ProBlue Liberty Adhesive Application System

435 Pages·2015·11.54 MB·English

(cid:2)
ProBlue Liberty Hot Melt
Adhesive System
Customer Product Manual
Part 1124685_01
Issued 8/15
This document contains important safety information
Be sure to read and follow all safety information in this
document and any other related documentation.
NORDSON CORPORATION  DULUTH, GEORGIA  USA
www.nordson.com
For CE Declaration, refer to equipment documentation.
Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General information
about Nordson can be found on the Internet using the following address: http://www.nordson.com.
Address all correspondence to:
Nordson Corporation
Attn: Customer Service
11475 Lakefield Drive
Duluth, GA 30097
Notice
This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2014.
No(cid:2)part(cid:2)of(cid:2)this(cid:2)document may be photocopied, reproduced, or translated to another language without the prior written
consent of Nordson(cid:2)Corporation. The(cid:2)information(cid:2)contained in this publication is subject to change without notice.
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Porous(cid:2)Coat, PowderGrid, Powderware, Precisecoat, PrintPlus, Prism, ProBlue, Prodigy, Pro‐Flo, Program‐A‐Bead, Program‐A‐Shot,
Program‐A‐Stream, Program‐A‐Swirl, ProLink, Pro‐Meter, Pro‐Stream, Pulsar, Quantum, RBX, Rhino, Saturn, Saturn with rings,
Scoreguard, Sealant Equipment & Engineering, Inc, SEE and design, See‐Flo, Seal Sentry, Select(cid:2)Charge, Select(cid:2)Coat, Select Cure,
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TrueBlue, TrueCoat, Tubesetter, Ultra, UpTime, u‐TAH, Value Plastics, Vantage, VersaBlue, Versa‐Coat, VersaDrum, VersaPail,
VersaPUR, Versa‐Screen, Versa‐Spray,VP Quick-Fit, VP Quick-Fit, VP Quick-Fit stylized, VP stylized, Watermark,
When you expect more., Xaloy, Xaloy - stylized, X-Plane, and YesTech are registered trademarks of Nordson Corporation.
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DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, EdgeControl, e.dot+, E‐Nordson, Equalizer, EquiBead, FillEasy, Fill(cid:2)Sentry,
FlexSeam, Flow Coat, FluxPlus, Genius, Get Green With Blue, G‐Net, G‐Site, IntelliJet, iON, Iso‐Flex, iTrend, Lacquer Cure, Maxima,
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SheetAire, Smart, Smartfil, SolidBlue, Spectral, SpeedKing, Spray Works, StediTherm, StrokeControl, Summit, SureFoam, Sure(cid:2)Mix,
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Universal, ValueMate, Versa, VersaPUR, Vista, Web Cure, and 2(cid:2)Rings (Design) are(cid:2)trademarks of Nordson(cid:2)Corporation.
Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes,
could lead to violation of the owners' rights.
Buna-N is a registered trademark of Pittway Corps.
DeviceNet is atrademark of Open DeviceNet Vendors Association, Inc.
Loctite is a registered trademark of Loctite Corporation.
Never Seez is a registered trademark of Bostik Inc.
Parker Lubricant is a registered trademark of Parker Seal.
PROFIBUS is a registered trademark of PROFIBUS International.
Viton is a registered trademark of DuPont Dow Elastomers. L.L.C.
