Nordson VersaBlue 100H/100H Manual Download Page 75

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Troubleshooting

6-1

P/N 7146386A

2008 Nordson Corporation

VBN w/o Control System

Section 6

Troubleshooting

WARNING:

Allow only qualified personnel to perform the following tasks.

Observe and follow the safety instructions in this document and all other

Summary of Contents for VersaBlue 100H/100H

Page 1: ...VersaBlue Adhesive Melters VBN without Controller Manual P N 7146386A English Issued 07 08 NORDSON ENGINEERING GMBH D L NEBURG D GERMANY...

Page 2: ...Select Cure Slautterback Smart Coat Solder Plus Spectrum Speed Coat Spraymelt Spray Squirt Super Squirt SureBead Sure Clean Sure Coat Sure Max Tela Therm Tracking Plus TRAK Trends Tribomatic TrueBlue...

Page 3: ...ilities 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 4 Intended Use of the Equipment 1 4...

Page 4: ...Melter Description 2 4 Illustration 2 4 Tank 2 5 Safety Valve Plate 2 5 Tank Isolation Valve 2 5 Safety Valve 2 5 Mechanical Pressure Control Valve 2 5 Pneumatic Pressure Control Valve 2 6 Air Relief...

Page 5: ...ltage 3 6 External Control Signal Circuits 3 6 Power Supply 3 7 Connecting Hose 3 8 Connecting Electrically 3 8 Connecting 3 9 Second Open end Wrench 3 9 Disconnecting 3 10 Relieving Pressure 3 10 Ins...

Page 6: ...cing Variseal 5 8 Gear Pumps with Gland 5 9 Retightening Fixing Screws 5 9 Motor Gear Box 5 10 Changing Lubricant 5 10 Pressure Control Valve 5 11 Important for Mechanical Pressure Control Valve 5 11...

Page 7: ...k of Burns 7 1 Observe Before Performing Repairs 7 1 Relieving Pressure 7 1 Replacing Gear Pump 7 2 Tank Isolation Valve 7 2 Detaching Gear Pump 7 2 Attaching Gear Pump 7 3 Important Regarding Couplin...

Page 8: ...nical Data 9 1 General Data 9 1 Temperatures 9 2 Electrical Data 9 3 Mechanical Data 9 4 Dimensions 9 5 Single Tank Units 9 5 Twin Tank Units 9 6 Options 10 1 General Instructions Regarding Working wi...

Page 9: ...1 894 149 Nordson UV 49 211 9205528 49 211 9252148 EFD 49 6238 920972 49 6238 920973 Italy 39 02 904 691 39 02 9078 2485 Netherlands 31 13 511 8700 31 13 511 3995 Norway Hot Melt 47 23 03 6160 47 23 6...

Page 10: ...n de bureaux ci dessous S Para obtener la direcci n de la oficina correspondiente por favor dir jase a unas de las oficinas principales que siguen abajo Contact Nordson Phone Fax Africa Middle East DE...

Page 11: ...ument can result in personal injury including death or damage to equipment or property Safety Alert Symbols The following safety alert symbol and signal words are used throughout this document to aler...

Page 12: ...rning regulations Contact the authority having jurisdiction for information S Maintain safety information including the safety labels affixed to the equipment in readable condition Instructions Requir...

Page 13: ...tion policies and procedures S Receive equipment and task specific training from another qualified individual NOTE Nordson can provide equipment specific installation operation and maintenance trainin...

Page 14: ...in the limits specified in this document S Do not modify the equipment S Do not use incompatible materials or unapproved auxiliary devices Contact your Nordson representative if you have any questions...

Page 15: ...isconnects to isolate the equipment and all independently powered auxiliary devices from their power sources S Properly ground all equipment Contact your local building code enforcement agency for spe...

Page 16: ...ad and comply with the manufacturer s instructions and the MSDS supplied with equipment cleaning compounds NOTE MSDSs for cleaning compounds that are sold by Nordson are available at www nordson com o...

Page 17: ...vels of shut down are Relieving System Hydraulic Pressure Completely relieve system hydraulic pressure before breaking any hydraulic connection or seal Refer to the melter specific product manual for...

Page 18: ...ump must be disabled before work can be performed on or around a gun that is connected to a pressurized system 1 Turn off or disconnect the gun triggering device pattern controller timer PLC etc 2 Dis...

Page 19: ...ents for safe handling ventilation first aid and personal protective equipment are met Failure to comply with MSDS requirements can cause personal injury including death HM WARNING Reactive material N...

