Installation

Installation 3-1
Section 3
Installation
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 damage to the equipment.
Quick-Start
If you have already installed the melter using the installation guide
(P/N 1024498) that is provided inside the shipping container, and you have
no questions concerning the installation, go to Setting Up the Melter later in
this section for information about how to prepare the melter to operate with
your manufacturing process.
Installing 400/480 Volt Melters

Refer to Appendix E for information about installing 400/480 volt ProBlue
adhesive melters. After completing the procedures described in Appendix E,
you will be referred back to this section to set up the melter.
Overview
ProBlue melters are factory-configured for each order and require only the
assembly and set up tasks described in this section. If your melter was
ordered as a complete system, the shipping container will also contain one
or more hot melt hoses and guns. ProBlue 400/480 volt melters include a
transformer assembly that is shipped separately from the melter.
The melter is shipped from the factory with an installation kit that contains
components that must be assembled onto the melter by the customer.
Some additional materials must also be supplied by the customer to
complete the installation.
If optional equipment was ordered with the melter, refer to the

documentation provided with the optional equipment for installation and
operating instructions.
2010 Nordson Corporation Part 1024496D04

3-2 Installation
Overview (contd)
The illustrations accompanying the procedures in this section depict the P4

melter. Unless otherwise noted, the instructions also apply to the P7 and
P10 melter.
Additional Information
This section presents installation procedures in their most commonly used
form. Procedural variations or special considerations are explained in the
additional information table that follows most procedures. Where applicable,
some table entries also contain cross-reference information. Additional
information tables are indicated by the symbol shown to the left.
Installation Tasks
The installation sequence is as follows:
1. Verify that the required environmental conditions and utilities exist.

2. Unpack and inspect the melter.
3. Mount the transformer/melter onto the parent machine or support
structure.
4. Configure the electrical service.
5. Connect a compressed air supply.
6. Connect hot melt hoses and guns.
7. Set up the melter to work with the manufacturing process.
8. (Optional) Install inputs and outputs.
9. Install optional equipment.
10. Connect a gun driver, pattern controller, or timer.
11. Flush the melter.
12. (Optional) Set up communications between the melter and a PC.
Experience of Installation Personnel

The instructions provided in this section are intended to be used by
personnel who have experience in the following subjects:
Hot melt application processes

Industrial power and control wiring
Industrial mechanical installation practices
Basic process control and instrumentation
Part 1024496D04 2010 Nordson Corporation

Installation 3-3
Installation Requirements
Before installing the melter, ensure that the desired installation location
provides the required clearances, environmental conditions, and utilities.
Clearances
Figure 3-1 illustrates the minimum clearances that are required between the
melter and surrounding objects. Table 3-1 describes each clearance.
NOTE: 400/480 volt melter clearances are provided in Appendix E.
Figure 3-1 Minimum installation clearances (Top and side views shown)
Table 3-1 Installation Clearances

Item Description Required Clearance
The distance from the outside edge of a 5/ -inch Nordson P4 = 370 mm (14.5 in.)
16
A hose to the front face of the melter when a short 90-degree P7 = 370 mm (14.5 in.)
hose fitting is used to connect the hose to the melter
P10 = 391 mm (15.4 in.)
The clearance required to open the pump enclosure door P4 = 243 mm (9.6 in.)
B P7 = 243 mm (9.6 in.)
P10 = 268 mm (10.55 in.)
The distance from the melter sub-base to the front edge of the P4 = 502 mm (20.0 in.)
C tank lid when the lid is at its highest point. P7 = 564 mm (22.2 in.)
P10 = 656 mm (26.0 in.)
The clearance required on the left side of the melter to open the P4 = 648 mm (25.5 in.)
D electrical enclosure door or remove a hose/gun module. P7 = 711 mm (28.0 in.)
P10 = 714 mm (28.1 in.)

3-4 Installation
Ventilation
See Figure 3-2. ProBlue melters are cooled by convection. Air is drawn in
through openings in the chassis of the melter and is exhausted out of the
ventilation slots at the top of the melter.
CAUTION! Do not block the air intake openings and ventilation slots.
Figure 3-2 Melter cooling
Electrical Power
Before installing the melter, ensure that the melter will not be overloaded
and that the plant’s electrical service is rated to handle the power required
by the melter and the hoses and guns that you plan to use.
Refer to Appendix A, Calculating Melter Power Requirements, for

information about how to calculate the maximum allowable hose lengths
and gun wattages that can be used in your manufacturing application.
WARNING! Risk of electrocution! Install a lockable power disconnect switch

between the electrical service and the melter. Failure to install or properly
use the disconnect switch when servicing the melter can result in personal
injury, including death.

Installation 3-5
Compressed Air
To achieve maximum hot melt output, the melter must be connected to an
air supply that is capable of providing a maximum of 6.2 Bar (90 psi) of dry,
nonlubricated air. The actual pressure required for the melter to support
your manufacturing process will depend on such factors as the type of hot
melt and gun you are using and the required dimensions of the hot melt
bead.
NOTE: The minimum operating air pressure is 0.7 bar (10 psi). Operating
the melter with the air pressure set to less than 0.7 bar (10 psi) may cause
the pump to function erratically.
Nordson recommends that an isolation valve be installed in the plant air

supply line just before the melter.
Other Considerations
Consider the following additional factors when evaluating where to install
the melter.
The maximum distance between the melter and each gun is dictated by
the power requirement of each hose. Refer to Appendix A, Calculating
Melter Power Requirements for information about how to determine the
maximum allowable length.
The operator must be able to safely reach the control panel and
accurately monitor the control panel indicators.
The operator must be able to safely observe the level of hot melt inside
the tank.
The melter must be installed so that it can be safely removed from its
sub-base.
The melter must be installed away from areas with strong drafts or
where sudden temperature changes occur.
The melter must be installed where it will be in conformance with the
ventilation requirements specified in the Material Safety Data Sheet for
the hot melt being used.
The melter should not be exposed to excessive vibration.
P4 and P7 melters provide an auxiliary hose port at the bottom of the
manifold. If the auxiliary hose port will be used, the parent machine or
other support structure must provide clearance under the melter to
connect the hose to the auxiliary hose port.

