Nordson ProBlue Flex Manual Download

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ProBlue Flex Adhesive Melter

Using the OLED User Interface

Customer Product Manual

Part 1128351_02

Issued 6/20

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.

Summary of Contents for ProBlue Flex

Page 1: ...ustomer Product Manual Part 1128351_02 Issued 6 20 NORDSON CORPORATION DULUTH GEORGIA USA www nordson com This document contains important safety information Be sure to read and follow all safety info...

Page 2: ...elect Coat Select Cure Servo Flo Shot A Matic Signature stylized Slautterback Smart Coat Smart Gun SolderPlus Spectrum Speed Coat StediFlo Stratablend SureBead Sure Coat SureWrap Symphony Tip Seal TRA...

Page 3: ...er Qualifications 3 Applicable Industry Safety Practices 3 Intended Use of the Equipment 3 Instructions and Safety Messages 4 Installation Practices 4 Operating Practices 4 Maintenance and Repair Prac...

Page 4: ...d Monitoring 34 Electronic Pressure Control Settings 35 Defining Pressure Runup Settings and Monitoring Alert Settings 36 Pressure Runup Output Settings 36 Pressure Runup Alert Threshold Settings 38 P...

Page 5: ...71 Setting up User Management 72 Setting up User Management and Modifying Password Codes 72 Resetting Password Codes to Default 72 Modifying the Timeout Intervals 72 About System I O 73 Assigning Inpu...

Page 6: ...estoring to a Previous Version 104 Managing Licenses 104 Adding a New License 105 Viewing System and Configuration Information 106 Viewing Original Factory Nameplate Information 106 Viewing Accessory...

Page 7: ...is document 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 t...

Page 8: ...governing regulations Contact the authority having jurisdiction for information S Maintain safety information including the safety labels affixed to the equipment in readable condition Instructions Re...

Page 9: ...job function S are physically capable of performing their job function and are not under the influence of any substance that degrades their mental capacity or physical capabilities Applicable Industr...

Page 10: ...e required installation configuration does not match the installation instructions contact your Nordson representative for assistance S Position the equipment for safe operation Observe the requiremen...

Page 11: ...ounds NOTE SDSs for cleaning compounds that are sold by Nordson are available at www nordson com or by calling your Nordson representative S Confirm the correct operation of all safety devices before...

Page 12: ...ed to the equipment system 2 To prevent the equipment from being accidentally energized lock and tag the disconnect switch es or circuit breaker s that provide input electrical power to the equipment...

Page 13: ...rdson melter read and comply with the material s SDS Ensure that the material s processing temperature and flashpoints will not be exceeded and that all requirements for safe handling ventilation firs...

Page 14: ...ly of air to the solenoid valve s can result in personal injury HM CA PC WARNING Risk of electrocution Even when switched off and electrically isolated at the disconnect switch or circuit breaker the...

Page 15: ...pecifically designed to process polyurethane reactive PUR hot melt Attempting to process PUR in equipment not specifically designed for this purpose can damage the equipment and cause premature reacti...

Page 16: ...end 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 t...

Page 17: ...es the location of the product safety labels and tags affixed to the equipment Table 2 provides an illustration of the hazard identification symbols that appear on each safety label and tag the meanin...

Page 18: ...1 242867 TAG WARNING 78x 78 2 1100256 TAG WARNING HOT ADH HYD PRESS 1 6X6 5 3 178475 TAG CAUTION HOT SURFACE 4 1025795 TAG WARNING HAZARDOUS VOLTS DURABLUE 5 1024721 90 P S I 6 2 BAR TAG MAXIMUM AIR...

Page 19: ...ter tank 2 Starting the melter 3 Monitoring and adjusting melter operation 4 Shutting the melter down Before proceeding with the next set of tasks make sure the melter is fully installed and connected...

Page 20: ...a brief moment then the Home screen appears Navigation Controls Use the Home screen to navigate monitor and change melter settings NOTE You can order your melter with additional options from the facto...

