Fulfill Retrofit Kit DuraBlue/VersaBlue 25L and 50L Meltersemanuals.nordson.com/adhesives/English_Manuals/1121937.pdf · Fulfill Retrofit Kit − DuraBlue/VersaBlue 25L and 50L Melters

Fulfill� Retrofit Kit −DuraBlue/VersaBlue 25L and 50L

Melters

Customer Product ManualPart 1121937_01

Issued 4/13

NORDSON CORPORATION DULUTH, GEORGIA USAwww.nordson.com

This document contains important safety informationBe sure to read and follow all safety information in thisdocument and any other related documentation.

ATTENTION: Information on a new control box, PCA and level sensor is included in Appendix A.

Please refer to the Appendix if your unit was manufactured after May 2013. This information is found in theserial code of your unit; for example, SA13EXXXXX, where “E” represents the date code “May,” or any sequential letter after “E.”

Part 1121937_01 � 2013 Nordson CorporationAll rights reserved

For CE Declaration, refer to equipment documentation.

Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General informationabout Nordson can be found on the Internet using the following address: http://www.nordson.com.

Address all correspondence to:

Nordson CorporationAttn: Customer Service11475 Lakefield Drive

Duluth, GA 30097

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2010.No�part�of�this�document may be photocopied, reproduced, or translated to another language without the prior written

consent of Nordson�Corporation. The�information�contained in this publication is subject to change without notice.

Trademarks

AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, Bowtie, Build‐A‐Part, CanWorks, Century, CF, CleanSleeve,CleanSpray, ColorMax, Color‐on‐Demand, Control�Coat, Coolwave, Cross‐Cut, cScan+, Dage, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber,

DuraPail, Dura‐Screen, Durasystem, Easy�Coat, Easymove Plus, Ecodry, Econo‐Coat, e.DOT, EFD, Emerald, Encore, ESP, e stylized, ETI‐stylized,Excel 2000, Fibrijet, Fillmaster, FlexiCoat, Flex‐O‐Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Fulfill, GreenUV, HDLV, Heli‐flow, Horizon, Hot Shot,iControl, iDry, iFlow, Isocoil, Isocore, Iso‐Flo, iTRAX, Kinetix, LEAN�CELL, Little�Squirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, Microcoat,

Micromark, Micromedics, MicroSet, Millennium, MiniBlue, Mini Squirt, Mountaingate, NexJet, Nordson, Optimum, Package of Values, Pattern View,PermaFlo, PicoDot, Porous�Coat, PowderGrid, Powderware, Precisecoat, PRIMARC, Printplus, Prism, ProBlue, Prodigy, Pro‐Flo, ProLink, Pro‐Meter,

Pro‐Stream, RBX, Rhino, Saturn, Saturn with rings, Scoreguard, Seal Sentry, Select�Charge, Select�Coat, Select Cure, Signature, Slautterback, Smart‐Coat,Solder Plus, Spectrum, Speed‐Coat, SureBead, Sure Coat, Sure‐Max, Sure Wrap, Tracking�Plus, TRAK, Trends, Tribomatic, TrueBlue, TrueCoat,

Tubesetter, Ultra, UpTime, u‐TAH, Value Plastics, Vantage, VersaBlue, Versa‐Coat, VersaDrum, VersaPail, Versa‐Screen, Versa‐Spray, VP Quick Fit, Watermark, and When you expect more. are registered trademarks of Nordson Corporation.

Accubar, Active Nozzle, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AltaSlot, Alta Spray, Artiste, ATS, Auto‐Flo, AutoScan, Axiom, Best Choice, Blue Series, Bravura, CanPro, Champion, Check Mate, ClassicBlue, Classic IX, Clean�Coat, Cobalt, Controlled Fiberization, Control�Weave,

ContourCoat, CPX, cSelect, Cyclo‐Kinetic, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, e.dot+,E‐Nordson, Equalizer, EquiBead, FillEasy, Fill�Sentry, Flow Coat, Fluxplus, Get Green With Blue, G‐Net, G‐Site, IntelliJet, iON, Iso‐Flex, iTrend,

Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros, MiniEdge, Minimeter, Multifill, MultiScan, Myritex, Nano, NexJet, OmniScan, OptiMix, OptiStroke,Partnership+Plus, PatternJet, PatternPro, PCI, PharmaLok, Pinnacle, Plasmod, Powder�Pilot, Powder Port, Powercure, Process Sentry, Pulse Spray,

PURBlue, PURJet, Ready Coat, RediCoat, RollVIA, Royal Blue, Select�Series, Sensomatic, Shaftshield, SheetAire, Smart, Smartfil, SolidBlue, Spectral,SpeedKing, Spray Works, StediFlo, StediTherm, Summit, SureFoam, Sure�Mix, SureSeal, Swirl�Coat, TAH, ThruWave, Trade�Plus, Trilogy, Ultra FoamMix,UltraMax, Ultrasaver, Ultrasmart, Universal, ValueMate, Versa, Vista, Web Cure, YESTECH, and 2�Rings (Design) are�trademarks of Nordson�Corporation.

Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes, could lead to violation of the owners' rights.

Table of Contents i

Part 1121937_01� 2013 Nordson Corporation

Fulfill� Retrofit Kit - DuraBlue�/VersaBlue� 25L and 50L Melters . . . .1

Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Alert Symbols 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Responsibilities of the Equipment Owner 2. . . . . . . . . . . . . . . . . . . . . . . . .

Safety Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instructions, Requirements, and Standards 2. . . . . . . . . . . . . . . . . . . .User Qualifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applicable Industry Safety Practices 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use of the Equipment 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instructions and Safety Messages 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation Practices 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Practices 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance and Repair Practices 5. . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Safety Information 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Equipment Shutdown 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving System Hydraulic Pressure 6. . . . . . . . . . . . . . . . . . . . . . .De‐energizing the System 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disabling the Applicators 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Safety Warnings and Cautions 7. . . . . . . . . . . . . . . . . . . . . . . .Other Safety Precautions 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .First Aid 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Labels and Tags 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Theory of Operation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overview 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pneumatic & Mechanical Components 14. . . . . . . . . . . . . . . . . . . . . . . . . .

(1). Adhesive Storage Bin 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2). Air Pressure Regulator/Solenoid Assembly 15. . . . . . . . . . . . . . . .(3). Suction Lance 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(4). Adhesive Transfer Hose 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(5). Lid Assembly 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Components 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(6). Control Box 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(7). Sensor 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Prepare the Melter 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Install the Tank Lid Components 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Install the Control Box/Regulator Assembly 28. . . . . . . . . . . . . . . . . . . . . . .Assemble the Transfer Hose, Air Line, and Suction Lance 29. . . . . . . . . .Level Sensor Adjustment and Calibration 31. . . . . . . . . . . . . . . . . . . . . . . .

Baseline Setting 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Final Setting 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Time Settings 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monitoring Refill Operation 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsii

Part 1121937_01 � 2013 Nordson Corporation

Maintenance 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Refill PCA Troubleshooting Diagnostic Instructions 37. . . . . . . . . . . . . . . .

Parts 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using the Illustrated Parts Lists 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DuraBlue/VersaBlue 25L and 50L Retrofit Kit Assemblies 40. . . . . . . . . .

Ship With Fastener Kit 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DuraBlue/VersaBlue 25L Lid Assembly Parts 41. . . . . . . . . . . . . . . . . . .DuraBlue/VersaBlue 50L Lid Assembly Parts 45. . . . . . . . . . . . . . . . . . .Lid Switch Assembly for 25L Melters 48. . . . . . . . . . . . . . . . . . . . . . . . . .Lid Switch Assembly for 50L Melters 49. . . . . . . . . . . . . . . . . . . . . . . . . .25L Clamp Assembly With Actuator 50. . . . . . . . . . . . . . . . . . . . . . . . . . .50L Clamp Assembly With Actuator 51. . . . . . . . . . . . . . . . . . . . . . . . . . .Level Probe Holder Assembly 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pneumatic Control Assembly 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Box Assembly 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Container/Wand Kit 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Kits 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Accessories 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Service Parts 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Diagram 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RetroFit Refill System with Nordson Level Sensor A‐1. . . . . . . . . . . . .Sensor Features A‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wide Sensing Area A‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Simplified Mechanical Mounting A‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Push Button Calibration A‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .RTD Temperature Compensation A‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sensor Diagnostics A‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Features A‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Delay Timer A‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overfill Fault Timer A‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Status Relay Contact Output A‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Configuration Switch A‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sensor Calibration A‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Calibration Summary A‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Basic (Empty Level) Calibration A‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Precision (Full Level) Calibration A‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting A‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fault LED/Red Status LED A‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fill Enable LED/Yellow Status LED/Yellow Light Tower A‐11. . . . . . . . . . . . .

