of the unit feeding the material to 0 min‐1; switch off
the motor(s).
2. Place a container under the TruFlow applicator nozzle or under the
pressure relief valves or drain valves of the Flow Divider.
3. Manually operate the solenoid valves of the TruFlow applicator or open
the pressure relief valves / drain valves of the Flow Divider to allow
adhesive to flow out. Collect the adhesive in the container.
4. Properly dispose of material according to local regulations.
Maintenance Table
Unit Part
Electrical Cables
Activity
Inspect for damage
Air Hoses
Flow‐Splitter
Flow Applicator
Interval
Daily
Daily
Check for leakage
Daily
Tighten fixing screws
Every 500 hours of operation
External cleaning
Daily
Check control module (when
present) for leakage
Daily
Replace control module
When defective
Clean filter cartridge and replace
filter screen
Depending on degree of
adhesive pollution.
Recommendation: Every 100
hours of operation
Flow Divider
Part 1130505_01
Purge with cleaning agent
Regularly as required by
operating conditions or before
changing the adhesive
Clean completely
Depending on operating
conditions
Forcibly activate the safety valve
piston
Monthly
E 2021 Nordson Corporation
Maintenance
5-3
Flow Applicator
External Cleaning
External cleaning prevents impurities created during production from causing
the unit to malfunction.
Always follow manufacturer's instructions when using cleaning agents!
1. Electrically heat the applicator until the adhesive is liquid.
2. Thoroughly remove warm adhesive with a cleaning agent and/or a soft
cloth.
3. Remove dust, fluffs, etc. with a vacuum cleaner or a soft, lint‐free cloth.
CAUTION: Do not damage or remove warning labels. Damaged or removed
warning labels must be replaced by new ones.
Changing Material
NOTE: Before changing the type of material, determine whether the old and
new material may be mixed.
S May be Mixed - Remaining old material can be flushed out using the new
material.
S May not be Mixed - Thoroughly purge the unit with a cleaning agent
recommended by the material supplier.
NOTE: Properly dispose of the material and cleaning agent according to
local regulations.
Cleaning Filter Cartridge
NOTE: Remove the filter cartridge only when the applicator is hot and not
under pressure. Install only when the applicator is hot.
WARNING: Hot! Risk of burns. Wear safety goggles and heat‐protective
gloves.
WARNING: System and adhesive pressurized. Relieve system of pressure
before replacing a filter cartridge. Failure to observe can result in serious
burns.
E 2021 Nordson Corporation
Part 1130505_01
5-4
Maintenance
Flow Divider
Purging with Cleaning Agent
CAUTION: Use only a cleaning agent recommended by the adhesive
manufacturer. Observe the material Safety Data Sheet (SDS) for the
cleaning agent.
Before starting production again, flush out residue of the cleaning agent
using the new adhesive.
NOTE: Properly dispose of cleaning agent according to local regulations.
WARNING: Hot! Risk of burns. Wear safety goggles and heat‐protective
gloves.
WARNING: Risk of explosion or fire. Fire, open flames, and smoking
prohibited.
Cleaning Complete Flow Divider
CAUTION: Use only a cleaning agent recommended by the adhesive
manufacturer. Observe the material SDS for the cleaning agent.
The Flow Divider must be regularly detached and cleaned.
Forcibly Actuating Safety Valve
Forcibly actuate the safety valve piston once a month. This prevents material
from blocking the safety valve.
X
1. Relieve pressure to the Flow Divider. If there are pressure relief screws,
open them. Collect the escaping material and dispose of properly.
2. Disconnect all hoses.
3. Close hose connections with proper Nordson plugs.
4. Measure and make a note of the insertion depth (dimension X in the
illustration) of the adjusting screw. This allows the insertion depth to be
reproduced.
Figure 5-1 Safety valve piston
5. Run the metering station at full speed with the hose connections closed.
Switch the motor on and off several times during operation.