Page 20: ...lectrically isolate all auxiliary devices before servicing the equipment Failure to properly isolate electrical power to auxiliary equipment before servicing the equipment can result in personal injur...

Page 21: ...damage the equipment and cause premature reaction of the hot melt If you are unsure of the equipment s ability to process PUR contact your Nordson representative for assistance HM CA CAUTION Before u...

Page 22: ...dispensing handguns by their proper suspension point First Aid If molten hot melt comes in contact with your skin 1 Do NOT attempt to remove the molten hot melt from your skin 2 Immediately soak the a...

Page 23: ...on 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 inf...

Page 24: ...osive and corrosive materials S Food products Residual Risks In the design of the unit every measure was taken to protect personnel from potential danger However some residual risks can not be avoided...

Page 25: ...wing tank extension is also available S Tank extension for 50 liter tank 25 liters S Tank extension for 100 liter tank 50 liters S Tank extension for 200 liter tank 100 liters Twin Tank Units Type Tan...

Page 26: ...cal Cabinet 2 Air filter 3 Recirculation connections 4 Protective panel 5 Tank lid 6 Pressure gauge when present 7 Hose 8 Filling valve 9 Machine foot 10 Fan 11 Main switch 12 Fan 13 Electrical cabine...

Page 27: ...Plate Tank Isolation Valve The tank isolation valve 1 enables replacement of the gear pump without first emptying the tank Safety Valve The standard safety valve 2 is fixed at 8500 kPa 85 bar 1235 psi...

Page 28: ...valves They are also located in the manifold They are connected to the pneumatic control unit in the melter with one pneumatic hose each Fig 2 5 1 Pressure control valve 2 Filter cartridge Air Relief...

Page 29: ...onnections on the second tank continue with 5 to 8 NOTE Two hose connections per single stream pump are possible Four hose connections per double stream pump are possible Fig 2 8 Example 1 Hose connec...

Page 30: ...XS 2 Transmits the digital input and output signals between the parent machine and the Nordson melter Options Level Control Overflow Protection The long level sensor 1 is connected to the analog leve...

Page 31: ...m is equipped with a pressure sensor for the pressure display in systems with only double stream pumps and in systems with both single stream and double stream pumps Pressure Build up Box 26 Code N Th...

Page 32: ...ter Refer to Fig 2 1 ADHESIVE MELTER VersaBlue Nordson Engineering GmbH Lilienthalstr 6 D 21337 L neburg Germany www nordson com Serial No 3 4 5 1 2 Year LISTED US C UL Fig 2 12 1 Melter designation 2...

Page 33: ...e angle brackets to fasten the melter S Use sturdy cardboard or a box 1 to protect from damage S Protect from humidity and dust S Avoid jolts and vibrations Fig 3 1 Storage CAUTION Do not store melter...

Page 34: ...an environment that corresponds to the stated Degree of Protection Refer to section Technical Data Do not set up in a potentially explosive atmosphere Protect from vibration CAUTION Protect the contr...

Page 35: ...VBN 100 VBN 100 H VBN 200 VBN 200 H Width W max mm 1886 2136 3035 Width W mm 1250 1500 2400 Width W1 mm 632 882 882 Width W3 mm 1932 2182 2182 Height H1 mm 1374 1597 1374 1597 1374 1597 Height H2 mm 2...

Page 36: ...100 100 100H 100H Width W max mm 2535 2785 3035 Width W mm 1900 2150 2400 Width W1 W2 mm 632 632 632 882 882 882 Width W3 mm 1932 1932 1932 2182 2182 2182 Height H1 mm 1374 1597 1374 1597 1374 1597 H...

Page 37: ...seals may not be installed in the application system Screwing on Light Tower Option The light tower is not attached upon delivery of the melter Use the two screws M5 to fasten the light tower to the...

Page 38: ...or universal current 30 mA Laying Cable WARNING Use only temperature resistant cable in warm areas of the equipment Ensure that cables do not touch rotating and or hot melter components Do not pinch...

Page 39: ...er must be installed securely permanent power supply connection Operating voltage Terminals Mains terminals in electri cal cabinet L1 L2 L3 N PE 200 VAC 3 phase without neutral Delta D D D D 230 VAC 3...

Page 40: ...onnect the hose 3 electrically to the unit Use hose receptacles XS10 to XS17 Fig 3 8 bottom row for the plugs of the hoses NOTE For more than one hose Every hose connection is allocated to a correspon...

