3000v Series PDF

Part A, Section 1
Installation
This section Covers the following unit configurations.

Model All
Voltage 1, 2, 3
Pump All
Manifold All
Control Vista Pattern (PC)
E 2000 Nordson Corporation 41-3000V A3EN-04-[3V-A-AAXP]-12

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A 1-0 Installation
A3EN-04-[3V-A-AAXP]-12 41-3000V E 2000 Nordson Corporation

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Installation A 1-1
Section A 1
Installation
WARNING: Allow only qualified personnel to perform the

following tasks. Follow the safety instructions in this document
and all other related documentation.
1. Introduction This section of the manual describes how to

S install the unit, hoses, and guns
S program system settings
S prepare the unit for operation
If you have purchased optional features with your unit, such as a
low-level indicator or an input/output (I/O) board, refer to the Options
section of this manual for installation instructions.
2. Unpacking Besides using normal care, you need no special instructions to unpack
the unit or the equipment you purchased with it. All hoses and guns are
shipped in separate packages.
3. Inspection After unpacking the equipment, inspect it for any damage that may have
occurred during shipping. Look for dents and scratches and make sure
all fasteners are tight. Report any damage to your Nordson
representative.
4. Installation This part of the installation section gives you the installation requirements
and recommendations that you need to know before installing your unit.
Requirements It includes
S Location Requirements
S Wiring Requirements
S Hose/Gun Power Requirements
Other requirements and recommendations are provided in the installation
procedures when they are needed.

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A 1-2 Installation
Location Requirements Carefully select the location for the unit and its associated guns and
hoses. Make sure that the location meets the following requirements:
S There is enough room to open the tank lid, open the electrical
enclosure, remove the filter assembly, remove the pump enclosure,
and make electrical connections for the hoses. For unit dimensions
and recommended clearances, refer to Dimensions in the Description
section of this manual.
S An operator can reach all controls.
S Maintenance personnel have room to service and repair the unit.
S Installers can route the hoses without bending them. The minimum
bend radius for hoses is shown in Figure A 1-8.
S The mounting surface can support the weight of the unit when the unit
is filled with adhesive. Refer to Specifications in the Description
S The mounting surface is level.
S The mounting surface is raised at least 152 mm (6 in.) for draining

adhesive. See Figure A 1-1.
S The drain valve projects over the edge of the mounting surface.
152 mm
(6.0 in.)
4130685A
Fig. A 1-1 Required Clearance for Draining and Filter Flushing

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Installation A 1-3
Wiring Requirements Follow these guidelines when installing wiring to the unit:
S Allow enough room to route your electrical service line to the unit.
You can use either of the two access holes in the base of the unit for
electrical service. One hole is for rear access and the other is for
bottom access.
S Route any wires away from AC power lines, solenoid output lines,
and electrical equipment such as motors, contacts, and relays.
S Make connections with the minimum length of wire needed. A long

wire can act as an antenna for electrical noise.
Hose/Gun Power Requirements The power requirements of your hoses and guns must be determined to
make sure that you do not overload the unit. If your Nordson
representative has not already checked to see that your unit can support
all of the hoses and guns you plan to install, you need to calculate your
hose/gun power requirements now. You also need to check your
calculations if you change your system configuration or add new hoses
and guns.
To determine your hose/gun power requirements, refer to Calculating

Hose/Gun Capacity at the end of this manual. If you need help with this
procedure, contact your Nordson representative.

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A 1-4 Installation
5. Mechanical Installation This part of the installation section gives you the procedures for installing
the unit mechanically. It includes
S Mounting the Unit
S Installing the Tank Strainer
S Connecting the Air Supply
S Installing Guns
S Installing Hoses
On some units, you will not be required to complete all of these
procedures. For electrical installation procedures, refer to Electrical
Installation later in this section.
Mounting the Unit Use this procedure to mount your unit.
1. Remove the bolts that secure the unit to the shipping pallet. Save the
bolts for later use.
2. For installation within the European Community, find the packet of

adhesive-backed, local-language warning tags that was shipped with
the unit. Overlay the non-English language part of the tags already
on this unit with the tags from the packet in your own language.
Carefully follow the instructions in the packet for the correct
placement of the tags.
WARNING: Take care when lifting the unit. Using inadequate

means to lift the unit can cause equipment damage, personal
injury, or both.
3. Using a suitable lifting device that is capable of lifting the unit, position
the unit on the mounting surface. To determine the weight of your
unit, refer to Specifications in the Description section of this manual.
4. Check to see that the unit is level. Provide shims as needed.
5. Using the unit’s base as a guide, drill four holes in the mounting
surface for 8-mm (5/16-in.) mounting bolts.

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Installation A 1-5
6. See Figure A 1-2. Secure the unit to the mounting surface with the
bolts you removed in step 1.
4130009A
Fig. A 1-2 Securing the Unit to the Mounting Surface

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A 1-6 Installation
Installing the Tank Strainer This procedure describes how to install the tank strainer on Series 3000V
units that have tank strainers. The following units have tank strainers:
S Series 3100V
S Series 3400V
S Series 3500V
S Series 3700V
The model number of each unit is listed on the front panel of the unit. If
your unit does not have a strainer, go to the next procedure, Connecting
the Air Supply. If it has a strainer, complete this procedure.
1. Locate the tank strainer that was shipped with your unit. If you have
a Series 3500V or Series 3700V unit, you will find two strainers.
2. Series 3500V and 3700V units only: See Figure A 1-3. Determine
the correct strainer to use for your adhesive, the small strainer or the
large strainer. If the solid adhesive form you plan to use is small
enough to pass through the holes in the strainers (both strainers have
the same size holes), use the large strainer. If the solid adhesive is
too large to pass through the holes, use the small strainer.
4130686
Fig. A 1-3 Small Strainer (left) and Large Strainer (right)
3. Remove all wrapping from the strainer. Small pieces of wrapping can
cause blockage in the pump.
4. Open the tank lid.
5. Place the strainer on the fins in the bottom of the tank. Position the
cutout in the strainer around the pump.
6. Close the tank lid.

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Installation A 1-7
Connecting the Air Supply Follow this procedure to connect the air supply to units with piston
pumps. If your unit has a gear pump, which is motor-driven, you do not
need to connect air to your unit. To determine which kind of pump your
unit has, see Figure A 1-4.
If your unit has a gear pump, go to the next procedure, Installing Guns. If
your unit has a piston pump, complete this procedure.
4130687
Fig. A 1-4 Piston Pump (left) and Gear Pump (right)

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A 1-8 Installation
Connecting the Air Supply 1. See Figure A 1-5. Install the air pressure regulator, gauge, and filter
(contd.) that were shipped with your unit.
4130014A
Fig. A 1-5 Installing the Air Pressure Regulator, Gauge, and Filter
2. Turn the regulator fully counterclockwise (off).
NOTE: Nordson recommends installing a shutoff valve with a

lock-out in the air supply line to isolate the unit from the air supply for
maintenance procedures.
3. Connect a supply of clean, dry air to the input air fitting or

shutoff valve.
NOTE: To achieve the rated adhesive output of the unit, you must
connect a plant air supply that is capable of providing the maximum
air pressure specified on the unit. The maximum air pressure is
either 483 kPa (70 psi) or 620 kPa (90 psi), depending upon the type
of pump your unit has. To find the maximum air pressure for your
unit, check the air pressure tag, which is located next to the inlet air
port, above the hose connectors.

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Installation A 1-9
Installing Guns This part of the installation section refers you to the correct installation
procedure for the type of gun you plan to install. Use Figure A 1-6 to
determine which type of gun you are installing, an air-operated gun, an
electric gun, or a hand-operated gun. Then refer to one of the following
procedures:
S To Install an Air-Operated Gun
S To Install an Electric Gun
S To Install a Hand-Operated Gun
NOTE: Air-operated and electric guns are also referred to as
automatic guns.
4130692
Fig. A 1-6 Air-Operated Gun (left), Electric Gun (center), and Hand-Operated Gun (right)
To Install an Air-Operated Gun

Follow the instructions in the manual shipped with the gun to complete
these procedures:
S Mount the gun on the production line.
S Install the gun solenoid valve.
S Connect air to the solenoid valve.
S Connect a triggering device to the solenoid valve.
S Connect a hose to the gun.
Instructions for connecting the hose and gun cordsets are given later in
this section. Refer to Connecting Gun and Hose Cordsets.

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A 1-10 Installation
To Install an Electric Gun

Follow the instructions in the manual shipped with the gun to complete
the following procedures:
S Mount the gun on the production line.
S Install the gun driver.
S Connect power to the driver.
S Connect a triggering device to the driver.
S Connect a hose to the gun.
Instructions for connecting the hose and gun cordsets are given later in
this section. Refer to Connecting Gun and Hose Cordsets.
To Install a Hand-Operated Gun

Follow the instructions in the manual shipped with the gun to connect the
hose to the hand-operated gun. One end of the hose is wired to the gun;
the other end connects to the unit. Instructions for connecting the hose
and gun cordsets are given later in this section. Refer to Connecting Gun
and Hose Cordsets.

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Installation A 1-11
Installing Hoses Follow this procedure to route the hoses and connect them to the guns
and the unit.
If your system is designed for external circulation of the adhesive, which

requires both supply and return hoses, you must follow a different
procedure for installing hoses. Go to Installation Procedures for
Externally Circulating Systems at the end of this section.
1. Follow the instructions in the gun manual to connect a hose to each

gun, but do not connect the gun cordsets at this time.
2. Determine whether your unit has a four-port or a six-port manifold.

Figure A 1-7 shows both manifolds and the hose port numbers on
each type of manifold. Note that the first hose port on a six-port
manifold is located on the back side of the unit.
6 5 4 3 2 1 6 5 4 3 2 1
4 3 2 1 6 5 4 3 2 4130688
Fig. A 1-7 Four-Port Manifold (left) and Six-Port Manifold (right)

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A 1-12 Installation
Installing Hoses (contd.) 3. Decide where to install the first hose by referring to the following
table. Choose the instructions that apply to the type of manifold on
your unit.
Type of Manifold Instructions
Four-port manifold Use hose port number 1.
Six-port manifold Use hose port number 1 or 2. If

you plan to install six hoses
(either now or in the future), use
hose port number 1 for the first
hose (see Note A). If you plan to
install less than six hoses, you
can use hose port number 2 for
the first hose.
NOTE A: To install six hoses, your unit must have the ability to heat
six hoses. Check to see if your unit has six hose electrical
receptacles. Units can be ordered with two, four, or six
receptacles.
CAUTION: Failure to connect the first hose as instructed

creates a dead area where char builds up, causing downtime.
WARNING: Hose ports that are unused must be closed with a

plug. Removing plugs can cause hot adhesive to spray or flow
from the port and injure operators.
4. Route the hose from the gun back to the unit. Make sure the hose
does not contact sharp or abrasive surfaces. Follow the hose-routing
guidelines shown in Figure A 1-8.

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Installation A 1-13
P/N 111 940
X=13 mm (0.50 in.)
R=203 mm (8.00 in.)
P/N 271 486 -- 8 mm (5/16 in.)

