Nordson VersabBlue Adhesive Melter User Manual

Table of Contents

Nordson VersabBlue Adhesive Melter

Installation Practices

Install the equipment in accordance with the instructions provided in this document and in the documentation supplied with auxiliary devices.
Ensure that the equipment is rated for the environment in which it will be used and that the processing characteristics of the material will not create a hazardous environment. Refer to the Material Safety Data Sheet (MSDS) for the material.
If the required installation configuration does not match the installation instructions, contact your Nordson representative for assistance.
Position the equipment for safe operation. Observe the clearance requirements between the equipment and other objects.
Install lockable power disconnects to isolate the equipment and all independently powered auxiliary devices from their power sources.
Properly ground all equipment. Contact your local building code enforcement agency for specific requirements.
Ensure that fuses of the correct type and rating are installed in fused equipment.
Contact the authority having jurisdiction to determine the requirement for installation permits or inspections.

Introduction

Intended Use:

Adhesive melters of the series VersaBlue may be used only to melt and convey suitable materials, e.g., thermoplastic hot melt adhesives. Any other use is considered to be unintended. Nordson will not be liable for personal injury or property damage resulting from unintended use. Intended use includes the observance of Nordson safety instructions. Nordson recommends obtaining detailed information on the materials to be used.

Area of Use (EMC)

About electromagnetic compatibility (EMC), the melter is intended for use in industrial applications.

Unintended Use − Examples −

The melter may not be used under the following conditions:

In a defective condition
Without an insulation blanket and protective panels
With the electrical cabinet door open
With the tank lid open
In a potentially explosive atmosphere
When the values stated under Technical Data are not complied with.

The melter may not be used to process the following materials

Polyurethane hot melt adhesive (PUR)
Explosive and flammable materials
Erosive and corrosive materials
Food products.

Series Overview

This manual describes the following melters:

Melter Description

Illustration

Machine foot (option: casters)
Electrical cabinet
Motor circuit switch (option)
Main switch
Control panel
ID plate
Receptacles (XS2, XS3, XS5, XSD, XSP, …)
Tank lid
Protective panel
Receptacles for guns, hoses, and valve control
Tank
Pressure control valve
Filter cartridge
Hose connection
Motor
Coupling
Gear pump
Safety valve plate
Insulation blanket

Tank

The tank is divided into grid (low melt) and reservoir (high melt) sections. An insulating seal (2) provides a temperature barrier between the two sections. The temperature barrier allows the material in the grid section (1) to be gently melted at a low temperature. The material is then melted to the processing temperature in the reservoir (3).

Melter Description

Pneumatic Pressure Control Valve

Pressure control valve
Filter cartridge

The pneumatic pressure control valves (1) can be installed instead of the mechanical pressure control valves. They are also located in the manifold. They are connected to the pneumatic control unit in the melter with one pneumatic hose each.

Air Relief Valve

There are air relief valves (1) in the manifold. Their purpose is to allow the air entering the manifold when the filter cartridge is replaced to escape.

Material Flow

Identification of Hose Connections

The melter supplies various adhesive streams (pump streams) that are guided through the hoses to the different gear metering pump stations or guns. Engraved numbers identify the hose connections so that the pump streams can be correctly paired with the hoses. The hose connection that leads down is number 1; the one above it is number 2. The hose connections are numbered from right to left, beginning with 1.

Electrical Cabinet

Interface Level control (option), XS 3
Cable duct PROFIBUS (option), XS D
Cable gland Power supply
Interface Key-to-line, XS 5
Interface Standard I/O, XS 2
Mains filter (accessory)
Interfaces Line speed signal inputs (XS 5.1 to XS 5.4)
Interface Pneumatic pressure control/bypass control (option), XS 4
Heat exchanger (option)
Pressure displays Pneumatic bypass (option)
Pressure display Inert gas (option)
Light tower (accessory/option)
Circuit breakers (for 3 x 200 VDC and 3 x 230 VDC)
Circuit breakers (for 3 x 400 VDC, 3 x 400 VDC + N and 3 x 480 VDC)
Solid-state relay
Evaluator Level control (option)
Evaluator: Separate overflow protection (option)
Fan (not present with heat exchanger)
Motor controller
Power supply 24 VDC
Circuit breaker Main fuse
Main contactor
Mains terminals
I/O board 1
I/O board 2
Gateway (option)
ControlNet tap (option)
Coprocessor (option)
Ethernet switch (option)
Transformer module
Temperature control board

Installation

Transport

Refer to the section Technical Data for weight. Use only suitable transport devices.
If possible, use the pallet (3) that came with the melter and use angle brackets (2) to fasten the melter.
Use a sturdy box (1) or the folding box (4) to protect from damage.
Protect from humidity and dust.
Avoid jolts and vibrations.

