Fulfill Retrofit Kit for

AltaBlue™ TT and
DuraBlueD10/D16Melters
Customer Product Manual
Part 1121940_02
Issued 5/13

This document contains important safety information

Be sure to read and follow all safety information in this
document 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 the
serial code of your unit; for example, SA13EXXXXX, where “E” represents the date code “May,” or any se­
quential letter after “E.”

NORDSON CORPORATION  DULUTH, GEORGIA  USA

www.nordson.com
 For CE Declaration, refer to equipment documentation.

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

Address all correspondence to:

Nordson Corporation
Attn: Customer Service
11475 Lakefield Drive
Duluth, GA 30097

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2010.
Nopartofthisdocument may be photocopied, reproduced, or translated to another language without the prior written
consent of NordsonCorporation. Theinformationcontained in this publication is subject to change without notice.

Trademarks

AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, Bowtie, Build‐A‐Part, CanWorks, Century, CF, CleanSleeve,
CleanSpray, ColorMax, Color‐on‐Demand, ControlCoat, Coolwave, Cross‐Cut, cScan+, Dage, Dispensejet, DispenseMate, DuraBlue, DuraDrum,
Durafiber, DuraPail, Dura‐Screen, Durasystem, EasyCoat, 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, LEANCELL, LittleSquirt, 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, PorousCoat, PowderGrid, Powderware, Precisecoat, PRIMARC, Printplus, Prism, ProBlue, Prodigy,
Pro‐Flo, ProLink, Pro‐Meter, Pro‐Stream, RBX, Rhino, Saturn, Saturn with rings, Scoreguard, Seal Sentry, SelectCharge, SelectCoat, Select Cure,
Signature, Slautterback, Smart‐Coat, Solder Plus, Spectrum, Speed‐Coat, SureBead, Sure Coat, Sure‐Max, Sure Wrap, TrackingPlus, 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, CleanCoat, Cobalt, Controlled Fiberization, ControlWeave,
ContourCoat, CPX, cSelect, Cyclo‐Kinetic, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, e.dot+,
E‐Nordson, Equalizer, EquiBead, FillEasy, FillSentry, 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, PowderPilot, Powder Port, Powercure, Process Sentry, Pulse Spray,
PURBlue, PURJet, Ready Coat, RediCoat, RollVIA, Royal Blue, SelectSeries, Sensomatic, Shaftshield, SheetAire, Smart, Smartfil, SolidBlue, Spectral,
SpeedKing, Spray Works, StediFlo, StediTherm, Summit, SureFoam, SureMix, SureSeal, SwirlCoat, TAH, ThruWave, TradePlus, Trilogy, Ultra FoamMix,
UltraMax, Ultrasaver, Ultrasmart, Universal, ValueMate, Versa, Vista, Web Cure, YESTECH, and 2Rings (Design) aretrademarks of NordsonCorporation.

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

Part 1121940_02  2013 Nordson Corporation

All rights reserved
 Table of Contents i

Fulfill) Retrofit Kit for AltaBlue™ TT and DuraBlue)D10/D16Melters

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
(2). Air Pressure Regulator/Solenoid Assembly . . . . . . . . . . . . . . . . . 15
(3). Suction Lance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
(4). Adhesive Transfer Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
(5). Lid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
(6). Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
(7). Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Install the Lid Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Install the Control Box and Level Probe . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install the Lid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Make the Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assemble the Transfer Hose, Air Line, and Suction Lance . . . . . . . . . . 26
Level Sensor Adjustment and Calibration . . . . . . . . . . . . . . . . . . . . . . . . 28
Baseline Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Final Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Time Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Monitoring Refill Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

 2013 Nordson Corporation Part 1121940_02

ii Table of Contents

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Refill Board Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Using the Illustrated Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fulfill Retrofit Kit Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Lid Assembly Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Control Assembly With Bracket Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Control Box Assembly Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Regulator/Solenoid Assembly Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Service Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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

Part 1121940_02  2013 Nordson Corporation

 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters 1

Fulfill Retrofit Kit for AltaBlue™ TT and

DuraBlueD10/D16Melters

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

WARNING! Failure to follow the safety messages, recommendations, and

hazard avoidance procedures provided in this document can result in
personal injury, including death, or damage to equipment or property.

Safety Alert Symbols

The following safety alert symbol and signal words are used throughout this
document to alert the reader to personal safety hazards or to identify
conditions that may result in damage to equipment or property. Comply with
all safety information that follows the signal word.

WARNING! Indicates a potentially hazardous situation that, if not avoided,

can result in serious personal injury, including death.

CAUTION! Indicates a potentially hazardous situation that, if not avoided,

can result in minor or moderate personal injury.

CAUTION! (Used without the safety alert symbol) Indicates a potentially

hazardous situation that, if not avoided, can result in damage to equipment or
property.

 2013 Nordson Corporation Part 1121940_02

2 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters

Responsibilities of the Equipment Owner

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

Safety Information
 Research and evaluate safety information from all applicable sources,
including the owner‐specific safety policy, best industry practices,
governing regulations, material manufacturer's product information, and
this document.
 Make safety information available to equipment users in accordance with
governing regulations. Contact the authority having jurisdiction for
information.
 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 best
industry practices.
 If applicable, receive approval from your facility's engineering or safety
department, or other similar function within your organization, before
installing or operating the equipment for the first time.
 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.

Part 1121940_02  2013 Nordson Corporation

 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters 3

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 Nordson
representative 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 mental
capacity or physical capabilities

Applicable Industry Safety Practices

The following safety practices apply to the use of the equipment in the
manner described in this document. The information provided here is not
meant to include all possible safety practices, but represents the best safety
practices for equipment of similar hazard potential used in similar industries.

Intended Use of the Equipment

 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 on
material compatibility or the use of non‐standard auxiliary devices.

 2013 Nordson Corporation Part 1121940_02

4 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters

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 Tags
at 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 the
ATEX directive nor as nonincendive and should not be installed in
potentially 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 required
environmental conditions exist.
 Use the personal protective equipment (PPE) specified for each task.
Refer to Equipment Safety Information or the material manufacturer's
instructions and MSDS for PPE requirements.
 Do not use equipment that is malfunctioning or shows signs of a potential
malfunction.

