ProBlue Adhesive Melter Models P15, P30, and P50

300 Pages·2011·8.93 MB·English


ProBlue Adhesive Melter
Models P15, P30, and P50
CustomerProductManual
Part1058683_05
Issued7/11
Thisdocumentcontainsimportantsafetyinformation
Besuretoreadandfollowallsafetyinformationinthis
documentandanyotherrelateddocumentation.
NORDSONCORPORATIONDULUTH,GEORGIAUSA
www.nordson.com
ForCEDeclaration,refertoequipmentdocumentation.
NordsonCorporationwelcomesrequestsforinformation,comments,andinquiriesaboutitsproducts. Generalinformation
aboutNordsoncanbefoundontheInternetusingthefollowingaddress: http://www.nordson.com.
Addressallcorrespondenceto:
NordsonCorporation
Attn:CustomerService
11475LakefieldDrive
Duluth,GA30097
Notice
ThisisaNordsonCorporationpublicationwhichisprotectedbycopyright. Originalcopyrightdate2006.
Nopartofthisdocumentmaybephotocopied,reproduced,ortranslatedtoanotherlanguagewithoutthepriorwritten
consentofNordsonCorporation. Theinformationcontainedinthispublicationissubjecttochangewithoutnotice.
Trademarks
AccuJet,AeroCharge,Apogee,AquaGuard,Asymtek,Automove,Baitgun,BlueBox,Bowtie,CanWorks,Century,CF,CleanSleeve,CleanSpray,ColorMax,
Color-on-Demand,ControlCoat,Coolwave,Cross-Cut,cScan+,Dispensejet,DispenseMate,DuraBlue,DuraDrum,Durafiber,DuraPail,Dura-Screen,
Durasystem,EasyCoat,EasymovePlus,Ecodry,Econo-Coat,e.DOT,EFD,Emerald,Encore,ESP,estylized,ETI-stylized,Excel2000,Fillmaster,
FlexiCoat,Flex-O-Coat,FlowSentry,Fluidmove,FoamMelt,FoamMix,Fulfill,GreenUV,HDLV,Heli-flow,Horizon,HotShot,iControl,iDry,iFlow,Isocoil,
Isocore,Iso-Flo,iTRAX,Kinetix,LEANCELL,LittleSquirt,LogiComm,Magnastatic,March,Maverick,MEG,Meltex,Microcoat,Micromark,MicroSet,
Millennium,MiniSquirt,Mountaingate,Nordson,Optimum,PackageofValues,PatternView,PermaFlo,PicoDot,PorousCoat,PowderGrid,Powderware,
Precisecoat,PRIMARC,Printplus,Prism,ProBlue,Prodigy,Pro-Flo,ProLink,Pro-Meter,Pro-Stream,RBX,Rhino,Saturn,Saturnwithrings,Scoreguard,
SealSentry,SelectCharge,SelectCoat,SelectCure,Signature,Slautterback,Smart-Coat,SolderPlus,Spectrum,Speed-Coat,SureBead, SureCoat,
Sure-Max,SureWrap,TrackingPlus,TRAK,Trends,Tribomatic,TrueBlue,TrueCoat,Ultra,UpTime,u-TAH,Vantage,VersaBlue,Versa-Coat,VersaDrum,
VersaPail,Versa-Screen,Versa-Spray,Watermark,andWhenyouexpectmore.areregisteredtrademarksofNordsonCorporation.
Accubar,AdvancedPlasmaSystems,AeroDeck,AeroWash,AltaBlue,AltaSlot,AltaSpray,Artiste,ATS,Auto-Flo,AutoScan,Axiom,BestChoice,
BlueSeries, Bravura,CanPro,Champion,CheckMate,ClassicBlue,ClassicIX,CleanCoat,Cobalt,ControlledFiberization,ControlWeave,ContourCoat,
CPX,cSelect,Cyclo-Kinetic,DispensLink,DryCure,DuraBraid,DuraCoat,DuraPUR,EasyClean,EasyOn,EasyPW,Eclipse,e.dot+,E-Nordson,Equalizer,
EquiBead,FillEasy,FillSentry,FlowCoat,Fluxplus,GetGreenWithBlue,G-Net,G-Site,IntelliJet, iON,Iso-Flex,iTrend,LacquerCure,Maxima,Mesa,
MicroFin,MicroMax,Mikros,MiniBlue,MiniEdge,Minimeter,Multifill,MultiScan,Myritex,Nano,NexJet,OmniScan,OptiMix,OptiStroke,Partnership+Plus,
PatternJet,PatternPro,PCI,Pinnacle,Plasmod,PowderPilot,PowderPort,Powercure,ProcessSentry,PulseSpray,PURBlue,PURJet,ReadyCoat,
RediCoat,RoyalBlue,SelectSeries,Sensomatic,Shaftshield,SheetAire,Smart,Smartfil,SolidBlue,Spectral,SpeedKing,SprayWorks,Summit,SureFoam,
SureMix,SureSeal,SwirlCoat,TAH,ThruWave,TradePlus,Trilogy,UltraFoamMix,UltraMax,Ultrasaver,Ultrasmart,Universal,ValueMate,Versa,Vista,
WebCure,and2Rings(Design)aretrademarksofNordsonCorporation.