Installation A‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Common Chassis Connection A‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Parts A‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Retrofit Wiring Diagram A‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fulfill Retrofit Kit - DuraBlue/VersaBlue 25L and 50L Melters 1


Fulfill Retrofit Kit -DuraBlue/VersaBlue 25L and 50LMelters

Safety Read this section before using the equipment. This section containsrecommendations and practices applicable to the safe installation, operation,and maintenance (hereafter referred to as “use”) of the product described inthis document (hereafter referred to as “equipment”). Additional safetyinformation, in the form of task‐specific safety alert messages, appears asappropriate throughout this document.

WARNING! Failure to follow the safety messages, recommendations, andhazard avoidance procedures provided in this document can result inpersonal injury, including death, or damage to equipment or property.

Safety Alert Symbols

The following safety alert symbol and signal words are used throughout thisdocument to alert the reader to personal safety hazards or to identifyconditions that may result in damage to equipment or property. Comply withall 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 potentiallyhazardous situation that, if not avoided, can result in damage to equipment orproperty.

Fulfill Retrofit Kit - DuraBlue/VersaBlue 25L and 50L Melters2


Responsibilities of the Equipment Owner

Equipment owners are responsible for managing safety information, ensuringthat all instructions and regulatory requirements for use of the equipment aremet, and for qualifying all potential users.

Safety Information � 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, andthis document.

� Make safety information available to equipment users in accordance with

governing regulations. Contact the authority having jurisdiction forinformation.

� Maintain safety information, including the safety labels affixed to the

equipment, in readable condition.

Instructions, Requirements, and Standards � Ensure that the equipment is used in accordance with the information

provided in this document, governing codes and regulations, and bestindustry practices.

� If applicable, receive approval from your facility's engineering or safety

department, or other similar function within your organization, beforeinstalling or operating the equipment for the first time.

� Provide appropriate emergency and first aid equipment.

� Conduct safety inspections to ensure required practices are being

followed.

� Re‐evaluate safety practices and procedures whenever changes are

made to the process or equipment.



User Qualifications

Equipment owners are responsible for ensuring that users:

� receive safety training appropriate to their job function as directed by

governing regulations and best industry practices

� are familiar with the equipment owner's safety and accident

prevention policies and procedures

� receive equipment and task‐specific training from another qualified

individual

NOTE: Nordson can provide equipment‐specific installation,operation, and maintenance training. Contact your Nordsonrepresentative for information

� possess industry‐ and trade‐specific skills and a level of experience

appropriate to their job function

� are physically capable of performing their job function and are not

under the influence of any substance that degrades their mentalcapacity or physical capabilities

Applicable Industry Safety Practices

The following safety practices apply to the use of the equipment in themanner described in this document. The information provided here is notmeant to include all possible safety practices, but represents the best safetypractices for equipment of similar hazard potential used in similar industries.

Intended Use of the Equipment � Use the equipment only for the purposes described and within the limits

specified in this document.

� Do not modify the equipment.

� Do not use incompatible materials or unapproved auxiliary devices.

Contact your Nordson representative if you have any questions onmaterial compatibility or the use of non‐standard auxiliary devices.



Instructions and Safety Messages � Read and follow the instructions provided in this document and other

referenced documents.

� Familiarize yourself with the location and meaning of the safety warning

labels and tags affixed to the equipment. Refer to Safety Labels and Tagsat the end of this section.

� If you are unsure of how to use the equipment, contact your Nordson

representative for assistance.

Installation Practices � Install the equipment in accordance with the instructions provided in this

document and in the documentation provided with auxiliary devices.

� Ensure that the equipment is rated for the environment in which it will be

used. This equipment has not been certified for compliance with theATEX directive nor as nonincendive and should not be installed inpotentially explosive environments.

� Ensure that the processing characteristics of the material will not create a

hazardous environment. Refer to the Material Safety Data Sheet (MSDS)for the material.

� If the required installation configuration does not match the installation

instructions, contact your Nordson representative for assistance.

� Position the equipment for safe operation. Observe the requirements for

clearance between the equipment and other objects.

� Install lockable power disconnects to isolate the equipment and all

independently powered auxiliary devices from their power sources.

� Properly ground all equipment. Contact your local building code

enforcement agency for specific requirements.

� Ensure that fuses of the correct type and rating are installed in fused

equipment.

� Contact the authority having jurisdiction to determine the requirement for

installation permits or inspections.

Operating Practices � Familiarize yourself with the location and operation of all safety devices

and indicators.

� Confirm that the equipment, including all safety devices (guards,

interlocks, etc.), is in good working order and that the requiredenvironmental conditions exist.

� Use the personal protective equipment (PPE) specified for each task.

Refer to Equipment Safety Information or the material manufacturer'sinstructions and MSDS for PPE requirements.

� Do not use equipment that is malfunctioning or shows signs of a potential

malfunction.



Maintenance and Repair Practices � Allow only personnel with appropriate training and experience to operate

or service the equipment.

� Perform scheduled maintenance activities at the intervals described in

this document.

� Relieve system hydraulic and pneumatic pressure before servicing the

equipment.

� De‐energize the equipment and all auxiliary devices before servicing the

equipment.

� Use only new Nordson‐authorized refurbished or replacement parts.

� Read and comply with the manufacturer's instructions and the MSDS

supplied with equipment cleaning compounds.

NOTE: MSDSs for cleaning compounds that are sold by Nordson areavailable at www.nordson.com or by calling your Nordson representative.

� Confirm the correct operation of all safety devices before placing the

equipment back into operation.

� Dispose of waste cleaning compounds and residual process materials

according to governing regulations. Refer to the applicable MSDS orcontact the authority having jurisdiction for information.

� Keep equipment safety warning labels clean. Replace worn or damaged

labels.

Equipment Safety Information

This equipment safety information is applicable to the following types ofNordson equipment:

� hot melt and cold adhesive application equipment and all related

accessories

� pattern controllers, timers, detection and verification systems, and all

other optional process control devices



Equipment Shutdown

To safely complete many of the procedures described in this document, theequipment must first be shut down. The level of shut down required varies bythe 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 hydraulicconnection or seal. Refer to the melter‐specific product manual forinstructions on relieving system hydraulic pressure.

De‐energizing the System

Isolate the system (melter, hoses, applicators, and optional devices) from allpower sources before accessing any unprotected high‐voltage wiring orconnection point.

1. Turn off the equipment and all auxiliary devices connected to theequipment (system).

2. To prevent the equipment from being accidentally energized, lock andtag the disconnect switch(es) or circuit breaker(s) that provide inputelectrical power to the equipment and optional devices.

NOTE: Government regulations and industry standards dictate specificrequirements for the isolation of hazardous energy sources. Refer to theappropriate regulation or standard.

Disabling the Applicators

NOTE: Adhesive dispensing applicators are referred to as “guns” in someprevious publications.

All electrical or mechanical devices that provide an activation signal to theapplicators, applicator solenoid valve(s), or the melter pump must bedisabled before work can be performed on or around an applicator that isconnected 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; thenrelieve the residual air pressure between the regulator and the applicator.



General Safety Warnings and Cautions

Table 1 contains the general safety warnings and cautions that apply toNordson hot melt and cold adhesive equipment. Review the table andcarefully read all of the warnings or cautions that apply to the type ofequipment described in this manual.

Equipment types are designated in Table 1 as follows:

HM = Hot melt (melters, hoses, applicators, etc.)

PC = Process control

CA = Cold adhesive (dispensing pumps, pressurized container, andapplicators)

Table 1 General Safety Warnings and Cautions

EquipmentType Warning or Caution

HM

WARNING! Hazardous vapors! Before processing any polyurethanereactive (PUR) hot melt or solvent‐based material through a compatibleNordson melter, read and comply with the material's MSDS. Ensurethat the material's processing temperature and flashpoints will not beexceeded and that all requirements for safe handling, ventilation, firstaid, and personal protective equipment are met. Failure to comply withMSDS requirements can cause personal injury, including death.

HM

WARNING! Reactive material! Never clean any aluminum componentor flush Nordson equipment with halogenated hydrocarbon fluids.Nordson melters and applicators contain aluminum components thatmay react violently with halogenated hydrocarbons. The use ofhalogenated hydrocarbon compounds in Nordson equipment cancause personal injury, including death.

HM, CAWARNING! System pressurized! Relieve system hydraulic pressurebefore breaking any hydraulic connection or seal. Failure to relieve thesystem hydraulic pressure can result in the uncontrolled release of hotmelt or cold adhesive, causing personal injury.

Continued...



General Safety Warnings and Cautions (contd)

Table 1 General Safety Warnings and Cautions (contd)

EquipmentType Warning or Caution

HM

WARNING! Molten material! Wear eye or face protection, clothing thatprotects exposed skin, and heat‐protective gloves when servicingequipment that contains molten hot melt. Even when solidified, hot meltcan still cause burns. Failure to wear appropriate personal protectiveequipment can result in personal injury.