Unpacking

Unpack carefully and check for damage caused during transport. Save pallets, angle brackets, and boxes for later use, or dispose of them properly according to local regulations.

Lifting (Unpacked Melter)

Refer to the section Technical Data for weight. Lift melter only at the chassis only, using suitable lifting equipment or a forklift.

Installation Requirements

Set up only in an environment that corresponds to the stated Degree of Protection (Refer to section Technical Data). Do not mount in a potentially explosive atmosphere! Protect from vibration.

Melters with Transformer

The transformer is located under the melter.

Keep cables and hoses out of the space under the melter.
Position the unit such that air can circulate sufficiently under the melter.

Exhausting Material Vapors

Ensure that material vapors do not exceed the prescribed limits. Always observe the safety data sheet (MSDS) for the material to be processed. If necessary, exhaust material vapors and provide sufficient ventilation of the location of the system.

Required Space

Installation Personnel’s Experience

The instructions contained in this section are intended for personnel with experience/authorization in the following fields:

Application methods with hot melt adhesive or similar materials
Industrial electrical wiring of power and control lines
Industrial mechanical installation
General knowledge of process control.

Power Supply

Disconnecting

Relieving Pressure

Set motor speed to 0 min-1 (rpm). Switch off the motor(s) (Refer to section Operation).
Place a container under the air relief valves (1, Fig. 3-14) to be opened.
Use a screwdriver to turn the air relief valve screws counterclockwise and open the valves.
Material flows out of the air relief holes, and the melter is relieved of pressure.
Use a screwdriver to turn the air relief valve screws clockwise and close the valves.
Place a container under the nozzle(s) of the gun/assembly handgun.
Activate the solenoid valve(s) electrically or manually, or pull the trigger of the assembly handgun. Repeat this procedure until no more material flows out.
Properly dispose of material according to local regulations.

Conditioning Compressed Air

The quality of the compressed air must be at least class 2 in compliance with ISO 8573−1. This means:

Max. particle size 30 m
Max. particle density 1 mg/m3
Max. pressure dew point − 40 °C
Max. oil concentration 0.1 mg/m3

Interface Level Control

Light Tower

Installing Kit (Accessory)

Break out the plate from the top of the melter tower (1) along the punched lines and remove it.
Swivel the melter tower open.
Guide the cable through the resulting hole.
Use the two screws M5 to fasten the light tower.
Guide the cable through the top opening of the melter tower and to the inside wall (tank side) of the electrical cabinet.
Release knurled nut (4) from the bracket Cable duct (3). Slide the bracket up in the slot.
Guide the cable through the resulting hole and then through the cable ducts to the I/O board (2) in the electrical cabinet door.

Operation

General Information

The control panel is a touch screen. The melter can also be operated via the Web server. The user interface is the same as the control panel. Refer to Operation via the IPC Webserver at the end of this section.

Transparent Keys

If a feature − e.g., pressure control − is available according to the melter configuration but contradicts the feature currently selected on the control panel (e.g., speed control), all of the keys relevant for pressure control will appear transparent.

Control Panel − Overview −

Recommended Temperature Setpoints

The temperature setting is determined, among other things, by the processing temperature prescribed by the material supplier.

Heatup Guided by Reference Channel

Heat-up guided by reference channel prevents individual temperature channels from reaching their setpoint temperature long before the slowest temperature channel (reservoir/high melt = reference channel). It prevents hot melt material from charring in hoses/guns and the build-up of material expansion pressure during heat-up. It also helps to save energy. The actual reservoir temperature serves as the current temperature setpoint for the guided channels until the reservoir has reached a temperature of 10 °C (18 °F) below its setpoint temperature. Then heat-up is guided by the reference channel ends automatically. This way, all channels reach their setpoint temperatures more or less at the same time.

When the current temperature setpoint of a guided channel (= current value of reservoir/high melt) reaches the guided channel’s own setpoint minus 2 °C (3.6 °F), it is excluded from heatup guided by the reference channel and then heats to its own setpoint independently (Refer to Fig. 4-13).

Undertemperature Interlock

The undertemperature interlock prevents the melter motors from being switched on as long as the material is too cold and thus too thick. This could damage the pumps. The undertemperature interlock is active during every heat-up phase (status
display) and after every standby. Also refer to section Troubleshooting, Undertemperature Fault Triggered. If the system-ready delay time is activated, this time must also have expired before the interlock is disabled.