P/N 274 174 -- 16 mm (5/8 in.)
P/N 274 174 -- 29 mm (1 1/8 in.)
5920010
Fig. A 1-8 Hose Installation Guidelines

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A 1-14 Installation
Installing Hoses (contd.) 5. Remove the O-ring plug from the hose port where you plan to install
the first hose. Keep the O-ring plug for later use during maintenance
and servicing procedures.
6. See Figure A 1-9. Take one of the hose-connector fittings that was
shipped with the unit and apply an anti-seize compound to the
threads. Thread the fitting into the hose port.
4103398A
Fig. A 1-9 Threading the Hose Connector Fitting into the Hose Port
7. Tighten the fitting with a wrench.
8. Connect a hose to the gun fitting. Use two wrenches to tighten the
hose as shown in Figure A 1-8.
9. Install any additional hoses by repeating steps 4--8. Be sure to

connect a second hose next to the first, working from right to left.
Depending upon your unit, you can connect a maximum of four or six
hoses this way.

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Installation A 1-15
6. Electrical Installation This part of the installation section includes procedures that require
installing wiring or making electrical connections. Before making any
electrical connections, first make the required mechanical connections.
Refer to Mechanical Installation in this section.
WARNING: Allow only qualified personnel to perform electrical

connections. Observe the safety instructions.
CAUTION: If you are adding hoses and guns to an existing

system, make sure that you do not exceed the maximum power
capabilities of your unit. Refer to the Calculating Hose/Gun
Capacity section of this manual.
Connecting Gun and Hose Follow this procedure to connect gun and hose cordsets.
Cordsets
1. Determine whether you are installing an automatic gun or a
hand-operated gun. An automatic gun is either air-operated or
electrically operated. A hand-operated gun is manually operated (see
Figure A 1-6).
2. Follow the instructions below that apply to the type of gun you are
installing.
CAUTION: If you are connecting a hand-operated gun, take

care not to connect the heater wires to the resistance
temperature detector (RTD) wires. Otherwise , the control
system or RTD will be destroyed when the system is placed in
operation.
Type of Gun Connection
Automatic Connect the gun cordset to the electrical

connector at the end of the hose.
Hand-operated Follow the instructions in the gun manual to

connect the cordset and wires at the end of the
hose to the gun. Be sure not to connect the
wires for heater power to the RTD. Otherwise,
the control system or RTD will be destroyed
when the system is placed in operation.

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A 1-16 Installation
Connecting Gun and Hose 3. If you installed hoses for an externally circulating system, you must
Cordsets (contd.) follow a different procedure to connect hose cordsets. Go to
Installation Procedures for Externally Circulating Systems at the end
of this section. Return here and go to step 6.
4. Find the hose plug of the first hose you connected to the manifold.
5. See Figure A 1-10. Connect this hose plug to electrical receptacle

number 1 on the unit.
6. If you have additional guns and hoses, continue connecting gun and
hose cordsets. Connect the cordset of the next hose (the hose
closest to the rear of the unit) to the hose electrical receptacle labeled
number 2 on the unit. Continue connecting gun and hose cordsets,
working from the rear of the unit to the front of the unit, until you have
connected all gun and hose cordsets.
4103958A
Fig. A 1-10 Connecting a Hose Cordset to the Unit

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Installation A 1-17
Opening the Electrical To make the electrical connections inside the unit, follow this procedure
Enclosure to open the unit and access the electrical enclosure.
WARNING: Risk of equipment damage, personal injury, or

death. Disconnect and lock out electrical power to the unit.
1. Place the unit’s POWER switch in the off position and disconnect and
lock out electrical power to the unit at the branch circuit disconnect
switch.
2. See Figure A 1-11. Loosen the captive screws on the electrical

enclosure lid, lift the lid from the unit, and prop it against the pump
cover. Take care not to disconnect the ground wire.
3. Make sure the support strap is not wrapped around any board
components. Untangle the strap if necessary.
4. Loosen the two captive screws on either side of the control-end frame
and lower the frame. You may need to pull the front and rear panels
apart to release the frame.
5. Avoid direct contact with internal electrical connections, components,

or wiring.
6. Make sure all ground wires are securely connected.
4130849A
Fig. A 1-11 Opening the Electrical Enclosure

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A 1-18 Installation
Connecting a Triggering Device If your unit has a triggering solenoid valve on the pump, follow this
for the Pump Solenoid Valve procedure to connect a 24 VDC triggering device to the center frame
terminal block. See Figure A 1-12 to determine whether your pump has a
triggering solenoid valve (1). If your pump does not have this valve, skip
to the next procedure, Connecting Output Contacts (Optional).
1 2 1
2 3 2
3
3
4
4
4130879A
Fig. A 1-12 Connecting a Triggering Device for the Pump Solenoid Valve
1. Triggering solenoid valve 3. Wires from 24 VDC triggering 4. Strain relief
2. Center frame terminal block device

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Installation A 1-19
WARNING: Risk of equipment damage, personal injury or

death. Install a strain relief to protect wires from being
damaged by the edges of the knockout hole.
CAUTION: Circuit boards can be easily damaged. Avoid any

contact with circuit boards when removing a knockout hole plug.
1. See Figure A 1-12. Remove and discard the plug from a knockout
hole on either the back side or the bottom of the unit (whichever is
most convenient for your operation) and install a strain relief (4) in the
hole. Refer to the following table for the appropriate size strain relief.
NOTE: Your unit may have several knockout holes. You should
route your triggering device wires through a larger hole.
Size of Knockout Hole Size of Strain Relief to Install

23 mm (15/16 in.) PG-16 or 1/2-in. trade size
29.5 mm (15/32 in.) PG-21
35 mm (13/8 in.) 1-in. trade size
CAUTION: Use 0.34--0.25 mm2 (22--24 AWG) wire. Using a

different wire size can cause internal stress-related damage to
the unit.
2. Route the wires from a 24 VDC triggering device (3) through the
strain relief and connect them to terminals 3 and 4 on the center
frame terminal block (2).

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A 1-20 Installation
Connecting Output Contacts Follow this procedure to connect the standard output contacts that are
(Optional) provided on all units. If you do not wish to connect any outputs, skip to
the next procedure, Connecting External Devices to the Pattern Control.
Output contacts allow you to automatically activate other equipment or to

activate devices for remote monitoring of the unit’s operations.
Table A 1-1 describes the standard output contacts. If your unit has an
optional input/output (I/O) board, there are additional outputs and several
inputs you can connect. Refer to Series 3000V Input/Output Board in the
Options section.
Table A 1-1 Standard Output Contacts

Output Contact Function
System Warning Used to signal a device that will alert remotely
located operators of a warning condition
System Fault Used to signal a device that will alert remotely
located operators of a system fault condition. This
output is typically used to turn on a light or to sound
an alarm.
System Ready Used to signal a device that will alert remotely
located operators that the system is ready for
operation (up to temperature) or that the unit’s
pump is on. This output is typically used to send a
ready signal to a production line so that the line
turns on only when the unit is ready to pump
adhesive.
3. If you have not already done so, open the electrical enclosure. Refer
to Opening the Electrical Enclosure in this section.
4. If you have not already done so, carefully remove a knockout hole
plug from one of the larger holes on either the back side or the bottom
of the unit (whichever is most convenient for your operation). Avoid
contact with any printed circuit boards.
5. To protect the wiring, install a strain relief in the hole. Refer to the
following table for the appropriate size strain relief.
Table A 1-2 Strain Relief Sizes for Knockouts

29.5 mm (15/32 in.) PG-21

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Installation A 1-21
WARNING: Risk of equipment damage, personal injury, or

death. For a proper and safe installation, make sure you meet
the requirements in the following step.
6. See Figure A 1-13. Route the output contact wires (2) through the
strain relief (1) to terminal block TB2 (3). Make sure your installation
meets these requirements:
S Use 0.34--0.25 mm2 (22--24 AWG) stranded wire that is suitable
for National Electrical Code (NEC) Class 1 remote control and
signaling circuits. Output contacts are rated for 250 VAC, 2 A
maximum.
S Use the proper length of wire and route the wires so they do not
touch any of the printed circuit boards. Make sure the wires reach
terminal block TB2 when the electrical enclosure is opened.
4130923A
Fig. A 1-13 Connecting Output Contacts

1. Strain relief 3. TB2 terminal block
2. Output contact wires

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A 1-22 Installation
Connecting Output Contacts 7. Connect the output wires to the plug for terminal block TB2 from the
(Optional) (contd.) ship-with kit. Refer to Table A 1-3.
Table A 1-3 Output Contact Connections

Output Contact as Behavior of Contact TB2 Positions
Labeled on Power
Unit Power Off Unit Power On (see Note A)
Board
Warning Contact Open Closed Open 1, 2
(System Warning) (no warning) (warning exists)
Fault Contact Open Closed Open 3, 4
(System Fault) (no fault) (fault exists)
Ready Contact Open Open Closed 5, 6
(System Ready) (unit not ready) (unit ready)
NOTE A: The output contacts are not polarity sensitive. It does not matter which wire is inserted into a position.
8. Connect the plug to TB2. See Figure A 1-13 for the location of TB2.
9. Go to the next procedure, Connecting External Devices to the Pattern

Control.
Connecting External Devices to This procedure describes how to connect the following devices that
the Pattern Control operate pattern control features:
S a trigger device, which controls the operation of automatic gun

solenoid valves or the gun driver used with the pattern control feature
S an optional enable/disable device, which sends a signal from a

remote location to enable or disable the pattern controller
S the solenoid valves or gun driver that is used to activate the guns on
outputs 1 and 2

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Installation A 1-23
CAUTION: Use 0.34--0.25 mm2 (22--24 AWG) stranded wire.

Using a different wire size can cause internal stress-related
damage to the unit
1. Make sure that your system meets the following requirements:
S Trigger signals are 9 to 24 VDC.
S The enable/disable device is an active low signal.
S Each solenoid valve (or other gun driver device) is rated for no
more than 1 A at 24 VDC.


2. If you have not already done so, remove and discard the plug from a
knockout hole on either the back side or the bottom of the unit
(whichever is most convenient for your operation) and install a strain
relief in the hole. Refer to the following table for the appropriate size
strain relief.
NOTE: Your unit may have several knockout holes. You should
route your pattern control wiring through a larger hole.

29.5 mm (15/32 in.) PG-21

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A 1-24 Installation
Connecting External Devices 3. Route the wiring from the following devices into the electrical
to the Pattern Control (contd.) enclosure.
S trigger devices
S each gun solenoid valve (or other gun driver device)
S remote enable/disable device (if used)
WARNING: Risk of electrical shock or equipment damage.

Failure to install ferrites as shown can result in equipment
damage, personal injury, or death. Ferrites must not come into
contact with an energized component.
4. See Figure A 1-14. Route the input wires from your trigger devices
and your remote enable/disable device (if used) through the two
round (2) and two square (1) ferrites provided in the ship-with kit.
4130700A
Fig. A 1-14 Installing Ferrites

1. Square ferrites 2. Round ferrites
5. Locate terminal block X6P (1) on the pattern control driver board.

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Installation A 1-25
6. See Figure A 1-15. The trigger device, usually a photosensor, and

the enable/disable devices are connected at terminal block X6P on
the pattern control driver board. To connect these devices, refer to
Table A 1-4.
1 X6P
2
3
4
4130254
Fig. A 1-15 Terminal Block X6P on the Pattern Control Driver Board
1. Position 1 3. Position 3
Table A 1-4 Connections for Trigger and Enable/Disable Devices
Functional Description Position on Terminal Block Note

X6P
+15V 1
trigger 2 A
common 3 B
enable/disable 4 B
NOTE A: The driver board accepts either a current-sourcing or a
current-sinking trigger input.
B: If you are not using a remote enable/disable device, install a
jumper wire between positions 3 and 4.