HM, PC

WARNING! Equipment starts automatically! Remote triggering devicesare used to control automatic hot melt applicators. Before working onor near an operating applicator, disable the applicator's triggeringdevice and remove the air supply to the applicator's solenoid valve(s).Failure to disable the applicator's triggering device and remove thesupply of air to the solenoid valve(s) can result in personal injury.

HM, CA, PC

WARNING! Risk of electrocution! Even when switched off andelectrically isolated at the disconnect switch or circuit breaker, theequipment may still be connected to energized auxiliary devices.De‐energize and electrically isolate all auxiliary devices beforeservicing the equipment. Failure to properly isolate electrical power toauxiliary equipment before servicing the equipment can result inpersonal injury, including death.

HM, CA, PC

WARNING! Risk of fire or explosion! Nordson adhesive equipment isnot rated for use in explosive environments and has not been cerfifiedfor the ATEX directive or as nonincendive. In addition, this equipmentshould not be used with solvent‐based adhesives that can create anexplosive atmosphere when processed. Refer to the MSDS for theadhesive to determine its processing characteristics and limitations.The use of incompatible solvent‐based adhesives or the improperprocessing of solvent‐based adhesives can result in personal injury,including death.

HM, CA, PC

WARNING! Allow only personnel with appropriate training andexperience to operate or service the equipment. The use of untrainedor inexperienced personnel to operate or service the equipment canresult in injury, including death, to themselves and others and candamage to the equipment.



Warning or CautionEquipment

Type

HM

CAUTION! Hot surfaces! Avoid contact with the hot metal surfaces ofapplicators, hoses, and certain components of the melter. If contactcan not be avoided, wear heat‐protective gloves and clothing whenworking around heated equipment. Failure to avoid contact with hotmetal surfaces can result in personal injury.

HM

CAUTION! Some Nordson melters are specifically designed toprocess polyurethane reactive (PUR) hot melt. Attempting to processPUR in equipment not specifically designed for this purpose candamage the equipment and cause premature reaction of the hot melt. Ifyou are unsure of the equipment's ability to process PUR, contact yourNordson representative for assistance.

HM, CA

CAUTION! Before using any cleaning or flushing compound on or inthe equipment, read and comply with the manufacturer's instructionsand the MSDS supplied with the compound. Some cleaningcompounds 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 NordsonType R fluid that contains polyester adipate plasticizer. Certain hot meltmaterials can react with Type R fluid and form a solid gum that canclog the equipment. Before using the equipment, confirm that the hotmelt is compatible with Type R fluid.



Other Safety Precautions � Do not use an open flame to heat hot melt system components.

� Check high pressure hoses daily for signs of excessive wear, damage, or

leaks.

� Never point a dispensing handgun at yourself or others.

� 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 melthas cooled.

3. Do NOT attempt to remove the solidified hot melt from your skin.

4. In case of severe burns, treat for shock.

5. Seek expert medical attention immediately. Give the MSDS for the hotmelt to the medical personnel providing treatment.



Safety Labels and Tags Figure 1 illustrates the location of the product safety labels and tags affixed tothe equipment. Table 2 provides an illustration of the hazard identificationsymbols that appear on each safety label and tag, the meaning of thesymbol, or the exact wording of any safety message.

1

Figure 1 Safety labels and tags

Table 2 Safety Labels and Tags

Item Part Description

1. 1021984

WARNING! Hazardous voltage. Disconnect all power supplyconnections before servicing.



Description The DuraBlue/VersaBlue 25L and 50L Fulfill Retrofit Kit converts aDuraBlue/VersaBlue 25L and 50L melter into an automatic fill system thatmaintains adhesive in the melter , improving productivity and reducingmaintenance. The retrofit kit adds adhesive to the sealed tank, reducing thepossibility of char, contaminants, thermal shock and incorrect adhesivetemperatures that result in poor adhesive bonding.

The Fulfill system is shipped with the components illustrated in Figure 2.

2 3

1

6

7

5

4

Figure 2 Fulfill system components

1. Adhesive storage bin

2. Transfer hose

3. Suction lance

4. Lid assembly with control box andmounting bracket with level sensor,filter-regulator w/ gauge, andsolenoid

5. Hose clamp (2)

6. Air line (4m)7. Wire tie (5)

Optional accessories available for the Fulfill Retrofit include:

� a vibrator kit for the adhesive storage bin

� a light tower kit for audio/visual fill/fault indication of the Fulfill processes.

Contact your Nordson representative for more information on these kits.



Theory of Operation � NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated

information.

Overview The system adds small quantities of adhesive to the sealed tank at regularintervals, reducing the possibility of adhesive char, contaminants, thermalshock and incorrect adhesive temperatures that result in poor bonding.

A capacitance sensor located in the melter detects low adhesive level, andthen sends a signal to the Fulfill system control box. A delay timer preventsthe fill system from frequently cycling on and off.

At the end of the delay, the control box activates the vacuum via a solenoidvalve. Air pressure flows to a suction lance that is placed in the supplied bulkadhesive container. Using vacuum, the system conveys adhesive from thebulk container to the adhesive melter tank. When the adhesive in the meltertank reaches the desired level, the control box shuts off the solenoid valve tostop the flow of adhesive.

The control box activates the suction lance for a limited amount of time toprevent over‐fill conditions. If the maximum fill time is exceeded, thecontroller activates a fault that stops the system from filling.

A safety interlock switch detects whether the melter tank lid is in place. If thetank lid is not in place, the fill system will not operate.



Pneumatic & Mechanical Components Refer to Figure 3 as you learn about the components of theDuraBlue/VersaBlue 25L and 50LL and 50L Fulfill retrofit assembly.

1

3

5

4

2

67

Figure 3 Assembled DuraBlue/VersaBlue 25L and 50LL and 50L Fulfill retrofit assembly.

(1). Adhesive Storage Bin Place adhesive in the adhesive storage bin. The bin contains a gasket thatprevents debris from entering the bin. For best results, break up theadhesive as much as possible when emptying into the bin. Do not get theadhesive wet.



(2). Air Pressure Regulator/Solenoid Assembly The supplied air pressure regulator is permanently set at 65 psig, the optimalsetting for most adhesives.

The solenoid valve turns on after the sensor indicates level state and the timedelay has been reached. The solenoid directs compressed air to flow to thesuction lance.

(3). Suction Lance The suction lance draws adhesive from the adhesive storage bin. Thesuction lance includes:

� A venturi pump to draw in and transport the adhesive.

� A vibrator to keep the adhesive in loose condition. The vibrator is active

as long as compressed air is supplied to the suction lance.

Air line tubing and the adhesive transfer hose are connected to the suctionlance. The lance is placed in the PVC pipe located in the adhesive storagebin.

(4). Adhesive Transfer Hose The adhesive transfer hose connects the suction lance to the lid assembly.The transfer hose conveys adhesive from the adhesive storage bin to themelter tank.

(5). Lid Assembly The lid assembly includes the filter stack, lid, fill tube, baffle and deflector:

� The filter stack contains a replaceable filter sock to prevent adhesive

fines and talc/powder in the adhesive from being emitted into the ambientair.

� The fill tube attaches to the adhesive transfer hose.

� The baffle prevents adhesive from entering the filter sock.

� The deflector distributes adhesive evenly in the tank.

A safety interlock switch detects whether the melter tank lid is in place. If thetank lid is not in place, the fill system will not operate.



Electrical Components � NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated

information.

(6). Control Box The control box contains the membrane panel and PCA.

Membrane Panel

The front panel of the electrical control box shown in Figure 4 contains threeLEDs that have different colored lights to indicate the unit condition:

� Enable On/Off LED (green light) - Indicates that the system is

enabled. Pressing the Enable On/Off key will toggle the indicator. Ifthe melter tank lid is open, this LED will flash, indicating that the fillsystem is disabled.

� Enable button - Press the enable button to turn the fill system on or

off.

� Adhesive transfer LED (blue light) - Indicates adhesive delivery is

active. When a low level is detected, the indicator notes thatadhesive is being transferred from the adhesive storage bin into themelter tank through the transfer hose.

� Fault LED (red light) - activates if the system exceeds the user

defined fill time limit. The system will not resume operation until thefault is cleared with the clear fault button.

� Clear fault button - Press the clear fault button to reset fault and

resume normal activity.

1 2 3

4

Figure 4 Fill system controls and indicators

1. Enable On/Off2. Filling activated symbol and blue LED

3. Fault symbol and red LED4. Clear fault



PCA � NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated

information.