Page 21: ...Reset S Acknowledges closes and resets the Temperature Pressure and Fill Alert and Fault and Stop conditions 3 Help Provides access the context sensitive help system 4 User Control Arrow keys S Accept...

Page 22: ...erface 16 Part 1128351_02 E 2020 Nordson Corporation Using the Master Controls Use the Master Controls to operate the melter Refer to the table below for additional details 1 4 2 3 Figure 3 Master Con...

Page 23: ...Master Heater control is On 3 Master Temperature Setback Control Toggles the Master Temperature Setback control On or Off The LED is illuminated when the Temperature Setback control is On 4 Access Add...

Page 24: ...OLED User Interface 18 Part 1128351_02 E 2020 Nordson Corporation About the System Status and LED Indicators Refer to the table below for additional details 1 4 2 3 Figure 4 System LED indicators...

Page 25: ...nications LED The LED illuminates when an input is assigned or when the melter is controlled from a PLC WiFi touch screen or laptop When the Communications Master Control is disabled the LED is not il...

Page 26: ...On heating S Master Heat is Off S Temperature Ready but one or more of the master controls such as Pump or optional Fill controls are Off S Ready Delay is enabled and in use S Setback is enabled and o...

Page 27: ...ED Color Description Stop Flashing red S An issue exists with one or more of the subsystems causing production to temporarily stop S The Master Heater control remains on but the Master Pump control is...

Page 28: ...ions detail the common operator tasks S Starting Shutting down the Melter S Switching the Master Heater and Pump Control On Off S Monitoring the Tank Adhesive Level S Manually Filling the Tank S Manag...

Page 29: ...on 1 Switch the melter power to On The melter performs a self check You will see all the LEDs and indicators briefly illuminate When done the Commissioning Wizard starts NOTE On subsequent melter powe...

Page 30: ...vior S To toggle the Master Pump control On press The Pump LED flashes S If AutoPump is enabled then the pump button will flash indicating that the Master Pump control will be toggled On as soon as sy...

Page 31: ...o display the amount of adhesive displayed as a percent that is available for viewing from the Home screen S If you have a Melt on Demand system or a tank with an optional Fill system then from the Ho...

Page 32: ...ill the tank with hot melt Never use your bare hands Using your bare hands to fill the tank may result in personal injury 1 Open the tank lid Width 16 51 cm 6 5 in Length 18 2 cm 7 2 in Do not fill ad...

Page 33: ...ion pad to toggle the Fill system On for as long as you want Toggle it again to deactivate the Fill system Timed Force Fill 1 Enter the Force Fill Time or the amount of time you want the Fill system t...

Page 34: ...turn to the previous screen S To change the set point temperature press the Up Down keys on the Navigation pad to select the zone you want to change its set point temperature then press and enter the...

Page 35: ...ne Indicates a Fault condition 3 Heated Zone Indicates an Alert condition NOTES S In most cases you have approximately 2 minutes to resolve an Alert condition before the heated zone changes to a Fault...

Page 36: ...p when the event occurred Some events occur quickly Look at the seconds in the time stamp for additional troubleshooting 3 Opens the Event Log with the newest event displayed first NOTE Go to Tools Re...

Page 37: ...e the controller monitoring the minimum and maximum absolute system air pressure before causing an alarm Electrical Pressure Adjust Optional requires additional equipment From the Home screen you can...

Page 38: ...ssure However if the system was not configured from the factory you can purchase Part Number 1128345 PNEUMATIC ASSY P3 UPGRADE kit 1 Select Pressure press then select Set Point press and enter the sys...

Page 39: ...t Pressure Setting Range Alert and press the on the Navigation pad to toggle Pressure Setting Range Alert to Enabled or Disabled The default is Enabled 2 Select Minimum Pressure Alert press then enter...

Page 40: ...Electronic Pressure Alert and Monitoring You will receive an alert alarm if pressure is out of tolerance for more than 10 seconds NOTES S A symbol appears next to the High Pressure Alert threshold set...