3-6 Installation
Unpacking the Melter

Before starting the installation, remove the melter from the pallet, locate the
installation kit, and inspect the melter for damaged and missing parts.
Report any problems to your Nordson representative.
Contents of the Installation Kit

The installation kit provided with the melter contains the components shown
in Figure 3-3. The quantity and type of hose fittings provided in the kit
depends upon the melter’s model number and configuration.
NOTE: 400/480 volt transformers are shipped with a separate installation

kit. Refer to Appendix E for information about the contents of the
transformer installation kit.
The installation kit also contains a package of safety label overlays that are
printed in a variety of languages. If required by local regulations, the
appropriate language overlay should be applied over the English version of
the same label. Refer to Section 1, Safety Labels and Tags, for the location
of each safety label.
NOTE: P10 melters also include a manifold guard kit P/N 1031871.
Customer-Supplied Materials
The following additional materials are also required to install the melter.
A power cable. If the cable clamp that is provided in the installation

kit is not used, rigid or flexible electrical conduit will be required.
Four 8 mm (5/16 in.) machine bolts with locking hardware
A plant air supply with an in-line isolation valve

Installation 3-7
Figure 3-3 Installation kit components

1. Voltage plug (2) 6. NPTF-to-BSPP adapter
2. Voltage plug with neutral (2) 7. Air filter
3. Input and Output connector (2) 8. 45-degree hose fitting
4. Cable clamp 9. 90-degree hose fitting
5. Electrical connector 10. 6-hose manifold guard (P10 only)

3-8 Installation
Mounting the Melter

ProBlue melters use a unique mounting sub-base that allows the melter to
be easily mounted onto and removed from the parent machine or support
structure, without the need to unbolt the melter.
Before mounting the melter, ensure that the parent machine or support
structure is level with respect to the floor, provides an even mounting
surface, is free of excessive vibration, and that it is capable of supporting
the combined weight of the melter, a full tank of hot melt, and the hoses and
guns.
Melter sub-base
Refer to Section 8, Technical Data, for the dimensions of the sub-base and
the weight of the melter. Refer to the technical data provided by the hot melt
manufacturer for information about the volumetric weight of the hot melt.
To mount the melter

See Figure 3-4.
1. Remove the PG-21 conduit knockout from the sub-base. See Figure 8-4
for the location of the conduit knockout.
2. Lay out the sub-base bolt pattern on the parent machine or support
structure and then drill/tap holes for four 8 mm (5/16 in.) mounting bolts
(customer-supplied).
NOTE: The mounting sub-base has the same bolt-mounting pattern as
Nordson’s 3100V and 3400V melters.
3. Bolt the sub-base to the parent machine using four 8-mm (5/16 in.)
machine bolts with locking hardware.
WARNING! Risk of electrical shock or short circuit. Use the cable clamp that
is provided or use electrical conduit to protect the power cable from the
sharp edge of the conduit knockout.
4. Install the cable clamp in the PG-21 conduit knockout.

5. Route the power cable between the power disconnect switch and the
melter and through the cable clamp. Tighten the cable clamp.
CAUTION! Before setting the melter down onto the sub-base, ensure that
both locking srews on the front chassis of the melter are turned fully
counterclockwise until they stop.

Installation 3-9
6. Carefully lower the melter onto the sub-base so that the back of the
melter is approximately 1/2 inch in front of the rear locking tabs.
7. Slide the melter to the rear of the sub-base until the rear locking tabs
enter the slots in the back of the melter.
8. Lock the melter to the sub-base by turning each of the locking screws,
which are located in the front of the melter, clockwise until they stop.
Figure 3-4 Mounting the sub-base and the melter

3-10 Installation
Configuring the Electrical Service

ProBlue melters are shipped from the factory without an attached power
cable and without an electrical service type specified. To configure the
melter to function in your facility, you must connect a power cable and a
Nordson-supplied voltage plug to the melter.
To connect a power cable to the melter

1. Select a power cable rated for the maximum amperage required by the
melter. Ensure that the power cable meets applicable electrical codes
and standards.
The maximum power draw for each ProBlue shipping configuration,
operating at 230 volt, in both 1-phase and 3-phase are listed in
Table 3-2. The values presented in Table 3-2 assume that each hose
gun module is being used at its maximum capacity of 2000 watts.
NOTE: Contact your Nordson representative for assistance in
calculating the melter’s power draw for operating voltages other than
230 volts or for assistance in calculating the exact power draw for
specific hoses and guns that are manufactured by Nordson Corporation.
Table 3-2 Melter Power Requirement

Number of 1-Phase Power
Melter
Hose/Guns Draw (Amps) 3-Phase Power
Without Neutral With Neutral
P4 2 17 15 9
4 26 23 17
P7 2 18 16 10
4 27 24 17
P10 2 18 16 10
4 27 24 17
6 36 31 18
WARNING! Risk of electrocution! Install a lockable power disconnect switch

between the electrical service and the melter. Failure to install or properly
use the disconnect switch when servicing the melter can result in personal
injury, including death.
2. Open the electrical enclosure door.

