Nordson VersaBlue VA - Maintenance Record Form

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Maintenance

5‐25

P/N 213828_11

 2014 Nordson Corporation

VersaBlue_PPA

Maintenance Record Form

Melter part Activity Date / Name Date / Name Date / Name

Complete melter

- external cleaning

- Visual inspection

Gear pump

Motor / gear box

Fan / air filter

Tank

Pressure control valve

Filter cartridge

Safety valve

Safety valve plate with tank

isolation valve

Safety valve for pneumatics

Pressure sensor

Filling valve

Main Page

Table of Contents3
Nordson International13
Europe13
- Distributors in Eastern & Southern Europe13
Outside Europe14
- Africa / Middle East14
- Asia / Australia / Latin America14
- China14
- Japan14
- North America14
Safety15
Safety Alert Symbols15
Responsibilities of the Equipment Owner16
- Safety Information16
- Instructions, Requirements, and Standards16
- User Qualifications17
Applicable Industry Safety Practices17
- Intended Use of the Equipment17
- Instructions and Safety Messages18
- Installation Practices18
- Operating Practices18
- Maintenance and Repair Practices19
Equipment Safety Information19
- Equipment Shutdown20
- General Safety Warnings and Cautions21
- Other Safety Precautions24
- First Aid24
Safety Labels and Tags25
Electrostatic Discharge27
- Damage to Electronic Components27
- Personal Injury and Risk of Fire27
Introduction29
Intended Use29
- Area of Use (EMC)29
  - Operating Restrictions29
- Unintended Use - Examples29
Residual Risks30
Note on Manual30
- Other Sources of Information30
  - User's Guide30
  - Product Resource Disc30
- Definition of Terms31
- Symbols32
Melter Description33
- Illustration33
- Safety Valve Plate34
  - Tank Isolation Valve34
  - Safety Valve34
- Tank34
  - Pressure Control Valve34
- Material Flow35
  - Labeling with Two Pumps35
- Electrical Cabinet36
- Level Display, Level Control / Overflow Protection (Option)37
- Pressure Display / Pressure Control (Options)38
  - Pressure Display38
  - Pressure Control38
- ID Plate39
Installation42
- Lifting (Unpacked Melter)42
Installation Requirements42
- Required Space42
  - Melters with Transformer43
- Exhausting Material Vapors43
Screwing on Light Tower (Option)44
Installation Personnel's Experience44
Electrical Connections45
- Observe When Using Residual Current Circuit Breakers45
- Laying Cable45
  - Labels45
- Operating Voltage45
- Power Supply46
Mains Filter46
- Installing Kit (Accessory)46
Connecting Hose47
- Connecting Electrically47
- Connecting47
  - Second Open-End Wrench47
- Disconnecting48
  - Relieving Adhesive Pressure48
Installing Applicator49
- Conditioning Compressed Air for Applicator Control Modules49
Connecting Filling Valve (Option)49
Key-To-Line: Selecting Line Speed Voltage or Line Speed Current on I/O Board50
Interface Assignment51
- Interface Standard I/O51
  - General Notes51
- Interface Key-To-Line53
  - One Line Speed Signal Input for All Motors (XS5)53
  - Separate Line Speed Signal Inputs (XS5.1, XS5.2)53
- Interface Level Control54
Pneumatic Connections55
- Pneumatic Pressure Control / Bypass Control55
- Inert Gas58
- Condensate Disposal When Dry Air Is Used as Inert Gas58
Light Tower59
- Installing Kit (Accessory)59
Casters60
- Installing Kit (Accessory)60
Air Relief Valve (Accessory)61
Retrofitting Pressure Sensors61
Retrofitting a Temperature Control Board61
IPC Webserver61
Removing Melter61
Disposing of Melter61
Operation63
General Information63
- Channel Numbers63
  - On the Control Panel63
  - On the Field Bus64
- Transparent Keys64
- Keys with and Without Indication Lamp64
- Meaning of Colors64
- Description of Symbols65