Designationsandtrademarksstatedinthisdocumentmaybebrandsthat,whenusedbythirdpartiesfortheirownpurposes,
couldleadtoviolationoftheowners'rights.
DeviceNetisatrademarkofOpenDeviceNetVendorsAssociation,Inc.
EtherNet/IPtisatrademarkusedunderlicensebyODVA.
LoctiteisaregisteredtrademarkofLoctiteCorporation.
NeverSeezisaregisteredtrademarkofBostikInc.
ParkerLubricantisaregisteredtrademarkofParkerSeal.
PROFIBUSisaregisteredtrademarkofPROFIBUSInternational.
TeflonisaregisteredtrademarkofE.I.DuPontdeNemoursandCompany.
VitonisaregisteredtrademarkofDuPontDowElastomers.L.L.C.
Part1058683_05 E2011NordsonCorporation
Allrightsreserved
TableofContents i
Table of Contents
Safety..................................................... 1-1
SafetyAlertSymbols ........................................ 1-1
ResponsibilitiesoftheEquipmentOwner ....................... 1-2
SafetyInformation ........................................ 1-2
Instructions,Requirements,andStandards .................. 1-2
UserQualifications ....................................... 1-3
ApplicableIndustrySafetyPractices ........................... 1-3
IntendedUseoftheEquipment ............................. 1-3
InstructionsandSafetyMessages .......................... 1-4
InstallationPractices ...................................... 1-4
OperatingPractices ...................................... 1-4
MaintenanceandRepairPractices .......................... 1-5
EquipmentSafetyInformation ................................ 1-5
EquipmentShutdown ..................................... 1-6
RelievingSystemHydraulicPressure ..................... 1-6
De-energizingtheSystem ............................... 1-6
DisablingtheApplicators ................................ 1-6
GeneralSafetyWarningsandCautions ...................... 1-7
OtherSafetyPrecautions .................................. 1-10
FirstAid ................................................. 1-10
SafetyLabelsandTags ..................................... 1-11
Description ................................................ 2-1
OtherSourcesofInformation ................................. 2-2
InstallationGuide ....................................... 2-2
User'sGuide .......................................... 2-2
OnlineSupport ......................................... 2-2
ProductDescription ......................................... 2-3
IntendedUse ............................................ 2-3
LimitationsofUse ........................................ 2-4
ModesofOperation ...................................... 2-4
MelterIdentification ....................................... 2-5
KeyComponents ........................................... 2-6
OptionalEquipment ......................................... 2-8
E2011NordsonCorporation Part1058683_05
ii TableofContents
Installation ................................................ 3-1
Quick-Start ................................................ 3-1
Overview .................................................. 3-1
AdditionalInformation ..................................... 3-2
InstallationTasks ........................................ 3-2
ExperienceofInstallationPersonnel ......................... 3-2
InstallationRequirements .................................... 3-3
Clearances .............................................. 3-3
Ventilation .............................................. 3-4
ElectricalPower .......................................... 3-4
CompressedAir ......................................... 3-5
OtherConsiderations ..................................... 3-5
UnpackingtheMelter ....................................... 3-6
ContentsoftheInstallationKit .............................. 3-6
Customer-SuppliedMaterials .............................. 3-6
MountingtheMelter ......................................... 3-8
ConfiguringtheElectricalService ............................. 3-10
ConnectingaPumpControlSignal ............................ 3-15
PumpControlGuidelines .................................. 3-15
ConnectingaCompressedAirSupply ......................... 3-16
ConnectingHosesandGuns ................................. 3-18
SettingUptheMelter ........................................ 3-22
QuickSetup ............................................. 3-22
OperatingParameters .................................... 3-24
Set-pointTemperatureoftheTank,Hoses,andGuns .......... 3-29
SaveandRestoreMelterSettings ........................... 3-31
ReviewParameterandSet-pointTemperatureChanges ....... 3-32
InstallingMelterInputs ...................................... 3-36
InstallingMelterOutputs ..................................... 3-40
InstallingOptionalEquipment ................................ 3-43