See Figure 5. The PCA is inside the control box:

Figure 5 PCA board (located inside the control box)

� A potentiometer labeled ”Delay” is for a fill time delay. This delay is

the time duration between the level sensor calling for more adhesiveand when the fill system activates. The delay time prevents thesystem from frequently turning on and off. The delay time is presetfrom the factory at 60 seconds, but can be adjusted from 0 to 119seconds. The factory sets the potentiometer at the 12 o'clockposition, sufficient for the majority of applications. For reference, 9o'clock is 20 seconds and 3 o'clock is 100 seconds.



PCA (contd)

� A potentiometer labeled “Fault” limits the amount of filling time in case

of level sensor failure. It is only for overflow protection. The factorysetting is at the 12 o'clock position, sufficient in most applications.The time can be adjusted from 5 to 115 seconds. For reference, the 9o'clock position is 22 seconds and the 3 o'clock position is 98seconds.

� A potentiometer labeled ”AIR” is a pre‐vibrate timer for the optional

storage bin vibrator kit. The range for this potentiometer is 0 to 20seconds. When installed, this vibrator will activate up to 20 secondsbefore the fill system activates and stay on until the level sensor issatisfied. This kit is well suited for adhesives and plant conditionsthat are prone to bridging.

� A dip switch labeled SW1 is preset at the factory. Position M1 should

always be OFF and position M2 should always be ON.

� A terminal block labeled ”XT2”. An optional light tower may be

attached here. The functions of the light tower are

‐ Fill (Blue) - visual

‐ Fault (Red) - visual

‐ Fault (Alarm) - audible.

NOTE: The fault outputs will engage simultaneously.

(7). Sensor � NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated

information.

The level sensor detects the level of adhesive in the melter tank. When theadhesive falls below the set point, the level sensor sends a signal to the Fulfillcontrol box.

For optimal performance based on specific applications, see the LevelSensor Adjustment and Calibration detailed later in the manual.



Installation WARNING! Allow only personnel with appropriate training and experience tooperate or service the equipment. The use of untrained or inexperiencedpersonnel to operate or service the equipment can result in injury, includingdeath, to themselves and others, and damage to the equipment.

Prepare the Melter 1. De‐energize the system as directed in the Maintenance section of the

DuraBlue/VersaBlue 25L and 50LL and 50L melter manual.

CAUTION! Remove dirt and debris from the melter before proceeding withthese procedures.



Install the Tank Lid Components 1. Remove the front, right and rear cover panels.

Figure 6 Installing the tank components

2. See Figure 6. Remove (8) tank cover screws (2 per corner) as shown inDetail F.

NOTE: 25L melters use screws; 50L melters use nuts.



3. See Figure 7. Remove (2) nuts holding the enclosure cover to the sidebracket and (4) screws holding the enclosure cover to the electricalpanel.

Figure 7 Install the clamp assemblies

4. Remove the tank cover, insulation ring and enclosure (which has lidattached). Leave the folding brace.

5. Place the new enclosure cover onto the hopper top, replace insulationring and tank cover. Attach all with the (8) tank cover screws.

6. Reattach the nuts and screws from Step 3.



Install the Tank Lid Components (contd)

Figure 8 Installing the tank components (25L shown)

7. See Figure 8 . Attach the folding brace with the screw and nut as shownin Detail A.



X

Figure 9 Secure the lid to the hinge

8. See Figure 9. 25L melters (Detail A): Attach two hinges to the bottomof the cover with nuts. 50L melters (Detail B): Attach (2) hinges to topof enclosure cover with screws.




Figure 10 Installing the tank components

9. Attach (2) hinges to the bottom of the enclosure cover.

10. Assemble the remaining components.

11. See Figure 11.

� 25L melters - Open the lid, and then thread the ground wire through

the slot between the hinge and tank cover.



� 50L melters - Open the lid and then route the ground wire through the

gap between the tank cover and the central control tower.

DB/VB 25 DB/VB 50

Figure 11 Route the ground wire (DuraBlue/VersaBlue 25L and 50L)

12. Close the lid, and ensure that it seats correctly on top of the tank. Tightenthe screws securing the lid assembly (1) to the lid bracket (6).

13. See Figure 12. Open the lid and attach the folding brace to the undersideof the lid with the M4 flathead screw and locknut from the ship‐with kit.



Figure 12 Attach the folding brace

14. Thread the level sensor probe through the slot in the lid into the holder.Set the level probe to the desired height and tighten the nut on the holder.




15. See Figure 13. Route the level probe cable as shown. Provide enoughslack for the lid to open and close freely. Coil the extra cable and secureit to the bracket with cable ties from the ship‐with kit.

Figure 13 Route the level probe cable

16. See Figure 11. Remove one screw from the underside of the tank flangeand install the spade terminal from the ship‐with kit.

17. Route the ground wire from the lid assembly as shown and connect thespade terminal.

18. Replace the rear and right side panels.



Install the Control Box/Regulator Assembly � NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated

information.

1. See Figure 14. Thread a customer supplied, 14-18 AWG power cord intothe control box.

2. Connect the power wiring to the terminal blocks in the control box.

21

3

Figure 14 Connect the customer-supplied power cord to the control box

1. L1−L2/N wire power cord connection(interchangeable)

2. Ground wire power cord connection

3. Power cord strain relief

3. Tighten the strain relief.



Assemble the Transfer Hose, Air Line, and Suction Lance

CAUTION! Allow for 10 in. bend radius for installation/use of the adhesivetransfer hose.

1. See Figure 15. Using one hose clamp, attach the transfer hose (A) to theend of the suction lance (B).

2. Insert the suction lance into the PVC pipe inside the adhesive storagebin.

3. Use the remaining hose clamp to attach the transfer hose to the feedsystem inlet tube (C). The hose should be routed without sharp bends orkinks.

NOTE: If necessary, loosen the inlet tube retaining screws and thenreposition the inlet tube.

4. Connect the air line (D) to the suction lance air inlet (E).

5. Route the air line along the transfer hose, securing it with wire ties as yougo. The hose should be routed without sharp bends or kinks.

6. Leaving enough air line to reach the outlet (F) of the air solenoid, cut theair line to length and then insert the end of the air line into the outlet.

7. Connect plant air to the regulator. For best results, run the air pipingfrom the main header.



C

E

B

A

D

F

Figure 15 Assembling the transfer hose, air line, and suction lance



Level Sensor Adjustment and Calibration � NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated

information.

The level sensor consists of a level probe and a control box. The level probepermanently connects to the control box by a wire. The level probe has ablack line around its diameter near the tip to note the maintained adhesivelevel.

CAUTION! Do not raise the fill line of the probe above 2 inches from bottomof the probe holder. Doing so will degrade the level sensor's performance.

Figure 16 Adjustment potentiometer

See Figure 16. The LED indicator next to the adjustment potentiometer onthe control box changes color from green to amber, depending on theadhesive level that the probe detects. When adhesive drops below thedesired level, the LED will turn green. When adhesive reaches or exceedsthe desired level, the LED will turn amber. The adjustment potentiometersets the sensitivity of the level sensor. Different adhesives require differentcalibration settings. Adhesives that build up on the level probe require lesssensitivity, while adhesives that do not build up on the level probe requiremore sensitivity. The level sensor should be recalibrated any time the levelprobe's height is changed or the type of adhesive being used changes.



Baseline Setting � NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated

information.

Upon setting the probe's height, calibrate the level sensor.

1. Remove the threaded plug on the front face of the level sensor controlbox to reveal the adjustment potentiometer.

2. Fill the tank with adhesive up to the black line on the level probe. Theadhesive does not have to be liquid.

3. If the LED on the control box is amber, turn the adjustment potentiometercounter‐clockwise until it turns green. If the LED on the control box isgreen, turn the adjustment potentiometer clockwise until it just turnsamber. The point at which the LED transitions from green to amber is theswitching point.

4. Once the switching point is found, rotate the adjustment potentiometer 1/2turn clockwise and leave it at that position.

Final Setting � NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated

information.

1. Begin normal operation. Check the adhesive level in the tank after 30minutes of operation.

2. If the adhesive level is satisfactory, the calibration procedure is complete.Re‐install the plug over the calibration pot to discourage tampering.

3. If unmelted adhesive is piled up to the top of the tank or the system hasalready faulted due to overfilling, rotate the adjustment pot 1/2 turnclockwise to increase the level sensor's sensitivity. Wait 10 minutes andcheck the adhesive level again. If the adhesive level is still too high,repeat this process until the adhesive level is satisfactory. Whenfinished, reinstall the plug over the calibration potentiometer.

4. If unmelted adhesive has built up on the probe and the adhesive level inthe tank has dropped below the black line on the probe, rotate theadjustment potentiometer 1/2 turn counter‐clockwise to decrease thelevel sensor's sensitivity. Wait 10 minutes and check the adhesive again.If the adhesive level is still too low, repeat this process until the adhesivelevel is satisfactory. When finished, re‐install the plug over the calibrationpot to discourage tampering.