  - Standard Symbols of Temperature Channels65
- Input Window66
- Screen Replacing Motor Controller66
- Status Display67
Initial Startup68
- Purging Melter68
  - Control Panel Settings69
  - Standard I/O: Observe for Edge-Controlled Signals (Example)70
- Note on Recipes73
- After the First Day73
- Control Panel - Overview75
  - Working with Application Groups and Numbering of Temperature Channels80
Filling Tank83
- Manually83
- Level Display and Control (Options)84
  - Automatic Tank Filling84
- Maximum Level84
Recommended Temperature Setpoints85
Heatup Guided by Reference Channel86
Undertemperature Interlock87
Motor Startup Protection87
- Acknowledging Startup Protection87
Daily Startup88
Daily Switchoff89
Switching off in an Emergency89
Control Panel of the Industrial PC (IPC)90
- Melter Modes - Overview90
- Screen Saver91
- Starting Screen91
- Temperature Parameters92
- Melter101
- Motor128
Settings Record141
Operation Via the IPC Webserver143
- Webserver Login from the Customer's Windows®7 Operating System143
- Setting up Connection between the Server and the Client144
  - Connecting Ethernet Cable144
  - Calling up Melter (Versaweb)145
- Upload and Download of Customer Recipes146
Maintenance149
Risk of Burns149
Relieving Adhesive Pressure149
Important When Using Cleaning Agents149
Processing Materials150
Preventive Maintenance150
External Cleaning152
- Control Panel152
Visual Inspection for External Damage153
Safety and Function Tests153
Detaching Protective Panels153
Detaching Insulation Blanket153
- Important Regarding Hooks (Insulation Blanket Support)154
Fan and Air Filter154
Gear Pump155
- Checking for Leakage155
- Retighten Gland155
- Replacing Pump Shaft Seal155
- Retightening Fixing Screws155
Motor156
Gear Box156
- Selecting Lubricant156
- Changing Lubricant157
Pressure Control Valve158
- Installing Service Kit158
  - Important for Mechanical Pressure Control Valve159
Filter Cartridge160
- Replacing Filter Cartridge160
  - Removing Filter Cartridge160
  - Installing Filter Cartridge161
- Relieving Air with Air Relief Valve161
- Cleaning Filter Cartridge (until Week 17/2012)162
  - Assembling Filter Cartridge162
- Cleaning Filter Cartridge (Week 17/2012 and Later)163
  - Assembling Filter Cartridge163
- Filter Cartridge: Installing Service Kit164
Tank165
- Draining Material165
- Cleaning Tank by Hand165
- Retightening Fixing Screws165
Safety Valve Plate166
- Installing Service Kit166
Tank Isolation Valve167
- Installing Service Kit167
Safety Valve168
Changing Type of Material168
Purging with Cleaning Agent168
Pressure Sensor169
- Cleaning Adhesive Bore169
- Cleaning Separating Membrane169
  - Screwing in169
  - Inserting/Extracting with Brass Washer170
Filling Valve171
- Replace Control Module171
Safety Valve for Pneumatics172
- Performance Check172
Maintenance Record Form173
Troubleshooting175
Helpful Tips175
Alarm Number, Alarm Text and Optional Light Tower176
Triggering and Resetting Alarms180
- Graphic Presentation of Temperature Parameters180
- Undertemperature and Overtemperature - Warning181
  - Undertemperature Warning Triggered181
  - Overtemperature Warning Triggered181
- Undertemperature and Overtemperature - Fault182
  - Undertemperature Fault Triggered182
  - Overtemperature Fault Triggered182
- Overtemperature - Shutdown183
  - Software-Triggered183
- Shutdown by Thermostats183
  - Tank Thermostat183
  - Transformer Thermostat183
- Underpressure - Warning184
  - Underpressure Warning Triggered184
- Overpressure - Warning - / Overpressure - Fault185
  - Overpressure Warning Triggered185
  - Overpressure Fault Triggered185
- Temperature Sensor - Fault186