Part 1121940_02  2013 Nordson Corporation

 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters 5

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 are
available 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 or
contact 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 of
Nordson 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

 2013 Nordson Corporation Part 1121940_02

6 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters

Equipment Shutdown
To safely complete many of the procedures described in this document, the
equipment must first be shut down. The level of shut down required varies by
the type of equipment in use and the procedure being completed.
If required, shut down instructions are specified at the start of the procedure.
The levels of shut down are:

Relieving System Hydraulic Pressure

Completely relieve system hydraulic pressure before breaking any hydraulic
connection or seal. Refer to the melter‐specific product manual for
instructions on relieving system hydraulic pressure.

De‐energizing the System

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

1. Turn off the equipment and all auxiliary devices connected to the
equipment (system).
2. To prevent the equipment from being accidentally energized, lock and
tag the disconnect switch(es) or circuit breaker(s) that provide input
electrical power to the equipment and optional devices.
NOTE: Government regulations and industry standards dictate specific
requirements for the isolation of hazardous energy sources. Refer to the
appropriate regulation or standard.

Disabling the Applicators

NOTE: Adhesive dispensing applicators are referred to as “guns” in some

previous publications.

All electrical or mechanical devices that provide an activation signal to the

applicators, applicator solenoid valve(s), or the melter pump must be
disabled before work can be performed on or around an applicator that is
connected to a pressurized system.

1. Turn off or disconnect the applicator triggering device (pattern controller,

timer, PLC, etc.).
2. Disconnect the input signal wiring to the applicator solenoid valve(s).
3. Reduce the air pressure to the applicator solenoid valve(s) to zero; then
relieve the residual air pressure between the regulator and the applicator.

Part 1121940_02  2013 Nordson Corporation

 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters 7

General Safety Warnings and Cautions

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

Equipment types are designated in Table 1 as follows:

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

PC = Process control
CA = Cold adhesive (dispensing pumps, pressurized container, and
applicators)

Table 1 General Safety Warnings and Cautions

Equipment
Type Warning or Caution

WARNING! Hazardous vapors! Before processing any polyurethane

reactive (PUR) hot melt or solvent‐based material through a compatible
HM Nordson melter, read and comply with the material's MSDS. Ensure
that the material's processing temperature and flashpoints will not be
exceeded and that all requirements for safe handling, ventilation, first
aid, and personal protective equipment are met. Failure to comply with
MSDS requirements can cause personal injury, including death.

WARNING! Reactive material! Never clean any aluminum component

or flush Nordson equipment with halogenated hydrocarbon fluids.
HM Nordson melters and applicators contain aluminum components that
may react violently with halogenated hydrocarbons. The use of
halogenated hydrocarbon compounds in Nordson equipment can
cause personal injury, including death.

WARNING! System pressurized! Relieve system hydraulic pressure

HM, CA before breaking any hydraulic connection or seal. Failure to relieve the
system hydraulic pressure can result in the uncontrolled release of hot
melt or cold adhesive, causing personal injury.

Continued...

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8 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters

General Safety Warnings and Cautions (contd)

Table 1 General Safety Warnings and Cautions (contd)
Equipment
Type Warning or Caution

WARNING! Molten material! Wear eye or face protection, clothing that

HM protects exposed skin, and heat‐protective gloves when servicing
equipment that contains molten hot melt. Even when solidified, hot melt
can still cause burns. Failure to wear appropriate personal protective
equipment can result in personal injury.

WARNING! Equipment starts automatically! Remote triggering devices

are used to control automatic hot melt applicators. Before working on
HM, PC or near an operating applicator, disable the applicator's triggering
device and remove the air supply to the applicator's solenoid valve(s).
Failure to disable the applicator's triggering device and remove the
supply of air to the solenoid valve(s) can result in personal injury.

WARNING! Risk of electrocution! Even when switched off and

electrically isolated at the disconnect switch or circuit breaker, the
HM, CA, PC equipment may still be connected to energized auxiliary devices.
De‐energize and electrically isolate all auxiliary devices before
servicing the equipment. Failure to properly isolate electrical power to
auxiliary equipment before servicing the equipment can result in
personal injury, including death.

WARNING! Risk of fire or explosion! Nordson adhesive equipment is

not rated for use in explosive environments and has not been cerfified
for the ATEX directive or as nonincendive. In addition, this equipment
HM, CA, PC should not be used with solvent‐based adhesives that can create an
explosive atmosphere when processed. Refer to the MSDS for the
adhesive to determine its processing characteristics and limitations.
The use of incompatible solvent‐based adhesives or the improper
processing of solvent‐based adhesives can result in personal injury,
including death.

WARNING! Allow only personnel with appropriate training and

HM, CA, PC experience to operate or service the equipment. The use of untrained
or inexperienced personnel to operate or service the equipment can
result in injury, including death, to themselves and others and can
damage to the equipment.

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 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters 9

Equipment
Type Warning or Caution

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

CAUTION! Some Nordson melters are specifically designed to

process polyurethane reactive (PUR) hot melt. Attempting to process
PUR in equipment not specifically designed for this purpose can
HM
damage the equipment and cause premature reaction of the hot melt. If
you are unsure of the equipment's ability to process PUR, contact your
Nordson representative for assistance.

CAUTION! Before using any cleaning or flushing compound on or in

the equipment, read and comply with the manufacturer's instructions
HM, CA and the MSDS supplied with the compound. Some cleaning
compounds can react unpredictably with hot melt or cold adhesive,
resulting in damage to the equipment.

CAUTION! Nordson hot melt equipment is factory tested with Nordson

Type R fluid that contains polyester adipate plasticizer. Certain hot melt
HM materials can react with Type R fluid and form a solid gum that can
clog the equipment. Before using the equipment, confirm that the hot
melt is compatible with Type R fluid.

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10 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters

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 melt
has cooled.
3. Do NOT attempt to remove the solidified hot melt from your skin.
4. In case of severe burns, treat for shock.
5. Seek expert medical attention immediately. Give the MSDS for the hot
melt to the medical personnel providing treatment.

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Safety Labels and Tags

Figure 1 illustrates the location of the product safety labels and tags affixed to
the equipment. Table 2 provides an illustration of the hazard identification
symbols that appear on each safety label and tag, the meaning of the
symbol, or the exact wording of any safety message.

1 2

Figure 1 Safety labels and tags

Table 2 Safety Labels and Tags

Item Part Description
1. 1087952 Tag, warning, hyd pressure
2. 1100253
WARNING! Hazardous voltage. Disconnect all power supply
connections before servicing.