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A 1-26 Installation
Connecting External Devices 7. See Figure A 1-16. Remove the connector on jumper 1 (JPR1) and
to the Pattern Control (contd.) reconnect it according to the type of trigger signal you wish to use.
Refer to Table A 1-5.
JPR1
1 2 3
4130271
Fig. A 1-16 Jumper 1 (JPR1) on the Pattern Control Driver Board

2. Position 2
Table A 1-5 Connections for Jumper JPR1
Position on Jumper JPR1 Type of Signal

1 and 2 Current sourcing (leading edge)
2 and 3 Current sinking (trailing edge)

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Installation A 1-27
8. See Figure A 1-17. To connect gun solenoid valves, locate terminal

blocks X3P and X4P and make the appropriate connections. Refer to
Table A 1-6.
1
2 X3P
1 X4P
2
4130255
Fig. A 1-17 Terminal Blocks X3P and X4P on the Pattern Control Driver Board
Table A 1-6 Connections for Solenoid Valves
Output Channel Position on Terminal Position on Terminal

Block X3P Block X4P
1 1 and 2
2 1 and 2
9. To continue making electrical connections, go to the next procedure,

Connecting Electrical Service.

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A 1-28 Installation
Connecting Electrical Service Follow this procedure to connect electrical service to your unit.
1. Open the electrical enclosure. Refer to Opening the Electrical

Enclosure in this section.
2. See Figure A 1-18. Locate the identification plate on your unit.
6 5 4 3 2 1
4130690A
Fig. A 1-18 Location of Identification Plate
3. See Figure A 1-19. Determine the voltage specification of your unit

by looking at the VOLTS (ac) portion (1) of the identification plate.
4130689A
Fig. A 1-19 Unit Identification Plate

1. VOLTS (ac) portion 2. AMPS (max.) portion

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Installation A 1-29
CAUTION: Operate the unit only when it is connected to the

correct line voltage, as shown in Table A 1-7. Operating the unit
at a different voltage can damage the unit or impair its
performance.
4. Ensure that your unit has the correct voltage specification to accept
the type of electrical service that you will be connecting to it.
Table A 1-7 shows all the Series 3000V voltage specifications and the
types of electrical service that you can connect to each.
Table A 1-7 Types of Electrical Service for Each Voltage Specification

Unit Voltage Voltage Types of Service You Can Connect to the Unit See Note
Specification Code (see
Note B)
200--240 VAC 1  200--240 VAC 1 (two wire service without a neutral)

or  200--240 VAC 3 (three wire service without a neutral)
3 AC 230V
or
3/PE AC 200--240V
3/N/PE AC 400/230V 2  230 VAC 1 (two wire service, including a neutral) C

 400/230 VAC 3 (four wire service, including a neutral) D
3 AC 400V 3  400 VAC 3 (three wire service without a neutral)
NOTE A: The voltage specification is shown in the VOLTS (ac) portion of the unit’s identification plate.
B: The voltage code is part of your unit configuration code. It is included here for information only and is
not something you need to know to install your electrical service line. For more information about your
unit configuration code, refer to Explanation of Configuration Code at the end of the Description section.
C: This type of service also includes voltage used primarily in the British Commonwealth: 240 VAC 1
(two wire service, including a neutral).
D: This type of service also includes voltage used primarily in the British Commonwealth:
415/240 VAC 3 (four wire service, including a neutral).

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A 1-30 Installation
Connecting Electrical Service 5. See Figure A 3-19. Size your electrical service line based on the
(contd.) maximum amperage shown in the AMPS (max.) portion (2) of the
identification plate. The line must also meet local electrical code
requirements.


6. If you have not already done so, remove and discard the plug from a
knockout hole on either the back side or the bottom of the unit
(whichever is most convenient for your operation) and install a strain
relief in the hole. Refer to the following table for the appropriate size
strain relief.
NOTE: Your unit may have several knockout holes. You should route
your electrical service wiring through a smaller hole.

29.5 mm (15/32 in.) PG-21

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Installation A 1-31
7. Route the electrical service line to the unit.
WARNING: Use the proper length of cable. Inadequate wire

length could result in disconnection at TB1 when you open the
operator panel. Excess wiring can be pinched when you close
the panel, causing equipment damage, personal injury, or
death.
8. See Figure A 1-20. Route the electrical service line through the strain
relief, determine the length of cable required to reach terminal
block TB1 and the ground terminal, and cut the cable.
4130764
Fig. A 1-20 Routing the Electrical Service Line Through the Strain Relief
1. Strain relief 2. Electrical service line

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A 1-32 Installation
Connecting Electrical Service 9. Remove the required amount of cable insulation and wire insulation
(contd.) and then secure the cable with a cable strap of the correct size, as
shown in Figure A 1-21. Three different sizes of cable strap are
provided: one is attached to the unit just below the power board and
the other two are included in the ship-with kit.
4130763
Fig. A 1-21 Installing the Cable Strap on the Electrical Service Line
1. Electrical service line 2. Cable strap
10. Connect the ground wire of your electrical service line to the ground
terminal below TB1 as shown in Figure A 1-22.
4130765
Fig. A 1-22 Connecting the Ground Wire

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Installation A 1-33
11. Connect the remaining wires of the electrical service line to TB1 as
shown in Figure A 1-23. Refer to Table A 1-8 to determine which
illustration in Figure A 1-23 shows the type of service line you are
connecting.
Table A 1-8 Key to Illustrations in Figure A 1-23

Number of Wires in Your Service Line Illustration in Figure A 1-23 to See
Type of Service
(excluding the ground wire) Use for Connecting Service Note
Four wires (including a neutral)  400/230 VAC 3 Illustration A
Three wires (without a neutral)  200--240 VAC 3 Illustration B

 400 VAC 3
Two wires (including a neutral)  230 VAC 1 Illustration C A
Two wires (without a neutral)  200--240 VAC 1 Illustration D B
NOTE A: If the VOLTS (ac) label on your unit is 3/N/PE AC 400/230V (voltage code 2), your unit is designed to
accept two wires with a neutral. Check the identification plate on your unit for the VOLTS (ac) label.
B: If the VOLTS (ac) label on your unit is 3 AC 230 V (voltage code 1), your unit is designed to accept two
wires without a neutral. Check the identification plate on your unit for the VOLTS (ac) label.
L1 L2 L3 N L1 L2 L3 N L1 L2 L3 N L1 L2 L3 N
A B C D 4130766
Fig. A 1-23 Electrical Service Connections at TB1 (with ground wire shown)
12. If you connected three-phase power to the unit, go to Closing the

Electrical Enclosure in this section. If you connected single-phase
power to the unit, go to the next procedure, Preparing the Unit for
Single-Phase Operation.

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A 1-34 Installation
Preparing the Unit for All units are shipped to accept three-phase power. If you are supplying
Single-Phase Operation single-phase power to your unit, use this procedure to modify your unit to
accept single phase power.
CAUTION: Units with 400 Vac 3 (without neutral) service are

factory-wired for three-phase operation only and cannot be
modified for single-phase operation. If you install a
single-phase voltage plug on a 400 Vac 3 unit, you may
damage the unit or make it inoperable.
1. See Figure A 1-24. Locate the voltage plug on the power board. It is
plugged into connector X3.
X3
4130551
Fig. A 1-24 Location of Voltage Plug on Power Board

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Installation A 1-35
2. Remove this three-phase voltage plug from connector X3 and replace

it with the appropriate voltage plug supplied in the installation kit. A
voltage plug is shown in Figure A 1-25. The part number of the plug
you must install is listed in Table A 1-9 and on the label of the
electrical enclosure lid.
Table A 1-9 Voltage Plug Part Numbers

Type of Service Part Number of
Single-Phase Plug to Install
200--240 VAC single phase 227 567
230 VAC (with neutral) single phase 232 617
NOTE: If you are supplying 230 VAC (with neutral) single-phase

service, the voltage plug consists of two connectors jumpered
together. The large plug connects to connector X3 on the power
board and the small plug connects to connector X4, which is located
next to connector X3.
4130427
Fig. A 1-25 Typical Voltage Plug

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A 1-36 Installation
Preparing the Unit for 3. Determine whether your unit is equipped with a contactor board,
Single-Phase Operation (contd.) which is located on a large bracket at the rear of the electrical
enclosure, as shown in Figure A 1-26.
4130550
Fig. A 1-26 Location of Contactor Board

1. Contactor board 2. Wiring harness X1C/X2C
4. If your unit has a contactor board, go to step 5. If it does not, go to

the next procedure, Closing the Electrical Enclosure.
5. Find wiring harness X1C/X2C on the contactor board and remove it.
It is identified in Figure A 1-26.

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Installation A 1-37
6. Replace the harness you just removed with the appropriate

single-phase harness supplied in the installation kit. A wiring harness
is shown in Figure A 1-27. The part number of the wiring harness you
must install is listed in Table A 1-10 and on the label of the electrical
enclosure lid.
4130428
Fig. A 1-27 Contactor Board Wiring Harness
Table A 1-10 Wiring Harness Part Numbers

Part Number of Wiring
Type of Service
Harness to Install
200--240 VAC single phase 232 719
230 VAC (with neutral) single phase 232 709
7. Go to the next procedure, Closing the Electrical Enclosure.