3. Route the power cable into the wire tray in the base of the electrical
enclosure.
NOTE: If the power cable cannot be routed through the conduit
knockout provided in the sub-base (Refer to Mounting the Melter earlier
in this section), route the cable through the optional knockout provided
on the left side of the chassis.
Opening the electrical enclosure

door

Installation 3-11
See Figure 3-5.
4. Connect each power cable lead to the appropriate terminal on the

electrical connector (P/N 1022993). Table 3-3 describes the terminal
connections for each type of electrical service.
5. Plug the electrical connector into receptacle TB1 on the main board.
6. Connect the ground lead from the power cable to the ground lug that is
Electrical connector located on the chassis. The lug is marked PE/G.
(P/N 1022993)
7. Connect the ground jumper that is connected to the ground lug, to the
ground post that is located on the sub-base.
TB1
EXAMPLE ONLY
PE / G (3/N/PE AC wiring shown)
Figure 3-5 Connecting the power cable, ground lead, and ground jumper

3-12 Installation
To connect a power cable to the melter (contd)
Table 3-3 Electrical Service Information

Use Electrical Connector
Terminals..
Use Voltage Plug..
L1 L2 L3 N
If the Electrical Service Type is..
• • • •
400/230 VAC 3-phase 227569
3/N/PE AC
(4-wire service, including a
400/230V Red/Yellow
neutral) See note.
• •
230 VAC 1-phase 232617
1/N/PE AC
(2-wire service, including a
200–240V Blue/Yellow
neutral) See note.
• • •
200 to 240 VAC 3-phase 227568
3/PE AC
(3-wire service without a
200–240V Red/Green
neutral)
• •
200 to 240 VAC 1-phase 227567
1/PE AC
(2-wire service without a
200–240V Blue/Green
neutral)
NOTE: The 400/230 VAC 3-phase service (4-wire service including neutral) includes the 415/240 VAC 3-phase
(4-wire service, including neutral) voltage. The 230 VAC 1-phase service (2-wire service, including a neutral)
includes the 240 VAC 1-phase (2-wire service, including a neutral) voltage.
To connect a voltage plug to the melter

1. Refer to Table 3-3 to determine the part number of the
voltage plug that matches the required electrical service.
NOTE: Each voltage plug is color-coded and is labeled with its part
number and service type.
See Figure 3-6.
2. Insert the correct voltage plug into receptacle J1 on the main board.
Ensure that the plug snaps into place. If the plug contains a neutral lead,
connect the neutral lead to receptacle J2 on the main board.
3. When the electrical service is completely installed and inspected in
Voltage plugs with and without the accordance with local electrical codes and standards, close the electrical
neutral lead
enclosure door and switch the local power disconnect switch on.
If the electrical service was configured correctly, the melter control panel
will display dashes.

Installation 3-13
Figure 3-6 Connecting a voltage plug

3-14 Installation
Connecting a Compressed Air Supply

CAUTION! Do not force the air pressure adjustment screw beyond its
normal range of adjustment. Forcing the adjustment screw beyond its
normal range of adjustment will damage the pneumatic assembly.
To connect an air supply

1. Use a 5 mm hex wrench to turn the pressure adjustment screw
counterclockwise until it stops (off).
See Figure 3-7.
2. Insert the male fitting located on the outlet side of the air filter
(P/N 1023267) into the air inlet port on the back of the melter.
CAUTION! Rigidly support the plant air supply before connecting it to the air
Pressure regulator and adjustment filter.
screw
3. Connect a regulated plant air supply to the inlet of the air filter. If
required, use the 1/4 NPTF-to-G1/4 BSPP male adapter fitting
(P/N 1034145) that is provided in the installation kit.
NOTE: The air filter inlet is threaded to receive a male G1/4 BSPP
fitting.
4. Open the plant air supply to the melter.

5. Turn the pressure regulator adjustment clockwise to set the melter’s
operating air pressure (pressure supplied to the pump) to
1.4 Bar (20 psi). The operating air pressure should be adjusted later to
meet the requirements of the manufacturing process.
NOTE: The minimum operating air pressure is 0.7 bar (10 psi). Operating
the melter with the air pressure set to less than 0.7 bar (10 psi) may cause
the pump to function erratically.

Installation 3-15
P/N 1034145
1/ NPTF G 1/4 BSPP

4
Figure 3-7 Connecting the air filter and the plant air supply line

3-16 Installation
Connecting Hoses and Guns

ProBlue melters use standard Nordson hoses and guns. The P4 and P7
melters support the connection of up to four hose/gun pairs. The P10 melter
supports the connection of up to six hose/gun pairs.
The hose/gun capacity of each melter is determined by the number of

hose/gun modules installed on the melter. Each hose/gun module supports
the connection of two hose/gun pairs. The hose/gun capacity of melters that
were ordered with less than their full hose/gun capacity can be increased by
b adding additional hose/gun modules. Unused hose/gun module positions
a are covered by blank modules.
Hose/gun module 1
a) Receptacle 1 b) Receptacle 2
WARNING! Risk of fire or equipment damage. Before connecting hoses and

guns to the melter, confirm that the power required by each hose/gun pair
and each hose/gun module, does not exceed the maximum wattages
specified in Appendix A, Table A-2, Maximum Allowable Wattages.
To connect hoses
See Figure 3-8.
1
Observe the following guidelines:
For information about choosing the correct Nordson hot melt hose for
your manufacturing process, refer to the latest edition of Nordson’s hot
melt dispensing equipment Replacement Parts Catalog or contact your
Nordson representative.
Refer to the user’s guide provided with each Nordson hose. The guide
Hose port 1 contains important information about routing and installing the hose.
(P4/P7 melter manifold shown)
Always use hose port 1 first. The position of port 1 is stamped on the
face of the manifold. The P4 and P7 melters provide four hose ports on
the face of the manifold and a fifth hose port at the bottom of the
manifold. The P10 melter provides nine ports, six of which can be used
at any one time.
If you install an additional hose/gun module, you must restart the melter
and enter a set-point temperature for each hose/gun that you connect to
the new module in order for the new hoses/guns to be recognized.