Operation Once enabled, the fill system immediately begins operation. Maintainadhesive level in the storage bin to maintain automatic operation.

NOTE: During warm‐up, the melter's ready-delay time may need to beincreased for the Fulfill to operate properly. The proper ready-delay timedepends on the tank size and shape, adhesive type, and applicationtemperature.

Time Settings � NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated

information.

See Figure 17. There are three timers found on the refill board located insidethe control box:

� Fault (overfill timer)—This timer is used to limit the amount of filling time

in case of level sensor failure. It is only for overflow protection. The faultlimit time is preset from the factory at 60 seconds, but can be adjustedfrom 5 to 115�seconds. The factory sets the potentiometer at the 12o'clock position, which is sufficient for the majority of applications. Forreference, the 9�o'clock position is 22 seconds and the 3 o'clock positionis 98 seconds.

� Delay—This timer is used to set the number of seconds that should

elapse between the time the level sensor calls for more adhesive and thetime the fill system activates. The delay time prevents the system fromfrequently turning on and off. The delay time is preset from the factory at60 seconds, but can be adjusted from 0 to 119�seconds. The factory setsthe potentiometer at the 12 o'clock position, which is sufficient for themajority of applications. For reference, the 9�o'clock position is 20seconds and the 3 o'clock position is 100�seconds.

� Air—This timer is used only with the optional storage bin vibrator kit.

When installed, the vibrator will actuate for up to 20 seconds before thefill system activates and will stay on until the level sensor is satisfied. Theair timer range is 0 to 20 seconds.



Figure 17 PCA timer settings (located inside the control box)

Use a flat head screwdriver to turn the timers clockwise to increase the timesettings, counterclockwise to decrease the timer settings.



Monitoring Refill Operation See Figure 18.

Under normal conditions, the operator need not monitor or intervene in theoperation of the fill system.

However, if the fill system is unable to satisfy the tank sensor in the time limitset for the Fill Time, the refill alarm LED will illuminate. Refer toTroubleshooting for a list of possible fault causes and solutions.

1 2 3

4

Figure 18 Fill system controls and indicators

1. Enable On/Off2. Filling activated symbol and blue LED

3. Fault symbol and red LED4. Clear fault

Maintenance Inspect the system daily to ensure that hose fittings are secure and that theunit is free from dirt and debris. Inspect the filter sock weekly to ensure thatit's not clogged; replace as needed.



Troubleshooting � NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated

information.

Problem Possible Cause Corrective Action

1. System overfilled Solenoid stuck open Clean or replace.

Sensor ground wire not connected Connect.

Refill board not working Replace if defective. See Refill PCATroubleshooting Instructions shownlater in the Troubleshooting section.

Sensor not calibrated properly Calibrate the sensor. Refer to LevelSensor Adjustment and Calibrationprovided earlier.

2. System underfilled No adhesive Add adhesive.

No power Ensure that power is available to thesystem.

Adhesive bridging Dislodge adhesive. Add optionalvibrator kit if problem persists.

Clogged wand/hose/lid Inspect the parts for improperconnections, clogs or kinks. Replaceas needed.

Clogged filter sock Replace if needed.

No/low air pressure Verify that sufficient air pressure andflowrate is supplied to the Fulfill unitfrom your factory. Static pressureshould be 65 psi min.; operatingpressure should be 45 psi min.Replace the regulator if defective.

No power to the level sensor Verify that power is being supplied tothe level sensor (LED not lit = nopower) and that the power cord isinstalled properly.

Deflector bent Repair or replace.

No power to fill board Verify power to the control box and atthe board. Replace if needed.

Solenoid failure Verify the connections to thesolenoid. Replace if defective.

Bad fill board Replace. See Refill PCATroubleshooting Instructions shownlater in the Troubleshooting section.

Overfill timer too short Adjust timer.

Sensor not calibrated properly Calibrate the sensor. Refer to LevelSensor Adjustment and Calibrationprovided earlier.

3. Frequent overfillalarms with no cause

Timers not properly set Adjust the timer settings. See TimeSettings provided earlier.



Refill PCA Troubleshooting Diagnostic Instructions � NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated

information.

Perform the following steps, in order, to either isolate the problem within thePCA board or to eliminate the PCA board as a cause. These tests shouldonly be performed by personnel qualified to work on high voltage circuits.

1. Verify input power is reaching the PCA. Measure line voltage across theinput side (side of the fuse closest to the input connectors J1 and J2) offuses F1 and F2. The input voltage should be between 100-240 VAC. Ifinput voltage not present, correct input power.

2. Verify that the 24 VDC power supply on the Refill PCA board is workingby measuring the voltage between XT1 pin ”24V” and XT1 pin ”COM”. Itshould be 24 VDC (+/- 5%). If not 24 VDC, verify fuses are not blown. Iffuses have been blown, replace fuses. If fuses blow again, replace RefillPCA. If fuses OK but 24 VDC not present, replace Refill PCA.

3. Check to make sure the DIP switch settings have not been changed.SW1 DIP switch settings: M1 should be OFF; M2 should be ON.

4. Make sure the timer potentiometers are set as expected:

� FAULT potentiometer adjustment range: 5 to 115 seconds (60

seconds at 12:00 position),

� DELAY potentiometer adjustment range: 1 to 119 seconds (60

seconds at 12:00 position),

� AIR (optional pre‐vibrator) potentiometer adjustment range: 0 to 20

seconds (10 seconds at 12:00 position).

5. Make sure the Refill PCA is enabled by verifying that the ”ENA” LEDclose to the membrane panel connector (X1) is illuminated. If not, pressthe ENABLE button on the membrane panel to enable the Refill PCA. Ifthe ”ENA” LED does not turn on with the membrane panel, the membranepanel or PCA may be bad. With a piece of wire, briefly touch X1 pin 1 toX1 pin 2 (the membrane tail will need to be unplugged to perform thistest). If the ”ENA” LED illuminates after this test, replace the membranepanel. If not, then replace the Refill PCA.

6. To ensure that the level sensor signal is getting to the Refill PCA with thelevel sensor calling for adhesive, verify that there is 24 VDC (+/- 5%)between XT1 pin ”SIG” and XT1 pin ”COM”. If not, repair the level sensorcable, recalibrate level sensor, or replace level sensor.

7. To ensure that the Refill PCA fill output is working correctly with the levelsensor calling for adhesive and after waiting the DELAY time duration,verify that 24 VDC (+/-5%) is applied to the fill control output (XT2 pin”FILL” measured to any ”COM” pin). Verify with the level sensor is NOTcalling for adhesive that the fill control output is 0 to 0.5V.

If the problem has not be isolated to this point, replace the Refill PCA and/ormembrane panel.



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Parts This section provides information about parts that are associated with the fillsystem. Refer to the melter manual for information about all other meltercomponents.

Using the Illustrated Parts Lists To order parts, call the Nordson Customer Service Center or your localNordson representative. Use these five-column parts lists, and theaccompanying illustrations, to describe and locate parts correctly. Thefollowing chart provides guidance for reading the parts lists.

The number in the Item column corresponds to the circled item number in theparts list illustration. A dash in this column indicates that the item is anassembly.

The number in the Part column is the Nordson part number you canuse to order the part. A series of dashes indicates that the part isnot saleable. In this case, you must order either the assembly inwhich the part is used or a service kit that includes the part.

The Description column describes the part and sometimesincludes dimensions or specifications.

The Note column contains letters that refer to notes at thebottom of the parts list. These notes provide importantinformation about the part.

The Quantity column tells you how many of the part isused to manufacture the assembly shown in the partslist illustration. A dash or AR in this column indicatesthat the amount of the item required in the assembly isnot quantifiable.

Item Part Description Quantity Note— 0000000 Assembly A —1 000000 � Part of assembly A 2 A2 - - - - - - � � Part of item 1 13 0000000 � � � Part of item 2 AR

NS 000000 � � � � Part of item 3 2NOTE A: Important information about item 1

AR: As Required

NS: Not Shown



DuraBlue/VersaBlue 25L and 50L Retrofit Kit Assemblies

Item Part Description Quantity Note------- 1104171 Kit, Fulfill retrofit, DuraBlue/VersaBlue 25------- 1104673 Kit, Fulfill retrofit, DuraBlue/VersaBlue 50

1 1103806 � Lid assembly, DuraBlue 25, Fulfill retrofit 1 A2 1103802 � Plate, level probe, DuraBlue 25 Fulfill 13 1099250 � Holder assy, level probe 1 B4 1103805 � Clamp assy w/ actuator, DB 25 Fulfill retrofit 1 C5 1103804 � Clamp assy, Fulfill retro 16 1103796 � Bracket, lid, Fulfill retro, DuraBlue 25 17 1104172 � Kit, ship with 1 D8 1097984 � Kit, container, wand, hose assy, Fulfill 1 E9 1101362 � Kit, ship with, misc. parts 1— 1079193 � � Adapter, 1/4 BSPP female X 1/4 NPT male 1— 939995 � � Fuse, time−lag, 2A, 5 x 20 mm 2— 1088282 � � Filter, sock, 200 micron, Fulfill 1

NOTE A: Further listing provided in Lid Assembly table provided later in the Parts section.