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A 1-38 Installation
Closing the Electrical After you have completed electrical installation, follow this procedure to
Enclosure close the electrical enclosure.
1. Reconnect any ground wires that may have become disconnected

during electrical installation.
2. Raise the control-end frame into place and tighten the captive screws
on each side of the frame. You may need to pull the front and rear
panels apart to position the frame.
3. Position the electrical enclosure lid on top of the unit and secure it
with the captive screws.
4. Remove the lock-out and turn on the power at the branch circuit
disconnect switch.
7. System Programming Before running your unit, follow the procedures in this part of the
Installation section to program the unit for your operations. All
Procedures programming is done from the System Setup area of the operator panel.
From the System Setup area, you can program
S how the unit operates (SYSTEM SETTINGS)
S the temperature at which each zone operates (TEMPERATURE)

TEMPERATURE
SETPOINT 2
1 S when the system operates (CLOCK)
STANDBY INTERNAL HOSE GUN
S the type of adhesive pattern applied to your product or package
SYSTEM
SETTINGS
(PATTERN CONTROL)
CLOCK You will probably find it helpful to read Control System in the Description
section of this manual before programming any system controls. Control
SET TIME
System briefly describes the function of each control you will program.
ENTER
STANDBY
EXIT
STANDBY
HEATERS ON
INTERVAL
HEATERS OFF
1 2
1 PATTERN CONTROL
2
LINE
SPEED
STORE
USE
4130218
Fig. A 1-28 System Setup Area of the

Operator Panel

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Installation A 1-39
Programming System Controls The system controls determine how the unit will operate.
1. To begin programming system controls, first turn power on to the unit

by pressing the POWER switch. The following occur:
S The system scans each heated zone, displaying each zone’s

temperature in sequence.
S The Multipurpose display shows four dashes (– – – –) for each

zone until a setpoint temperature is entered. After a setpoint is
entered, the display will show the setpoint that was entered as the
default when power is turned on.
S The Actual Temperature display shows the room temperature

because no heat has been applied to the zones.
2. Customize the system to your operations by completing the

procedures listed below. Refer to Table A 1-11 for a summary of all
the features that you can customize.
S Programming Optional Features
S Programming SYSTEM SETTINGS Controls
S Programming TEMPERATURE Controls
S Programming CLOCK Controls
S Programming PATTERN CONTROL Settings
4130217
Fig. A 1-29 Turning the Power On

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A 1-40 Installation
Programming System
Controls (contd.)
Table A 1-11 Summary of Features to Customize
Control Area Features to Customize
SYSTEM SETTINGS From SYSTEM SETTINGS you can customize the following features, which are explained
in more detail in Table A 1-12:
 Password Enable
 System-Ready Time Delay period
 Overtemperature Setpoint
 Celsius or Fahrenheit display
 Global Temperature Band setting
 Individual Temperature Bands setting
 Sequential or Simultaneous Startup
 Display Heater Proportioning
 Warning or Power notification
 Ready or Pump notification
 Auto-Energize Pump (piston pump units only)
 Auto-Energize Pump Temperature setting (piston pump units only)
 Auto-Energize Heaters
 Auto-Energize Pattern Control
 Time with Heaters On
TEMPERATURE SETPOINT Temperature: This feature sets the temperature that a zone will maintain
during normal operation.
STANDBY Temperature: This feature sets the desired temperature to which a zone will
be reduced when the system is in the standby mode.
CLOCK SET TIME: This feature keeps the current day and time. The clock must be on before
you can use the HEATERS ON, HEATERS OFF, ENTER STANDBY, and EXIT STANDBY
features.
ENTER STANDBY and EXIT STANDBY: This feature sets the time that you want the
system to automatically enter and exit the standby mode.
HEATERS ON and HEATERS OFF: This feature sets the time that you want heaters to
automatically turn on and off.
PATTERN OUTPUT 1: This feature allows you to control how output 1 applies a pattern.
CONTROL
OUTPUT 2: This feature allows you to control how output 2 applies a pattern.
LINE SPEED: This feature allows you to enter your line speed so the pattern controller
accurately applies pattern sets to your product.
STORE: This feature allows you to store as many as 99 pattern sets in the controller’s
memory. Once a pattern set is stored, it can be used any time.
USE: This feature allows you to use a stored pattern set.

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Installation A 1-41
Programming Optional If your unit has an optional I/O board, you can program additional
Features features. Refer to Series 3000V Input/Output Board in the Options
section for information on programming these additional features.
Programming SYSTEM Use this procedure to program the SYSTEM SETTINGS features shown
SETTINGS Controls in Table A 1-11.
1. If you have not already done so, turn power on to the unit by pressing
the POWER switch.
2. See Figure A 1-30. Press the Move Up (1) and Move Down (2) keys
until the SYSTEM SETTINGS light turns on. When you select
SYSTEM SETTINGS, the following occur:
S The values in the Displays area change.
S The number in the Selector display changes to a feature number.
S The Multipurpose display changes to the current value for the

feature selected.
4103988
Fig. A 1-30 Selecting SYSTEM SETTINGS Features

1. Move Up key 2. Move Down key
NOTE: If you have enabled the password feature, you must

change the number in the Multipurpose display (500) to the
password (321) and press the Enter key before the system will
allow you to change any SYSTEM SETTINGS features.

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A 1-42 Installation
Programming SYSTEM 3. Determine which SYSTEM SETTINGS feature to customize. Refer to

SETTINGS Controls (contd.) Table A 1-12 for a list of defaults and options for customizing each
feature.
WARNING: Risk of fire. The default for the overtemperature

setpoint is 218 _C (425 _F). If the Material Safety Data Sheet
(MSDS) for your adhesive gives a flash point that is below
218 _C (425 _F), be sure to reset the overtemperature setting to
at least 42 _C (75 _F) below the flash point.
4. See Figure A 1-31. Press the Up key (1) below the Selector
display (2) until the number of the feature you want appears on the
display. As the feature number changes, the Multipurpose display (3)
changes to show the setting of each feature selected.
5. Press the Up or Down keys (4) below the Multipurpose display to

change the setting. The display flashes.
6. Press the Enter (5) key to save the new setting. The display stops
flashing.
2 3
4 5
4130012
Fig. A 1-31 Changing the Setting of a Selected Feature

1. Up key 4. Up and Down keys
2. Selector display 5. Enter key
3. Multipurpose display
7. Record your setting in the forms provided at the end of this section.
Refer to Records of System Settings.
8. Repeat steps 4 through 7 for each feature you wish to change.
9. To exit the System Setup area, press the MONITOR/SCAN key.

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Installation A 1-43
Table A 1-12 SYSTEM SETTINGS Features

Feature Feature Description Default Optional Settings
No. Setting
0 Password Provides a password if the password enable feature is 321 none
turned on. The password (321) cannot be changed.
1 Password Allows you to turn the password enable feature on or off. 0 0 (off)
Enable When the password enable feature is on, operators can (off) 1 (on)
view the settings for TEMPERATURE, SYSTEM
SETTINGS, or CLOCK. To change the settings,
operators must enter the correct password (321). When
the feature is off, operators can change all settings
without entering a password.
2 System-Ready Allows you to specify the amount of additional time 18 (minutes) 0--60 (minutes)
Time Delay needed for the adhesive to melt after all zones have
reached their setpoint temperatures. At the end of the
time delay, the READY light turns on.
3 Overtemperatur Allows you to specify the maximum temperature any 218/425 52--246/125--475
e Setpoint zone can reach before the system initiates a fault (_C/_F) (_C/_F)
condition. This setting should be at least 14 _C (25 _F)
above the highest operating setpoint. The system will not
allow you to set the overtemperature setpoint lower than
this, or the operating setpoint higher. (See Note A.)
4 Celsius/ Allows you to display temperature measurements in F (Fahrenheit) F (Fahrenheit)
Fahrenheit Celsius or Fahrenheit. C (Celsius)
5 Global Allows you to specify the degree to which a temperature 17/30 6--28/10--50
Temperature may deviate from any zone before the system indicates (_C/_F) (_C/_F)
Band an out-of-band warning. (See Note B.)
6--19 Individual Allows you to specify the degree to which a temperature 17/30 6--28/10--50
Temperature may deviate for an individual zone before the system (_C/_F) (_C/_F)
Bands initiates a warning. (See Note C.)
(See Note D.)
20 Sequential or Allows you to specify whether the system will perform a 1 0 (simultaneous)
Simultaneous sequential startup (internal zones and hose zones heat (sequential) 1 (sequential)
Startup first, then gun zones) or simultaneous startup (all zones
heat at once).
21 Display Heater Allows you to display the heater proportioning (a flashing 0 0 (no display)
Proportioning INTERNAL, HOSE, or GUN light). (no display) 1 (show display)
22 System Warning Allows you to change the System Warning output contact 1 0 (power)
or Power to alert remotely located operators that a system warning (warning) 1 (warning)
Notification has occurred or that power is on.
23 System Ready Allows you to change the System Ready output contact 1 0 (pump)
or Pump to alert remotely located operators that the system is (ready) 1 (ready)
Notification ready (up to temperature) or that the pump is on.
24 Auto-Energize Piston pump units only: Allows you to turn the 1 0 (off)
Pump auto-energize pump feature on or off. If this feature is on, (on) 1 (on)
the system turns the pump on automatically once the
tank reaches the preset temperature of Feature No. 32.
If the auto-energize pump feature is off, you must turn the
pump on by pressing the PUMP key until the PUMP light
turns on.
NOTE A: The overtemperature setting should be at least 42 _C (75 _F) below the flash point temperature.
B: If you enter a setting that is higher than the tank setpoint, the pump will start when the tank reaches its setpoint.
C: If you enter a new setting for this feature, the new setting is immediately entered for the individual zones (Feature
Nos. 6--19). However, it is not saved as the setting for Feature No. 5. Feature No. 5 always returns to the default
setting of 6 _C (10 _F).
D: Feature No. 6 = tank, Feature No. 7 = grid, Feature Nos. 8--13 = hoses 1--6, Feature Nos. 14--19 = guns 1--6.

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A 1-44 Installation
Programming SYSTEM
SETTINGS Controls (contd.)
Feature Feature Description Default Optional
No. Setting Settings
25 Auto-Energize Allows you to turn the auto-energize heaters feature on or off. If 1 0 (off)
Heaters the feature is on, the system turns heaters on automatically once (on) 1 (on)
the POWER switch is turned on. However, if you have
programmed the system to turn heaters on and off automatically,
using the clock feature, your clock settings override the
auto-energize heaters feature. If the auto-energize heaters
feature is off, you must turn heaters on manually, or allow any
clock settings you have programmed to turn heaters on or off.
26 Time With Allows you to display the total time (in hours) that the heaters See Note A none
Heaters On have been running to assist with servicing and maintenance.
Refer to Checking Run Time of Heaters in the Maintenance
27 Fault Log (most Allows you to display the cause of the most recent system fault. See Note A none
recent) Refer to Checking the Warning or Fault Log in the Operation
section for a list of fault codes.
28 Fault Log Allows you to display the cause of the second most recent See Note A none
(second most system fault. Refer to Checking the Warning or Fault Log in the
recent) Operation section for a list of fault codes.
29 Fault Log (third Allows you to display the cause of the third most recent system See Note A none
most recent) fault. Refer to Checking the Warning or Fault Log in the
Operation section for a list of fault codes.
30 & 31 Auto Standby These features are available only on units with an I/O board.
Timeout and In Refer to Series 3000V Input/Output Board in the Options section
Standby of this manual for information on customizing these features.
Timeout
32 Auto-Energize Piston pump units only: Allows you to determine when the pump 0 (ready) 0 (ready
Pump automatically starts if you are using the auto-energize pump condition) or
Temperature feature (Feature No. 24). You can have the pump start either 1--232/1--450
Setting when the system reaches the READY condition or when the tank
reaches a temperature you have specified. (See Note B.) (_C/_F)
34 Remote Pump This feature is available only on units with an I/O board. Refer to
Enable/Remote Series 3000V Input/Output Board in the Options section of this
Heaters On manual for information on customizing this feature.
35 Warning Log Allows you to display the cause of the most recent system See Note A none
(most recent) warning. Refer to Checking the Warning or Fault Log in the
Operation section for a list of warning codes.
36 Warning Log Allows you to display the cause of the second most recent See Note A none
(second most system warning. Refer to Checking the Warning or Fault Log in
recent) the Operation section for a list of warning codes.
37 Warning Log Allows you to display the cause of the third most recent system See Note A none
(third most warning. Refer to Checking the Warning or Fault Log in the
recent) Operation section for a list of warning codes.
50 Auto-Energize Allows you to turn the Auto-Energize Pattern Control feature on 1 0 (off)
Pattern Control or off. If the feature is on, the system automatically turns the (on)
pattern control on when power switch is turned on. The READY 1 (on)
and PUMP lights must be on for the pattern control to operate.
51 Remote Pattern This feature is available only on units with an enhanced I/O
Select board. Refer to Series 3000V Input/Output Board in the Options
section of this manual for information on customizing this
feature.
NOTE A: Features 26--29 and 35--37 are always on. There is no default setting.
B: If you enter a setting that is higher than the tank setpoint, the pump will start when the tank reaches its setpoint.

