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Nordson ProBlue Flex User Manual

Nordson ProBlue Flex
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ProBlue Flex Adhesive Melter
with BBconn Controls
Core Customer Product Manual
Part 1128350_02
Issued 06/20
NORDSON CORPORATION DULUTH, GEORGIA USA
www.nordson.com
This document contains important safety information.
Be sure to read and follow all safety information in this
document and any other related documentation.

Table of Contents

Other manuals for Nordson ProBlue Flex

Questions and Answers:

Nordson ProBlue Flex Specifications

General IconGeneral
BrandNordson
ModelProBlue Flex
CategoryMelting Machines
LanguageEnglish

Summary

Section 1 Safety

Safety Alert Symbols

Describes the meaning of safety alert symbols used to indicate hazards and precautions.

Intended Use of the Equipment

Defines the designed purpose and limitations for using the ProBlue Flex adhesive melter to prevent misuse.

Installation Practices

Provides guidelines for safe and compliant installation of the equipment.

Operating Practices

Outlines key safe practices for operating the equipment, including device checks and PPE.

Maintenance and Repair Practices

Details safe procedures for performing maintenance and repairs on the equipment.

Equipment Shutdown

Details procedures for safely shutting down the equipment, including pressure relief and de-energizing.

Relieving System Hydraulic Pressure

Procedure to safely relieve trapped hydraulic pressure before disconnecting any hydraulic fitting.

De-energizing the System

Steps to isolate the system from all power sources before accessing high-voltage wiring.

Disabling the Applicators

Instructions on how to disable applicators and associated components before performing work.

General Safety Warnings and Cautions

Lists general safety warnings and cautions applicable to hot melt and cold adhesive equipment.

Section 2 Description

Melter User Interface

Details the OLED user interface used for navigating, configuring, and fine-tuning system settings.

Low Voltage Controller (LVC)

Details the LVC as the system's brain, coordinating activities and supporting various communications channels.

Section 3 Installation

Melter Installation

Provides an overview of the melter installation process and the sequence of tasks required.

Installation Requirements

Ensures the installation location meets required clearances, environmental conditions, and utilities before installation.

Electrical Power

Ensures plant electrical service is rated for melter, hoses, and applicators, and discusses power disconnect switches.

Compressed Air

Details the compressed air supply requirements for maximum hot melt output, including pressure and consumption.

Melter Mounting Considerations

Factors for evaluating melter mounting location, including distance to applicators and support structure guidelines.

Mount the Melter

Describes the process of removing the sub-base, mounting it, and then remounting the melter.

Removing the Melter from the Sub-base

Provides step-by-step instructions for removing the melter from its sub-base plate.

Mounting the Melter

Details steps for marking bolt patterns, drilling holes, bolting the sub-base, and securing the melter.

Connecting Incoming Power

Provides methods for connecting incoming power, including cable clamp usage and conduit knockouts.

Configure the Electrical Service

Details electrical service configuration, including power cable and voltage plug requirements.

Connecting Power Cables

Details connecting power cables, including selecting rated cables and accessing electrical boards.

Connect a Pump Control Signal

Explains how to provide 24VDC power to operate a single acting pump via a solenoid valve.

Connecting Power to the Solenoid Valve

Provides steps for connecting 24VDC control wiring to the solenoid valve connector and coil assembly.

Connect a Compressed Air Supply

Details how to connect the compressed air supply, including pressure adjustment and air filter installation.

Connect Hoses and Applicators

Explains how ProBlue Flex melters use standard hoses and applicators, and capacity limits.

Set Up the Melter

Details how to set up the melter after installation to support manufacturing processes and set operating parameters.

Using the OLED User Interface

Explains how to use the OLED user interface components for setup, operation, and fine-tuning system settings.

Input Parameters

Details various input parameters for system control, such as setback, heater, pump, and fill control.

Output Parameters

Lists output parameters for system status, fill, temperature, flow monitoring, and alarms.

Section 4 Basic Melter Operation

Operator Level Tasks

Lists operator-level tasks including filling, starting, operating, and shutting down the melter.

Melter Operation

Provides information on basic melter operating tasks and customization options.

Filling the Melter Tank

Instructions on filling the tank, confirming material compatibility, and using the tank sensor alert.

Starting the Melter for the First Time

Details the steps for initial melter startup, including self-check, filling, and purging air.

OLED User Interface

Explains how the OLED user interface allows navigation through menus for setup, operation, and fine-tuning.

Commissioning Setup Wizard

Describes the setup menu sequence that starts upon first power-up or after a factory reset.

Navigation Controls

Details the use of Home screen components and navigation buttons for monitoring and changing melter settings.

Master Controls

Describes the master system On/Off components for controlling pump, heater, and temperature setback.