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12 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters

Description
The AltaBlue TT/DuraBlue Fulfill retrofit kit converts an AltaBlue TT A10/A16
or DuraBlue D10/D16 melter into an automatic fill system that maintains
adhesive in the melter, improving productivity and reducing maintenance.
The retrofit kit adds adhesive to the sealed tank, reducing the possibility of
char, contaminants, thermal shock, and incorrect adhesive temperatures that
result in poor adhesive bonding.

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

1
4
2 3

6
5 8
7

Figure 2 Fulfill system components

1. Adhesive storage bin 4. Control box and mounting bracket 6. Air line (4 m)
2. Transfer hose with level sensor, filter and 7. Wire tie (5)
regulator with gauge, and solenoid
3. Suction lance 8. Lid assembly
5. Hose clamp (2)

Optional accessories available for the Fulfill retrofit include:

 a vibrator kit for the adhesive storage bin
 a remote power harness kit
 a light tower kit for audio/visual fill/fault indication of the Fulfill
processes
 a powered cable kit
Contact your Nordson representative for more information on these kits.

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 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters 13

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 regular
intervals, reducing the possibility of adhesive char, contaminants, thermal
shock, and incorrect adhesive temperatures that result in poor bonding.

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

At the end of the delay, the control activates the vacuum via a solenoid valve.
Air pressure flows to a suction lance that is placed in the supplied bulk
adhesive container. Using vacuum, the system conveys adhesive from the
bulk container to the adhesive melter tank.

The controller activates the suction lance for a limited amount of time to
prevent over‐fill conditions. If the maximum fill time is exceeded, the
controller activates a fault that stops the system from filling.

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Pneumatic & Mechanical Components

See Figure 3 as you learn about the components of the Fulfill retrofit
assembly.

4
6

3 5

Figure 3 Fuflill retrofit kit assembly components

1. Adhesive storage bin 4. Adhesive transfer hose 6. Control box assembly
2. Air pressure regulator/solenoid 5. Lid assembly 7. Level sensor probe
assembly
3. Suction lance

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(1). Adhesive Storage Bin

Place adhesive in the adhesive storage bin. The bin contains a gasket that
prevents debris from entering the bin. For best results, break up the adhesive
as much as possible when emptying into the bin. Do not get the adhesive
wet.

(2). Air Pressure Regulator/Solenoid Assembly

The supplied air pressure regulator is permanently set at 65 psig, the optimal
setting for most adhesives.

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

(3). Suction Lance

The suction lance draws adhesive from the adhesive storage bin. The
suction 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 suction
lance. The lance is placed in the PVC pipe located in the adhesive storage
bin.

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(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 the
melter 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
ambient air.
 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.
Four thumb screws mount the lid to the melter. The thumbscrews can be
replaced with the Allen head screws supplied in the ship with kit. Do not
remove the lid during operation, unless the system is disabled by turning
power off at the control box.

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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 refill board. It connects to
the melter via the supplied bracket. An optional remote‐mount kit is available
to mount the control box away from the melter.

Membrane Panel
The front panel of the electrical control box shown in Figure 4 contains three
LEDs 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.
 Enable On/Off key—Press the Enable On/Off key 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 that adhesive
is being transferred from the adhesive storage bin into the melter 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 the
fault is cleared by pressing the Clear Fault key.
 Clear Fault key—Press the Clear Fault key to reset the fault status
and resume normal activity.

2 3
1

Figure 4 Fulfill system controls and indicators

1. Enable On/Off key and LED (green) 3. Fault LED (red) 4. Clear Fault key
2. Adhesive transfer LED (blue)

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Refill Board
 NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated
information.

See Figure 5. The refill board is inside the control box:

Figure 5 Refill board (located inside the control box)

 Connect line voltage to the control box at the supplied terminal block
and ground. Power can be supplied from the plant service to the
control box or directly from the melter using the optional power
harness kit.
 A potentiometer labeled “Fault” limits the amount of filling time in case
of level sensor failure. It is only for overflow protection. The fault limit
time is preset from the factory at 60 seconds, but can be adjusted
from 5 to 115seconds. The factory sets the potentiometer at the 12
o'clock position, which is sufficient for the majority of applications. For
reference, the 9o'clock position is 22 seconds and the 3 o'clock
position is 98 seconds.
 A potentiometer labeled “Delay” is for a fill time delay. This delay is
the time duration between the level sensor calling for more adhesive
and when the fill system activates. The delay time prevents the
system from frequently turning on and off. The delay time is preset
from the factory at 60 seconds, but can be adjusted from 0 to
119seconds. The factory sets the potentiometer at the 12 o'clock
position, which is sufficient for the majority of applications. For
reference, the 9o'clock position is 20 seconds and the 3 o'clock
position is 100seconds.

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

storage bin vibrator kit. The range for this potentiometer is 0 to 20
seconds. When installed, this vibrator will activate up to 20 seconds
before the fill system activates and stay on until the level sensor is
satisfied. This kit is well suited for adhesives and plant conditions that
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 the
adhesive falls below the set point, the level sensor sends a signal to the Fulfill
control box.

The sensor comes preset from the factory for an average application
whereby the tank is typically molten. For optimal performance based on
specific applications, see the Level Sensor Adjustment and Calibration
detailed later in the manual.

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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.

Install the Lid Tray

1. Operate the melter until the tank is empty.
2. De‐energize the system as directed in the Maintenance section of the
melter manual.
3. See Figure 6. Remove the existing melter lid and associated screws.

Figure 6 Removing the existing lid

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 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters 21

CAUTION! Remove dirt and debris from the melter before proceeding with
the next steps.

4. See Figure 7. Remove any buildup from the mounting surface onto which
the lid tray (2) will be placed.
5. Install the lid tray from the retrofit kit using the screws (1) provided in the
ship‐with kit.

Figure 7 Installing the lid tray

1. M5 x 10 screw 2. Lid tray

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22 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters

Install the Control Box and Level Probe

1. See Figure 8. Position and secure the control box assembly (4) from the
retrofit kit as shown below, using the M5 screws and washers (1), the
M12 screws and washers (2), and the spacers (3) provided in the
ship‐with kit.
NOTE: Do not remove the existing external tooth washers from the left
and right frames (where the M12 screws are installed). The washers are
required for proper grounding.

2. Ensure that the electrical enclosure door can be opened and then tighten
all securing screws.

2
3 4

Figure 8 Installing the control box assembly

1. M5 x 10 screw and M5 washer 3. Spacer 4. Control assembly with
2. M12 x 50 screw and M12 washer bracket

Note: The level probe holder assembly attached to the control box is not shown.