Page 41: ...instructions apply to recirculation hoses The connecting block for the recirculation hoses is located on the tank cover Refer to Fig 3 10 The manual pressure control valves on the left side of the con...

Page 42: ...ntainer under the air relief valves 1 Fig 3 12 to be opened 3 Use a screwdriver to turn the air relief valve screws counterclockwise and open the valves 4 Material flows out of the air relief holes an...

Page 43: ...compliance with ISO 8573 1 This means S Max particle size 30 mm S Max particle density 1 mg m3 S Max pressure dew point 40 C S Max oil concentration 0 1 mg m3 1 Connect customer s compressed air suppl...

Page 44: ...lenoid valves connected to the melter must be equipped with a protective device e g recovery diode that disables the inductive voltage generated when an inductive load is switched off S The permitted...

Page 45: ...Pin Input Output Feature 1 24 VDC Internal voltage supply of separate overflow protection 2 0 VDC 3 24 VDC 2 A Fill tank Signal to filling valve Additionally with level control with overflow protecti...

Page 46: ...Installation 3 14 P N 7146386A E 2008 Nordson Corporation VBN w o Control System...

Page 47: ...aterial can char collect on surfaces and cause malfunctioning Manually WARNING Hot Risk of burns Wear appropriate protective clothing equipment Tank and tank lid are hot When filling hot material may...

Page 48: ...must be adapted to the new material on the control panel Fig 4 2 Automatic Tank Filling Automatic tank filling is performed e g by a bulk melter connected to the optional filling valve with a hose Le...

Page 49: ...Switching Off in an Emergency WARNING Switch off the melter immediately in any emergency situation 1 Set the main switch to 0 OFF 2 After standstill and before switching the melter on again have the e...

Page 50: ...ufacturer Flash point Processing temperatures Setpoints Grid Reservoir high melt Filling valve Option Hose accessory 1 2 3 4 Gun accessory 1 2 3 4 Air heater accessory 1 2 3 4 Speeds pressures Setpoin...

Page 51: ...s WARNING Hot Risk of burns Wear appropriate protective clothing equipment Some maintenance work can only be done when the melter is heated up Relieving Pressure WARNING System and material pressurize...

Page 52: ...enance 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 neces...

Page 53: ...and clean Every six months Section Parts Filter cartridge Replace filter cartridge Disassemble and clean filter cartridge Depending on degree of material pollution Recommendation Every 1000 hours of...

Page 54: ...5 22 External Cleaning External cleaning prevents impurities created during production from causing the melter to malfunction CAUTION Observe the unit s Degree of Protection when cleaning Refer to se...

Page 55: ...y qualified personnel Use only original Nordson spare parts Safety and Function Tests During power up of the melter the lights in the light tower are all switched on briefly as a test The operator sho...

Page 56: ...he Material Safety Data Sheet for the cleaning agent Cleaning agent residue can be flushed out of the unit with new material before production begins again NOTE Properly dispose of cleaning agent acco...

Page 57: ...ection Refer to section Installation Cleaning Tank by Hand Cold material can usually be peeled off of the sides of the tank Refer to Fig 5 4 If necessary first heat tank to material softening temperat...

Page 58: ...rning it has a bracing flange that is clamped in place axially when installed Variseals are fixed in place on the gear pump with a flange If material escapes along the shaft the Variseal must be repla...

Page 59: ...the old one in to be repaired Only trained personnel can replace the pump shaft seal Retighten gland NOTE Retighten only when the melter and the pump are warm Retighten the gland approx of a revolutio...

Page 60: ...ricant can result in premature wear and or damage to the gear box NOTE Drain lubricant only when the melter is warm and the lubricant fluid Remove gear box from the motor to change lubricant Wash out...

Page 61: ...g Pressure NOTE Screw in out only when valve is warm and material is soft approx 70 C 158 F depending on material Important for Mechanical Pressure Control Valve Measuring Insertion Depth Measure and...

Page 62: ...3 Close compressed air supply 4 Refer to Measuring Insertion Depth 4 Unscrew air hose 5 Use an open end wrench to screw out the pressure control valve then extract with a pliers If the tank is not emp...

Page 63: ...ptions in production NOTE Remove the filter cartridge when the melter is hot and not under pressure M10 Size 24 Fig 5 12 CAUTION Stop turning as soon as the thread is free otherwise part of the filter...

Page 64: ...er screw 2 O ring 3 Thread 4 Filter sheath 5 Filter screen 6 Nut 7 Hexagon nut locknut Assembling Filter Cartridge 1 Clamp the filter screw vertically in a vice 2 Carefully inspect O rings replace if...

