Nordson VersaBlue VA

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Installation

3‐22

P/N 213828_11

 2014 Nordson Corporation

VersaBlue_PPA

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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 - Page 62

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