Installation 3-17
CAUTION! Failure to connect a hose to port 1 may create spaces within the
manifold where hot melt will not circulate. The presence of these spaces
can result in the build-up of hot melt char, which can lead to an increase in
the frequency of melter maintenance.
Use the 6-hose manifold guard that is shipped with all P10 melters.
Instructions for installing the guard are provided with the guard.
Coordinate the connection of each hose with the receptacles on each
hose/gun module. For example, connect the cordset from the hose that
is connected to port 1 (marked) to receptacle 1.
Save all of the port plugs removed from the manifold. A port plug will
need to be reinstalled into the manifold if a hose is later removed.
Use the 45- or 90-degree hose fittings provided in the installation kit.
P10 6-hose manifold guard NOTE: Only 90-degree fittings are shipped with the P4 and P7 melters.
Figure 3-8 Connecting a hose

3-18 Installation
Connecting Hoses and Guns (contd)
P10 Hose Routing Options

The unique angled design of the manifold on the P10 melter allows each
hose (six hoses maximum) to be routed in the same or different directions
without interfering with each other. Use the 45- or 90-degree hose fitting
supplied with the melter. Additional 45-degree, 90-degree, and straight
fittings may be ordered to customize your hose configuration.
To connect guns
Observe the following guidelines:
P10 hose routing options
ProBlue melters support all T-style handguns.
For information about choosing the most appropriate Nordson hot melt
gun for your manufacturing process, refer to the latest edition of
Nordson’s hot melt dispensing equipment Replacement Parts Catalog or
contact your Nordson representative. Refer to Appendix A, Calculating
Melter Power Requirements, for information about how to calculate the
power required by Nordson hot melt guns.
Refer to the user’s guide that is shipped with each gun for information
about installing the gun and connecting a hose to the gun.
NOTE: ProBlue melters are shipped with a 100-mesh (.15 mm) hot melt
filter installed in the pump. Order the appropriate gun nozzle based on this
filter mesh size.

Installation 3-19
This page intentionally left blank.

3-20 Installation
Setting Up the Melter

After physically installing the melter, it must be set up to support your
manufacturing process. Melter setup consists of enabling or making
changes to factory-set operating parameters that affect the use and function
of the melter. The operating temperature (set-point) of the tank and each
hose and gun is also established during melter setup.
The melter is shipped from the factory with the most commonly used
operating parameters already set up. The factory setup can be modified at
any time to suit your manufacturing process.
Quick Setup
Table 3-4 describes the most commonly used operating parameters and
their factory settings. Review the table to determine if the factory settings for
each parameter will support your manufacturing process. If the default
values for each of these operating parameters are appropriate for your
manufacturing process, then no melter setup is required. Go directly to
Set-point Temperature of the Tank, Hoses, and Guns later in this section to
complete the installation process.
If you need to make changes to the factory setup or if you want to learn
about other operating parameters, go to the next part in this section,
Operating Parameters.

Installation 3-21
Table 3-4 Common Operating Parameters

Parameter Parameter Name Purpose Default Value
A timer that delays the activation of the ready

LED for a pre-defined time period after the tank,
hoses, and guns are at the desired set-point
temperature. The ready delay timer will only
4 Ready Delay Time 0 minutes
activate if the temperature of the tank, at the
time the melter is turned on, is below its
assigned set-point temperature by
27 °C (50 °F) or more.
A timer that turns on a service LED when the

value set for the timer equals the number of
5 Service Interval Time hours that the heaters have been on. The 500 hours
service LED is used to signal the need for
maintenance.
Determines whether the pump will turn on

automatically when the all components are at
8 Automatic Pump On their desired set-point temperature (enabled) or Enabled
whether the pump must be turned on manually
(disabled).
Sets a password that must be entered before

11 Create Password any melter operating parameter or set-point 5000
temperature can be changed.
Sets the units of the temperature display to

20 Temperature Units degrees Celsius (C) or to degrees Fahrenheit C
(F).
Sets the number of degrees that any heated

Over Temperature component can exceed its assigned set-point
21 15 °C (25 °F)
Delta temperature before an over temperature fault
occurs.
Sets the number of degrees that any heated

Under Temperature component can drop below its assigned
22 25 °C (50 °F)
Delta set-point temperature before an under
temperature fault occurs.
Sets the number of degrees that the

temperature of all heated components will be
23 Standby Delta 50 °C (100°F)
decreased when the melter is placed into the
standby mode.
Sets the amount of time the melter will remain

Manual Standby
26 in the standby mode after the standby key is Disabled
Time
pressed.
A group of parameters that control the melter’s

clock. The clock is used to automatically turn
50 to 77 Seven-day Clock the Disabled
heaters on and off and to place the melter into
the standby mode.