Page 41: ...ntrol Settings menu or to return to the Home screen Electronic Pressure Control Settings 1 Select Minimum Pressure Set Point Range press then enter the minimum pressure you want to use while in produc...

Page 42: ...on only if the pressure meets or exceeds the high low thresholds for more than 10 seconds S You can change the pressure scaling from the System Settings Preferences The default is pneumatic S The Set...

Page 43: ...Pressure Pressure Default Minimum Maximum PSI 50 10 100 BAR 3 45 0 69 6 90 kPa 345 69 690 S High Line Speed Pressure Default Minimum Maximum Meter Minute 30 5 1 5 300 2 Feet Minute 100 5 985 2 When d...

Page 44: ...ssure Alert threshold setting indicating the offset or delta from the Maximum Pressure Set Point Range setting S A symbol appears next to the Low Pressure Alert threshold setting 3indicating the offse...

Page 45: ...Pressure Pressure Default Minimum Maximum PSI 0 0 90 BAR 0 0 6 21 kPa 0 0 621 2 When done press to return to the Runup Settings menu or to return to the Home screen Pressure Runup General Settings 1...

Page 46: ...l be lost the next time the melter is power cycled or when another recipe is loaded Tip S Create or Save the current default settings to a recipe such as recipe 1 so you can always return to a known g...

Page 47: ...as 1 indicates that change was made to one or more recipe settings but those changes have not been saved 2 The number of the currently loaded recipe 3 Recipe management is controlled through the Inpu...

Page 48: ...lect imported recipes with alphanumeric characters if the recipe was saved or re named using the BBconn Cloud Application S A recipe must be saved as a number if you want to use the Remote Recipe Inpu...

Page 49: ...Log by pressing the on the OLED panel to clear and reset any zone Alert or Fault conditions S You can also access the Event Log from the Alert Fault or Stop pop up message by selecting the icon then...

Page 50: ...ned only once NOTE Not all system settings are saved to a recipe unless otherwise indicated The following is a list of tasks to be accomplished by a technician S Temperature S Fill Level S Pressure S...

Page 51: ...e tune the low empty adhesive messaging TIP S You can also assign a system output for Tank Low and connect that to a light tower 1 Press the on the Navigation pad to toggle Low Level Alert to Enabled...

Page 52: ...em Status indicator flashes Red S Press on the OLED panel to clear and reset the Empty Stop condition S Empty Stop automatically detects the near empty level of the tank just before the pump starts to...

Page 53: ...e lid is left open for too long 1 Press the on the Navigation pad to toggle Lid Open Alert to Enabled or Disabled The default is Enabled 2 Select Lid Open Alert Time press and enter the number of minu...

Page 54: ...consistent level of adhesive is in the tank suitable for product production 1 Select Maximum Fill Time press and enter the maximum number of seconds the controller can attempt to fill the tank before...

Page 55: ...or a user specified amount of time thereby preventing adhesive degradation The system continues to maintain ready status until a fill signal is generated again 1 Press the on the Navigation pad to tog...

Page 56: ...melter is in Setback the System Status is Blue and the Master Setback control LED is illuminated System Status Master Setback Manually Entering Exiting Setback S Press the master control button to to...

Page 57: ...bled or Disabled The default is Disabled 2 Select Automatic System Setback Source and press to make your selection When done press S Fill is available for Melt on Demand configured systems or tank ver...

Page 58: ...nting the adhesive from charring or degrading 1 Press the on the Navigation pad to toggle Manual Setback Auto Exit Time to Enabled or Disabled The default is Disabled 2 Select Auto Exit Time Delay pre...

Page 59: ...abled The default is Disabled 2 Select Time press and enter the amount of time you want the melter to continue to heat thereby preventing the melter from immediately exiting out of Heating This provid...

Page 60: ...On Upon Startup S Define Over Under Temperature Thresholds before receiving alarms S Define the Temperature Setback for all Setback options The following sections detail each global temperature settin...

Page 61: ...n Under Temperature alarm The default is 25_ C 45_ F the minimum is 9_ C 10_ F and the maximum is 60_ C 110_ F Press the on the Navigation pad to accept your change and to return to the Global Setting...