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Installation A 1-45
Programming TEMPERATURE From the operator panel you can control each of the system’s heated
Controls components at a temperature specific to your needs. You can program
individual setpoints for the tank, each hose, each gun, and, on Series
3900V units, the grid. For programming purposes, each heated system
component is referred to as a zone.
In addition to being able to heat each zone individually, you can assign
two different temperature settings to each active zone: a setting for the
setpoint (operating) temperature and one for the standby temperature.
Table A 1-13 Types of Temperature Settings

Setting Description
Setpoint Temperature Desired temperature of a zone during

normal operation.
Standby Temperature Temperature to which a zone will be

reduced when the system is in the standby
mode.
If you do not enter standby temperatures, the standby default of OFF will
remain in effect for each zone. If you place the system in the standby
mode, the zones will cool to room temperature (while the HEATERS light
remains on). If you make the standby temperatures equal to the
setpoints, pressing the STANDBY key will have no effect on the
temperatures, but it will turn the READY light off and disable the pump.
NOTE: The default setting for all zones is OFF (less than 38 _C
or 100 _F). To turn a zone on, set the setpoint temperature to
38 _C (100 _F) or higher.

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A 1-46 Installation
Programming TEMPERATURE Because Series 3000V units can have up to six hose and gun zones and
Controls (contd.) one or two internal zones, zone numbers are used to identify specific
zones of each type. When you program TEMPERATURE settings, the
number in the Selector display represents a particular zone number.
Table A 1-14 Heating Zone Numbers

Zone Number Zone Type
(See Note A)
INTERNAL HOSE GUN
0 Set All
(See Note B)
1 Tank Hose 1 Gun 1
2 Grid Hose 2 Gun 2

(See Note C)
3 Hose 3 Gun 3
4 Hose 4 Gun 4
5 Hose 5 Gun 5
(See Note D)
6 Hose 6 Gun 6
(See Note D)
NOTE A: Your unit may be able to control the temperature of two, four,
or six hoses and guns, depending upon the unit and features
you have selected.
B: Use Set All to set all zones to the same temperature. Only
zones that are turned on are affected.
C: Some units do not have a grid.
D: Some units can accept only four hoses and four guns.

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Installation A 1-47
Follow these guidelines when programming temperature settings:
S Check the Manufacturer’s Safety Data Sheet (MSDS) for the

recommended operating temperature of the adhesive that you
will use.
S For a zone to be on, the operating temperature must be set at

38 _C (100 _F) or higher.
S Set the standby temperature 56 _C (100 _F) lower than the operating
temperature.
S Before programming any temperature settings, make sure that the

overtemperature setpoint is at least 14 _C (25 _F) higher than the
highest operating setpoint used. Refer to Table A 1-12,
Feature No. 3.
Use this tip to program temperature settings quickly:
Zone Procedure
All zones to the same Follow the procedure To Program All

temperature Zones to the Same Temperature.
Most zones to the same 1. First, follow the procedure To

temperature Program All Zones to the Same
Temperature.
2. Then, follow the procedure To
Program Setpoint and Standby
Temperatures Individually to change
the settings that you wish.

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A 1-48 Installation
To Program Setpoint and Standby Temperatures Individually

Follow this procedure to set the setpoint and standby temperatures for
each zone.
the POWER switch.
2. In the System Setup area, press the Move Up and Move Down keys
until the SETPOINT or STANDBY light turns on. The system defaults
to the internal zone type and the INTERNAL light turns on.
NOTE: If you have enabled the password feature, you must change
the number in the Multipurpose display (500) to the password (321)
and press the Enter key before the system will allow you to change
any of the temperature setpoints.
3. If you want to select the hose-zone type or the gun-zone type instead
of the internal-zone type, press the Move Right key until the light
beneath the zone type you want to set turns on.
4. See Figure A 1-32. In the Displays area, press the Up key (1) below
the Selector display (2) until the zone number you want appears on
the display. (Refer to Table A 1-14.) The Multipurpose display (3)
changes to show the current temperature setting for the zone you
selected.
5. In the Displays area, press the Up or Down key (4) below the
Multipurpose display to change the temperature. The display flashes.
NOTE: Pressing the Up or Down keys in the Displays area once

changes the number shown in increments of one. Pressing and
holding the key changes the number in increments of five.

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Installation A 1-49
6. Press the Enter key (5) to save the setting. The display stops
flashing.
2 3
4 5
4103931
Fig. A 1-32 Using the Displays Keys to Set the Temperature of a Zone
(Displays Area)
1. Up key 4. Up and Down keys
2. Selector display 5. Enter key
3. Multipurpose display
8. Press the Up key below the Selector display to select the next zone
number for the zone that you wish to customize, and repeat this
procedure until you have set temperatures for all zones.
To Program All Zones to the Same Temperature

Follow this procedure to set all zones to the same temperature. Also use
this procedure along with the procedure To Program Setpoint and
Standby Temperatures Individually to set most zones to the same
temperature.
NOTE: This procedure works only for zones that have been
previously turned on. The default setting for all zones is OFF. To turn
a zone on, refer to the previous procedure, To Program Setpoint and
Standby Temperatures Individually, and set the temperature of each
zone you want to turn on to at least 38 _C (100 _F).
the POWER switch.

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A 1-50 Installation
To Program All Zones to the Same Temperature (contd.)

2. See Figure A 1-33. In the System Setup area, press the Move Up (1)
and Move Down (2) keys until the SETPOINT or STANDBY light turns
on. The system defaults to the internal-zone type and the INTERNAL
light turns on.
any of the temperature setpoints.
4130305A
Fig. A 1-33 Selecting the Set All Feature (System Setup Area)
1. Move Up key 2. Move Down key
3. In the Display area, press the Up key below the Selector display
until 0 (Set All) appears on the display. All three zone-type lights turn
on and the Multipurpose display shows a default temperature of
177 _C (350 _F).
4. Press the Up or Down keys below the Multipurpose display to change

the temperature. The Multipurpose display flashes.
5. Press the Enter key to change the temperature setting of all zones
that are turned on to the temperature shown in the Multipurpose
Display. The display stops flashing.
NOTE: When you exit the Set All feature, it always returns to the
default setting of 177 _C (350 _F).

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Installation A 1-51
Programming CLOCK Controls The seven-day clock feature turns the heaters on and off or takes the unit
into and out of the standby mode at preset times that you program. This
feature works in conjunction with the clock on the unit, which keeps the
correct day and time. It does not matter whether you set the current day
and time first, or set the standby and heater times. However, both
features must be set for the heaters to turn on and off correctly.
NOTE: If you experience a power outage, the unit’s internal clock will
continue to keep time. Once power is restored and the unit is turned on,
the unit will resume normal operations. You do not need to reprogram
any features controlled by the clock.
NOTE: The clock does not automatically adjust for seasonal time shifts,
such as daylight savings time.
To Set the Clock

Follow this procedure to set the clock for the current time and day.
1
NOTE: The clock uses a seven-day, 24-hour format.
2
the POWER switch.
2. See Figure A 1-34. In the System Setup area, press the Move Up
and Move Down keys (1) until the SET TIME light (2) turns on.
4103934
the clock settings.
Fig. A 1-34 Selecting SET TIME

1. Move Up and Move Down keys
2. SET TIME light

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A 1-52 Installation
To Set the Clock (contd.)

3. Check the Selector display. The display flashes a number
representing the day of the week as shown in Table A 1-15.
Table A 1-15 Selector Display Codes Shown

When Clock Feature is Activated
Day Code Day of Week Represented
1 Monday
2 Tuesday
3 Wednesday
4 Thursday
5 Friday
6 Saturday
7 Sunday
1 2 3
6 5 4
4103935
Fig. A 1-35 Setting the Correct Day and Time

1. Day code (Selector display) 4. Enter key
2. Hours (Multipurpose display) 5. Up and Down keys
3. Minutes (Multipurpose display) 6. Up key

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Installation A 1-53
4. See Figure A 1-35. Check that the day code (1) is correct.
Correct? Action:
Yes Press the Enter key (4) to save the setting.
No Press the Up key (6) below the Selector display until

the correct code appears on the display; then press
the Enter key to save the setting.
5. When you press the Enter key, the Selector display stops flashing
and the hour (2) shown in the Multipurpose display begins flashing.
Check that the hour shown in the Multipurpose display is correct.
NOTE: Clock hours must be set to come on between 01:00 and

24:00 hours. If the clock is set from 00:01 to 00:59, it will not operate.
Correct? Action:
Yes Press the Enter key to save the setting.
No Press the Up or Down key below the Multipurpose

display until the correct hour appears on the display;
then press the Enter key to save the setting.
6. When you press the Enter key, the hour shown in the Multipurpose
display stops flashing and the minutes (3) shown begin flashing.
Check that the minutes shown in the Multipurpose display are correct.
Correct? Action:
Yes Press the Enter key to save the setting.
No Press the Up or Down key below the Multipurpose

display until the correct minutes appear on the display;
then press the Enter key to save the setting.
NOTE: Once the clock is set, all displays stop flashing.

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A 1-54 Installation
To Set Standby and Heater Times

The clock feature turns the heaters on or off, or takes the unit into and
out of the standby mode at preset times. Using a seven-day, 24-hour
format, the clock can store two sets of times, referred to as intervals, for
each day of the week. Each interval can store four time settings:
S one to enter standby
S one to exit standby
S one to turn the heaters on
S one to turn the heaters off
Follow this procedure to set times for entering and exiting standby and for
turning heaters on and off. After you have programmed the clock, use
the CLOCK key to turn the clock feature on and off. The CLOCK light
turns on when the clock feature is active.
NOTE: If you have enabled the password feature, you must change the
number in the Multipurpose display (500) to the password (321) and
press the Enter key before the system will allow you to change the
clock settings.
1. See Figure A 1-36. In the System Setup area, press the Move Up
1 and Move Down keys (1) until the light next to the feature you wish to
set turns on.
NOTE: When you select any of the standby or heater on/off settings,
the unit selects an interval. The INTERVAL 1 light (2) turns on as a
2 default.
4103936
Fig. A 1-36 Selecting Standby and

Heater Times
1. Move Up and Move Down keys
2. INTERVAL lights

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Installation A 1-55
2. Check the Selector display. The display flashes a number (the day
code) representing the day of the week as shown in Table A 1-16.
Table A 1-16 Selector Display Codes Shown

When Clock Feature is Activated
Day Code Day of Week Represented
1 Monday
2 Tuesday
3 Wednesday
4 Thursday
5 Friday
6 Saturday
7 Sunday
1 2 3
6 5 4
4103935
Fig. A 1-37 Setting the Correct Day and Time

1. Day code (Selector display) 4. Enter key
2. Hours (Multipurpose display) 5. Up and Down keys
3. Minutes (Multipurpose display) 6. Up key

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A 1-56 Installation
To Set Standby and Heater Times (contd.)