3-22 Installation
Operating Parameters
The melter uses operating parameters to store noneditable and editable
values. Noneditable values are those that provide information about the
historical performance of the melter. Editable values are either a numeric
set-point or a control option setting. Control options settings affect the
display of information or the function of the melter.
Operating parameters are stored in the melter’s firmware in the form of a

sequentially numbered list. The list is organized into the logical groups
described in Table 3-5.
Table 3-5 Parameter Groups

Parameter
Group Group Description
Numbers
Noneditable and other frequently used
Standard 0 to 11 and 14
parameters
Temperature Control 20 to 26 Control heaters
Input Setup 30 to 39 Configure the standard and optional inputs
Output Setup 40 to 46 Configure the standard and optional outputs
Seven-day Clock 50 to 77 Configure the clock feature
In addition to the ability to read and edit parameter values, you can also
save and restore the current value of every operating parameter and review
a log of the last ten changes that were made to editable parameters.
Selecting Operating Parameters

Table 3-6 provides a complete list of the operating parameters.
Review the list to determine which operating parameters would best support
your manufacturing process. Refer to Appendix B, Operating Parameters,
for detailed information about each parameter. Appendix B contains a
complete description of each parameter, including its affect on the melter,
default value, and format.
NOTE: Parameters that are used to configure optional equipment or that

are otherwise reserved in the firmware are excluded from Table 3-6 and
Appendix B.
Reading or Editing Operating Parameters

Regardless of whether a parameter’s value is editable or not, the procedure
for accessing each parameter in order to read or edit its current value is the
same.

Installation 3-23
To read or edit a parameter

1. Switch the melter on.
The melter performs a start-up check.
2. Press the Setup key.
The left display flashes parameter 1.
Melter control switch (On/Off) 3. Use the numeric keypad to enter the number of the desired parameter.
Refer to Table 3-6 for a complete list of parameters.
NOTE: If you incorrectly enter the parameter number, press the
Clear/Reset key to return to parameter 1 and then re-enter the correct
parameter number.
When you have finished entering the one- or two-digit parameter

Setup key number, the right display indicates the parameter’s current value.
4. Do one of the following:
If the value is noneditable, refer to Section 4, Monitoring the Melter.
If the value is editable go to step 5.
5. Press the Enter key.
The right display flashes.
Clear/Reset key 6. Use the keypad to enter the desired numeric set-point or control option
into the right display. Refer to Appendix B for information about the
numeric value or control option choices for each parameter.
NOTE: If the keypad has no affect on the right display, the melter is
password protected. You must enter a valid password before you can
edit parameters. Refer to Section 4, Enter the Melter Password.

Enter key
The melter checks that the new value or control option is acceptable.
If the numeric set-point or control option is accepted, the left and
right displays index to the next sequential parameter number and
value.
If the numeric set-point or control option is not accepted, the right
display will indicate dashes (----) for three seconds and then it will
change back to the original value.
8. Repeat step 5 through step 7 to read or change the next sequential
parameter number or press the Setup key to exit the setup mode.

3-24 Installation
Table 3-6 Operating Parameters

Parameter Name Range of Values Default Value
Standard
0 Enter Password 0 to 9999 4000
1 Total Hours with Heaters On
0−999,999 0
(noneditable)
2 Fault Log (noneditable) — _-F0 (empty)
3 Change History Log (noneditable) — P-_ (empty)
4 Ready Delay Time 0 to 60 minutes 0 minutes
5 Service Interval Time 0 to 8736 hours 500 hours
6 Service LED Heater Hours 0 to 9999 hours 0
8 Automatic Pump On 0 (disabled) or 1 (enabled) 1 (enabled)
9 Automatic Pump On Temperature 0 (disabled) or (1 to 230 C) 0 (disabled)
10 Enable or Disable Password 0 (disabled) or 1 (enabled) 0 (disabled)
11 Create Password 0 to 9999 5000
14 External Communications Lock-out 0 or 1 0 (disabled)
Temperature Control
20 Temperature Units (degrees C or F) C (degrees Celsius) or F
C (degrees Celsius)
(degrees Fahrenheit)
21 Over Temperature Delta 5 C (10 F) to 60 C (110 F) 15 C (25 F)
22 Under Temperature Delta 5 C (10 F) to 60 C (110 F) 25 C (50 F)
23 Standby Delta 25 C (50 F) to 190 C (350
50 C (100 F)
F)
24 Automatic Standby Timeout 0 to 1440 minutes 0 (disabled)
25 Automatic Heaters Off Time 0 to 1440 minutes 0 (disabled)
26 Manual Standby Time 0 to 180 minutes 0 (disabled)
Input Setup
30 Standard Input 1 10 (Automatic
0−10, 15−16
Standby)
31 Standard Input 2 0−9, 15−16 1 (Standby on/off)
32 Standard Input 3 0−9, 15−16 2 (Heaters on/off)
33 Standard Input 4 4 (Hose/gun 1
0−9, 15−16
enable/disable)
34 Optional Input 5 0−9, 15−16 0 (disabled)
Output Setup
40 Standard Output 1 0–6 1 (Ready)
41 Standard Output 2 0–6 3 (Fault)
42 Standard Output 3 0–6 4
43 Optional Output 4 0–6 0 (disabled)