Page 65: ...3 Place a container under the respective air relief valve 1 Fig 5 15 4 Use a screwdriver to turn the air relief valve screw counterclockwise and open the valve 5 Allow the pump to run and feed materia...

Page 66: ...our fixing screws M8 from the safety valve plate and remove plate 5 Remove old O rings and when present the filter screen in the suction hole 6 Clean sealing surfaces on tank safety valve plate and pu...

Page 67: ...ture 2 Empty tank 3 Release four Allan screws M5 and lift off plate Use a pliers to extract the tank isolation valve from the safety valve plate 4 Remove old O ring and clean tank isolation valve 5 Ap...

Page 68: ...nce of the safety valve should be checked approx every six months Do this by turning the knurled screw until the compressed air is audibly released If the safety valve does not function properly it sh...

Page 69: ...and then carefully wiped off with a soft cloth Fig 5 21 Screwing in Pressure Sensor NOTE The melter part and the pressure sensor should be at room temperature or at nearly the same temperature before...

Page 70: ...n material WARNING System and adhesive pressurized Relieve system pressure Failure to observe can result in serious burns 1 Disconnect air supply and electrical connection 2 Release screws M5 and extr...

Page 71: ...rial is soft approx 70 C 158 F depending on material WARNING System and adhesive pressurized Relieve system pressure Failure to observe can result in serious burns 1 2 3 Fig 5 25 1 Filling valve 2 Fil...

Page 72: ...008 Nordson Corporation VBN w o Control System Maintenance Record Form Unit part Activity Date Name Date Name Visual inspection of melter Test displays and lamps External cleaning of melter Tank Safet...

Page 73: ...te Name Date Name Pressure control valve Filter cartridge Safety valve plate Tank isolation valve Pneumatic safety valve Pressure sensor Filling valve option Replace control module Filling valve optio...

Page 74: ...Maintenance 5 24 P N 7146386A E 2008 Nordson Corporation VBN w o Control System...

Page 75: ...ive WARNING Troubleshooting activities may sometimes have to be carried out when the unit is energized Observe all safety instructions and regulations concerning energized unit components active parts...

Page 76: ...tivated Switch on main circuit breaker Main circuit breaker activated again Check for short circuit in melter or accessories 24 VDC power supply defective Replace One Channel does not Heat Problem Pos...

Page 77: ...too cold Set temperature accordingly Motor defective Replace Motor not supplied with voltage Technical inspection Pump not turning Pump is cold so material is cold Switch on pump heater Replace heate...

Page 78: ...ean or replace filter screen Pressure control valve defective Clean or replace Processing temperature set too low Correct temperature setting Pump block of the gear pump worn Replace pump Material Pre...

Page 79: ...ption pressurized with too low pressure Increase pressure Material Residue in Tank Problem Possible Cause Corrective Action Tank setpoint temperature set too high Correct temperature setting Material...

Page 80: ...iggered or is defective Trigger via customer s PLC or replace solenoid valve Others Problem Possible Cause Corrective Action Leakage at pump shaft seal Pump shaft seal VarisealR is worn Replace pump s...

Page 81: ...equipment Some melter components can only be detached when the melter is heated up Observe Before Performing Repairs WARNING Risk of electrical shock Failure to observe may result in personal injury...

Page 82: ...p only when the material is soft 70 C 158 F depending on material CAUTION The motor is precisely aligned and may not be be slid back with the bracket in the slot 2 Turn the coupling until the screws o...

Page 83: ...screws and attach only when the tank is cold Tighten screws crosswise using a torque wrench Torque 25 Nm 220 lbin for pump types SN and DN Torque 50 Nm 440 lbin for pump types SF and DF 3 Refer to Imp...

Page 84: ...aft and output shaft should be parallel to one another If the axes lean towards one another excess load is applied to the edges of the bearings causing premature wear S The coupling may not be twisted...

Page 85: ...nd protect them from dust They will be needed again CAUTION The bracket may not be slid back in the slot or unscrewed 6 Unscrew motor from bracket 1 7 If there is protective varnish on the shaft of th...

Page 86: ...rformed best without gloves 5 Release the coupling on the motor side 6 Mark the position of the motor then slide back the motor bracket with the motor and coupling broken sensor in the slot Fig 7 7 7...