ConnectingaGunDriver,PatternController,orTimer ............ 3-43
FlushingtheMelter ......................................... 3-43
SettingUpMelterCommunications ............................ 3-43
Operation ................................................. 4-1
AdditionalInformation ....................................... 4-1
MoreaboutHeatedComponents ........................... 4-2
FillingtheTank ............................................. 4-3
StartingtheMelter .......................................... 4-4
MonitoringtheMelter ........................................ 4-6
ConfirmthattheMelterisOperatingCorrectly ................ 4-6
MonitorComponentTemperatures ......................... 4-7
MonitorMelterFaults ..................................... 4-10
HowF1,F2,andF3FaultsareHandled ................... 4-11
HowF4FaultsareHandled ............................. 4-12
MonitortheLevelofHotMeltintheTank .................... 4-16
MonitorandAdjusttheOperatingAirPressure ................ 4-16
MonitortheServiceInterval ................................ 4-17
AdjustingComponentTemperatures .......................... 4-18
EntertheMelterPassword ................................. 4-22
UsingMelterFunctionKeys .................................. 4-24
HeaterKey .............................................. 4-24
PumpKey ............................................... 4-24
SetupKey ............................................... 4-25
Seven-dayClockKey ..................................... 4-25
StandbyKey ............................................ 4-26
ShuttingDowntheMelter .................................... 4-27
Part1058683_05 E2011NordsonCorporation
TableofContents iii
Maintenance .............................................. 5-1
RelievingSystemPressure .................................. 5-2
LockingOutExternalCommunications ........................ 5-2
CleaningtheMelter ......................................... 5-4
ReplacingtheFilter ......................................... 5-6
CleaningtheTank .......................................... 5-8
RemovingtheMelterfromtheSub-base ....................... 5-10
Troubleshooting ........................................... 6-1
Safety ..................................................... 6-1
MelterFaults ............................................... 6-2
UsingtheTroubleshootingFlowchart .......................... 6-4
TroubleshootingQuick-checks ............................. 6-4
IdentifyingElectricalComponents .......................... 6-4
DiagnosticProcedures ...................................... 6-11
DP.1IsolateaFailedControlComponent .................... 6-11
DP.2ChecktheTankorManifoldRTD ...................... 6-12
ReheatingtheMelterDuringanF1Fault .................. 6-13
RemovetheTankRTD ................................. 6-13
RemovetheManifoldRTD .............................. 6-14
DP.3ChecktheOperationofthePowerRelayorThermostats .. 6-15
DP.4ChecktheOperationoftheTankorManifoldTRIAC ...... 6-16
DP.5ChecktheResistanceoftheTankandManifoldHeaters .. 6-17
TroubleshootingFlowCharts .............................. 6-21
Parts...................................................... 7-1
UsingtheIllustratedPartsLists ............................... 7-1
P15Melter ................................................. 7-2
P30Melter ................................................. 7-4
P50Melter ................................................. 7-6
P15ChassisAssembly ...................................... 7-10
P30ChassisAssembly ...................................... 7-11
P50ChassisAssembly ...................................... 7-12
ElectricalEnclosureAssembly ................................ 7-16
Pump/ManifoldAssembly .................................... 7-18
Double-Acting,High-OutputPumpAssembly ................... 7-20
StandardDouble-ActingPumpAssembly ...................... 7-27
Single-ActingPumpAssembly ................................ 7-34
ManifoldAssembly ......................................... 7-38
LidAssembly .............................................. 7-40
ServiceKits ................................................ 7-42
PneumaticAssembly-StandardDoubleActingPump-
P/N1058380 ............................................ 7-42
PneumaticAssembly-High-outputDouble-ActingPump-
P/N1058383 ............................................ 7-42
PneumaticAssembly-SingleActingPump-P/N1058385 ..... 7-42
StandardDouble-ActingPumpReplacementKit-P/N1028303 . 7-42
Single-ActingPumpReplacementKit-P/N1058306 .......... 7-42
High-OutputDouble-ActingPumpReplacementKit-P/N1058305 7-43
Double-ActingPumpServiceKit-P/N1028304 .............. 7-43