Installation 3-25

Seven-day Clock
50 Current Day 1 to 7 (1 = Monday) —
51 Current hour 0000 to 2359 —
55 Schedule 1 Heaters On 0000 to 2359 06:00
56 Schedule 1 Heaters Off 0000 to 2359 17:00
57 Schedule 1 Enter Standby 0000 to 2359 —:—
58 Schedule 1 Exit Standby 0000 to 2359 —:—
60 Schedule 2 Heaters On 0000 to 2359 —:—
61 Schedule 2 Heaters Off 0000 to 2359 —:—
65 Schedule 3 Heaters On 0000 to 2359 —:—
66 Schedule 3 Heaters Off 0000 to 2359 —:—
71 Schedule for Monday 0−7 0
72 Schedule for Tuesday 0−7 0
73 Schedule for Wednesday 0−7 0
74 Schedule for Thursday 0−7 0
75 Schedule for Friday 0−7 0
76 Schedule for Saturday 0−7 0
77 Schedule for Sunday 0−7 0
You can exit the setup mode at any time by

pressing the Setup key.
Parameter numbers that are not applicable are

skipped when you scroll through the operating
parameter list in the left display.
When the right display is flashing, you can

quickly set the value of the current parameter to
it’s lowest possible value by simultaneously
pressing both of the right-display scroll keys.
While in the setup mode, if no key is pressed for

two minutes, the melter will return to the
automatic scan mode.
You can also use the right-display scroll keys to

enter or change a parameter’s value or control
option. After entering the parameter’s number in
the left display, press either of the right-display
scroll keys to change the value or control option.
If password protection is enabled, the melter will Appendix B, Parameter 10

return to the password protected mode
whenever you exit the setup mode.

3-26 Installation
Set-point Temperature of the Tank, Hoses, and Guns

The melter is shipped from the factory with the tank set-point temperature at
175 °C (350 °F) and the hose and gun set-point temperatures at 0 degrees
(turned off).
Before the melter can be used, a set-point temperature must be assigned to

the tank, hoses, and guns. Assign set-point temperatures using any of the
following methods:
Global—The tank and all hoses and guns are set to the same set-point
temperature.
Global-by-component group—All of the hoses or all of the guns are
set to the same set-point temperature.
Individual Component—The set-point temperature of the tank and
each hose and gun is set individually.
Since most manufacturing processes will require the tank, hoses, and guns
to be set to the same temperature, only the global method of assigning
set-point temperatures is described in this section. For information about the
other two methods of assigning set-point temperatures, refer to Section 4,
Adjusting Component Temperatures.
As with operating parameters, you can also save and restore set-point
temperatures and review past changes that were made to set-point
temperatures.

Installation 3-27
To assign a global set-point temperature

1. Press and hold the Tank key for three seconds.
The left display flashes 1.
Tank key
2. Scroll the left display to 0.
The right display indicates all dashes (----) and the LEDs on the tank,
hose, and gun keys turn green.
The right display flashes.
4. Use the numeric keypad to enter the set-point temperature

Left display and
scroll key recommended by the manufacturer of the hot melt.
Refer to the technical data sheet provided by the manufacturer of the

hot melt to determine the optimal set-point temperature.
5. Press the Tank key.
Enter key Each component begins to heat or cool to the new global set-point
temperature and the melter returns to the automatic scan mode.
When all of the components reach the global set-point temperature, the
ready LED turns on (green).
Ready LED

3-28 Installation
Save and Restore Melter Settings

The current value of all editable operating parameters and the set-point
temperature of each component can be saved and, if necessary, restored at
a later time. When saved settings are restored, they overwrite the settings
that are presently in use.
This save-restore feature is useful in instances where the settings that are
in use are deliberately or accidentally changed and you need to return the
melter to its pre-change setup.
To save current settings

With the melter in the automatic scan mode, simultaneously press the
number 1 key and the Setup key.
+
S-1 appears momentarily in the right display.
Saving current settings

To restore saved settings
CAUTION! All melter settings will be deleted! Before restoring saved

settings, ensure that use of the restored settings will not disrupt the current
process or create an unsafe operating condition.
With the melter in the automatic scan mode, simultaneously press the
+ number 2 key and the Setup key.
S-2 appears momentarily in the right display.

Restoring saved settings
If you use the restore feature before the save

feature is used for the very first time, the factory
default set-point temperatures will be restored.
This will cause the hoses and guns to stop
heating.
You can transfer melter settings from one melter Refer to Appendix C,
to another using the Nordson Configuration Melter Communications
Manager software utility.

Installation 3-29
Review Parameter and Set-point Temperature Changes

The melter stores in a change history log, a record of the last ten changes
that were made to either operating parameters or set-point temperatures.
Since the log only stores ten changes, old log entries are overwritten
beginning with the first log entry, by the eleventh and following log entries.
To review the change history log

1. Press the Setup key.
Operating parameter 1 flashes in the left display.
Setup key 2. Press the left display scroll key to change the display to parameter 3
(the change history log).
The following occurs:
If the last change was to an editable parameter, all of the component
key LEDs remain off.
or
If the last change was to a set-point temperature, the LED on the
associated component key(s) turns on.
Left display and scroll key and
The right display indicates the four-digit log entry associated with the
last change that was made.
Table 3-7 provides the meaning, from left to right, of each digit in the
log entry. Following the table are two example log entries.
3. Press the right-display scroll key to review each of the remaining nine
Component key LEDs log entries. Each press of the scroll key displays a progressively older
log entry.
4. Press the Setup key to return to the automatic scan mode.
Scrolling through the log

3-30 Installation
Table 3-7 Change History Log

First Digit Second Digit Third and Fourth Digits
P Indicates the number of the parameter that was changed

(Parameter)
Are used in conjunction with the LEDs on the component keys to indicate
the location and method of a set-point temperature change.
And the
When this LED And the Fourth The change
Method of
is on.. Digit Indicates.. was to..
Change was..
−
Tank Key 1 The tank Individual
S Hose Key 1– 6 A single hose Individual

(Set-point)
Gun Key 1– 6 A single gun Individual
All Keys 0 All components Global
Global-by-
Hose Key 0 All hoses
component
Global-by-
Gun Key 0 All guns
component
Change History Log Examples

Example 1:
Parameter 4 (ready delay) was changed.
Example 2:
If the LED on the gun key is on, then this display would
indicate that the global-by-component method was used to change the
temperature of the guns.
Unused log entries in the change history log are

indicated by “P-_” in the right display.
To view how many heater hours have elapsed

since a specific change (displayed) was made,
simultaneously press both of the right-display
scroll keys.