Page 62: ...e time When the system temperature ready is achieved the Master pump Control remains Off In this case pushing the Master Pump Control button again will switch the Master Pump Control On since system T...

Page 63: ...reporting data collected by ATS can be used to improve process control ATS provides the following capabilities S The system can be taught the average add on to simplify setup S The following real time...

Page 64: ...sive before the system begins monitoring products Setup involves ensuring that the flow meter is accurately measuring the amount of adhesive referred to as add on applied to products Upon initial star...

Page 65: ...ettings Flow Settings Adhesive Settings and select Specific Gravity Press the button on the navigation pad and enter the specific gravity for your adhesive The default is 0 95 The minimum is 0 80 and...

Page 66: ...ach mode make sure the number of products meets or exceeds a weight total of 8 grams S If you make use of the Teach option any value you enter will be overwritten S Use a smaller value if you want a f...

Page 67: ...ht On for normally open triggers Dark On for normally closed triggers Dark On Trigger Type Refer to the documentation that came with your trigger for this information This is also known as Trigger Sou...

Page 68: ...ended that you calibrate the Flow Meter You must define the Product and Trigger settings S The melter must be in a Run state with the pump enabled 1 Start production from the pattern controller 2 Go t...

Page 69: ...n continues but attention may be needed Disabled N A N A Low Alert Threshold How much lower the add on weight mg can be from the Target Add On value before an Alert alarm is generated 2 Target add on...

Page 70: ...products allowed before the system considers them defective and generates a Stop alarm 4 1 15 Monitoring and Viewing Adhesive Flow Output Go to Home Flow to view the following flow data Flow Descripti...

Page 71: ...OTE S Make sure the Adhesive Flow Monitoring option is enabled Home System Settings Flow Settings 1 Go to Home System Settings Flow Settings and select Reports Exporting Flow Reports You can export th...

Page 72: ...ng the ATS PCA Board LEDs WARNING Allow only personnel with appropriate training and experience to operate or service the equipment The use of untrained or inexperienced personnel to operate or servic...

Page 73: ...OLED User Interface 67 Part 1128351_02 E 2020 Nordson Corporation Figure 3 ATS PCA Board...

Page 74: ...tected S Red Sensor failure or not connected DS6 Flowmeter Sensor A Status S Green Flow detected S Amber Sensor connected but no flow detected S Red Sensor failure or not connected DS7 General Status...

Page 75: ...ors on the manifold and re tighten loose sensors to hand tight If a sensor has failed replace the sensor If an Encoder Phase Error alarm continues to occur replace the flow control board 1 Output valu...

Page 76: ...not displaying or generating alarms Alert and or Stop Alarms are disabled Enable the Alert and Stop Alarms Enabled Output or Alarm Output wiring loose or disconnected Check and correct the wiring 5 Ad...

Page 77: ...r Technician password S When you enable user management it is for both Operator and Technician You cannot enforce one without the other S To enable or disable user management requires the technician p...

Page 78: ...d press then select from which user management profile you want to change the password code Enter the New password code then enter it again to confirm 3 When done press to return to the User Managemen...

Page 79: ...is Automatic Setback 2 Decide if you want to Invert reverse the polarity of the input Select Invert and press to change the polarity The default is not inverted active high 3 Use the Up key on the Nav...

Page 80: ...Part 1128351_02 E 2020 Nordson Corporation S The default input selections for the Legacy I O expansion kit are as follows Input 1 Automatic Setback Input 2 Setback Control Input 3 Heater Control Inpu...

Page 81: ...nt is controlled through the Inputs NOTES S You cannot load a new recipe while in Remote Recipe Management S Although you can save any changes you have made any changes will not become part of the act...

Page 82: ...recipe management options are disabled unless you enable the Remote Recipe Management System Settings Preferences with the exception of Loading a recipe S You can assign up to 15 recipes as Remote Re...

Page 83: ...vious input assignments will be lost when you assign an input to Remote Recipe S Remote Recipe inputs are sequentially assigned top down and are dedicated only for Remote Recipe For example if you ass...