Part 1124685_01 (cid:2) 2015 Nordson Corporation
All rights reserved
Table of Contents i
Table of Contents
Safety ..................................................... 1-1
Safety Alert Symbols ......................................... 1‐1
Responsibilities of the Equipment Owner ....................... 1‐2
Safety Information ........................................ 1‐2
Instructions, Requirements, and Standards ................... 1‐2
User Qualifications ........................................ 1‐3
Applicable Industry Safety Practices ........................... 1‐3
Intended Use of the Equipment ............................. 1‐3
Instructions and Safety Messages ........................... 1‐4
Installation Practices ...................................... 1‐4
Operating Practices ....................................... 1‐4
Maintenance and Repair Practices .......................... 1‐5
Equipment Safety Information ................................. 1‐5
Equipment Shutdown ..................................... 1‐6
Relieving System Hydraulic Pressure ..................... 1‐6
De‐energizing the System ............................... 1‐6
Disabling the Applicators ................................ 1‐6
General Safety Warnings and Cautions ...................... 1‐7
Other Safety Precautions .................................. 1‐10
First Aid .................................................. 1‐10
Safety Labels and Tags ...................................... 1‐12
Description ................................................ 2-1
Introduction ................................................ 2‐1
Intended Use ............................................. 2‐2
Limitations of Use ......................................... 2‐2
Other Sources of Information ................................. 2‐3
Installation Guide ......................................... 2‐3
User's Guide ............................................. 2‐3
Online Support ............................................ 2‐3
Product Description ......................................... 2‐4
Melter Identification ....................................... 2‐4
Modes of Operation—Melter Control ........................ 2‐5
Modes of Operation—Fill Control ........................... 2‐5
Theory of Operation ....................................... 2‐6
Component Identification ..................................... 2‐7
Description of Mechanical Components ........................ 2‐11
Lid Assembly ............................................. 2‐11
Adhesive Storage Bin ..................................... 2‐12
Pump Box ............................................... 2‐13
Solenoid Harness Quick‐Disconnect (Optional) ............... 2‐14
Hose/Pump Assembly ..................................... 2‐15
Quick-disconnect Hose/Pump Assembly (Optional) ............ 2‐15
Suction Lance Kit ......................................... 2‐16
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Description contd.
Description of Electrical Components .......................... 2‐17
Fill System Control Panel .................................. 2‐17
Sequencer (Multi‐Melter Systems Only) ...................... 2‐18
Refill PCA ............................................... 2‐19
Level Sensor ............................................. 2‐21
Lid Switch ............................................... 2‐22
Solenoid Harness Connector ............................... 2‐22
Optional Equipment ......................................... 2‐23
Installation ................................................. 3-1
Quick‐Start ................................................. 3‐1
Installing 400/480 Volt Melters ................................ 3‐1
Overview .................................................. 3‐2
Additional Information ...................................... 3‐2
Installation Tasks ......................................... 3‐3
Experience of Installation Personnel ......................... 3‐3
Installation Requirements .................................... 3‐4
Clearances .............................................. 3‐4
Ventilation ............................................... 3‐7
Electrical Power .......................................... 3‐7
Compressed Air .......................................... 3‐8
Other Considerations ...................................... 3‐8
Unpacking the Melter ........................................ 3‐10
Contents of the Installation Kit ............................... 3‐10
Customer‐Supplied Materials ............................... 3‐10
Mounting the Melter ......................................... 3‐12
Configuring the Electrical Service .............................. 3‐15
Connecting a Compressed Air Supply .......................... 3‐20
Connecting the Fill System ................................... 3‐22
Connect to a Single‐Feed Adhesive Storage Bin .............. 3‐22
Connect to a Multi-Feed Adhesive Storage Bin ................ 3‐27
Connect to a Single Suction Lance .......................... 3‐32
Connect to Multiple Suction Lances ......................... 3‐33
Connecting Supply Hoses and Applicators ...................... 3‐34
Setting Up the Melter ........................................ 3‐37
Quick Setup .............................................. 3‐37
Operating Parameters ..................................... 3‐39
Selecting Operating Parameters .......................... 3‐39
Reading or Editing Operating Parameters .................. 3‐39
Set‐Point Temperature of the Grid, Hoses, and Applicators...... 3‐45
Fill System Setup ......................................... 3‐47
Changing a Fill System Parameter ........................ 3‐47