3. See Figure 9. Install the level probe holder assembly (1) in the lid tray
using the M5 nuts and washers (2) from the ship‐with kit.

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 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters 23

NOTE: The level sensor is precalibrated with the fill line 50.8 mm (2 in.)
from the bottom of the probe holder. The level can be reduced by
loosening the holder's hex nut and then sliding the probe lower. Tighten
the nut to keep the probe from moving.

4. Use the cable ties supplied in the ship‐with kit to secure the probe cable
to the cable tie clips (3). Trim the cable ties.

Figure 9 Installing the level probe holder assembly

1. Level probe holder assembly 3. Cable tie clips
2. M5 nut and washer

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24 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters

Install the Lid Assembly

See Figure 10. Carefully position the lid assembly (1) from the retrofit kit on
the top of the melter and tighten the lid knobs (2).

Figure 10 Installing the lid assembly

1. Lid assembly 2. Lid knobs

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 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters 25

Make the Electrical Connections

1. See Figure 11. Thread a customer supplied 14-18 AWG power cord
through the strain relief (3) into the control box.
2. Connect the wiring to the terminal blocks (1) and the ground wire
connection (2) inside the control box.
3. Tighten the strain relief.

2 3

Figure 11 Connecting the customer-supplied power cord to the control box

1. L1/L2 wire power cord connection 3. Power cord strain relief
(interchangeable)
2. Ground wire power cord connection

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Assemble the Transfer Hose, Air Line, and Suction Lance

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

See Figure 12.

1. Using one hose clamp, attach the transfer hose (1) to the end of the
suction lance (2).
2. Insert the suction lance into the PVC pipe inside the adhesive storage
bin.
3. Use the remaining hose clamp to attach the transfer hose to the feed
system inlet tube (3). The hose should be routed without sharp bends or
kinks.
NOTE: If necessary, loosen the inlet tube retaining screws and then
reposition the inlet tube.

4. Connect the air line (4) to the suction lance air inlet (5).
5. Route the air line along the transfer hose, securing it with wire ties as you
go. The hose should be routed without sharp bends or kinks.
6. Leaving enough air line to reach the outlet (6) of the air solenoid, cut the
air 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 piping from
the main header.

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 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters 27

5
6

Figure 12 Assembling the transfer hose, air line, and suction lance
1. Transfer hose 3. Feed system inlet tube 5. Suction lance air inlet
2. Suction lance 4. Air line 6. Solenoid valve air outlet

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28 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters

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 probe
permanently connects to the control box by a wire. The level probe has a
black line around its diameter near the tip to note the maintained adhesive
level.

CAUTION! Do not raise the fill line of the probe above 50.8 mm (2 in.) from
bottom of the probe holder. Doing so will degrade the level sensor's
performance.

Figure 13 Location of the adjustment potentiometer

See Figure 13. The LED next to the adjustment potentiometer on the control
box changes color from green to amber, depending on the adhesive level
that the probe detects. When adhesive drops below the desired level, the
LED will turn green. When adhesive reaches or exceeds the desired level,
the LED will turn amber. The adjustment potentiometer sets the sensitivity of
the level sensor. Different adhesives require different calibration settings.
Adhesives that build up on the level probe require less sensitivity, while
adhesives that do not build up on the level probe require more sensitivity.
The level sensor should be recalibrated any time the level probe's height is
changed or the type of adhesive being used changes.

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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 control
box to reveal the adjustment potentiometer.
2. Fill the tank with adhesive and allow it to melt completely.
3. Adjust the liquid level to coincide with the black line on the level probe.
4. If the LED on the control box is amber, turn the adjustment potentiometer
counter‐clockwise until it turns green. If the LED on the control box is
green, turn the adjustment potentiometer clockwise until it just turns
amber. The point at which the LED transitions from green to amber is the
switching point.
5. Once the switching point is found, rotate the adjustment potentiometer 1/2
turn 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 has
already faulted due to overfilling, rotate the adjustment pot 1/2 turn
clockwise to increase the level sensor's sensitivity. Wait 10 minutes and
check the adhesive level again. If the adhesive level is still too high,
repeat this process until the adhesive level is satisfactory. When finished,
reinstall the plug over the calibration potentiometer.
4. If unmelted adhesive has built up on the probe and the adhesive level in
the tank has dropped below the black line on the probe, rotate the
adjustment potentiometer 1/2 turn counter‐clockwise to decrease the
level sensor's sensitivity. If the adhesive level is still too low, repeat this
process until the adhesive level is satisfactory.

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Operation
 NOTE: Refer to Appendix A, Retrofit Refill System With Nordson Level Sensor, for updated
information.

Once enabled, the fill system immediately begins operation. Maintain

adhesive level in the storage bin to maintain automatic operation.

NOTE: During warm‐up, the melter's ready‐delay time may need to be

increased for the Fulfill unit to operate properly. The proper ready‐delay time
depends on the tank size and shape, adhesive type, and application
temperature.

Time Settings
See Figure 14. There are three timers found on the refill board located inside
the 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 fault
limit time is preset from the factory at 60 seconds, but can be adjusted
from 5 to 115seconds. The factory sets the potentiometer at the 12
o'clock position, which is sufficient for the majority of applications. For
reference, the 9o'clock position is 22 seconds and the 3 o'clock position
is 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 the
time the fill system activates. The delay time prevents the system from
frequently turning on and off. The delay time is preset from the factory at
60 seconds, but can be adjusted from 0 to 119seconds. The factory sets
the potentiometer at the 12 o'clock position, which is sufficient for the
majority of applications. For reference, the 9o'clock position is 20
seconds and the 3 o'clock position is 100seconds.
 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 the
fill system activates and will stay on until the level sensor is satisfied. The
air timer range is 0 to 20 seconds.

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 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters 31

Figure 14 Refill board timer settings (located inside the control box)

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

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Monitoring Refill Operation

See Figure 15.

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

However, if the fill system is unable to satisfy the tank sensor in the time limit
set for the Fill Time, the Fault LED will illuminate. Refer to Troubleshooting for
a list of possible fault causes and solutions.

2 3
1

Figure 15 Fulfill system controls and indicators

1. Enable On/Off key and LED (green) 3. Fault LED (red) 4. Clear Fault key
2. Adhesive transfer LED (blue)

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

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

If the fill system fails and the condition cannot be corrected, to continue
operating the melter (and filling it manually), disable the fill system (ensure
that the fill system Enable On/Off LED is not illuminated).