3. See Figure A 1-37. Press the Up key (6) below the Selector display
to select the day code (1) for which you want to set a time.
4. Press the Enter key (4) to save the day code setting. The Selector
display stops flashing and the hour (2) shown in the Multipurpose
display flashes.
5. Press the Up or Down keys (5) below the Multipurpose display until
the hour for which you want to set a time appears in the display.
6. Press the Enter key to save the hour setting. The hour shown in the
Multipurpose display stops flashing and the minutes flash.
7. Press the Up or Down keys until the minutes (3) for which you want to
set a time appear on the Multipurpose display.
8. Press the Enter key to save the minutes setting. All displays stop
flashing.
10. To set a second time for the same day, press the Move Right key until
the INTERVAL 2 light turns on. Press the Enter key to save the day
and repeat steps 5 through 9.
To Change a Standby or Heater Time

To change a set time, follow the procedure for setting the standby and
heater times.

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Installation A 1-57
To Delete a Standby or Heater Time

Follow this procedure to delete a Standby or Heater time.
1. From the System Setup area, press the Move Up and Move Down
keys until the light next to the feature you wish to change turns on.
the clock settings.
2. Check the Selector display. The display flashes the day code
representing a day of the week.
3. Refer to Table A 1-16, and press the Up key below the Selector
display until the day code of the day that you want to change appears
in the Selector display.
4. Press the Enter key to save the setting. The Selector display stops
flashing and the hour shown in the Multipurpose display flashes.
5. Press the Up or Down keys below the Multipurpose display until four
dashes (– – – –) appear on the display. (The dashes indicate that no
setting has been entered.)
6. Press the Enter key to save the setting. All displays stop flashing.
To Delete Times for an Entire Day

To delete times for an entire day, follow the procedure To Delete a
Standby or Heater Time and turn the clock off for each feature: entering
standby, exiting standby, turning heaters on, turning heaters off.

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A 1-58 Installation
An Example of How to Use the Seven-Day Clock Feature

At one company, the production line runs for two shifts each day and
shuts down on weekends. Both shifts shut down for 45 minutes twice
each day: once at 12:00 noon for lunch and again at 6:00 in the evening
for dinner. By using the clock feature, the company can have the unit
start and stop by setting the clock feature to
S Put the unit into the standby mode (ENTER STANDBY) at 12:00 P.M.
(INTERVAL 1) and again at 6:00 P.M. (INTERVAL 2).
S Take the unit out of the standby mode (EXIT STANDBY) at 12:30 P.M.
(INTERVAL 1) and at 6:30 P.M. (INTERVAL 2), allowing 15 minutes
for the system to reach application temperature.
S Turn the heaters on (HEATERS ON) Monday through Friday

30 minutes before the start of the first shift (INTERVAL 1).
S Turn the heaters off (HEATERS OFF) Monday through Friday at the
end of the second shift (INTERVAL 1).
NOTE: The clock is not set for Saturday or Sunday when the
company is closed.
8. Programming PATTERN The pattern control feature allows you to control how adhesive is applied
to your product. The feature works only for constant speed applications.
CONTROL Settings
This part of the manual describes how to create pattern sets and how to
program the system to apply pattern sets automatically. It includes
S Defining a Pattern Set
S Programming a Pattern Set
S Storing a Pattern Set
S Creating a New Pattern Set from an Existing Pattern Set

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Installation A 1-59
For programming purposes, this manual uses the following pattern

control terminology:
S Line: the path your product follows.
S Bead: the segments of adhesive within a pattern.
S Pattern: all the beads that are generated by one output. An output
may control one or more guns. A pattern is usually a bead, followed
by a space, followed by a bead, followed by a space. A pattern may
also be one continuous bead, or one bead only.
S Pattern set: all the patterns that are applied to a product by both
outputs. A product may have up to two patterns, with each pattern
applied by one or more guns.
Figure A 1-38 provides a graphic illustration of the pattern control

process.
Before programming the pattern control, you must decide how many
beads you need, how long each bead should be, and how much space to
leave between each bead.
To apply a pattern set, the pattern control receives a signal from a sensor
that monitors your line. The process starts when the sensor detects a
product. The sensor then relays this information to the unit, which begins
firing guns in timed intervals. The intervals are based on the pattern set
you programmed. You have the option of defining pattern sets in units of
time or distance.

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A 1-60 Installation
8. Programming PATTERN
CONTROl Settings (contd.)
3
6 7 8 9
4
14
15 2
10 11 1 12 13
4130814
Fig. A 1-38 Pattern Control Process

1. Direction of line 10. Start point of first bead
2. Product (output 2)
3. Sensor 11. End point of first bead (output 2)
4. Gun (output 1) 12. Start point of second bead
(output 2)
5. Guns (output 2)
13. End point of second bead
6. Start point of first bead (output 1) (output 2)
7. End point of first bead (output 1) 14. Pattern (output 1)
8. Start point of second bead 15. Pattern (output 2)
(output 1)
9. End point of second bead
(output 1)

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Installation A 1-61
Defining a Pattern Set Use this procedure to define a pattern set. To define a pattern set, you
must enter a line speed and define a pattern for each output (output 1
and output 2).
To Enter a Line Speed

1. See Figure A 1-39. In the System Setup area, press the Move Down
key (1) until the LINE SPEED light (2) turns on.
2. Check the Multipurpose display. The display shows the current

1 setting.
3. Press the Up or Down key below the Multipurpose display until the
display shows the line speed setting you want. Use the following
steps to determine your line speed setting:
a. If you plan to use units of time to define your patterns, set the line
speed to 0 and go to step 4. You must also use units of time in
the next procedure, To Define a Pattern for Output 1 or Output 2.
1 PATTERN CONTROL
2 2 b. If you plan to use units of distance to define your patterns, refer to
Table A 3-17 to set your line speed, then go to step 4.
LINE
SPEED
STORE
USE
4130226
Fig. A 1-39 Selecting the Line Speed

Function
1. Move Down key
2. LINE SPEED light
Table A 1-17 Line Speed Settings for Units of Distance

If your unit displays Determine your line Use the following Use this unit of measure
temperature in speed in setting for your line to define your patterns
speed: (see Note A):
Celsius degrees meters per minute (M/min) a number from 1--150 millimeters (mm)
Fahrenheit degrees feet per minute (ft/min) a number from 1--500 inches (in.)
NOTE A: This is the unit of measure you will use in the next procedure, To Define a Pattern for Output 1 or
Output 2.
4. Press the Enter key to accept the line speed setting. The
Multipurpose display stops flashing.

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A 1-62 Installation
To Define a Pattern for Output 1 or Output 2

1. Follow the appropriate procedure in Table A 3-18 to define the pattern
for output 1. Repeat the procedure for output 2.
Table A 1-18 Defining a Pattern Using Time or Distance Units.

For each pattern, determine the length of each bead and the length of the space between each bead. To
apply only one bead or a continuous bead, see Note A.
Follow these steps to define a Follow these steps to define a Calculate a number (measurement
pattern in time units pattern in distance units unit) to program into the system.
(milliseconds). (millimeters or inches).
1. Estimate the amount of time from 1. Measure the distance between The start point for the first bead is
the point the sensor detects the the sensor and the gun nozzle. equal to the number from step 1.
product to the point the gun should Measure the additional
begin firing. distance that your product will Example: 150 ms or 75 mm (3.0 in.)
travel before the gun begins
Example: 150 ms
firing. Add the two
measurements.
Example: 75 mm (3.0 in.)

2. Estimate the amount of time the 2. Determine the length of the The end point for the first bead is
gun should fire to give you the first bead to be applied to your equal to the sum of the numbers from
desired length of the first bead. product. steps 1 and 2.
Example: 50 ms
Example: 25 mm (1.0 in.) Example: 200 ms or 100 mm (4.0 in.)
3. Estimate the amount of time the 3. Determine the length of the The start point for the second bead is
gun should shut off to give you the space between the first and equal to the sum of the numbers from
desired space between the first and second beads. steps 1, 2, and 3.
second beads.
Example: 50 mm (2.0 in.) Example: 300 ms or 150 mm (6.0 in.)
Example: 100 ms
4. Estimate the amount of time the 4. Determine the length of the The end point for the second bead is
gun should fire to give you the second bead. equal to the sum of the numbers from
desired length of the second bead. steps 1, 2, 3, and 4.
Example: 25 mm(1.0 in.)
Example: 50 ms
Example: 350 ms or 175 mm (7.0 in.)
NOTE A: To disable an output, set the start point for the first bead to 0. To apply a continuous bead, use the same
number you calculated for the end point for the first bead for both the start and end points for the second
bead.
5. Go to the next procedure, Programming a Pattern Set.

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Installation A 1-63
Programming a Pattern Set After you have defined the patterns for outputs 1 and 2, follow this
procedure to program the pattern set into the system.
1. See Figure A 1-40. In the System Setup area, press the Move Up (1)
1 or Move Down (2) key until the OUTPUT 1 or OUTPUT 2 light (4)
turns on.
2 NOTE: Outputs are limited to 1 amp per output or 2 amps total per
unit. Ensure that the guns connected to your unit do not exceed this
rating.
3
2. Press the Move Right key (See Figure A 1-40, item 3) until the light
for the bead start or end point you want to program turns on (begin
with the start point for the first bead). See Figure A 1-41.
4 1 PATTERN CONTROL
2
LINE
SPEED
STORE
USE
4130224
Fig. A 1-40 Selecting an Output

1. Move Up key
2. Move Down key
3. Move Right key
4. Output lights
1 2 3 4
4130223
Fig. A 1-41 Pattern Definition Lights

1. Light for start point for first bead 3. Light for start point for second
2. Light for end point for first bead bead
4. Light for end point for second
bead

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A 1-64 Installation
Programming a Pattern Set 3. Check the Multipurpose display. The displays shows the default
(contd.) setting for the bead start or end point. Refer to Table A 3-19.
Table A 1-19 Defaults for Bead Start and End Points

Start or End Default Setting
Point Time (ms) Distance (mm) Distance (in.)
Start point for 50 ms 50 mm 5.0 in.
first bead
End point for 100 ms 100 mm 10.0 in.
first bead
Start point for 150 ms 150 mm 15.0 in.
second bead
End point for 200 ms 200 mm 20.0 in.
second bead
4. Press the Up or Down key below the Multipurpose display to change

the current setting. The display flashes.
5. Press the Enter key to save the new setting. The Multipurpose
display stops flashing.
6. Repeat steps 2--5 until you have programmed all bead start and end
points for the pattern.
7. If you have a second pattern to apply to your product, repeat

steps 1--6 to program the bead start and end points for the
second pattern.
8. Go to the next procedure, Storing a Pattern Set.
NOTE: Although the system will allow you to use a pattern set as
soon as you program it, it is best to define and store all the pattern
sets you will need. If you use a pattern set you have not stored and
then you later program a new pattern set, the system will replace the
pattern you were using with the new pattern as you program it into the
system.