Page 84: ...ation pad to select Assign then press to view the output menu list selection Use the Up Down keys on the Navigation pad to scroll through the list Press to assign the output selection you want When do...

Page 85: ...nu 4 Decide if you want to test the current output assignment Select Test then press to toggle Start Stop the test 5 Press to return to the Home screen NOTES S You can assign the same output selection...

Page 86: ...he list and select Done S Select Beginning then press and enter the time you want the Master Heater control to switch On For 12 hour clock use the Up Down key to toggle between AM and PM Press to cont...

Page 87: ...iew Modify Shifts then press to continue 2 Press to select which shift you want to view or modify When done press the Down key to the bottom of the list and select Done S Select which shift you want t...

Page 88: ...m pressure set point ranges for the optional electronic pressure adjust Importing and Exporting Recipes 1 Be sure to insert a USB drive in the melter port 2 Select Manage Recipes then press to continu...

Page 89: ...edule menu 3 Select Add a Setback Event press then do the following S Press to select which day or days of the week you want to set up a heat schedule When done press the Down key to the bottom of the...

Page 90: ...or modify a heat schedule When done press the Down key to the bottom of the list and select Done S Select Heat Event then press to view the On and Off heat events Press to Delete or Modify Press Done...

Page 91: ...time S Decide which system preference you want to change S Language S Temperature Unit S Pressure Scaling S Mass Unit S Date Format S Date S Time Format S Set Clock S Melter ID S Enable Disable Recipe...

Page 92: ...ss to continue 2 Decide if you want to use DHCP or not Select DHCP and press to enable or disable this option The default is Disabled 3 Enter the following information to continue Press the on the Nav...

Page 93: ...erver license is no longer available for melter1 but is available for melter2 You will need to purchase another Web Server license for melter1 1 Select WiFi and press to continue 2 Enter or select the...

Page 94: ...but disabled S Flashing when enabled but nobody is connected SSID Broadcast On Enable Disable whether the WiFi module broadcasts its SSID or not when module is turned on Enabled 3 When done press to r...

Page 95: ...directly to the melter with an Ethernet cable use the HMI Ethernet port on the Low Voltage Controller board 1 Select which Web Server options you want to use Press to continue Option Description Defau...

Page 96: ...ess is Enabled S Disable provides read write access if PLC Access is Enabled PLC I O Data Decide which PLC data process you want to use Index Full Map legacy or the new Flexible Map Flex map Import Ex...

Page 97: ...US 1129161 1129124 KIT ACCESS PB FLEX COMM ETHERCAT 1129162 1129293 KIT ACCESS PB FLEX COMM CCLINK 1129163 1129294 KIT ACCESS PB FLEX COMM SERCOS III 1129164 1129295 KIT ACCESS PB FLEX COMM DEVICENET...

Page 98: ...evious page for more information Use the following instructions to connect your PLC directly to the ProBlue Flex melter 1 Switch the melter off and disconnect power to the melter at the local power di...

Page 99: ...use based on the packet information Figure 3 d External 1 x14 e External 2 x15 5 Route the Ethernet cable through the knockout and connect the other end to your PLC 6 Refer to Figure 1 Using a 4mm he...

Page 100: ...p you created using BBconn Cloud S Select Export to place the PLC file into the PLC folder on the USB drive so you can modify the PLC file in BBconn Cloud Refer to the BBconn Cloud manual for more inf...

Page 101: ...list for accomplishing technician level tasks S Backing up Restoring and Resetting S Upgrading the melter software S Managing Licenses S Viewing System Information S Viewing Installed Accessories S V...

Page 102: ...WiFi settings are restored but only If serial number AND the Unique ID of the unit matches the backup file S The following is NOT restored S Machine name S Tank level calibration S Logs reports and hi...

Page 103: ...your selection or selections 2 When done press to return to the Home screen or press to return to the Tools menu NOTE Custom Names refer to external zones that were given alphanumeric names using the...