  - Short-Circuit-Triggered186
  - Triggered by Broken Sensor or Open Sensor Input186
- Level (Variable Measuring Points)186
- Level (Fixed Measuring Points - 5-Point Sensor)187
Troubleshooting Tables188
- Melter Not Functioning188
- One Channel Does Not Heat188
- No Line Speed Signal (Voltage / Current / Frequency)189
- Control Panel Does Not Function189
- No Material (Motor Does Not Rotate)190
- No Material (Motor Rotating)192
- Too Little Material or Irregular Feeding192
- Material Pressure too High193
- Material Pressure too Low193
- Incorrect Motor Rotation in Key-To-Line Mode193
- Material Residue in Tank194
- Material Hardens in Tank194
- Others195
- Filling Valve (Option)196
Leds and Plugs of I/O Board196
- Frequency Input196
- Analog Inputs197
- Digital Inputs/Outputs (Leds)197
Leds of Temperature Control Board199
Leds of Motor Controller200
LED of Overflow Protection Evaluator200
LED of Proportional Valve200
Leds of 5-Point Sensor Evaluator201
Leds of IPC202
Checking Transmitted Field Bus Data203
Repair205
Observe before Performing Repairs205
After Repair205
Control Panel206
- Detaching Control Panel206
- Replacing Memory Board207
- Installing/Replacing the Communication Assembly208
  - Important208
Replacing Motor Controller210
- CAN Bus Terminating Resistor210
- On the Control Panel: Allocating Replaced Motor Controllers (MC) to Their Motors210
Attaching Shielding Plate (EMC)212
- Retrofitting First Pressure Sensor (Electrical)213
Replacing Pressure Sensor213
- Information on T-Tap and CAN Bus Cables with Hexagon Nut213
- CAN Bus Terminating Resistor214
- Procedure214
Replacing Gear Pump215
- Installing Service Kit215
Replacing Variseal218
- Assembly Tool218
Replacing Motor219
- Aligning Motor220
Replacing Safety Valve221
- Installing Service Kit221
Replacing Filter Cartridge222
Observe When Performing Work Behind Electrical Equipment Cover222
Replacing Thermostat222
Replacing Heater Connection Insulation223
Replacing Temperature Sensor224
- Installing Service Kit224
Replacing I/O Board, Temperature Control Board225
- Setting ni 120 or Pt 100226
- Switching Bus Terminating Resistor ON/OFF226
- Setting DIP Switch S3226
Replacing Level Evaluator (Option) of Analog Sensor227
- Important Notes227
- Calibrating228
  - Prerequisites228
Replacing Overflow Protection Evaluator (Option)229
- Important Notes229
- Calibrating230
Replacing 5-Point Sensor Evaluator (Option)231
- Important Notes231
- Calibrating232
  - Prerequisites232
Replacing Coupling Component (Option: Separate Line Speed Voltage)233
Parts235
How to Use Illustrated Parts List235
- Fasteners235
- Component Designation235
- Special Models236
  - Software Configuration Code for Special Models236
Technical Data237
General Data237
Temperatures238
Electrical Data238
- Max. Melter Load (Without Accessories)239
- Max. Load (Accessories)239
- Max. Load (Accessories) - 1-Phase V12239
- Melter Fuse Protection239
Mechanical Data240
Options and Accessories241
Accessories244
Password245
Control Panel P/N 207023 and P/N 207850 (First Generation249
Validity249
- Visible Distinguishing Features249
- Save Recipe249
Troubleshooting250
- From Communication Data List250
- Control Panel Does Not Function251
- Control Panel251
- Detaching Control Panel252
- Replacing Battery253
- Replacing Memory Board253
Parts254
General Instructions Regarding Working with Application Materials255
Definition of Terms255
Manufacturer Information255
Liability255
Risk of Burns255
Vapors and Gases256
Substrate256
Processing Temperature256
Glossary257

Nordson VersaBlue VA - Maintenance Record Form

Table of Contents

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