Installation 3-31

3-32 Installation
Installing Melter Inputs

ProBlue melters are equipped with four standard inputs. Each input is
customer-wired to the melter and then set up to provide one of the following
control options:
Place the melter into the standby mode

Turn the heaters on and off
Enable or disable a specific hose or gun
Turn the pump on and off
Inputs are activated using a constant 10 to 30 VDC signal voltage, which is
supplied by the customer’s control equipment. The inputs are not polarity
sensitive.
WARNING! The operator can override the melter inputs by using the control
panel function keys. Ensure that the control logic for any external device
that sends an input signal to the melter is programmed to prevent the
creation of an unsafe condition in the event that the operator overrides an
external input to the melter.
To wire inputs to the melter

1. Route a 2-, 4, 6, or 8-conductor signal cable from the control equipment
to the melter, and through the PG-16 penetration in the sub-base. Use
rigid or flexible conduit or a suitable strain relief to protect the cable from
the sharp edge of the conduit penetration.
NOTE: Use a signal cable suitable for NEC class1 remote control and
Opening the electrical enclosure signaling circuits. To reduce the possibility of electrical shorting, route
door the cable so that it does not touch nearby circuit boards.
See Figure 3-9.
2. Connect each pair of input wires to the appropriate terminals (8 through

14) on connector P/N 277909. If input number four is used, terminal 7 on
connector P/N 277908 must also be used. Both connectors are provided
in the installation kit. Table 3-8 lists the terminal numbers that
correspond to each input.
NOTE: Connector P/N 277909 is physically keyed to prevent it from

being used in place of connector P/N 277908, which has terminals
numbered 1 through 7.
Connector P/N 277909
3. Plug the connector (P/N 277909) into the bottom receptacle of terminal
TB2, which is located on the right side of the main board. If input
number four is used, plug connector P/N 277908 into the top receptacle
on terminal TB2.

Installation 3-33
TB2
8 9 10 11 12 13 14
Figure 3-9 Wiring inputs
To set up an input
Set up the parameter control option for each input that you connected to the
melter. Table 3-8 list the available control options. Refer to Setting Up the
Melter, earlier in this section for information about how to select operating
parameters and edit parameter control options.
With the exception of the pump enable/disable Appendix B, Input Setup

control option (Table 3-8), All inputs are
transition-based.
The input capacity of the melter may be Section 7, Parts

increased from four inputs to a total of ten inputs
by adding an optional I/O card that is available
from Nordson Corporation.

3-34 Installation
Table 3-8 Input Data

Input Terminals Operating Parameter Control Option Note
Standard Inputs
0 - Input Disabled A, B
1 - Standby On/Off
2 - Heaters On/Off
3 - Pump Enable/Disable C
4 - Hose/Gun 1 Enable/Disable
1 8 and 9 30 5 - Hose/Gun 2 Enable/Disable
9 - Hose/Gun 6 Enable/Disable F
10 – Automatic standby (Default) D
0 - Input Disabled
1 - Standby On/Off (Default)
2 - Heaters On/Off
3 - Pump Enable/Disable
2 10 and 11 31
9 - Hose/Gun 6 Enable/Disable F
3 12 and 13 32 Same as parameter 31 (Default=2)
Optional Inputs
5 11 and 12 34 0 (Disabled) E
NOTE A: Parameter 30 has 10 control options. parameters 31, 32, and 33 each have only 9 control options.
B: Parameters 34 through 39 are reserved for the six inputs created when the optional I/O expansion card is installed.
The six optional inputs have the same control options as parameter 31.
C: If control option 3 is selected, the pump will not turn on—even if you press the pump key—if voltage is not present on
the input’s contacts.
D: If control option 10 is selected for input 1, a time must be set in parameter 24.
E: Refer to the instruction sheet provided with the optional I/O expansion card for wiring information.
F: When the 8-Hose/Gun Expansion option is installed, the option for Hose/Gun 7 or 8 Enable/Disable
appear as options 15 and 16 respectively.

Installation 3-35

3-36 Installation
Installing Melter Outputs

The melter is equipped with three user-configurable outputs. Outputs are
used to communicate with user-supplied production equipment or control
hardware, such as a programmable logic controller.
Each output is customer-wired and then set up in the melter’s firmware to

provide one of the following outputs:
The melter is ready

The melter is ready and the pump is on
A fault has occurred
The hot melt level is low
The service LED is on
A potential fault is detected
All outputs contacts are rated at 240 VAC 2 A or 30 VDC 2 A. All contacts
are normally open when the melter is turned off.
To connect an output to the melter
See Figure 3-10.
1. Route a 2-, 4, or 6-conductor signal cable from the control equipment to

the melter, through the PG-16 penetration on the floor of the electrical
compartment. Use rigid or flexible conduit or a suitable strain relief to
protect the cable from the sharp edge of the conduit penetration.
NOTE: Use a signal cable suitable for NEC class1 remote control and
Opening the electrical enclosure signaling circuits. To reduce the possibility of electrical shorting, route
door the cable so that it does not touch nearby circuit boards.
2. Connect each pair of output wires to the appropriate terminals