Shutting Down the Melter

Provides instructions for shutting down the melter for extended periods and disabling applicators.

Section 5 Maintenance

Relieving System Pressure

Details the procedure to safely relieve trapped hydraulic pressure before disconnecting any hydraulic fitting.

Locking Out External Communications

Warns to disable external inputs and field-bus communications before maintenance to prevent unexpected operation.

Lubricating the Pump

Provides steps for lubricating the pump, including switching off the melter, removing covers, and reconnecting the air line.

Replacing the Filter

Details instructions for replacing the adhesive filter, including relieving system pressure and tightening the filter.

Draining the Tank

Provides steps for draining the tank, including relieving system pressure and lowering the drain chute.

Section 6 Troubleshooting

Troubleshooting Checklist

Provides a list of items to check for common melter control problems before extensive troubleshooting.

AC Power

Lists checks for AC power issues, including incoming power LED, disconnects, voltage plugs, and fuses.

DC Power

Lists checks for DC power issues, including AC input connections, power supply LED, and DC output connections.

Fill

Lists checks for fill system issues, including level items, master controls, output connections, and air supply.

Temperature Control

Covers general temperature control checks and specific checks for 6-channel and H/A modules.

Pump, Pneumatics and Pressure Control

Covers general checks for air supply, pressure gauge, tubing, and specific checks for pump and pressure.

Pump

Lists checks for pump issues, including general items, pump button, master controls, and solenoid connection.

User Interface

Lists checks for user interface issues, including ribbon cable, power LED, and membrane panel connections.

Communications

Provides troubleshooting steps for NordNet Masters, Ethernet, Fieldbus Module, and Wireless Module.

Melters with 480V Transformer Base

Provides troubleshooting guidance for power and internal zone temperature control on 480V transformer bases.

About Built-in Diagnostics

Explains that the system has built-in diagnostics that continually check for problems and provide troubleshooting tools.

Troubleshooting Nordnet

Provides steps for troubleshooting Nordnet connections, observing LEDs, and adding slaves one at a time.

Identifying Electrical Components

Describes circuit board indicators, connection points, and test points for Power Distribution PCA and Expansion PCA.

Melter Pneumatic Flow Control

Explains the four different pressure control options (P1, P2, P3, P4) and their functionalities.

P3 – Remote Pressure Adjustment with Digital pressure readout

Allows local or remote pressure adjustment via OLED or customer PLC/web server, with password protection.

Troubleshoot the Melter

Provides procedures for troubleshooting melter issues, including checking melt/manifold RTDs and thermostat operation.

Checking the Melt or Manifold RTD

Details steps to de-energize, remove, and measure RTD resistance to check functionality.

Removing the Level Sensor, Melt RTD, or Melt Thermostat

Provides instructions for removing melter panels, pump cover, and specific components like RTD or thermostat.

Checking the Operation of the Power Relay

Details diagnostic procedures for checking the power relay operation using LVC indicators DS1 and DS22.

Checking the Operation of the Tank, Grid, or Manifold TRIAC

Explains how to check TRIAC operation by measuring voltage across heater terminals under specific fault conditions.

Checking the Resistance of the Tank, Grid, and Manifold Heaters

Provides steps to measure resistance of tank, grid, and manifold heaters and compare to specified ranges.

Troubleshoot the Fill System

Covers troubleshooting for the fill system, including fill time limits and faults.

Calibrating the Level Sensor

Provides conditions for calibrating the level sensor, such as component replacement or temperature set point changes.

Section 7 Technical Data

Pump Specifications

Provides detailed specifications for various pump types, including pressure ratio, viscosity, rate, and air consumption.

Melter Specifications

Lists specifications for 4, 7, 10 Kg Tank Melters and 7 and 14 Kg MOD Melters, including melt rate and dimensions.

Melter Power Requirements

Provides tables of maximum amperage for melters without transformers, specific to tank and MOD configurations.

Fill System Specifications

Lists specifications for the Fulfill integrated fill system, including adhesive forms, transfer rate, and air consumption.

Wiring Diagram - Electrical Box Enclosure Layout

Illustrates the electrical cabinet layout, showing connections between various boards and components.

Wiring Diagram - Input Power

Shows the input power layout, including voltage, terminals, personality plugs, and power distribution board connections.

Wiring Diagram - Power Distribution

Illustrates the power distribution layout, showing connections to the 6-channel power module and DC power supply.

Wiring Diagram - Power Distribution Expansion Board

Shows the wiring diagram for the power distribution expansion board, detailing connections to power modules.

Wiring Diagram - Low Voltage Control Board

Illustrates the wiring for the Low Voltage Control board (1 of 3), showing connections to various components.

Wiring Diagram - Melt and Manifold (Melt on Demand)

Shows the wiring diagram for the melt and manifold components, illustrating connections for heater control.