B: Further listing provided in Level Holder Assembly table provided later in the Parts section

C: Further listing provided in Clamp Assembly table provided later in the Parts section

D: Further listing provided in Ship With Fastener Kit table provided later in the Parts section.

E: Further listing provided in Container/Wand Kit table provided later in the Parts section.

Ship With Fastener Kit

Part Description Quantity1104172 Kit, ship with, Versa/Dura 25 Fulfill982165 � Scr, btn, skt, cap, M6 X 16, zn 8345644 � Nut, lock, nylon, M6, stl, zn 4983034 � Washer, flt, M, oversized, 6, stl, zn 4982506 � Scr, flt, skt, M4 x 10, bl 2345642 � Nut, lock, nylon, M4, stl, zn 21023299 � Lug, 45, single, M5 .032 1939110 � Cabletie, 3.9 in, 185F/85C, nylon, natural 4

1052143 � Nut, hex w/ ext tooth washer, M5, stl, zn 2



DuraBlue/VersaBlue 25L Lid Assembly Parts See Figures 19 and 20.

Item Part Description Quantity1103806 Lid assy, DuraBlue/VersaBlue 25L Fulfill retrofit —

1 1095342 � Enclosure assy, filter, lid, Fulfill 12 1097016 � Tube, inlet, Fulfill 13 982349 � Scr, skt, M4 x 16, zn 34 983163 � Washer, flt, M, oversized, M4, zn 35 1088282 � Filter sock, 200 micron 16 982374 � Scr, skt, M5X40, bl 47 1096978 � Collar, lid, Fulfill 18 1097866 � Retainer, filter housing 19 1097018 � Tube, exhaust 110 982176 � Scr, skt, M6 x 16, bl 211 1050403 � Lid handle 112 1103801 � Lid, outer, Fulfill retrofit, Dura 25 113 1103807 � Switch assy, lid, Fulfill retrofit 114 1103795 � Insulation, lid, Fulfill retro, Dura 25 115 1103803 � Spacer, 13 mm OD x 15 mm ID x 7 mm LG 416 1103799 � Retainer, insulation, Fulfill retro 117 983418 � Washer, flt, M, oversized, M5, stl, zn 418 1052143 � Nut, hex, w/ext tooth washer, M5, stl, zn 419 1103800 � Insulation, inner lid, Fulfill retro, Dura 25 120 1097663 � Spacer, lid, Fulfill retrofit 121 1103798 � Lid, inner, Fulfill retrofit 122 816380 � Scr, skt, M5 x .08 x 80mm 1223 1095129 � Deflector, inlet, lid, fill system 124 1099398 � Baffle 125 1094058 � Grommet, .312 ID x .625 OD, rubber 426 982680 � Scr, hex, washhd, tf, M5 x 12, blk 427 271221 � Lug, 45, double, .250 128 1101305 � Clip, cable tie, M5. mounting, aluminum 329 939110 � Cabletie, 3.9 in, 185F/85C, nylon, natural 630 1104273 � Harness, ground, lid 131 1104650 � Kit, srvc., 300 mm lg. lev. sensor, Fulfill 132 982059 � Scr, skt, M4 x 8, bl 233 1104883 � Ctl box, Fulfill retrofit 134 1046998 � Connector, strain relief, PG7, nylon 135 1103793 � Bracket, control box, Fulfill retrofit 136 1103794 � Bracket, pneumatic & level controls 137 1095728 � Control unit, pneumatic, Fulfill 138 1098913 � Harness, solenoid, Fulfill retrofit 1



Figure 19 25L Lid assembly parts



DuraBlue/VersaBlue 25L Lid Assembly Parts (contd)







DuraBlue/VersaBlue 50L Lid Assembly Parts See Figures 21 and 22.

Item Part Description Quantity1104671 Lid assy, DuraBlue/VersaBlue 50 Fulfill retrofit —

1 1050403 � Handle, lid 12 982176 � Scr, skt, M6X16, bl 23 1105713 � Switch assembly, lid, D50, Fulfill retrofit 14 1094058 � Grommet, . 312 ID x .625 OD, rubber 45 1097018 � Tube, exhaust, Fulfull 16 1097866 � Retainer, filter housing 47 1095342 � Enclosure assy, filter, lid, Fulfill 18 1088282 � Filter, sock, 200 micron 19 1097016 � Tube, inlet 110 982349 � Scr, skt, M4X16, zn 311 983163 � Washer, flt, M, oversized, M4, zn 312 982374 � Scr, skt, M5X40, bl 413 1096978 � Collar, lid, Fulfill 114 816380 � Scr, skt, M5 X 0.8 X 8MM 1215 1095129 � Deflector, inlet, lid, fill system 116 1104664 � Lid, inner, Fulfill retro, DuraBlue 50 117 1104666 � Insulation, inner lid, Fulfill retro, DuraBlue 50 118 1052143 � Nut, hex, w/ext tooth washer, M5, stl, zn 419 983418 � Washer, flt, M, oversized, 5, stl, z 420 1104665 � Retainer, insulation, Fulfill retro, DuraBlue 50 121 1103803 � Spacer,13mm OD X 5mm ID X 7mm LG 422 1104662 � Insulation, lid, Fulfill retro, DuraBlue 50 123 1104667 � Lid, outer, Fulfill retro, DuraBlue 50 124 982680 � Scr, hex, washhd, tf, M5X12, blk 425 1097663 � Spacer, lid, Fulfull retrofit 126 1099398 � Baffle, Fulfill retrofit 127 982059 � Scr, skt, M4X8, bl 228 1104650 � Kit, srvc., 300 mm lg. lev. sensor, Fulfill 129 1103794 � Bracket, pneumatic & level controls 130 271221 � Lug, 45, double, .250, .438 131 939110 � Cabletie, 3.9 in,185f/85c, nylon, natural 632 1101305 � Clip, cabletie, M5 mounting, aluminum 433 1104880 � Wire, gnd 2, Fulfill retro 134 1046998 � Connector, strain−relief, PG7,nylon 135 1104883 � Cntrl. box assy, Fulfill retrofit 136 1103793 � Bracket, control box, Fulfill retrofit 137 1095728 � Control unit, pneumatic, Fulfill 138 1098913 � Harness, solenoid, Fulfill retrofit 1






DuraBlue/VersaBlue 50L Lid Assembly Parts (contd)




Lid Switch Assembly for 25L Melters See Figure 23.

Item Part Description Quantity— 1103807 Switch assembly, lid, Fulfill Retrofit —1 1103797 � Bracket, lid switch 12 1104086 � Switch assembly 13 225337 � Terminal block, 380V 14 1054073 � Scr, skt, hd, M3x20 mm 15 1104517 � Harness, lid switch 16 1036625 � Machscrm, pan, rec, M3x8 2

Figure 23 Lid switch assembly



Lid Switch Assembly for 50L Melters See Figure 24.

Item Part Description Quantity— 1105713 Switch assembly, lid, Fulfill Retrofit —1 1105712 � Bracket, lid switch 12 1104086 � Switch assembly 13 225337 � Terminal block, 380V 14 1054073 � Scr, skt, hd, M3x20 mm 15 1104517 � Harness, lid switch 16 1036625 � Machscrm, pan, rec, M3x8 2

Figure 24 Lid switch assembly



25L Clamp Assembly With Actuator See Figure 25.

Item Part Description Quantity— 1103805 Clamp assy w/ actuator, Fulfill retrofit1 1103792 � Body, clamp, Fulfill retrofit 12 982514 � Scr, set, cup, M6X12, bl 23 1093724 � Actuator,switch,magnetic 14 1036625 � Mach scrm, pan, rec, M3X8, sems 2

Figure 25 Clamp assembly



50L Clamp Assembly With Actuator See Figure 26.

Item Part Description Quantity— 1104669 Clamp assy w/ actuator, Fulfill retrofit1 1103792 � Body, clamp, Fulfill retrofit 12 982514 � Scr, set, cup, M6X12, bl 23 1093724 � Actuator,switch,magnetic 14 1036625 � Mach scrm, pan, rec, M3X8, sems 2

Figure 26 Clamp assembly



Level Probe Holder Assembly See Figure 27.

