Instruction Sheet P/N 1074604A02

Low Level Kit - P/N 1056172 Issued 6/07

This instruction sheet describes the installation of the low level sensor ona DuraBlue� D10 or D16 adhesive melter. This kit may be installed on aD4L, D10L, or D16L melter for remote low-level monitoring (an L melterdoes not have a low-level LED) if an input/output expansion card hasbeen installed on the melter.

WARNING: Risk of personal injury or equipment damage! Refer tothe safety information provided in the melter manual beforeservicing the melter. Failure to comply with the safety informationprovided can result in personal injury, including death.

Required Tools:

Flat-tip screwdriver3-mm hex wrench

Low level sensor assembly

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Low Level Kit Components

leer / low

NordsonKFA−5−1−I−KL−PG9P/N 734401

full

bU

voll

NO

BENC

NO

CO

M

NC

CO

M

0 11

5V

DC

23

0V

DC

LOW LEVEL SIGNAL

WHITE

POWER SUPPLY

6

5

13

2

12

8

1516

11

10

7

17

4

1. Sensor, capacitive, 16 D x 100 mm L (P/N 1070146)2. Bracket, sensor3. Strain relief, without nut, PG94. Locknut, PG95. Controller, sensor (P/N 1070147)6. Mounting plate7. Screw, socket, M4 x 88. Wire, TFE, 18 AWG, black9. Wire, 250C, 18 AWG, red10. Wire, TFE, 18 AWG, green/yellow11. Terminal, ring-tong, insulated, 12-28 AWG12. Connector, plug-in, F, 5-pos, 12−28 AWG13. Terminal block connector, 3-pos, 5.08 mm15. Fuse, 1.00, fast-acting, 250V (P/N 804261)16. Fuse holder, inline, 5 x 20 (P/N 1070162)17. Terminal, push-on, fully inserted

7

2 x 6 IN. WIRE, TFE, 18 AWG, BLACK

2 X 18 IN. WIRE, TFE 18 AWG, BLACK

13

9

24 IN. WIRE, TFE, 18 AWG, GREEN/YELLOW

2 X 18 IN. WIRE, 250 C, 18 AWG, RED

2. Secure the sensor bracket (1) to the tank cover using the two inner lid screwthreads (2). Ensure that the sensor is inside the tank.

1. Open the electrical enclosure door and remove theright-side melter panel.

Install the Sensor

1. Remove the melter lid by removing the four screws that secure the lid to the tankcover.

2. Using the two existing holes in the right-side panel,install the sensor controller and mounting plate assemblyon the right-hand side inside the electrical enclosure.

NOTE: You may need to remove the cable ties from themounting holes and then rearrange and reaffix the wirerouting.

3. Use a screw driver to bend back the sealing gasket on theinside of the tank and push the sensor plug through the opening.The sensor cable runs between the tank cover and the sealinggasket.

Install the Sensor Controller

Installed controller and mounting plate assembly

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1

Location of the mounting holes for the sensor controller assembly(side panel of melter removed for clarity)

Installed sensor cable

Mounting the sensor

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Excess cable rolled up and secured with a cable tie

Ground wire secured by upper thermostat screw

2. Connector the 5-position connector (black wires) to terminal XT2 (powersupply).

If remote low-level monotoring of the melter is desired, follow this procedure to connect acommunication cable from the melter to the external monitoring equipment. The melter controlsystem will send a low-level signal through the cable when the tank level falls below thelow-level setting.

Connect the communication cable leads to the READY and LOW LEVEL output terminalblocks on the I/O board inside the melter electrical enclosure.

NOTE: Before connecting the communication cable to the output terminal blocks, you mayneed to make appropriate changes to the configuration of the output signals of the melter.Refer to the procedure for installing melter outputs in the installation section of the melterproduct manual or to the I/O expansion card instruction sheet, as applicable.

Make the Electrical Connections

1. Connect the 3-position connector (red wires) to terminal XT4 (low level input).

3. Route the green/yellow tank ground wire toward themanifold and connect it as follows:

a. Remove the cover to access the heater cartridges and theovertemperature thermostat.

b. Remove the upper overtemperature thermostat screw.

c. Secure the tank ground wire terminal ring and theovertemperature thermostat using the screw removed in step b.

Connect the Communication Cable

4. Open the sensor controller cover and connect the gold plug ofthe sensor cable (coming from the tank) to the gold receptacle insidethe sensor controller.

5. Roll up any excess sensor cabling and secure with a cable tie.

XT4

XT2

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Adjust the Low-Level Sensor Open Sensor Adjustment

1. Turn the melter on.The adhesive low level sensor is factory-set to the lowest levelsetting. Use this procedure anytime the sensor or sensor controlleris replaced.

NOTE: The power to the low-level sensor shuts off whenever theheaters are turned off.

1. Ensure that:

� the level sensor is mounted in the melter

� the melter tank is empty (so the level sensorwill work at the highest sensitivity level)

2. Select one of the following ways to adjust the levelsensor:

� open sensor

� switch point

2. Turn the potentiometer 1 (or P1) twenty turnscounterclockwise. In this setting, the sensor controlreceives minimum input and cannot detect adhesive levels.A reading lower than the minimum input will generate afault condition resulting in an open sensor condition(blinking LED).

3. Turn P3 clockwise until the red LED turns off and thegreen LED starts blinking.

4. Turn P3 counterclockwise until the green LED turnsoff and the red LED turns on.

5. Turn P3 one to two turns counterclockwise.

6. Close the electrical enclosure door and reinstall theright-side melter panel.

Switch Point Adjustment

1. Turn the melter on.

2. Turn P1 clockwise until the red LED (low) turns off and thegreen LED turns on.

3. Turn P1 from the switching point between the LEDs one-half turn counterclockwise and leave it in its present position.

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3

Sensor Control LEDs1. Power (green)2. Full (on constantly) or open sensor (blinking green)3. Low level (red)

4. Close the electrical enclosure door and reinstall theright-side melter panel.