Troubleshooting Table

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. Refer to Refill
Board Troubleshooting in this section.
Sensor not calibrated properly Calibrate the sensor. Refer to Level
Sensor Adjustment and Calibration
under Installation.
2. System underfilled No adhesive Add adhesive.
No power Ensure that power is available to the
system.
Adhesive bridging Dislodge adhesive. Add optional
vibrator kit if problem persists.
Clogged wand/hose/lid Inspect the parts for improper
connections, clogs, or kinks. Replace
as needed.
Clogged filter sock Replace if needed.
No/low air pressure Verify that sufficient air pressure and
flow rate are supplied to the Fulfill
unit from the factory. Static pressure
should be 4.5 bar (65 psi) minimum;
operating pressure should be 3.1 bar
(45 psi) minimum. Replace the
regulator if defective.
No power to the level sensor Verify that power is being supplied to
the level sensor (LED not lit = no
power) and that the power cord is
installed properly.
Continued...

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34 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters

Troubleshooting Table (contd)

Problem Possible Cause Corrective Action

2. System underfilled
Deflector bent Repair or replace.
No power to refill board Verify power to the control box and at
the refill board. Replace if needed.
Solenoid failure Verify the connections to the
solenoid. Replace if defective.
Bad refill board Replace. See Refill Board
Troubleshooting later in this section.
Overfill timer too short Adjust the timer.
Sensor not calibrated properly Calibrate the sensor. Refer to Level
Sensor Adjustment and Calibration
under Installation.
3. Frequent overfill Timers not properly set Adjust the timer settings. Refer to
alarms with no cause Time Settings under Operation.

Part 1121940_02  2013 Nordson Corporation

 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters 35

Refill Board Troubleshooting

 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 the
refill board or to eliminate the refill board as a cause. These tests should only
be performed by personnel qualified to work on high voltage circuits.

1. Verify input power is reaching the refill board. Measure the line voltage
across the input side (side of the fuse closest to the input connectors J1
and J2) of fuses F1 and F2. The input voltage should be between
100-240 VAC. If input voltage not present, correct input power.
2. Verify that the 24 VDC power supply on the refill board is working by
measuring the voltage between XT1 pin “24V” and XT1 pin “COM.” It
should be 24 VDC (+/- 5%). If it is not 24 VDC, verify that the fuses are not
blown. If fuses have been blown, replace the fuses. If any fuses blow
again, replace the refill board. If the fuses are okay but 24 VDC is not
present, replace the refill board.
3. Ensure that 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
(60seconds at 12:00 position),
 DELAY potentiometer adjustment range: 1 to 119 seconds
(60seconds 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 board is enabled by verifying that the “ENA” LED
close to the membrane panel connector (X1) is illuminated. If not, press
the Enable On/Off key on the membrane panel to enable the refill board.
If the “ENA” LED does not turn on with the membrane panel, the
membrane panel or refill board may be bad. With a piece of wire, briefly
touch X1 pin 1 to X1 pin 2 (the membrane tail will need to be unplugged
to perform this test). If the “ENA” LED illuminates after this test, replace
the membrane panel. If not, then replace the refill board.
6. To ensure that the level sensor signal is getting to the refill board with the
level sensor calling for adhesive, verify that there is 24 VDC (+/- 5%)
between XT1 pin “SIG” and XT1 pin “COM.” If not, repair the level sensor
cable, recalibrate the level sensor, or replace the level sensor.
7. To ensure that the refill board fill output is working correctly with the level
sensor 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 NOT
calling for adhesive that the fill control output is 0 to 0.5V.

If the problem has not be isolated at this point, replace the refill board and/or
membrane panel.

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36 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters

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 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters 37

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

Using the Illustrated Parts Lists

To order parts, call the Nordson Customer Service Center or your local
Nordson representative. Use these five-column parts lists, and the
accompanying illustrations, to describe and locate parts correctly. The
following chart provides guidance for reading the parts lists.

The number in the Item column corresponds to the circled item number in the
parts list illustration. A dash in this column indicates that the item is an
assembly.

The number in the Part column is the Nordson part number you can
use to order the part. A series of dashes indicates that the part is
not saleable. In this case, you must order either the assembly in
which the part is used or a service kit that includes the part.

The Description column describes the part and sometimes

includes dimensions or specifications.

The Note column contains letters that refer to notes at the

bottom of the parts list. These notes provide important
information about the part.

The Quantity column tells you how many of the part is

used to manufacture the assembly shown in the parts
list illustration. A dash or AR in this column indicates
that the amount of the item required in the assembly is
not quantifiable.

Item Part Description Quantity Note

— 0000000 Assembly A —
1 000000  Part of assembly A 2 A
2 ------   Part of item 1 1
3 0000000    Part of item 2 AR
NS 000000     Part of item 3 2
NOTE A: Important information about item 1
AR: As Required
NS: Not Shown

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38 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters

Fulfill Retrofit Kit Parts

See Figure 16.

Item Part Description Quantity Note

— 1100979 KIT,FULFILL RETROFIT,D10/16,ALTA TT —
01 1100977  LID,ASSEMBLED,KIT,FULFILL,D10/16, 1 A
ALTA TT
02 ------  PLATE,STAMPING,BLANK XFMR BASE 1
03 ------  TAG,STAMPING,2.938X2.188,TRANS BASE 1
04 ------  RIVET,POP, 1/8X.375,BLK,ALUM 4
05 ------  TAG,CE MARK,RIVETED 1
06 1098263  CTL.ASSY.W/BRKT,P4,7 FULFILL 1 B
07 984706  NUT,HEX,M5,STL,ZN 2
08 1101305  CLIP,CABLETIE,M5 MOUNTING,ALUMINUM 2
09 1100972  TRAY,LID,DURA,10/16 F 1
NS 1097984  KIT,CONTAINER,WAND, HOSE ASSY, 1
FULFILL
NS 1098864  KIT,LID FASTENERS,FULFILL RETROFIT 1 C
12 1101507  KIT,SHIP W/HDW,DURA 10/16,FULFILL 1
12A 984706   NUT,HEX,M5,STL,ZN 2
12B 983408   WASHER,FLT,M,NARROW,M5,STL,ZN 2
NS 182105   CABLETIE,4 IN,338F/170C,PTFE,BLUE 2
12C 1100975   SPACER,BRACKET,DURA 10/16 F 2
12D 983194   WASHER,FLAT,M12 2
12E 345509   SCR,CAP,SKTHD,M12X50,STL,BL 2
12F 1017010   SCR,BTN,SKT,M5X10,BL 8
13 ------  TAG,CE/EMC COMPLIANCE 1
NOTE A: Refer to Lid Assembly Parts later in this section.
B: Refer to Control Assembly With Bracket Parts later in this section.
C: If desired, these screws may be used to replace the plastic knobs (part 1098021) on the lid assembly.
AR: As Required
NS: Not Shown