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Installation A 1-65
Storing a Pattern Set After defining and programming a pattern set, you should store it so you
can use it any time you want. Refer to Using a Stored Pattern Set in the
Operation section of this manual. You can also replace an existing
pattern set with a new one. You can store up to 99 pattern sets.
1. If you have not already done so, program your pattern sets. Refer to
the preceding procedure, Programming a Pattern Set.
1 2. See Figure A 1-42. In the System Setup area, press the Move Down
key (1) until the STORE light (2) turns on.
3. Check the Multipurpose display. The display flashes the number of

the next available pattern set. For example, if you have already
stored three pattern sets in system memory, the Multipurpose display
will flash the number 4.
1 PATTERN CONTROL
2
2 LINE
SPEED
STORE
USE
4130227
Fig. A 1-42 Selecting the Store

Function
1. Move Down key
2. STORE light
4. Determine whether you want to save the pattern set as a new pattern
set or whether you want to replace an existing pattern set.
To Do this
Save the pattern set as a new Press the Enter key. The
pattern set Multipurpose display stops
flashing.
Replace an existing pattern set A. Press the Up or Down key below

with a new pattern set the Multipurpose display until the
number for the pattern set you
want to replace appears. The
Multipurpose display flashes.
B. Press the Enter key. The
Multipurpose display stops
flashing.

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A 1-66 Installation
Storing a Pattern Set (contd.) 5. Record the pattern set you stored on the form provided at the end of
this section. Refer to Records of System Settings.
NOTE: The form provides space to record up to 25 pattern sets.
Creating a New Pattern Set After you have programmed two or three pattern sets, it is faster to
from an Existing Pattern Set program and store a new pattern set by changing an existing one. Use
this procedure to create a new pattern set by changing an existing
pattern set.
1. If necessary, change your line speed setting. Refer to the procedure

To Enter a Line Speed in this section.
2. Press the Move Up key in the System Settings area until the light next
to the pattern you want to change (output 1 or output 2) turns on.
3. Press the Move Right key to select the bead start or end point to
change. The current value for the point is shown in the Multipurpose
display.
4. Use the Up and Down keys to change the setting in the Multipurpose
display. The Multipurpose display flashes.
NOTE: The first time you change any information about this pattern,
the number in the Selector display disappears to indicate that the
pattern is being changed.
5. Press the Enter key to accept the new setting. The number in the
Multipurpose display stops flashing.
6. Repeat steps 3--5 until you have changed all the settings you need to
change.
7. Repeat steps 2--6 to change the bead start and end points for the
other output.
8. Store the patterns you just changed as a new pattern set. Refer to
Storing a Pattern Set in this section.
NOTE: The pattern set you used to create the new pattern set will
remain unchanged in the controller’s memory.

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Installation A 1-67
9. System Preparation Follow these procedures to flush the system and prepare it for first
operation. This part of the Installation section also includes the
procedure for adjusting the pressure control valve on gear pump units.
WARNING: Allow only qualified personnel to operate the unit.
Filling the Tank with Adhesive Use this procedure to fill the tank with unmelted adhesive. Before
continuing, refer to General Hot Melt Material Processing Instructions at
the beginning of this manual.
1. If you have not already done so, program your unit. Refer to System
Programming Procedures in this section.
2. Open the tank lid.
WARNING: Use a metal or plastic scoop to fill the tank with

adhesive. Never use your bare hands.
3. See Figure A 1-43. Use a metal or plastic scoop and fill the tank with
adhesive to within 25 mm (1 in.) of the top of the tank.
4. Close the tank lid.
5. As the system scans through the system settings, check that all
temperatures are set as recommended by your adhesive supplier.
6. Go to the next procedure, Flushing the System.
4103270
Fig. A 1-43 Filling the Tank with

Adhesive

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A 1-68 Installation
Flushing the System Before operating your unit for the first time, flush the system by pumping
adhesive through it to remove trapped air and residue left during factory
testing.
1. Use one of the following methods to prevent accidental gun

triggering:
S Air-operated guns: turn off the operating air.
S Electric guns: turn off the gun driver.
S Hand-operated guns: lock the trigger.
WARNING: Hot! Risk of burns. Wear heat-protective clothing,

safety goggles, and heat-protective gloves.
2. Place a drain pan under each gun and remove all gun nozzles.
3. If the unit is not already on, press the power switch to turn the unit on.
Allow the unit to reach operating temperature.
4. See Figure A 1-44. Clean the manifold filter by following the

filter-cleaning procedure that applies to your filter. Determine whether
your system has a standard filter (1--3) or a reverse-flush filter (4).
Then refer to Table A 1-20 for the correct filter cleaning procedure.
1 2
3 4
4130774
Fig. A 1-44 Standard Filters (1--3) and Reverse-Flush Filter (4)

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Installation A 1-69
Table A 1-20 Filter Cleaning Procedures

Filter Type Cleaning Procedure
Standard Refer to Cleaning a Standard Manifold Filter in the

Maintenance section of this manual.
Reverse-flush Refer to Cleaning a Reverse-Flush Manifold Filter in

the Maintenance section of this manual.
5. Prepare each gun in your system for operation as follows:
S Air-operated guns: increase the operating air pressure to

240 kPa (35 psi).
S Electric guns: turn on the gun driver.
S Hand-operated guns: unlock the trigger.
WARNING: Trapped air may still be in the hoses and guns.

Shield the area and operator from splashing adhesive.
6. Trigger the guns, keeping them open so that no pressure builds up.
NOTE: You may need to adjust the gun air pressure depending on
the viscosity of the adhesive and the gun response.
7. Flush the system by using one of the following methods, depending

upon the type of pump your unit has (see Figure A 3-4).
Pump Type Flushing Method
Piston pump If the PUMP light is not on, press the PUMP key.
Gradually increase air pressure to the pump by
turning the air pressure regulator clockwise. Allow
adhesive to flow out of the guns until all trapped air,
cleaning solution, and impurities are flushed out of
the system. If the pump slows noticeably or stops,
increase pump air pressure slightly.
Gear pump with Press the PUMP key and allow adhesive to flow out
AC motor drive of the guns until all trapped air, cleaning solution,
and impurities are flushed out of the system.
8. Stop triggering the guns.

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A 1-70 Installation
Flushing the System (contd.) 9. Turn the pump off by using one of the following methods, depending
upon the type of pump your unit has.
Pump Type Method of Stopping Pump
Piston pump Reduce pump air pressure to 0 by turning the air

pressure regulator fully counterclockwise.
Gear pump with Press the PUMP key. The PUMP light will turn off.
AC motor drive
10. Trigger the guns momentarily to relieve trapped hydraulic pressure.
WARNING: Hot! Risk of burns. Wear heat-protective clothing,

safety goggles, and heat-protective gloves.
11. Attach the nozzles to the guns.
12. Piston pump units only: adjust the pump air pressure regulator until
the air pressure is at the desired operating setting. Test adhesive
patterns as necessary.
13. Air-operated guns only: adjust the gun air pressure regulator until the
air pressure is at the desired operating setting. Test adhesive
patterns as necessary.
14. If your system has an air-operated pump or gun, record the initial air
pressure settings in the Records of System Settings at the end of
this section.
15. Refer to the gun product manual for additional setup information for
the specific gun.
Adjusting the Circulation If you have an externally circulating system, adjust the circulation control
Control Valve valve. Refer to Adjusting the Circulation Control Valve in Installation
Procedures for Externally Circulating Systems at the end of this section.

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Installation A 1-71
Adjusting the Pressure Control After flushing the system, follow this procedure to adjust the pressure
Valve control valve on units with a gear pump. To determine which kind of
pump your unit has, see Figure A 1-4.
If your unit has a piston pump, you do not need to perform this
procedure. Go to the Operation section of this manual.
1. If the pump is turned on, turn it off by pressing the PUMP key. The
PUMP light will turn off.
2. See Figure A 1-45. Use a hex key to hold the pressure-adjusting

screw in place while using a wrench to loosen the locking nut as
much as possible.
4130779
Fig. A 1-45 Adjusting the Pressure Control Valve
3. Turn the pressure-adjusting screw clockwise until it stops turning.
4. Turn the pressure-adjusting screw counterclockwise eight full turns.
5. Hold the pressure-adjusting screw in place while using a wrench to

tighten the locking nut.
NOTE: This setting will work well for most applications. For some
applications, however, you may want to adjust the setting to increase
or decrease the pressure at which the valve opens to return adhesive
to the tank. Adjust the valve by turning it clockwise to increase
system pressure or counterclockwise to decrease system pressure.

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A 1-72 Installation
10. Records of System Use these forms to record your system settings. This record will be
useful if you ever need to reprogram the system. Store the forms in a
Settings convenient place. You may want to give a copy to others in your
workplace who need the information.
Record of SETPOINT
(Operating) Temperature
Settings
Table A 1-21 Record of SETPOINT (Operating) Temperature Settings

Zone Zone Zone Default Setpoint Range of Setpoints Revised Setpoint
Type Number Name (See Note B) (See Note C)
(See
Note A)
Internal 1 Tank - - - - 38--232 C
(100--450 F)
2 Grid - - - - 38--232 C
(100--450 F)
Hose 1 Hose 1 - - - - 38--232 C
(100--450 F)
2 Hose 2 - - - - 38--232 C
(100--450 F)
3 Hose 3 - - - - 38--232 C
(100--450 F)
4 Hose 4 - - - - 38--232 C
(100--450 F)
5 Hose 5 - - - - 38--232 C
(100--450 F)
6 Hose 6 - - - - 38--232 C
(100--450 F)
Gun 1 Gun 1 - - - - 38--232 C
(100--450 F)
2 Gun 2 - - - - 38--232 C
(100--450 F)
3 Gun 3 - - - - 38--232 C
(100--450 F)
4 Gun 4 - - - - 38--232 C
(100--450 F)
5 Gun 5 - - - - 38--232 C
(100--450 F)
6 Gun 6 - - - - 38--232 C
(100--450 F)
NOTE A: Only Series 3900V units have a grid zone (internal zone number 2). Your unit may be able to control
the temperature of two, four, or six hoses and guns, depending upon your unit’s features.
B: Four dashes (- - - -) show that the heaters for this zone have not been programmed.
C: For a zone to be on, the operating temperature must be set at or above 38 C (100 F).

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Installation A 1-73
Record of STANDBY
Temperature Settings
Table A 1-22 Record of STANDBY Temperature Settings

Zone Zone Zone Default Setpoint Range of Setpoints Revised Setpoint
Type Number Name (See Note B) (See Note C)
(See
Note A)
Internal 1 Tank - - - - 38--232 C
(100--450 F)
2 Grid - - - - 38--232 C
(100--450 F)
Hose 1 Hose 1 - - - - 38--232 C
(100--450 F)
2 Hose 2 - - - - 38--232 C
(100--450 F)
3 Hose 3 - - - - 38--232 C
(100--450 F)
4 Hose 4 - - - - 38--232 C
(100--450 F)
5 Hose 5 - - - - 38--232 C
(100--450 F)
6 Hose 6 - - - - 38--232 C
(100--450 F)
Gun 1 Gun 1 - - - - 38--232 C
(100--450 F)
2 Gun 2 - - - - 38--232 C
(100--450 F)
3 Gun 3 - - - - 38--232 C
(100--450 F)
4 Gun 4 - - - - 38--232 C
(100--450 F)
5 Gun 5 - - - - 38--232 C
(100--450 F)
6 Gun 6 - - - - 38--232 C
(100--450 F)
NOTE A: Only Series 3900V units have a grid zone (internal zone number 2). Your unit may be able to control
the temperature of two, four, or six hoses and guns, depending upon the unit and features you have
selected.
B: Four dashes (- - - -) show that the heaters for this zone have not been programmed.
C: For a zone to be on, the operating temperature must be set at or above 38 C (100 F).