Connecting a Fill System Status Output .................... 3‐50
Calibrating the Level Sensor ............................. 3‐51
Adjusting the Pneumatic Regulator ........................ 3‐52
Testing the Fill System................................... 3‐53
Save and Restore Melter Settings ........................... 3‐54
Review Parameter and Setpoint Temperature Changes ........ 3‐55
Part 1124685_01 (cid:2) 2015 Nordson Corporation
Table of Contents iii
Installing Melter Inputs ....................................... 3‐58
Installing Melter Outputs ..................................... 3‐63
Installing Optional Equipment ................................. 3‐67
Connecting a Driver, Pattern Controller, or Timer ................. 3‐67
Flushing the Melter .......................................... 3‐67
Setting Up Melter Communications ............................ 3‐67
Operation .................................................. 4-1
Additional Information ........................................ 4‐1
More About Heated Components .............................. 4‐2
Filling the Adhesive Storage Bin ............................... 4‐3
Filling the Melter Manually .................................... 4‐4
Starting the Melter ........................................... 4‐6
Monitoring the Melter ........................................ 4‐8
Confirm that the Melter is Operating Correctly ................. 4‐9
Monitor Component Temperatures .......................... 4‐10
Monitor Refill Operation .................................... 4‐12
Monitor Melter Faults ...................................... 4‐14
How F1, F2, and F3 Faults are Handled ................... 4‐18
How F4 Faults are Handled .............................. 4‐19
Monitor and Adjust the Operating Air Pressure ................ 4‐21
Monitor the Service Interval ................................ 4‐22
Adjusting Component Temperatures ........................... 4‐23
Entering the Melter Password ................................. 4‐28
Using the Melter Function Keys ............................... 4‐29
Fill System Enable Key .................................... 4‐29
Heater Key .............................................. 4‐30
Pump Key ............................................... 4‐30
Setup Key ............................................... 4‐30
Seven‐day Clock Key ..................................... 4‐31
Standby Key ............................................. 4‐32
Shutting Down the Melter ..................................... 4‐33
Maintenance ............................................... 5-1
Relieving System Pressure ................................... 5‐2
Locking Out External Communications ......................... 5‐2
Cleaning the Melter .......................................... 5‐4
Replacing the Filter .......................................... 5‐6
Removing the Melter from the Sub‐Base ....................... 5‐8
Troubleshooting............................................ 6-1
About This Section .......................................... 6‐1
400/480 Volt Melters ......................................... 6‐2
Safety...................................................... 6‐2
Melter Faults ............................................... 6‐3
Melter Troubleshooting ....................................... 6‐5
Using the Melter Troubleshooting Flowcharts.................. 6‐5
Troubleshooting Quick‐checks .............................. 6‐5
Returning the Melter Setup to Factory Settings ................ 6‐6
Identifying Electrical Components ........................... 6‐7
Melter Pneumatic Flow .................................... 6‐11
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iv Table of Contents
Troubleshooting contd.
Diagnostic Procedures ....................................... 6‐12
DP.1 Isolate a Failed Control Component .................... 6‐12
DP.2 Check the Grid or Manifold RTD ....................... 6‐13
Reheating the Melter During an F1 Fault ................... 6‐14
Removing the Level Sensor, Grid RTD, or Grid Thermostat ... 6‐15
Removing the Manifold RTD ............................. 6‐18
DP.3 Check the Operation of the Power Relay or Thermostats .. 6‐19
DP.4 Check the Operation of the Grid or Manifold TRIAC ....... 6‐20
DP.5 Check the Resistance of the Grid and Manifold Heaters ... 6‐21
Melter Troubleshooting Flowcharts ............................. 6‐25
Fill System Troubleshooting .................................. F‐53
About Fill System Faults ................................... F‐53
Refill PCA Board Status LEDs .............................. F‐54
Fault LED/Red Status LED ............................... F‐54
Fill Enable LED/Yellow PCA LED/Yellow Light Tower ........ F‐55
Fill System Troubleshooting Table .......................... F‐56
Fill System Troubleshooting Procedures ..................... F‐58
Calibrating the Level Sensor ............................. F‐58
Cleaning Adhesive Bin Blockage ......................... F‐58
Parts ...................................................... 7-1
Using the Illustrated Parts Lists ................................ 7‐1
Melter Parts Lists ........................................... 7‐2
Melter Part Numbers ...................................... 7‐2
ProBlue Liberty Melters ................................. 7‐2
Transformer Base Assemblies ........................... 7‐2
Optional 8 Hose/Applicator Expansion Base ............... 7‐2
Small Melter Assembly Parts ............................... 7‐4
Large Melter Assembly Parts ............................... 7‐10
Small Chassis Assembly Parts .............................. 7‐16