Part 1121940_02  2013 Nordson Corporation

 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters 39

04

03

02 05

01

13

09
12B 06

12F
12C
12D
12E

PROBE IS PART OF
ITEM 6 AND IS SHOWN 08 07
FOR REFERENCE

12A

12B

DETAIL A

Figure 16 Fulfill retrofit kit parts

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40 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters

Lid Assembly Parts

See Figure 17.

Item Part Description Quantity Note

— 1100977 LID,ASSEMBLED,KIT,FULFILL,D10/16,ALTA TT —
01 1095342  ENCLOSURE ASSY,FILTER,LID,FULFILL 1
02 1097016  TUBE,INLET,FULFILL,PROBLUE 1
03 982025  SCR,SKT,M4X14,BL 3
04 983163  WASHER,FLT,M,OVERSIZED,M4,ZN 3
05 1088282  FILTER,SOCK,200 MICRON,FULFILL 1
06 982374  SCR,SKT,M5X40,BL 4
07 1096978  COLLAR,LID,FULFILL 1
08 1097055  RETAINER,FILTER HOUSING,FULFILL, 1
PROBLUE
09 1097018  TUBE,EXHAUST,FULFULL,PROBLUE 1
10 1100974  LID,TOP,DURA 10/16 F 1
11 1097663  SPACER,LID,FULFULL RETROFIT 1
12 1100976  INSULATION,LID,DURA 10/16 F 1
13 1100973  LID,BOTTOM,DURA 10/16 F 1
14 1097738  BAFFLE,EXHAUST,FULFILL RETROFIT, 1
PROBLUE
15 982780  SCR,SKT,M5X10,ZN 4
16 1097739  DEFLECTOR,FULFILL RETROFIT,PROBLUE 1
17 1098021  KNOB, BLACK PLASTIC WITH M5 X 30 LG 4 A
STUD
18 983408  WASHER,FLT,M,NARROW,M5,STL,ZN 4
19 940073  O RING,VITON,.145ID X .070W.BR,10407 4
20 1087952  TAG,WARNING,HYD PRESSURE,FULFIL,CE 1
21 1098570  TAG,NAMEPLATE,FULFILL 1
22 1100509  GROMMET,2.125 OD X 1.5 ID,BUNA N 1
NOTE A: If desired, these screws may be replaced with the fasteners contained in kit 1098864.
AR: As Required
NS: Not Shown

Part 1121940_02  2013 Nordson Corporation

 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters 41

01

05

21 20
02

03 22

04 06

07
17

08
18

19 09

10
11

12

13

16 14

15

Figure 17 Lid assembly parts

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42 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters

Control Assembly With Bracket Parts

See Figures 18−19.

Item Part Description Quantity Note

— 1100978 CTL.ASSY,W/BRKT,D10/16,ALTA TT,FULFILL —
RETRO
01 1098169  CTL.BOX ASSY,FULFILL RETROFIT 1 A
02 1100970  BRACKET,CONTROL BOX,DURA 10/16 F 1
03 1098491  SENSOR,LEVEL,CAPACITIVE,W/150mm 1
PROBE
04 1042911  GROMMET,RUBBER,STD,.50IDX1.00ODX.09 1
05 982780  SCR,SKT,M5X10,ZN 2
06 933476  LUG, 45,SINGLE,.250,.438 1
07 1098248  REGULATOR/SOL.ASSY,FULFILL 1 B
08 1040003  SCR,SKT,M4X25,ZN 2
09 1052143  NUT,HEX,W/EXT TOOTH WASHER, M5, STL, 1
ZN
10 983163  WASHER,FLT,M,OVERSIZED,M4,ZN 2
11 1098913  HARNESS,SOLENOID,FULFILL RETROFIT 1
12 1100971  BRACKET,AMP,DURA 10/16 F 1
13 982680  SCR,HEX,WASHHD,TF,M5X12,BLK 4
14 939110  CABLETIE,3.9 IN,185F/85C,NYLON, 3
NATURAL
15 1099250  HOLDER ASSY,LEVEL PROBE,16 mm, 1
PROBLUE
16 982059  SCR,SKT,M4X8,BL 2
17 984706  NUT,HEX,M5,STL,ZN 1
18 1101305  CLIP,CABLETIE,M5 MOUNTING,ALUMINUM 1
NOTE A: Refer to Control Box Assembly Parts later in this section.
B: Refer to Regulator/Solenoid Assembly Parts later in this section.
AR: As Required
NS: Not Shown

Part 1121940_02  2013 Nordson Corporation

 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters 43

01

14

15
09
02

06

PROBE (PART OF ITEM 3)

08 04

13
07
12
17
18
05
11
03
10

16

Figure 18 Control assembly with bracket parts (1 of 2)

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44 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters

Control Assembly With Bracket Parts (contd)

17 18 14

SOLENOID
VALVE
PROBE CABLE CABLE

AMPLIFIER
CABLE
RED GROUND WIRE

TO PROBE

03

11

RED GROUND WIRE

CABLE ROUTING VIEWS

Figure 19 Control assembly with bracket parts (2 of 2)

Part 1121940_02  2013 Nordson Corporation

 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters 45

Control Box Assembly Parts

See Figure 20.

Item Part Description Quantity Note

— 1098169 CTL.BOX ASSY,FULFILL RETROFIT —
1 1098483  DOMEPLUG,.500”D,.250”PNL.THK.,NYLON, 2
BLAC
2 ------  MEMBRANE PANEL,FULFILL RETROFIT KIT 1 A
3 ------  PCA, REFILL CONTROLLER, PROBLUE 1 B
4 1098484  DOMEPLUG,.750”D,.250”PNL.THK.,NYLON, 1
BLAC
5 1046998  CONNECTOR,STRAIN-RELIEF,PG7,NYLON 2
6 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.