Part 1130505_01
E 2021 Nordson Corporation
Maintenance
5-5
Flow General and Technical Data
Name
UTA‐... (Universal TruFlow Applicator / Flow Divider)
Type of Heating
Electrical resistance heating elements
Temperature Sensors
Pt 100 / Ni 120
Maximum Processable Viscosity
Speed‐Coat, TrueCoat
25000 mPas
25000 cP
UM25, UM50
500 to mPas
10000
500 to cP
10000
Maximum Application Width
500 mm
Minimum Number of Control Modules
Per Stream
1
With UM50
1
Maximum Number of Control Modules
Per Stream
3
With UM50
1
Maximum Number of Control Modules
Per Applicator
24
With UM50
12
Installation Height (Distance Between Nozzle and Substrate)
Speed‐Coat
Recommendation
Contact
Contact
Recommendation
Contact
Contact
Recommendation
19 to 51 mm
0.75 to 2 inch
Recommendation
19 to 51 mm
0.75 to 2 inch
Recommendation
12 to 25 mm
0.5 to 1 inch
Recommendation
Contact
Contact
TrueCoat
CF
Meltblown
Summit
SureWrap
E 2021 Nordson Corporation
Part 1130505_01
5-6
Maintenance
Temperatures
Maximum Ambient Temperature
60 °C
140 °F
Maximum Operating Temperature
for Solenoid Valves
80 °C
176 °F
Maximum Operating Temperature
for Applicator
200 °C
392 °F
Spray Air Temperature
Meltblown
Recommendation 16 to 27 _C (30 to 50 _F) higher than the adhesive temperature
CF, Summit, SureWrap
Recommendation 9 to 15 _C (15 to 25 _F) higher than the adhesive temperature
Air pressure
Control Air
Approx.4
to 6 bar
Approx. 0.4
to 0.6 MPa
Approx. 58
to 87 psi
Approx. 0.8
to 1.5 bar
Approx. 0.08
to 0.15 MPa
Approx. 11.6
to 21.7 psi
Spray/Application Air
Speed‐Coat, TrueCoat
CF
0.3 to 3.4 bar
0.03 to 0.34 MPa
5 to 50 psi
Recommendation
0.8 to 1.2 bar
0.08 to 0.12 MPa
12 to 18 psi
Recommendation
2.1 to 3.1 bar
0.21 to 0.31 MPa
30 to 45 psi
Recommendation
0.3 to 1.7 bar
0.03 to 0.17 MPa
5 to 25 psi
0.5 to 1.5 bar
0.05 to 0.15 MPa
7 to 22 psi
0,8 bar
0,08 MPa
12 psi
Meltblown
Summit
Sure Wrap
Recommendation
Air Consumption UM Control Modules
~ 7.1 to 56.6 nlm (~ 0.25 to 2.0 scfm)
Dependent on type of application:
More for Meltblown, less for Summit
Part 1130505_01
E 2021 Nordson Corporation
Maintenance
5-7
Electrical Data
WARNING! The applicator is designed for only one operating voltage.
Operate only at the operating voltage shown on the ID plate.
Operating Voltage
230 VAC
Operating Voltage Frequency
50/60 Hz
Voltage for Solenoid Valve
Without overexcitation! Max. 24 VDC
Refer to Section 3: Installation, Connecting Solenoid Valves
Starting Current ION Solenoid Valve
2 A for P/N 7157157
Power Consumption Body
250 mm
Degree of Protection
IP 30
Dimensions and Weights
Dimensions
Refer to technical drawing.
Weight
See consignment note.
Processing Materials
Designation
Order number
High temperature grease
Use
Apply to O‐rings and threads.
S Can
10 g
P/N 394769
S Tube
250 g
P/N 783959
S Cartridge
400 g
P/N 402238
NOTE: The grease should not be
mixed with other lubricants.
Oily/greasy parts must be cleaned
before application.
Torques
Screws
E 2021 Nordson Corporation
Torque
Air Cap
1.7 Nm (15 lbin)
Control Module-Body
3.4 Nm (30 lbin)
Nozzle Clamp
1.7 Nm (15 lbin)
CF Nozzle
3.4 Nm (30 lbin)
CF Nozzle (Unibody)
0.6 Nm (5 lbin)
Part 1130505_01
5-8
Maintenance
Pressure Transducer Maintenance
The following table lists some common maintenance tasks. Refer to the
documentation that came with pressure transducer for more information.
Unit Part
Entire Sensor
Activity
Check performance
Dependent on purpose and conditions
of use of sensor
Calibrate zero point
Every year, or more often if conditions
of use require
Calibrate
Separating Membrane
Check for damage
Check if hardened or charred material
is stuck to the membrane. Clean if
necessary
Part 1130505_01
Interval
With every performance check, more
often if necessary
E 2021 Nordson Corporation
Troubleshooting
6-1
Section 6
Troubleshooting
WARNING! Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
This section contains troubleshooting procedures. These procedures cover
only the most common problems that you may encounter. If you cannot solve
the problem with the information given here, contact your local Nordson
representative for help.
Refer to the Toubleshooting section of the AltaBlue™ Plus Adhesive Melter
manual for additional touchscreen, system, and pump information.
E 2021 Nordson Corporation
Part 1130505_01
6-2
Troubleshooting
Flow and Pressure Alerts/Faults Pop-up Messages
The table column titled Alert\Fault Message lists the possible flow and/or
pressure channel alert or fault pop-up messages. Use the Possible Cause
and Corrective Action columns to help resolve the alert or fault condition.
Alert\Fault Message
1.
2.
3.
4.
5.