Large Chassis Assembly Parts ............................. 7‐19
Small Electrical Enclosure Parts ............................ 7‐24
Large Electrical Enclosure Parts ............................ 7‐27
Small Hydraulic Assembly Parts ............................ 7‐30
Large Hydraulic Assembly Parts ............................ 7‐32
Small Grid Assembly Parts ................................. 7‐34
Large Grid Assembly Parts ................................. 7‐36
Pump/Manifold Assembly Parts ............................. 7‐38
Lid Assembly Parts ....................................... 7‐40
Pump Assembly (15:1) Parts Lists ........................... 7‐42
Pump Shifter Assembly Parts ............................ 7‐45
Pump Piston Assembly Parts ............................. 7‐46
Pneumatic Component Parts ............................... 7‐47
Circuit Board and Control Panel Service Kits .................. 7‐48
Ribbon Cable Part Numbers ................................ 7‐49
Fill System Parts Lists ....................................... 7‐50
Single‐Feed (120L) Adhesive Storage Bin Parts ............... 7‐50
Multi‐Feed (240L) Adhesive Storage Bin Parts ................ 7‐52
Adhesive Transfer Hose Parts .............................. 7‐54
Standard Transfer Hoses ................................ 7‐54
Quick‐Disconnect Transfer Hoses ........................ 7‐56
Coupling Assembly, Pump Box ............................. 7‐58
Transfer Hose Pump Parts ................................. 7‐59
Transfer Hose Solenoid Harnesses .......................... 7‐60
Standard Harnesses .................................... 7‐60
Quick‐Disconnect Harnesses ............................ 7‐61
Sequencer ............................................... 7‐62
Part 1124685_01 (cid:2) 2015 Nordson Corporation
Table of Contents v
Service Kits ................................................ 7‐66
Adhesive Storage Bin Pneumatic Controls .................... 7‐66
Adhesive Storage Bin Transfer Pump O‐Rings ................ 7‐66
Central Processor Unit (CPU) .............................. 7‐66
Control Panel ............................................ 7‐66
Filter .................................................... 7‐67
Grid/Hopper Replacement ................................. 7‐67
Heater Block, 230V ....................................... 7‐67
Heater Block, 480V ....................................... 7‐68
Hose/Applicator Module ................................... 7‐68
Hose/Applicator Module Fuses ............................. 7‐68
Hose Cuffs ............................................... 7‐68
Level Sensor ............................................. 7‐69
Level Sensor Cable ....................................... 7‐69
Lid Assembly ............................................. 7‐69
Lid Filter ................................................. 7‐69
Lid Inlet Tube ............................................ 7‐70
Lid Switch ............................................... 7‐70
Main Board .............................................. 7‐70
Main Board Fuses ........................................ 7‐70
Manifold, 4‐ or 6‐Hose/230V or 480V ........................ 7‐71
Manifold Guard ........................................... 7‐71
Manifold O‐Rings ......................................... 7‐71
Pneumatic Panel ......................................... 7‐72
Pressure Discharge Valve .................................. 7‐72
Pump Replacement (15:1) ................................. 7‐72
Pump General Service .................................... 7‐73
Pump Magnetic Actuator ................................... 7‐73
Pump Air Valve ........................................... 7‐73
Pump Magnetic Fork ...................................... 7‐74
Refill PCA ............................................... 7‐74
RTD .................................................... 7‐74
Sequencer Board ......................................... 7‐74
Spare Parts, Basic ........................................ 7‐75
Spare Parts, Expanded .................................... 7‐75
Thermostat .............................................. 7‐75
Vent Guard (L14) ......................................... 7‐75
Optional Accessories ........................................ 7‐76
6 Hose Expansion ........................................ 7‐76
8 Hose/Applicator Expansion Base (L14) ..................... 7‐76
Adhesive Storage Bin Grates ............................... 7‐76
Air Flush Kit .............................................. 7‐77
Ethernet Card ............................................ 7‐77
DeviceNet Card .......................................... 7‐77
Input/Output Expansion Card ............................... 7‐78
PROFIBUS Card ......................................... 7‐78
Pump Box Kits ........................................... 7‐78
Solenoid Harness Quick‐Disconnect Kits ..................... 7‐79
Suction Lance Kits ........................................ 7‐80
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vi Table of Contents
Technical Data ............................................. 8-1
Specifications .............................................. 8‐1
Melter Specifications ...................................... 8‐1
Melter Electrical Specifications ............................. 8‐2
Melter Pump Specifications ................................ 8‐2
Melter Power Requirements ................................ 8‐2
Fill System Specifications .................................. 8‐3
Dimensions ................................................ 8‐4
Melter ................................................... 8‐4
Sub‐base ................................................ 8‐5