6
2

5 1

Figure 20 Control box assembly parts

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46 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters

Regulator/Solenoid Assembly Parts

See Figure 21.

Item Part Description Quantity Note

— 1098248 REGULATOR/SOL.ASSY,FULFILL —
1 1093650  VALVE,SOLENOID,3-WAY,24V,1/4 NPT 1
2 1058059  MUFFLER POLYETHYLENE 1/4” NPT, 1
SATURN
3 233785  ELBOW,MALE,1/4 NPT 1
4 1096668  REGULATOR/FILTER,40 MIC,1/4 NPT, 65 1
PSIG
5 972125  CONN,MALE,ELBOW,10MM T X 1/4UNI 1

1
3

PIPE PLUG
(PART OF ITEM 4) 5

GAUGE (PART OF ITEM 4)

Figure 21 Regulator/solenoid assembly parts

Part 1121940_02  2013 Nordson Corporation

 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters 47

Service Kits
Part Description
1099525 KIT, MEMBRANE PANEL, FULFILL RETROFIT
1099526 KIT, SERVICE, LEVEL SENSOR
1096221 SERVICE KIT,REFILL CONT.,PROBLUE
1082942 KIT,SERVICE,SOCK FILTER,5 PCS,FULFILL

Accessories
Part Description
1098962 KIT, VIBRATOR, CONTAINER, FULFILL RETROFIT
1099057 KIT, LIGHT TOWER, FULFILL RETROFIT
1102952 KIT, REMOTE MOUNT, FULFILL RETROFIT

Service Parts
Part Description
1098248 REGULATOR/SOLENOID ASSEMBLY
1096668 REGULATOR/FILTER, 40 MIC, 1/4 NPT, 65 PSIG
1093639 FILTER/REGULATOR W/GAuGE, 1/4 NPT (40 mic,
5-100 psig)
1093650 VALVE, SOLENOID, 3‐WAY, 24V, 1/4 NPT
1097983 CONTAINER ASSEMBLY,120L,BLUE, FULFILL
1099544 GASKET, NEOPRENE RUBBER, ADH. CONTAINER
7408012 SUCTION WAND, W/BOX, FULFILL
7408022 Vibrator, suction wand (VIBRATOR, BALL, K8,
FILLEASY)
1095962 HOSE, TRANSFER, FULFILL (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”. SS
1100977 LID, ASSEMBLED, KIT, FULFILL, D10/16, ALTA TT
939955 FUSE, TIME‐LAG, 2A, 5X20 MM, CERAM

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48 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters

Technical Data
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-phase VAC, 1 A
Power cord Customer supplied, 14−18 AWG
Adhesive transfer maximum rate 227 kg/hr (500 lb/hr) depending 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 l/min (24 SCFM) when feeding
Conditioning Dry, non-lubricated
Inlet air connection 1/in. NPT female
4
1/BSPP female
4
G1/4 female
Pump type Venturi
Noise emission 76 dBA
Suction lance dimensions (L) 615 mm x maximum (W) 105 mm (24.21 in. x maximum 4.14 in.)
Storage bin capacity 60 kg (132 lb)
Enclosure rating IP54

Part 1121940_02  2013 Nordson Corporation

 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters 49

Dimensions

429.1
16.89

COMPRESSED AIR CONNECTION

1/4 NPT OR G1/4
FEMALE THREADS

835.7 POWER CONNECTION

32.90 LID INSTALLED 100−240 VAC

771.1
[952.5]
30.36
37.50 CLEARANCE
REQUIRED TO
REMOVE LID

Figure 22 Fulfill retrofit kit dimensions

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50 Fulfill Retrofit Kit for AltaBlue™ TT and DuraBlueD10/D16Melters

Wiring Diagram

Figure 23 Wiring diagram

Part 1121940_02  2013 Nordson Corporation

 RetroFit Refill System with Nordson Level Sensor A-1

Appendix A
RetroFit Refill System with Nordson Level
Sensor

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.

Sensor Features
The Nordson level sensor features include a wide sensing area, simplified
mechanical mounting, push button calibration, RTD temperature
compensation, new diagnostics to help identify sensor problems and a
separate low level output.

Wide Sensing Area

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

Simplified Mechanical Mounting

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

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A-2 RetroFit Refill System with Nordson Level Sensor

Push Button Calibration

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

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

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

RTD Temperature Compensation

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

Sensor Diagnostics
The Nordson level sensor offers several diagnostic functions not present in
the previous Fulfill level sensor. These new diagnostic functions are reported
with LED flash codes. The flash codes are displayed on the membrane
panel.

Part 1121940_02  2013 Nordson Corporation

 RetroFit Refill System with Nordson Level Sensor A-3

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

Siren

Fill Enabled LED

Fault LED

ResetFault Button

Fill Enable Button Fill Active LED

Air filter/regulator

Fill Control Solenoid

Level sensor

Figure A‐1 Control box assembly and bracket

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A-4 RetroFit Refill System with Nordson Level Sensor

Unit Features(contd)
The picture shows the major components of the RetroFit control box.

24VDC power supply

Siren

Refill PCA

Figure A‐2 Control box

Delay Timer
The delay timer determines how long the Refill board waits when the sensor
calls for adhesive before the vacuum system is activated. The delay timer
potentiometer is adjustable from 1 to 60 seconds.

Overfill Fault Timer

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

Part 1121940_02  2013 Nordson Corporation

 RetroFit Refill System with Nordson Level Sensor A-5

Status Relay Contact Output

A form­C electromechanical relay contact output is available for to monitor
the fill system status. This relay provides a common (COM), normally closed
(NC), and normally open (NO) potential free contact. These contacts are
labeled COM, NC, and NO on the PCB and are located at terminal block
TB3.

If the fill system is working properly (powered, fill enabled, and no alarms
present) the COM contact will be connected to the NC contact and
disconnected from the NO contact. Any other system state will de­energize
the 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 24

VDC to the COM contact and then use the NC and NO contacts. Use the NC
contact for a signal that supplies 24 VDC when the fill system is working
normally and the NO contact for a signal that supplies 24 VDC when a
problem with the fill system exists. See Figure A‐3.

TB3

Figure A‐3 Photo of TB3

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A-6 RetroFit Refill System with Nordson Level Sensor

Configuration Switch
The configuration switches are used to set various system modes. Refer to
the 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
DuraBlue/VersaBlue 50 RETRO INT TcB 300
DuraBlue/VersaBlue 100 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 sensor

such as the level sensor used on previous Fulfill units.