(1 through 7) on connector P/N 277908. The connector is provided in
the installation kit. Table 3-9 lists the terminal numbers that correspond
to each output.
NOTE: Terminal number 7 on connector P/N 277908 is reserved for

input number four.Connector P/N 277908 is physically keyed to prevent
it from being used as connector P/N 277909, which has terminals
numbered 8 through 14.
3. Plug connector P/N 277908 into the top receptacle on terminal TB2,
which is located on the main board.
Connector P/N 277908

Installation 3-37
TB2
1 2 3 4 5 6 7
Figure 3-10 Wiring outputs
To set up an output
Set up the parameter control option for each output that you connected to
the melter. Table 3-9 lists the available control options. Refer to Setting Up
the Melter, earlier in this section, for information about how to select
operating parameters and edit parameter control options.
The output capacity of the melter may be Section 7, Parts

increased from three outputs to seven outputs by
adding an optional I/O expansion card that is
available from Nordson Corporation.

3-38 Installation
Table 3-9 Output Data

Operating
Output Terminals Control Options Note
Parameter
Standard Outputs
1 1 and 2 40 0 - Output Disabled A
1 - Ready (Default) A
2 - Ready and the pump is on A
3 - Fault B
4 - Tank Low Level A
5 - Service LED is On
6 - Alert C
3 5 and 6 42
Same as parameter 40 (Default=4)
Optional Outputs
4 1 and 2 43 0 (Disabled)
D
NOTE A: When control option condition occurs, contacts close. Contacts are normally open when power is off.
B: When control option condition occurs, contacts open. Contacts are normally open when power is off.
C: Control option 6 provides an output signal when a potential fault is detected. If control option 3 and 6 are both used,
then both a fault output and an alert output signal will be present when the fault LED turns on.
D: For wiring information, refer to the instruction sheet that is provided with the optional I/O expansion card

Installation 3-39
Installing Optional Equipment

Each item of optional equipment is shipped with instructions for installing
and operating the equipment. Refer to Section 7, Parts, for equipment part
numbers.
Connecting a Gun Driver, Pattern Controller, or

Timer
If applicable, complete the melter installation by connecting the guns to the
desired gun driver, pattern control, or timer. Refer to the product manual
provided with the device for information about installing and operating the
equipment.
Flushing the Melter

Before using the melter for production, it should be flushed to remove any
residue left over from factory-testing. Flushing the melter is accomplished
by processing a minimum of one tank volume of hot melt through the melter,
hoses, and guns.
Refer to Section 4, Operation, for information about filling the tank and
operating the melter.
Setting Up Melter Communications

You can transfer melter settings between melters, and upgrade or
downgrade the melters operating firmware by using a personal computer
that is connected to your melter’s serial port.
Refer to Appendix C, Melter Communications, for information about

downloading, installing, and using the software that is required to connect a
personal computer to your melter.

3-40 Installation

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Installation 3-1

WARNING! Allow only personnel with appropriate training and experience

Installing 400/480 Volt Melters

If optional equipment was ordered with the melter, refer to the

2010 Nordson Corporation Part 1024496D04

The illustrations accompanying the procedures in this section depict the P4

1. Verify that the required environmental conditions and utilities exist.

Experience of Installation Personnel

Hot melt application processes

Part 1024496D04 2010 Nordson Corporation

NOTE: 400/480 volt melter clearances are provided in Appendix E.

Table 3-1 Installation Clearances

2010 Nordson Corporation Part 1024496D04

Figure 3-2 Melter cooling

Refer to Appendix A, Calculating Melter Power Requirements, for

WARNING! Risk of electrocution! Install a lockable power disconnect switch

Part 1024496D04 2010 Nordson Corporation

Nordson recommends that an isolation valve be installed in the plant air

2010 Nordson Corporation Part 1024496D04

Unpacking the Melter

Contents of the Installation Kit

NOTE: 400/480 volt transformers are shipped with a separate installation

A power cable. If the cable clamp that is provided in the installation

Part 1024496D04 2010 Nordson Corporation

Figure 3-3 Installation kit components

2010 Nordson Corporation Part 1024496D04

Mounting the Melter

To mount the melter

4. Install the cable clamp in the PG-21 conduit knockout.

Part 1024496D04 2010 Nordson Corporation

Figure 3-4 Mounting the sub-base and the melter

2010 Nordson Corporation Part 1024496D04

Configuring the Electrical Service

To connect a power cable to the melter

Table 3-2 Melter Power Requirement

WARNING! Risk of electrocution! Install a lockable power disconnect switch

2. Open the electrical enclosure door.

Opening the electrical enclosure

Part 1024496D04 2010 Nordson Corporation

See Figure 3-5.

4. Connect each power cable lead to the appropriate terminal on the

2010 Nordson Corporation Part 1024496D04

To connect a power cable to the melter (contd)

Table 3-3 Electrical Service Information

To connect a voltage plug to the melter

See Figure 3-6.

Part 1024496D04 2010 Nordson Corporation

Figure 3-6 Connecting a voltage plug

2010 Nordson Corporation Part 1024496D04

Connecting a Compressed Air Supply

To connect an air supply

See Figure 3-7.

4. Open the plant air supply to the melter.

Part 1024496D04 2010 Nordson Corporation

1/ NPTF G 1/4 BSPP

2010 Nordson Corporation Part 1024496D04

Connecting Hoses and Guns

The hose/gun capacity of each melter is determined by the number of

WARNING! Risk of fire or equipment damage. Before connecting hoses and

Part 1024496D04 2010 Nordson Corporation