Motor Startup Protection

The motor startup protection prevents the motors from starting up on their own after heat-up or after a fault. The melter goes to startup protection if the condition for Motor running: All motors ON AND Enable motor is fulfilled. When the system is ready again (status display), the motors can be switched on again via the control panel or the interface Standard I/O.

Acknowledge Startup Protection

On the Control Panel
Press the key Switch on/off all motors (collective enable); startup protection is acknowledged, and all enabled motors run again.

Via Interface Standard I/O
Switch all motors ON/OFF from OFF to ON. All enabled motors run again.

Via Field Bus
Set Switch ON/OFF All Motors (Collective Enable) (Rising edge; refer to Melter control: If bit 1 = 0, then set to 1. If bit 1 = 1, set to 0, then back to 1). All enabled motors are running again.

Daily Startup

Set the main switch to I/ON. The melter begins to heat up.
Fill the tank if necessary.
Wait until the system is ready for operation (green status display: System ready.
Enable the motor(s) (password level 1). Refer to Fig. 4-28.
If desired, switch immediately to password-protected mode. Press Activate password protection.
Switch on the motor(s). Refer to Fig. 4-28.

Daily Switchoff

Switch off the motor(s).
Set the main switch to 0/OFF.
If necessary, secure the main switch with padlocks against unauthorized access.

Switching Off in an Emergency

Set the main switch to 0/OFF.
After the standstill and before switching the melter on again, have the emergency remedied by qualified personnel.

Control Panel of the Industrial PC (IPC)

Melter Modes – Overview –

Maintenance

Important when Using Cleaning Agents

Use only a cleaning agent recommended by the hot melt material manufacturer. Observe the Material Safety Data Sheet for the cleaning agent.
Properly dispose of the cleaning agent according to local regulations.

Processing Materials

Preventive Maintenance

The maintenance intervals are general guidelines based on experience. Depending on the operating environment, production conditions, and melter hours of operation, other scheduled maintenance tasks may prove necessary.

External Cleaning

External cleaning prevents impurities created during production from causing the melter to malfunction. Remove material residue only with a cleaning agent recommended by the material supplier. Heat with an air heater if necessary. Remove dust, flakes, etc. with a vacuum cleaner or a soft cloth. Nordson recommends the orange cleaning agent P/N 771 192 (12 spray
bottles, 0.5 liter each).

Control Panel

Clean the insides of the plastic frame on the control panel front regularly with a damp, soft cloth. Use caution to ensure that the surface is not scratched or scoured, particularly when removing hard residue and abrasive dust. Do not allow solvents to come into contact with the panel front; solvents could corrode the plastic frame.

Changing Type of Material

May be mixed: The Remaining old material can be flushed out using the new material.
May not be mixed: Thoroughly purge the unit with a cleaning agent recommended by the material supplier.

Troubleshooting

Helpful Tips

Before starting systematic troubleshooting, check the following:

Is the seven-day clock set correctly?
Are all parameters set correctly?
Is the interface wired correctly?
In key-to-line mode: Is there a line speed signal provided?
Do all plug connections have sufficient contact?
Have circuit breakers been activated?
Could the fault have been caused by an external PLC?
Are external, inductive loads (e.g., solenoid valves) equipped with recovery diodes?

Alarm Number, Alarm Text, and Optional Light Tower

The status display of the control panel indicates only Warning, Fault, or Shutdown. The special alarm text can be found under (V2, Alarm log) or is shown directly when the line Status display is touched.

Replacing Coupling

Disconnect the melter from the line voltage.
Detach protective panels and insulation blanket.
Turn the coupling far enough that assembly work can be performed easily.
Allow the coupling to cool; the following tasks can be performed best without gloves.
Release the coupling on the motor side.
Mark the position of the motor, then slide back the motor bracket (with the motor and coupling broken sensor) in the slot. Fig. 7-23
Release and detach the coupling from the pump side, then dispose of it properly.
Unscrew the sensor from the sensor bracket (The sensor will be used again) and replace the old sensor bracket with the new one from the spare parts kit. Coupling.
Slide the magnets into the square indentations on the surface of the coupling.
Degrease the edge of the coupling (e.g., with spirit) so that the adhesive labels remain affixed.
Stick the two warning labels from the parts kit to the edge of the coupling, next to the indentations.
Slide the motor in the slot until the motor shaft touches the pump shaft. The two shafts must be aligned vertically and horizontally. Then slide the motor back again.
Attach the new coupling to the pump shaft without using force (no jolting or pounding).

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