Part 1121940_02  2013 Nordson Corporation

 RetroFit Refill System with Nordson Level Sensor A-7

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

Fill low
LED
Status LED
Power LED

Configuration switches
Full calibration button

Empty calibration button

Delay timer Overfill fault
potentiometer potentiometer
Unit Low LED

Vibrator LED
Fault LED Siren LED

Fill enabled LED

Fill active LED

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

 2013 Nordson Corporation Part 1121940_02

A-8 RetroFit Refill System with Nordson Level Sensor

Sensor Calibration
The following sections will describe the various methods available to
calibrate the level sensor. For all calibrations, the button(s) must be held for
5 seconds in order to be recognized. For best results, the unit should be at
application temperature when calibration is performed.

The sensor also detects if the calibration is done out of sequence. For
example, if a full calibration is attempted before an empty calibration was
performed, then the calibration is ignored and the STATUS and LOW LEDs
on the circuit board will turn red for 5 seconds after attempting the calibration
indicating a bad calibration attempt.

The unit can also report the last calibration successfully performed. If the
ENABLE and RESET buttons on the front panel are held simultaneously, the
panel LEDs will illuminate to indicate the last calibration. An illuminated
green Enable LED indicates that a basic (empty level) calibration was
performed 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 and
the calibrated full point. The level at which the unit fills to is computed based
on the empty and full calibration points

Calibration Summary
The table below summarizes the different types of calibration available. The
different calibrations should be performed in the specific order shown below.
Order to Type Buttons Data Notes
Perform Calibration Used Points
Affected
1 Basic Blue Empty Full point is set to a predetermined level above
Calibration Button and Full empty that is suitable for a wide range of
(Empty (SW3) adhesives. This is the only calibration that most
Level) units will require.
2 Precision White Full only The empty calibration point is not changed, only
(optional) Calibration Button the full. Use this calibration (after an empty
(Full Level) (SW2) calibration) to provide more precise level
control than an empty calibration alone

Part 1121940_02  2013 Nordson Corporation

 RetroFit Refill System with Nordson Level Sensor A-9

Basic (Empty Level) Calibration

CAUTION! Do not attempt empty calibration with a full melter. Doing so will
result 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) Calibration

1. 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 stop
changing color (approximately 5 seconds).

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A-10 RetroFit Refill System with Nordson Level Sensor

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 also
performed on the FAULT LED located on the membrane panel.

Number of Diagnostic Action Required

Red Flashes
(DS3) and
Panel Fault
LED
1 Over­fill fault. Unit did not fill in the allowed Check adhesive level in bin. Check
time. hose lines for blockage. Increase overfill
timer value.
2 Blown Fuse. The fuse supplying 24V to the Find and fix the source of the excessive
outputs is blown. current draw and replace the fuse (2
Amp max.)
3 Shorted Cable. There is a problem with the If sensor was calibrated, replace sensor.
sensor cable. If sensor needed calibration, calibrate
sensor. If persists, replace sensor.
4 Communications failure. There is a problem Check cable between the Refill board
with the communications to the CPU board and the CPU board. If this is a RetroFit
(integrated unit only) unit, check DIP switch settings on Refill
board.
5 RTD shorted. The temperature compensation Replace sensor
RTD is electrically shorted.
6 Internal memory failure. Unit was not able to Replace Refill board if fault persists
store calibration settings.

Part 1121940_02  2013 Nordson Corporation

 RetroFit Refill System with Nordson Level Sensor A-1 1

Fill Enable LED/Yellow Status LED/Yellow Light Tower

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

Number of Diagnostic Action Required

Yellow
Flashes
(DS3) and
Panel
Enable LED
1 Pressure switch open (if used). Check air supply to pressure switch. If air
supply good, replace pressure switch.
Check jumper if pressure switch not
used.
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 probe Replace sensor
temperature compensation will be disabled.
4 Sensor is disconnected. Reconnect or tighten sensor connector.
If persists, recalibrate the sensor. If still
persists, replace sensor.
5 Melter ready input open (if used) This is normal during melter warm up. If
occurs while melter is ready, check
connections to input. If melter ready
signal not used, check jumper.
6 Unstable sensor readings Check the sensor cable connections. If
the problem persists, replace the sensor
and/or refill PCA.
7 Probe temperature is under 175 F Allow probe to heat above 175 F
(80 C)) and filling is prevented. (80 C)

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A-12 RetroFit Refill System with Nordson Level Sensor

Installation
Common Chassis Connection
CAUTION! Failure to install a wired connection as described below will
cause the Fulfill unit to not function.

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

Service Parts
Part Description
1121799 Kit, service, power cable, MKIII PB FF Retrofit
1121800 Kit, service, power supply, Fulfill
1121802 Kit, service, Nordson sensor, 150 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

Part 1121940_02  2013 Nordson Corporation

 RetroFit Refill System with Nordson Level Sensor A-13

Retrofit Wiring Diagram

 2013 Nordson Corporation Part 1121940_02

A-14 RetroFit Refill System with Nordson Level Sensor

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Part 1121940_02  2013 Nordson Corporation

 EC Declaration of Conformity
for Adhesive and Sealant Application Equipment
conforming to European Council Directives

PRODUCTS:
AltaBlue Melters, Models 15, 30, 50, 100 MiniPUR Melters
AltaBlue TT Melters, Models A4, A10, A16 ProBlue Melters, Models P4, P7, P10, P15, P30 and P50
Cobalt GR Series Bulk Material Unloaders ProBlue Fulfill, Models P4F, P7F, P10F
DuraBlueMelters PURBlue Melters
FoamMelt FM‐200 Melter Series 3000V Melters
Fulfill Retrofit Kit SureFoam Foam Dispensing System
Mesa Melters

Model Number_________________________

Serial Num ­
ber______________________________________

APPLICABLE DIRECTIVES: STANDARDS USED TO VERIFY COMPLIANCE:

Machinery Directive: 2006/42/EC EN ISO 12100 EN 60204‐1
Electromagnetic Compatibility Directive: 2004/108/EC 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
Peter Lambert, Senior Vice President Lilienthalstrasse 6
Adhesives Dispensing Systems 21337 Lueneburg
GERMANY
Date: 14 December 2012

Nordson Corporation  28601 Clemens Road Westlake, Ohio 1105311A03

DOC074R4