High-OutputDouble-ActingPumpServiceKit-P/N1058307 ... 7-44
Single-ActingPumpServiceKit-P/N1058308 ............... 7-45
E2011NordsonCorporation Part1058683_05
iv TableofContents
Parts(contd)
ForkAssemblyServiceKit-P/N1060354(High-outputpump),
166880(Standardpump) .................................. 7-45
SPValveServiceKit-P/N1006027 ......................... 7-45
MagneticActuatorServiceKit-P/N104606 .................. 7-45
Single-ActingPumpCheckValve-P/N1060355 .............. 7-46
Filter,100-mesh-P/N1028305 ............................ 7-46
PressureDischargeValveServiceKit-P/N1028308 .......... 7-46
CentralProcessorUnit(CPU)ReplacementKit-P/N1028325 .. 7-46
MainPCAReplacementKit-P/N1054008 ................... 7-46
400/480VFuseServiceKit-P/N1058426 ................... 7-46
Hose/GunModuleReplacementKit-P/N1028328 ............ 7-47
Hose/GunModuleFuseReplacementKit-1028331 .......... 7-47
DriverBoardFuseServiceKit-P/N1054009 ................. 7-47
RTDServiceKit-P/N1028320 ............................. 7-47
ThermostatServiceKit-P/N1028321 ....................... 7-47
Manifold(withHeaterBlock)ServiceKit,DAPumps-P/Ns1064651
(4H,230V),1064653(6H,230V),1064652(4H,480V),
1064654(6H,480V) ...................................... 7-48
HeaterBlockServiceKit-P/Ns1064639(230V),1064650(480V) 7-48
DisplacementPlugServiceKit-P/N1060358 ................. 7-48
ManifoldGuardReplacementKit-P/N1031871 .............. 7-48
ManifoldServiceKit-P/N1028309 ......................... 7-49
LidAssemblyP15-1060328 ............................... 7-49
LidAssemblyP30/P50-1060361 .......................... 7-49
MelterCoverReplacementKit-P/N1060357(P15),1059897(P30),
1059898(P50) ........................................... 7-50
P15/30/50PumpCoverReplacementKit-P/N1060350 ....... 7-50
EboxDoorReplacementKit-P/N1060352(P15),1059899(P30),
1059910(P50) ........................................... 7-50
Operator'sPanelReplacementKit-P/N1028327 ............. 7-50
FilterDoorServiceKit-P/N1060351 ........................ 7-50
TankReplacementKit-P/N1060356(P15),1061520(P30),
1061613(P50) ........................................... 7-50
Input/OutputExpansionCardAdd-onKit-P/N1036607 ....... 7-51
P15/P30Single-PositionLevelSwitch-P/N1060329 .......... 7-51
P50Single-PositionLevelSwitch-P/N1060362 .............. 7-51
P15/P303-PositionLevelSwitch-P/N1059911 .............. 7-51
ProfibusCard-P/N1053300 .............................. 7-52
EthernetIPCard-P/N1053289 ............................ 7-52
DeviceNet-P/N1053288 ................................. 7-52
Specifications ............................................. 8-1
GeneralSpecifications .................................... 8-1
PumpCharacteristics ..................................... 8-2
ElectricalSpecifications ................................... 8-2
MelterPowerRequirements ............................... 8-3
MelterDimensions .......................................... 8-4
P15Melter .............................................. 8-4
P30Melter .............................................. 8-5
P50Melter .............................................. 8-6
Sub-BaseDimensions ...................................... 8-7
P15Sub-base ........................................... 8-7
P30/P50Sub-base ....................................... 8-8
WiringDiagrams—200/240VACMelter ........................ 8-8
Part1058683_05 E2011NordsonCorporation
TableofContents v
CalculatingMelterPowerRequirements ..................... A-1
OperatingParameters ...................................... B-1
Standard .................................................. B-2
TemperatureControl ........................................ B-6
InputSetup ................................................ B-9
OutputSetup .............................................. B-12
Seven-dayClock ........................................... B-14
Example1 ............................................ B-15
Example2 ............................................ B-15
Example3 ............................................ B-15
MelterCommunications .................................... C-1
SoftwareAvailability ........................................ C-1
SystemRequirements ....................................... C-1
InstallingtheSoftware ....................................... C-2
RemovingtheSoftwarefromYourPC ....................... C-4
ConnectingthePCandtheMelter ............................ C-5
UsingNordsonConfigurationManager ......................... C-6
SavingandRestoringMelterSettings ....................... C-7
UpgradingorRestoringMelterFirmware ..................... C-8
Troubleshooting ............................................ C-11