Item Part Description Quantity— 1099250 Holder assy, level probe1 1099251 � Holder, level probe, 16mm 12 1099252 � Nut, holder, level probe, 16mm 13 941144 � O ring,Viton, .625 X .813 X .094 1

Figure 27 Level probe holder



Pneumatic Control Assembly See Figure 28.

Item Part Description Quantity Note— 1095728 Control unit, pneumatic Fulfill −−−−−−1 1093650 � Valve, solenoid, 3−way, 24V, 1/4 NPT 12 233785 � Elbow, male, 1/4 NPT 13 1096668 � Regulator/filter, 40 mic, 1/4 NPT, 65 psig 14 1058059 � Muffler polyethylene 1/4 NPT, Saturn 15 972125 � Conn,male,elbow,10mm t X 1/4UNI 16 982026 � Scr, skt, M4 x 25, bl 1

Figure 28 Pneumatic control assy.



Control Box Assembly See Figure 29.

Item Part Description Quantity Note— 1104883 Ctl.box assy,Fulfill retrofit —1 1098483 � Domeplug,.500”D,.250”pnl.thk.,nylon, blac 22 - - - - - - � Membrane panel,Fulfill retrofit kit 1 A3 - - - - - - � PCA, refill controller 1 B4 1098484 � Domeplug,.750”D,.250”pnl.thk.,nylon, blac 15 1046998 � Connector,strain-relief,pg7,nylon 26 933607 � Connector,strain relief,pg-11 1

NOTE A: To replace this item, order kit part 1099525.

B: To replace this item, order kit part 1096221.

4

15

3

26

Figure 29 Control box assembly parts



Container/Wand Kit

Part Description1097984 Kit, container, wand1097983 � Container7408012 � Suction wand1095962 � Transfer hose1095965 � Tubing, 10 mm OD x 8 mm ID, nylon, 15 ft1095983 � Cable tie231362 � Clamp, hose, worm dr, 1.06−2 in., ss

Service Kits Part Description

1099525 Kit, membrane panel

1104650 Kit, srvc., 300mm lg. lev. sensor, Fulfill

1096221 Kit, service, PCA

1082942 Kit, service, sock filter, 5 pc

Accessories Part Description

1098962 Kit, vibrator, adhesive container

1099057 Kit, light tower

Service Parts Part Description

1096668 Regulator/filter, 40 mic, 1/4 NPT, 65 psig

1093639 Regulator/filter, 40 mic, 1/4 NPT, 5-100 psig

1093650 Valve, solenoid, 3-way, 24V, 1/4 NPT

1097983 Container assembly, 120L

7408012 Suction wand

7408022 Vibrator, Suction Wand

1095962 Hose, transfer, 15 ft

1095965 Tubing, 10mm X 8mm, nylon, 15 ft

1095983 Cable tie, 14.5 ,nylon 6.6, 4.0 bundle

231362 Clamp, hose, worm dr, 1.06−2 in., ss

939955 Fuse, time−lag, 2A, 5X20 mm, ceramic

1099544 Gasket, container

1104086 Switch assembly, magnetic

1093724 Actuator, switch, magnetic



Specifications Parameter Specification

Adhesive Forms

Maximum size

Pellets, pastilles, mini-slats

� Pastilles: 12 mm (0.472 in.) diameter

� Mini‐slats:

12 mm X 12 mm (0.472 in. X 0.472 in.) in length

Input voltage 100−240/1 VAC, 1 A

Power cord Customer supplied, 14−18 AWG

Adhesive Transfer Maximum Rate 227 kg (500 lb)/hour (dependent on adhesive type)

Transfer Hose Length 4 m (13 ft)

Operating Air Minimum 4.5 bar (0.45 MPa or 65 psi)Maximum 8.6 bar (0.86 MPa or 125 psi)

Total Air Consumption 679 Liters/min (24 SCFM) when feeding

Conditioning Dry, non−lubricated

Inlet Air Connection 1/4 in. NPT female1/4 BSPP femaleG 1/4 female

Pump Type Venturi

Noise Emission 76 dBA

Suction Lance Dimensions (L) 615 mm x max (W) 105 mm(24.21 in. x max 4.14 in.)

Storage Bin Capacity 60 Kg (132 lb)

Enclosure rating IP54



Wiring Diagram



RetroFit Refill System with Nordson Level Sensor A-1


Appendix A

RetroFit Refill System with Nordson LevelSensor

WARNING! Allow only personnel with appropriate training and experience tooperate or service the equipment. The use of untrained or inexperiencedpersonnel to operate or service the equipment can result in injury, includingdeath, to themselves and others, and damage to the equipment.

Sensor Features

The Nordson level sensor features include a wide sensing area, simplifiedmechanical mounting, push button calibration, RTD temperaturecompensation, new diagnostics to help identify sensor problems and aseparate low level output.

Wide Sensing Area

The Nordson level sensor has a wide sensing range that is the nearly equalto the length of the sensor rod. The fill control point can be adjustedelectronically without the need to mechanically move the sensor.

Simplified Mechanical Mounting

The Nordson level sensor simply drops into the tank with no heightadjustments required.

RetroFit Refill System with Nordson Level SensorA-2


Push Button Calibration

The Nordson level sensor uses two push buttons to set levels as opposed tothe previous level sensor’s potentiometer.

Two buttons on the Refill board provide two types of calibration. Informationon calibration can be found later in this section.

The level sensor uses the calibration points to control the level of adhesive inthe tank. The system determines the appropriate fill level based on thecalibration information. When the tank is less than this point, the fill systemturns on. When the tank level is higher than this point, the fill system turnsoff.

RTD Temperature Compensation

Most capacitive sensor readings will vary with temperature. To minimizesensor reading inaccuracies due to temperature effects, the Nordson levelsensor incorporates a RTD to accurately measure the probe temperature andto compensate for changes in probe temperature.

Sensor Diagnostics

The Nordson level sensor offers several diagnostic functions not present inthe previous Fulfill level sensor. These new diagnostic functions are reportedwith LED flash codes. The flash codes are displayed on the membranepanel.



Unit Features

Figure A‐1 shows the Retrofit system and its components.

Level sensor

Fill Enable Button Fill Active LED

Fault LED

Reset Fault Button

Siren

Fill Enabled LED

Air filter/regulator

Fill Control Solenoid

Figure A‐1 Control box assembly and bracket



Unit Features(contd)

The picture shows the major components of the RetroFit control box.

Figure A‐2 Control box

Delay Timer

The delay timer determines how long the Refill board waits when the sensorcalls for adhesive before the vacuum system is activated. The delay timerpotentiometer is adjustable from 1 to 60 seconds.

Overfill Fault Timer

The overfill fault timer determines how long the vacuum system is operatedwhile trying to fill the unit. If the level sensor is not satisfied before the overfillfault timer expires, an overfill fault is generated. The overfill fault timerpotentiometer is adjustable from 5 to 300 seconds.

Siren

Refill PCA

24VDC power supply



Status Relay Contact Output

A formC electromechanical relay contact output is available for to monitorthe fill system status. This relay provides a common (COM), normally closed(NC), and normally open (NO) potential free contact. These contacts arelabeled COM, NC, and NO on the PCB and are located at terminal blockTB3.

If the fill system is working properly (powered, fill enabled, and no alarmspresent) the COM contact will be connected to the NC contact anddisconnected from the NO contact. Any other system state will deenergizethe relay and change the output state.

The relay contacts are rated for 30 VDC maximum at 1 Amp maximum.

If a 24 VDC signal is desired instead of a potential free contact, connect 24VDC to the COM contact and then use the NC and NO contacts. Use the NCcontact for a signal that supplies 24 VDC when the fill system is workingnormally and the NO contact for a signal that supplies 24 VDC when aproblem with the fill system exists. See Figure A‐3.

TB3

Figure A‐3 Photo of TB3:



Configuration Switch

The configuration switches are used to set various system modes. Refer tothe following table for the configuration switch settings on your unit.

Melter Configuration Switch Settings

Switch 1 Switch 2 Switch 3 Switch 4

ProBlue 4 Integrated INTEGR INT TcA 150

ProBlue 7 Integrated INTEGR INT TcA 150

ProBlue 10 Integrated INTEGR INT TcB 150

ProBlue 4 Retrofit RETRO INT TcA 150

ProBlue 7 Retrofit RETRO INT TcA 150

ProBlue 10 Retrofit RETRO INT TcB 150

ProBlue 15, 30/50 RETRO INT TcB 150

Mesa 4 RETRO INT TcA 150

Mesa 6 RETRO INT TcA 150

Mesa 9 RETRO INT TcB 150

Mesa 14 RETRO INT TcB 150

Series 3100 RETRO INT TcA 150

Series 3400 RETRO INT TcA 150

Series 3500 RETRO INT TcB 150

Series 3700 RETRO INT TcB 150

Series 3860/3960 RETRO INT TcB 300

DuraBlue 10 RETRO INT TcB 150

DuraBlue 16 RETRO INT TcB 150

DuraBlue/VersaBlue 25 RETRO INT TcB 300



NOTE: Each board setting is configured to the specific melter at the factory.