Adhesive Storage Bin ..................................... 8‐6
Wiring Diagrams ............................................ 8‐8
Refill PCA ............................................... 8‐8
Sequencer ............................................... 8‐10
200/240 VAC Melter ...................................... 8‐12
400/480 VAC Melter ...................................... 8‐12
Calculating Melter Power Requirements...................... A-1
Operating Parameters ...................................... B-1
Standard ................................................... B‐2
Temperature Control ........................................ B‐7
Input Setup ................................................. B‐11
Output Setup ............................................... B‐16
Seven‐day Clock ............................................ B‐18
Example 1 ............................................. B‐19
Example 2 ............................................. B‐19
Example 3 ............................................. B‐19
Fill System ................................................. B‐28
PID Selection ............................................... B‐29
Melter Communications..................................... C-1
Software Availability ......................................... C‐1
System Requirements ....................................... C‐1
Installing the Software ....................................... C‐2
Removing the Software from Your PC ........................ C‐4
Connecting the PC and the Melter ............................. C‐5
Using Nordson Configuration Manager ......................... C‐6
Saving and Restoring Melter Settings ........................ C‐6
Upgrading or Restoring Melter Firmware ..................... C‐8
Troubleshooting ............................................ C‐11
Using Nordson Configuration Manager ....................... C‐11
Part 1124685_01 (cid:2) 2015 Nordson Corporation
Table of Contents vii
SP Pump Diagnostics and Repair ............................ D-1
Introduction ................................................ D‐1
Pump Function ............................................. D‐1
Pump Isolation Valve ................................... D‐2
Pressure Discharge Valve ............................... D‐2
Pump Diagnostics ........................................... D‐4
Pump Disassembly and Reassembly ........................... D‐6
Melter Preparation ........................................ D‐6
Required Tools and Materials .............................. D‐6
Tools ................................................. D‐6
Service Parts .......................................... D‐7
Supplies .............................................. D‐7
Remove the Pump from the Melter .......................... D‐8
Special Reassembly Instructions ......................... D‐8
Remove the Actuator and Air Manifold and the Cylinder Assembly D‐10
Special Reassembly Instructions ......................... D‐10
Remove the Magnetic Actuator Assembly .................... D‐12
Remove the Valve Spool and Sleeve ........................ D‐15
Special Reassembly Instructions ......................... D‐16
Remove the Shifter Fork ................................... D‐18
Special Reassembly Instructions ......................... D‐18
Remove the Piston Cups ................................... D‐20
Special Reassembly Instructions ......................... D‐20
Remove the Pump Frame and the Insulator ................... D‐22
Special Reassembly Instructions ......................... D‐22
Remove the Lower Ball Seat Assembly and the Piston ......... D‐26
Special Reassembly Instructions ......................... D‐26
Disassemble the Lower Ball Seat and the Pressure Ball
Assemblies ............................................. D‐28
Special Reassembly Instructions ......................... D‐28
Remove the O‐ring and the Pump Seal ...................... D‐30
Special Reassembly Instructions ......................... D‐30
Pump Assembly Parts List .................................... D‐32
Pump Service Kit ......................................... D‐34
Other Pump Maintenance Kits .............................. D‐34
Schedule of Fasteners ..................................... D‐34
400/480 Volt Adhesive Melters ............................... E-1
Introduction ................................................ E‐2
Safety ................................................... E‐2
Intended Use ............................................. E‐2
Unintended Use .......................................... E‐2
Transformer Sizing ........................................ E‐3
Transformer Function ..................................... E‐5
Installation ................................................. E‐6
Clearances .............................................. E‐6
Installation Kit Components ................................ E‐7
Prepare the Transformer for Installation ...................... E‐8
Mount the Transformer to the Parent Machine ................ E‐10
Connect the Electrical Service to the Transformer .............. E‐12
Mount the Melter to the Transformer ......................... E‐14
Connect the Transformer to the Melter ....................... E‐16
Troubleshooting ............................................ E‐19
Parts ...................................................... E‐20
Transformer Assembly .................................... E‐20
Service Kits .............................................. E‐23
Wiring Diagram ............................................. E‐23
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Part 1124685_01 (cid:2) 2015 Nordson Corporation