UsingNordsonConfigurationManager ...................... C-11
E2011NordsonCorporation Part1058683_05
vi TableofContents
Double-ActingPumpDiagnosticsandRepair ................ D-1
Introduction ................................................ D-1
PumpFunction ............................................. D-1
PumpIsolationValve ................................... D-2
PressureDischargeValve ............................... D-2
PumpDiagnostics .......................................... D-4
PumpDisassemblyandReassembly .......................... D-6
MelterPreparation ....................................... D-6
RequiredToolsandMaterials .............................. D-6
Tools ................................................ D-6
ServiceParts .......................................... D-6
Supplies .............................................. D-7
RemovethePumpfromtheMelter .......................... D-8
SpecialReassemblyInstructions ......................... D-8
RemovetheActuatorandAirManifoldandtheCylinderAssembly D-10
SpecialReassemblyInstructions ......................... D-10
RemovetheMagneticActuatorAssembly .................... D-12
RemovetheValveSpoolandSleeve ........................ D-16
SpecialReassemblyInstructions ......................... D-17
RemovetheShifterFork .................................. D-20
SpecialReassemblyInstructions ......................... D-20
RemovethePistonCups .................................. D-22
SpecialReassemblyInstructions ......................... D-22
RemovethePumpFrameandtheInsulator .................. D-24
SpecialReassemblyInstructions ......................... D-24
RemovetheLowerBallSeatAssemblyandthePiston ......... D-28
SpecialReassemblyInstructions ......................... D-28
DisassembletheLowerBallSeatandthePressureBall
Assemblies ............................................. D-30
SpecialReassemblyInstructions ......................... D-30
RemovetheO-ringandthePumpSeal ...................... D-32
SpecialReassemblyInstructions ......................... D-32
ScheduleofFasteners .................................... D-36
Part1058683_05 E2011NordsonCorporation
Safety 1-1
Section 1
Safety
Readthissectionbeforeusingtheequipment.Thissectioncontains
recommendationsandpracticesapplicabletothesafeinstallation,operation,
andmaintenance(hereafterreferredtoas“use”)oftheproductdescribedin
thisdocument(hereafterreferredtoas“equipment”).Additionalsafety
information,intheformoftask-specificsafetyalertmessages,appearsas
appropriatethroughoutthisdocument.
WARNING!Failuretofollowthesafetymessages,recommendations,and
hazardavoidanceproceduresprovidedinthisdocumentcanresultin
personalinjury,includingdeath,ordamagetoequipmentorproperty.
Safety Alert Symbols
Thefollowingsafetyalertsymbolandsignalwordsareusedthroughoutthis
documenttoalertthereadertopersonalsafetyhazardsortoidentify
conditionsthatmayresultindamagetoequipmentorproperty.Complywith
allsafetyinformationthatfollowsthesignalword.
WARNING!Indicatesapotentiallyhazardoussituationthat,ifnotavoided,
canresultinseriouspersonalinjury,includingdeath.
CAUTION!Indicatesapotentiallyhazardoussituationthat,ifnotavoided,
canresultinminorormoderatepersonalinjury.
CAUTION!(Usedwithoutthesafetyalertsymbol)Indicatesapotentially
hazardoussituationthat,ifnotavoided,canresultindamagetoequipmentor
property.
E2011NordsonCorporation Issued8-09
1-2 Safety
Responsibilities of the Equipment Owner
Equipmentownersareresponsibleformanagingsafetyinformation,ensuring
thatallinstructionsandregulatoryrequirementsforuseoftheequipmentare
met,andforqualifyingallpotentialusers.
Safety Information
S Researchandevaluatesafetyinformationfromallapplicablesources,
includingtheowner-specificsafetypolicy,bestindustrypractices,
governingregulations,materialmanufacturer'sproductinformation,and
thisdocument.
S Makesafetyinformationavailabletoequipmentusersinaccordancewith
governingregulations.Contacttheauthorityhavingjurisdictionfor
information.
S Maintainsafetyinformation,includingthesafetylabelsaffixedtothe
equipment,inreadablecondition.
Instructions, Requirements, and Standards
S Ensurethattheequipmentisusedinaccordancewiththeinformation
providedinthisdocument,governingcodesandregulations,andbest
industrypractices.
S Ifapplicable,receiveapprovalfromyourfacility'sengineeringorsafety
department,orothersimilarfunctionwithinyourorganization,before
installingoroperatingtheequipmentforthefirsttime.
S Provideappropriateemergencyandfirstaidequipment.
S Conductsafetyinspectionstoensurerequiredpracticesarebeing
followed.
S Re-evaluatesafetypracticesandprocedureswheneverchangesare
madetotheprocessorequipment.
Issued8-09 E2011NordsonCorporation