Page 87: ...y valve then extract with a pliers 3 Remove outer O rings and clean outside of safety valve 4 Install new O rings 5 Apply grease to all threads and O rings 6 To prevent damage to the O rings carefully...

Page 88: ...ound conductor 2 must be reconnected after every repair Fig 7 10 Replacing Thermostat 1 Remove electrical equipment cover 2 Release the fixing screws and remove the defective thermostat 1 in grid or 2...

Page 89: ...ove electrical equipment cover 2 Disconnect connecting wires and extract defective temperature sensor 1 in grid or 2 in reservoir by the connecting wires or with the aid of a pliers 3 Apply heat trans...

Page 90: ...unction connected The operating ground must be linked to the metal casing of the melter along the shortest path Do not connect via ground conductor S All potentiometers have 20 revolutions and no mech...

Page 91: ...Calibration 4 into position 1 2 With potentiometer 1 2 find the switching point of the LED Calibration 3 LED just lights up Turn clockwise LED on Turn counterclockwise LED off 3 Plug jumper Calibrati...

Page 92: ...malfunction S All adjustments should be made with operating ground no ground conductor function connected The operating ground must be linked to the metal casing of the melter along the shortest path...

Page 93: ...he red LED full 6 begins to flash 3 Turn potentiometer P3 counterclockwise to the switching point green LED empty on red LED full off 4 Then turn counterclockwise one or two more revolutions past the...

Page 94: ...Repair 7 14 P N 7146386A E 2008 Nordson Corporation VBN w o Control System...

Page 95: ...opriate its dimensions and other properties The points in the column Description show the relationship between assemblies subassemblies and single parts Quantity The quantity needed per unit assembly...

Page 96: ...Parts 8 2 P N 7146386A E 2008 Nordson Corporation VBN w o Control System...

Page 97: ...re 5 to 85 bar 500 to 8500 kPa 73 to 1233 psi The pressure control valve is preset at the factory Default 35 bar 3500 kPa 508 psi Viscosity range 1 to 50 Pas 1000 to 50000 cP Degree of protection IP 5...

Page 98: ...lled gun and the other heated system components should be considered when setting temperatures on the melter control panel Min operating temperature 40 C 100 F Max operating temperature 230 C 450 F Ov...

Page 99: ...eviations Power supply 10 I O 10 Operating voltage frequency 50 60 Hz Melter fuse protection Refer to ID plate Key to line Max input 0 to 10 VDC Max no of gun hose connections 18 18 26 26 26 26 Max lo...

Page 100: ...20 1470 970 1170 1370 Tank volume liters 50 100 200 50 50 50 100 100 100 Tank extension liters 75 150 300 75 75 75 150 150 150 Capacity kg 47 5 95 190 47 5 47 5 47 5 95 95 95 with tank extension kg 71...

Page 101: ...n VBN w o Control System Dimensions Single Tank Units Type designation VBN 50 VBN 100 VBN 200 VBN 50 50 VBN 50 100 VBN 100 100 Width W mm 1250 1500 2400 Width W1 mm 632 882 882 Height H1 H2 mm 1374 15...

Page 102: ...o Control System Dimensions contd Twin Tank Units Type Designation 50 50 50H 50H 50 100 50H 100H 100 100 100H 100H Width W mm 1900 2150 2400 Width W1 W2 mm 632 632 632 882 882 882 Height H1 H2 mm 137...

Page 103: ...4F81002C662G8XNAEXB4A2XXFXXPX ADHESIVE MELTER VersaBlue Nordson Engineering GmbH Lilienthalstr 6 D 21337 L neburg Germany www nordson com Serial No Year 25 X 26 N 34 X 36 F 37 X 38 X 39 P 40 X 27 A 28...

Page 104: ...ure control valve This feature allows the material pressure to be regulated to an adjustable value as soon as the parent machine stops or when the line speed signal falls below an adjustable value Saf...

Page 105: ...external motors Additional gun hose connections 30 A Two additional guns and hoses each can be connected B Six additional guns and hoses each can be connected C Ten additional guns and hoses each can...

Page 106: ...control 38 G 24 VDC is supplied for the gun solenoid valves The voltage is controlled via standard I O P A control unit e g a pattern controller can be connected instead of the gun solenoid valve con...

Page 107: ...ended Use and Unintended Use When in doubt please contact your Nordson representative Manufacturer Information Materials may be processed only when the manufacturer s product descriptions and Safety D...

Page 108: ...e When materials require heating adherence to the prescribed processing temperature is imperative to ensure the quality of the application It may not be exceeded Overheating can cause material coking...

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