Flow Warning on
Channel #
Flow Fault on
Channel #
Pressure Warning on
Channel #
Pressure Fault on
Channel #
4‐20mA or 0-10V
Pressure Input #
Disconnected
Possible Cause
Corrective Action
The flow rate is either above or
below defined alert threshold
percentage deviation.
S Check flow configuration settings.
S Modify the high and low alert
The flow rate is either above or
below defined fault threshold
percentage deviation.
S Check flow configuration settings.
S Modify the high and low fault
The pressure is either above or
below defined alert threshold
percentage deviation.
S Check flow configuration settings.
S Modify the high and low alert
The pressure is either above or
below defined fault threshold
percentage deviation.
S Check flow configuration settings.
S Modify the high and low fault
No power detected between the
cable connecting the pressure
transducer to the melter.
S Make sure the connections are
threshold values.
threshold values.
threshold values.
threshold values.
properly seated.
S Visually check the cable for
damage.
6.
0-10V Line Speed
Input # Disconnected
No power detected between the
cable connecting the line speed
device to the melter.
S Make sure the connections are
properly seated.
S Visually check the cable for
damage.
7.
Pump Board Lost
Communication Fault
Communication lost between the
PLC and motor control board.
S Visually check the wiring for
damage.
S Check motor control board.
S Check the RS232-to-Nordnet
communication board.
8.
# Motor Drive Fault
The motor is no longer able to
operate.
Replace the motor.
9.
Motor # OT
Thermostat Fault
The motor is no longer able to
operate.
Replace the motor.
Part 1130505_01
E 2021 Nordson Corporation
Troubleshooting
6-3
Troubleshooting Flow Rate Issues
The table column titled Problem lists the possible flow issues. Use the
Possible Cause and Corrective Action columns to help resolve the problem.
Problem
Possible Cause
Corrective Action
1.
Leakage at pump
shaft seal
Pump shaft seal is worn
Have Flow-Splitter repaired
2.
Adhesive pressure
too low, output
quantity too low
Flow-Splitter is worn
Replace Flow-Splitter
3.
Flow-Splitter blocked
a. Processed material too cold
a. Change temperature setting
(observe data sheet of adhesive
manufacturer)
b.
Foreign matter in Flow-Splitter
b. Purge Flow-Splitter with solvent,
otherwise replace Flow-Splitter
4.
Flow applicator does
not heat
a. Temperature not set
b.
Plug not connected
c. Fuses in melter defective
d. Heater cartridge(s) in Flow
applicator defective
a. Check settings and modify if
required.
b.
Connect plug
c. Disconnect unit from line voltage,
check fuses and replace if
necessary
d. Replace
5.
Flow applicator does
not reach the set
temperature
Ambient temperature too low
Increase ambient temperature
Maximum ambient temperature is
60_C (140_F). Maximum operating
temperature for applicator is 200_C
(392_F)
6.
No adhesive
a. Reservoir is empty
a. Fill reservoir with adhesive
b.
b.
Master Pump Control is Off
c. Melter pump is not working
Access the Master Control
display and switch on the Pump
Control
c. Check, and replace if necessary
Continued…
E 2021 Nordson Corporation
Part 1130505_01
6-4
Troubleshooting
Troubleshooting Flow Rate Issues (contd)
7.
Problem
Possible Cause
Corrective Action
No adhesive at outlet
a. Flow applicator has not yet
reached operating temperature
a. Wait until temperature has been
reached; check temperature
setting if necessary
b. Compressed air not connected
c. Nozzle stem is stuck
d. Nozzle clogged
e. Filter cartridge clogged
f.
An adhesive channel is blocked
by a potentially defective
control module
g. Potentially defective solenoid
valve does not switch off
control module
8.
Application weight
too low
Control parameters not optimal
b. Connect
c. Replace control module
d. Clean nozzle
e. Clean or replace filter screen if
necessary
f.
Check control module, replace if
necessary
g. Check solenoid valve, replace if
necessary
a. Check and verify Specific Gravity
entered value is correct.
b. Check and verify Pump
Displacement (cc\rev) value is
correct.
9.
Application pattern
not exact
a. Temperature not set precisely
on melter
b. Temperature of Flow applicator
not set precisely
c. Adhesive quantity/pressure not
set precisely
d. Distance between nozzle and
substrate incorrect
e. Control unit not programmed
correctly
f.
External pollution on nozzle
g. Foreign material inside of
nozzle
a. Correct setting
b. Correct setting
c. Correct setting
d. Correct distance
e. Correct programming
f.
Clean
g. Clean
h. Replace nozzle
i.
Check settings; change so as to
be attuned to one another if
necessary
j.
Ask manufacturer
h. Nozzle damaged
Part 1130505_01
i.
Application quantity and
substrate processing speed not
attuned to one another
j.
Adhesive unsuitable
E 2021 Nordson Corporation