NOTE: Switch 2 is used to select an external (EXT) external amplifier sensorsuch as the level sensor used on previous Fulfill units.



Figure A‐4 shows the features of the Refill PCA.

Unit Low LED

Configuration switches

Power LED

Fill low

LEDStatus LED

Full calibration button

Empty calibration button

Delay timer

potentiometer

Overfill fault

potentiometer

Fault LED Siren LED

Vibrator LED

Fill enabled LED

Fill active LED

Figure A‐4 PCA board (ProBlue 4 Fulfill integrated settings shown)



Sensor Calibration

The following sections will describe the various methods available tocalibrate the level sensor. For all calibrations, the button(s) must be held for5 seconds in order to be recognized. For best results, the unit should be atapplication temperature when calibration is performed.

The sensor also detects if the calibration is done out of sequence. Forexample, if a full calibration is attempted before an empty calibration wasperformed, then the calibration is ignored and the STATUS and LOW LEDson the circuit board will turn red for 5 seconds after attempting the calibrationindicating a bad calibration attempt.

The unit can also report the last calibration successfully performed. If theENABLE and RESET buttons on the front panel are held simultaneously, thepanel LEDs will illuminate to indicate the last calibration. An illuminatedgreen Enable LED indicates that a basic (empty level) calibration wasperformed and an illuminated blue FILLING LED indicates that a precision(full level) calibration was performed.

Two levels are stored in nonvolatile memory, the calibrated empty point andthe calibrated full point. The level at which the unit fills to is computed basedon the empty and full calibration points

Calibration Summary

The table below summarizes the different types of calibration available. Thedifferent calibrations should be performed in the specific order shown below.

Order toPerform

TypeCalibration

ButtonsUsed

DataPoints

Affected

Notes

1 BasicCalibration

(EmptyLevel)

BlueButton(SW3)

Emptyand Full

Full point is set to a predetermined level aboveempty that is suitable for a wide range ofadhesives. This is the only calibration that mostunits will require.

2(optional)

PrecisionCalibration

(Full Level)

WhiteButton(SW2)

Full only The empty calibration point is not changed, onlythe full. Use this calibration (after an emptycalibration) to provide more precise levelcontrol than an empty calibration alone



Basic (Empty Level) Calibration

CAUTION! Do not attempt empty calibration with a full melter. Doing so willresult in an overfill condition.

1. Allow tank to reach application temperature.

2. Adhesive level should be at or below the bottom of the probe.

3. Close lid.

4. Press SW3 (blue button) until all LEDs stop changing color(approximately 5 seconds).

Precision (Full Level) Calibration1. Allow tank to reach application temperature.

2. Hand fill the adhesive level so that the pellets are at the top of the probe.

3. Close lid.

4. Within 30 seconds, press SW2 (white button) until all LEDs stopchanging color (approximately 5 seconds).



Troubleshooting

Fault LED/Red Status LED

The diagnostic fault messages (red flashes) for the STATUS LED (DS3,located on Refill PCA) are listed below. These flash codes are alsoperformed on the FAULT LED located on the membrane panel.

Number ofRed Flashes

(DS3) andPanel Fault

LED

Diagnostic Action Required

1 Overfill fault. Unit did not fill in the allowedtime.

Check adhesive level in bin. Checkhose lines for blockage. Increase overfilltimer value.

2 Blown Fuse. The fuse supplying 24V to theoutputs is blown.

Find and fix the source of the excessivecurrent draw and replace the fuse (2Amp max.)

3 Shorted Cable. There is a problem with thesensor cable.

If sensor was calibrated, replace sensor. If sensor needed calibration, calibratesensor. If persists, replace sensor.

4 Communications failure. There is a problemwith the communications to the CPU board(integrated unit only)

Check cable between the Refill boardand the CPU board. If this is a RetroFitunit, check DIP switch settings on Refillboard.

5 RTD shorted. The temperature compensationRTD is electrically shorted.

Replace sensor

6 Internal memory failure. Unit was not able tostore calibration settings.

Replace Refill board if fault persists



Fill Enable LED/Yellow Status LED/Yellow Light Tower

The table below lists the diagnostic warning (yellow flashes) messages forthe STATUS LED (DS3, located on Refill PCA). These flash codes are alsoshown on the FILL ENABLE LED located on the membrane panel.

Number ofYellow

Flashes(DS3) and

PanelEnable LED

Diagnostic Action Required

1 Pressure switch open (if used). Check air supply to pressure switch. If airsupply good, replace pressure switch. Check jumper if pressure switch notused.

2 Lid switch open (if used). Replace or realign lid switch, if used. Check jumper if not used.

3 RTD open. Unit will still function, but probetemperature compensation will be disabled.

Replace sensor

4 Sensor is disconnected. Reconnect or tighten sensor connector. If persists, recalibrate the sensor. If stillpersists, replace sensor.

5 Melter ready input open (if used) This is normal during melter warm up. Ifoccurs while melter is ready, checkconnections to input. If melter readysignal not used, check jumper.

6 Unstable sensor readings Check the sensor cable connections. Ifthe problem persists, replace the sensorand/or refill PCA.

7 Probe temperature is under 175 �F(80 �C)) and filling is prevented.

Allow probe to heat above 175 �F(80 �C)



Installation

Common Chassis Connection

CAUTION! Failure to install a wired connection as described below willcause the Fulfill unit to not function.

There must be a wired connection between the Retrofit box chassis and themelter chassis for stable operation. This connection is normally made fromthe Refill PCA ground tab to the quick connect tab on the Retrofit mountingbracket, but any terminal on the Refill PCA labeled “COM” can be used toconnect to the melter chassis.

Service Parts Part Description

1121799 Kit, service, power cable, MKIII PB FF Retrofit

1121800 Kit, service, power supply, Fulfill

1121803 Kit, service, Nordson sensor, 300 mm, Fulfill retrofit

1121804 Kit, service, PCA, MKIII Fulfill

1121406 Harness, Line in, Retrofit

1121491 Harness, 24 VDC, Retrofit

1121492 Harness, siren, Retrofit

1121493 Harness, low level

1121599 Harness, T.B. Plug, jumpered, Retrofit

1121794 Harness, AC, unit powered, Retrofit

1105320 Splitter, power supply, FM, sensor, 16 AWG

1121818 Control box assy, Fulfill Retrofit

1120695 Alarm, audible, panel mount, 24 VDC

1099525 Kit, membrane panel, Fulfill Retrofit

1121806 Kit, light tower



Retrofit Wiring Diagram




EC Declaration of Conformity

for Adhesive and Sealant Application Equipment conforming to European Council Directives

PRODUCTS:

AltaBlue� Melters, Models 15, 30, 50, 100

AltaBlue� TT Melters, Models A4, A10, A16

Cobalt� GR Series Bulk Material Unloaders

DuraBlue��Melters

FoamMelt� FM‐200 Melter

Fulfill� Retrofit Kit

Mesa� Melters

MiniPUR� Melters

ProBlue� Melters, Models P4, P7, P10, P15, P30 and P50

ProBlue� Fulfill�, Models P4F, P7F, P10F

PURBlue� Melters

Series 3000V Melters

SureFoam� Foam Dispensing System

APPLICABLE DIRECTIVES:

Machinery Directive: 2006/42/EC

Electromagnetic Compatibility Directive: 2004/108/EC

STANDARDS USED TO VERIFY COMPLIANCE:

EN ISO 12100 EN 60204‐1

EN ISO 13732‐1 EN 61000‐6‐2

EN 55011 (Class A, Group 2 for industrial environments. Use in

other environments may pose potential difficulty ensuring

electromagnetic compatibility due to conducted as well as

radiated disturbances.)

PRINCIPLES:

This product has been manufactured according to good engineering practice.

The product specified conforms to the directives and standards described above.

Technical File Contact:

Dieter Ziesmer

Nordson Engineering GmbH

Lilienthalstrasse 6

21337 Lueneburg

GERMANYDate: 14 December 2012

Peter Lambert, Senior Vice PresidentAdhesives Dispensing Systems

1105311A03

DOC074R4

Nordson Corporation � 28601 Clemens Road ��Westlake, Ohio

Model Number_________________________

Serial Number______________________________________

Documents

Fulfill Retrofit Kit DuraBlue/VersaBlue 25L and 50L Meltersemanuals.nordson.com/adhesives/English_Manuals/1121937.pdf · Fulfill Retrofit Kit − DuraBlue/VersaBlue 25L and 50L Melters