All rights reserved
Issued 5/00
A 1-74 Installation
Record of Set Times for

HEATERS ON and HEATERS
OFF
Table A 1-23 Record of Settings for Automatically Turning Heaters On and Off
Revised Times
Day Code Default Times Range of Times
(Day) (See Note A) INTERVAL 1 INTERVAL 2
Interval 1 Interval 2 On Off On Off
1 On at - - - - - - - - and 00:01 to 24:00
(Monday) 6:00 A.M.
Off at
5:00 P.M.
2 On at - - - - - - - - and 00:01 to 24:00
(Tuesday) 6:00 A.M.
Off at
5:00 P.M.
3 On at - - - - - - - - and 00:01 to 24:00
(Wednesday) 6:00 A.M.
Off at
5:00 P.M.
4 On at - - - - - - - - and 00:01 to 24:00
(Thursday) 6:00 A.M.
Off at
5:00 P.M.
5 On at - - - - - - - - and 00:01 to 24:00
(Friday) 6:00 A.M.
Off at
5:00 P.M.
6 - - - - - - - - - - - - and 00:01 to 24:00
(Saturday)
7 - - - - - - - - - - - - and 00:01 to 24:00
(Sunday)
NOTE A: Four dashes (- - - -) show that the heaters on feature has not been programmed for the indicated day of
the week.

All rights reserved
Issued 5/00
Installation A 1-75
Record of Set Times for

Entering and Exiting Standby
Table A 1-24 Record of Settings for Automatically Entering and Exiting Standby
Revised Times
Day Code Default Times Range of Times
(Day) (See Note A) INTERVAL 1 INTERVAL 2
Interval 1 Interval 2 Enter Exit Enter Exit
1 Enter at - - - - - - - - and 00:01 to 24:00
(Monday) 12:00 P.M.
Exit at
1:00 P.M.
2 Enter at - - - - - - - - and 00:01 to 24:00
(Tuesday) 12:00 P.M.
Exit at
1:00 P.M.
3 Enter at - - - - - - - - and 00:01 to 24:00
(Wednesday) 12:00 P.M.
Exit at
1:00 P.M.
4 Enter at - - - - - - - - and 00:01 to 24:00
(Thursday) 12:00 P.M.
Exit at
1:00 P.M.
5 Enter at - - - - - - - - and 00:01 to 24:00
(Friday) 12:00 P.M.
Exit at
1:00 P.M.
6 - - - - - - - - - - - - and 00:01 to 24:00
(Saturday)
7 - - - - - - - - - - - - and 00:01 to 24:00
(Sunday)
NOTE A: Four dashes (- - - -) show that the standby feature has not been programmed for the indicated day of
the week.

All rights reserved
Issued 5/00
A 1-76 Installation
Record of Customized SYSTEM

SETTINGS Features
Table A 1-25 Record of Customized SYSTEM SETTINGS Features

Feature Default Options Available Revised Setting
(Programming Code)
Password Enable Off (0) Off (0) or On (1)
System-Ready Time 18 minutes From 0 to 60 minutes
Delay
Overtemperature Setpoint 218 C (425 F) From 52 to 246 C
(From 125 to 475F)
Celsius/Fahrenheit Fahrenheit Celsius or Fahrenheit
Global Temperature Band 17 _C (30 F) From 6 to 28 C
(From 10 to 50 F)
Individual Temperature 17 _C (30 F) From 6 to 28 C
Bands (From 10 to 50 F)
Sequential or Sequential (1) Sequential (1) or
Simultaneous Startup Simultaneous (0)
Display Heater No display (0) No display (0) or
Proportioning Show display (1)
Warning or Power Warning (0) Warning (0) or
Notification Power (1)
Ready or Pump Ready (1) Pump (0) or
Notification Ready (1)
Auto-Energize Pump On (1) On (1) or Off (0)
(piston pump units only)
Auto-Energize Heaters On (1) On (1) or Off (0)
Auto-Energize Pump READY condition (0) READY (0) or
Temperature Setting From 1 to 232 C
(piston pump units only)
(From 1 to 450 F)
Auto-Standby Timeout 0 minutes From 0 to 1440 minutes
In Standby Timeout 0 minutes From 0 to 1440 minutes
Auto-Energize Pattern On (1) On (1) or Off (0)
Control

All rights reserved
Issued 5/00
Installation A 1-77
Record of Air Pressure

Settings
Table A 1-26 Record of Air Pressure Settings

System Component Air Pressure Setting
Pump (piston pump units only)
Gun 1
Gun 2
Gun 3
Gun 4
Gun 5
Gun 6

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Issued 5/00
A 1-78 Installation
Record of PATTERN
CONTROL Settings
Table A 1-27 Record of PATTERN CONTROL Settings
Pattern No. Output Bead Positions Line Speed

Channel
First Second Third Fourth
1 1
2
2 1
2
3 1
2
4 1
2
5 1
2
6 1
2
7 1
2
8 1
2
9 1
2
10 1
2
11 1
2
12 1
2
13 1
2
Continued on next page

All rights reserved
Issued 5/00
Installation A 1-79
Pattern No. Output Bead Positions Line Speed

Channel
14 1
2
15 1
2
16 1
2
17 1
2
18 1
2
19 1
2
20 1
2
21 1
2
22 1
2
23 1
2
24 1
2
25 1
2

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Issued 5/00
A 1-80 Installation
Record of System Faults
Table A 1-28 Record of System Faults

Fault Code Day Action Taken Additional Notes
(See Note A) Occurred
NOTE A: Fault Code 0 = No fault has occurred. Fault Code 5 = Control board is bad.
Fault Code 1 = Zone is below setpoint Fault Code 6 = Brownout has occurred.
temperature Fault Code 7 = Pattern control board is faulty.
Fault Code 2 = RTD is open Fault Code 8 = Gun circuitry is faulty.
Fault Code 3 = RTD is shorted. Fault Code 8 = Gun circuitry is faulty.
Fault Code 4 = Zone is Fault Code 9 = Control system cannot communicate
overtemperature. with pattern control.

All rights reserved
Issued 5/00
Installation A 1-81
Record of System Warnings
Table A 1-29 Record of System Warnings

Warning Day Action Taken Additional Notes
Code Occurred
(See Note A)
NOTE A: Warning Code 0 = No warning has occurred. Warning Code 6 = Not used.
Warning Code 1 = Not used. Warning Code 7 = Pattern control driver
Warning Code 2 = RTD is open. board is faulty.
Warning Code 3 = RTD is shorted. Warning Code 8 = Pattern control engine
Warning Code 4 = Temperature out of band. board is faulty.
Warning Code 5 = Not used. Warning Code 9 = Pattern control engine
board is faulty.

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Issued 5/00
A 1-82 Installation

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Issued 5/00

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Part A, Section 1

This section Covers the following unit configurations.

E 2000 Nordson Corporation 41-3000V A3EN-04-[3V-A-AAXP]-12

A3EN-04-[3V-A-AAXP]-12 41-3000V E 2000 Nordson Corporation

WARNING: Allow only qualified personnel to perform the

1. Introduction This section of the manual describes how to

E 2000 Nordson Corporation 41-3000V A3EN-04-[3V-A-AAXP]-12

S An operator can reach all controls.

S Maintenance personnel have room to service and repair the unit.

S The mounting surface is level.

S The mounting surface is raised at least 152 mm (6 in.) for draining

Fig. A 1-1 Required Clearance for Draining and Filter Flushing

A3EN-04-[3V-A-AAXP]-12 41-3000V E 2000 Nordson Corporation

S Make connections with the minimum length of wire needed. A long

To determine your hose/gun power requirements, refer to Calculating

E 2000 Nordson Corporation 41-3000V A3EN-04-[3V-A-AAXP]-12

Mounting the Unit Use this procedure to mount your unit.

2. For installation within the European Community, find the packet of

WARNING: Take care when lifting the unit. Using inadequate

4. Check to see that the unit is level. Provide shims as needed.

A3EN-04-[3V-A-AAXP]-12 41-3000V E 2000 Nordson Corporation

Fig. A 1-2 Securing the Unit to the Mounting Surface

E 2000 Nordson Corporation 41-3000V A3EN-04-[3V-A-AAXP]-12

Fig. A 1-3 Small Strainer (left) and Large Strainer (right)

4. Open the tank lid.

6. Close the tank lid.

A3EN-04-[3V-A-AAXP]-12 41-3000V E 2000 Nordson Corporation

Fig. A 1-4 Piston Pump (left) and Gear Pump (right)

E 2000 Nordson Corporation 41-3000V A3EN-04-[3V-A-AAXP]-12

2. Turn the regulator fully counterclockwise (off).

NOTE: Nordson recommends installing a shutoff valve with a

3. Connect a supply of clean, dry air to the input air fitting or

A3EN-04-[3V-A-AAXP]-12 41-3000V E 2000 Nordson Corporation

To Install an Air-Operated Gun

E 2000 Nordson Corporation 41-3000V A3EN-04-[3V-A-AAXP]-12

To Install an Electric Gun

To Install a Hand-Operated Gun

A3EN-04-[3V-A-AAXP]-12 41-3000V E 2000 Nordson Corporation

If your system is designed for external circulation of the adhesive, which

1. Follow the instructions in the gun manual to connect a hose to each

2. Determine whether your unit has a four-port or a six-port manifold.

Fig. A 1-7 Four-Port Manifold (left) and Six-Port Manifold (right)

E 2000 Nordson Corporation 41-3000V A3EN-04-[3V-A-AAXP]-12

Type of Manifold Instructions

Four-port manifold Use hose port number 1.

Six-port manifold Use hose port number 1 or 2. If

CAUTION: Failure to connect the first hose as instructed

WARNING: Hose ports that are unused must be closed with a

A3EN-04-[3V-A-AAXP]-12 41-3000V E 2000 Nordson Corporation

P/N 111 940

X=13 mm (0.50 in.)

R=203 mm (8.00 in.)

P/N 271 486 -- 8 mm (5/16 in.)

Fig. A 1-8 Hose Installation Guidelines

E 2000 Nordson Corporation 41-3000V A3EN-04-[3V-A-AAXP]-12

7. Tighten the fitting with a wrench.

9. Install any additional hoses by repeating steps 4--8. Be sure to

A3EN-04-[3V-A-AAXP]-12 41-3000V E 2000 Nordson Corporation

WARNING: Allow only qualified personnel to perform electrical

CAUTION: If you are adding hoses and guns to an existing

CAUTION: If you are connecting a hand-operated gun, take

Type of Gun Connection