Wiring Diagram - Hoses and Applicators

Illustrates the wiring diagrams for hoses and applicators, showing connections to the 6-channel power module.

Wiring Diagram - 4 Channel Power Module #2

Shows the wiring diagram for the 4 Channel Power Module #2, detailing connections to heaters and Nordnet.

Wiring Diagram - Light Tower

Shows the wiring diagram for the light tower board, detailing connections for control signals and outputs.

Wiring Diagram - Hose/Applicator Expansion Base

Illustrates the wiring diagram for the hose/applicator expansion base, showing connections to power modules.

Wiring Diagram - Hose/Applicator Expansion Power Module #3

Illustrates the wiring diagram for the 4 Channel Power Module #3, showing connections to melter and expansion base.

Wiring Diagram - Hose/Applicator Expansion Power Module #4

Illustrates the wiring diagram for the 4 Channel Power Module #4, showing connections to melter and expansion base.

Wiring Diagram - Adhesive Tracking Board

Shows the wiring diagram for the Adhesive Tracking System board, illustrating connections for sensors and controls.

Section 8 Parts

Using the Illustrated Parts Lists

Guides on how to order parts using five-column lists and accompanying illustrations for correct identification.

ProBlue Flex Melter Assembly

Lists ProBlue Flex Melter Assembly components, including modules for chassis, melt section, manifold, and pump.

4 Kg Tank Module

Lists parts for the 4 Kg tank module, including tank assembly, PCA, sensor, gaskets, strainers, and thermostats.

7 Kg Tank Module

Lists parts for the 7 Kg tank module, including tank assembly, PCA, sensor, gaskets, strainers, and thermostats.

10 Kg Tank Module

Lists parts for the 11 Kg tank module, including tank assembly, PCA, sensor, gaskets, strainers, and thermostats.

Appendix A Calculating Melter Power Requirements

Before locating the melter on the production floor...

Before locating the melter, calculate electrical power required by hoses/applicators and confirm it doesn't exceed maximum allowable wattages.

To evaluate the hose/applicator power requirements

Match hoses/applicators to modules, record wattages, sum them, and compare to maximum allowable wattages.

Appendix B SP Pump Diagnostics and Repair

WARNING! Allow only personnel with appropriate training...

Emphasizes that only trained personnel should operate or service the equipment to prevent injury or damage.

Double Acting Pump

Describes the double acting pump's operation, consisting of air and hydraulic sections, and material discharge.

Pump Diagnostics

Guides on determining pump failure causes through disassembly, referencing tables for failures and conditions.

Double Acting Pump Diagnostics

Provides a table of potential causes and corrective actions for double acting pump failures.

Single Acting Pump Diagnostics

Provides a table of potential causes and corrective actions for single acting pump failures.

Pump Disassembly and Reassembly

Provides sequential pump disassembly and reassembly procedures, including required tools and materials.

Remove the Pump from the Melter (All Pumps)

Provides steps for removing the pump, including disconnecting power, lines, and disengaging screws.

Installing the Pump (All Pumps)

Provides steps for installing the pump, including lubricating O-rings, inserting into manifold, and connecting air line.

Appendix C The BBconn Cloud

Appendix D Adhesive Tracking System

Theory of Operation

Explains ATS functionality, including flow meter, sensors, calibration factors, and product monitoring.

Appendix E Optional Accessories

Appendix F ProBlue Flex 400/480 Volt Transformer

Transformer Function

Explains how the transformer splits input electrical service for melter heaters and provides reduced voltage to the power distribution board.

Installation Tasks

Lists the sequence of installation tasks for the transformer: verifying location, removal, sizing, mounting, and electrical service.

Transformer Sizing

Details the procedure for sizing the transformer based on total power consumption of hoses and applicators.

Connecting Electrical Service to the Transformer

Guides on connecting electrical service, including selecting a 3-wire power cable and using strain relief.

Mounting the 400/480V Melter on the Transformer

Details mounting the melter onto the transformer using side spacers, ensuring harnesses are not pinched.

Appendix G Hose/Applicator Expansion Base

WARNING! Failure to follow the safety messages...

Warns that failure to follow safety messages can result in personal injury or equipment damage.

Intended Use

States that the expansion base is exclusively designed for use with ProBlue Flex melters.

Installation

Instructs qualified personnel to follow safety instructions and familiarize with Installation (Section 3) before proceeding.

Mounting the Melter to the Expansion Base

Provides instructions for mounting the melter onto the expansion base, ensuring wires are not pinched.

Troubleshooting

Provides expansion base-specific troubleshooting guidance and refers to general melter troubleshooting.

Troubleshooting Specific to Expansion Base

Addresses specific expansion base issues like overloaded fuses, no AC power to circuit board, and incorrect firmware.

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