Page 104: ...00 30000 Module Run System State hours 1000 480 30000 Solenoid 1000 480 30000 Nozzle 1000 160 30000 NOTES S Use the BBconn Cloud Application or the touch screen version to Add Modify or Delete mainten...

Page 105: ...Enabled 2 When done press to return to the Home screen or press to return to the Tools menu Setting Up Component Maintenance Notifications 1 Select Maintenance Notifications and press Use the Up Down...

Page 106: ...tenance is required 1 Select Maintenance Status and press You will see the icon next to the component that requires maintenance Use the Up Down navigation keys to highlight the component then press so...

Page 107: ...tion Viewing Maintenance History 1 Select Maintenance History and press Use the Up Down navigation buttons to highlight a view which component was snoozed or rest as well as the time and date 2 When d...

Page 108: ...S Upgrading Downgrading and Restoring to Previous Software Version S Viewing and Adding Licenses S Viewing System information such as software version and system configuration S View Factory Nameplat...

Page 109: ...e what you want to do Upgrade Software or Restore to previous version You can select which DAT file you want to use The DAT file includes the date and time in the name so you can decide whether you wa...

Page 110: ...such as NTFS and exFAT are supported S After the last reboot the Home screen appears S Licensing and WiFi settings are restored but only If serial number AND the Unique ID of the unit matches the bac...

Page 111: ...must enter the license key to activate it 1 Select from the available list which license permanent or trial you want to activate Press to continue 2 Enter the license code then press the on the Navig...

Page 112: ...oll through the system configuration list 2 Press on the Navigation pad to view additional information 3 Press to return to the Home screen or press to return to the Tools System Configuration menu Vi...

Page 113: ...essory from the list and press to view whether or not the accessory has been successfully installed or not 2 Press to return to the Home screen or press to return to the System Settings menu Updating...

Page 114: ...Log S AutoTune the heated zones S Force the Fill system to activate S Calibrate Full Empty Tank CAUTION Wear eye protection and long sleeve shirt when draining the melter Draining or Purging the Melt...

Page 115: ...t head screw driver turn the screw slowly counterclockwise allowing for the adhesive to drain When done turn the screw clockwise to close the valve NOTE you can manually activate each applicator solen...

Page 116: ...vigation pad to toggle the Fill system On for as long as you want Toggle it again to deactivate the Fill system Timed Force Fill 1 Enter the Force Fill Time or the amount of time you want the Fill sys...

Page 117: ...not have to repeat this process again S The tuning process takes approximately 10 to 15 minutes per zone 1 Make sure all the preconditions are met S The external zones that you want to tune must be en...

Page 118: ...on first to get as much of the adhesive out of the tank as possible 1 Make sure the melter is in a Temperature Ready state Specifically the tank are at set point 2 Do the following to continue S To pe...

Page 119: ...themselves and others and damage to the equipment This section of the manual details those tasks typically performed by a technician Additional Information This section presents operating procedures i...

Page 120: ...NOTES S You can access the Event Log by pressing on the OLED panel to clear and reset any zone Alert or Fault conditions S You can also access the Event Log from the Alert Fault or Stop pop up messag...

Page 121: ...ize file typically contains the 50 of the most recent events Older events will be in the other file S 1910810 The date format is yy mm dd_hh mm which cannot be changed S 1002 Current system time when...

Page 122: ...ill occur Check heater connections for intermittent wiring open circuit condition and for external conditions that may cause a drop in component temperature Fault Zone Under Temperature Fault The zone...

Page 123: ...ault RTD resistance reading is below the short circuit time threshold Fault Manifold or Reservoir Thermostat Open Manifold or reservoir Thermostat is activated because of a high temperature condition...

Page 124: ...ystem Status LED The System status indicator will change to Red for a Fault and Yellow for an Alert condition 2 Heated Zone Indicates an Alert condition 3 Indicates a Fault condition NOTES S In most c...

Page 125: ...nt is detected for zone 2 Item Description 1 Type of alarm generated This can be an Alert Fault or Stop 2 Date and time stamp when the event occurred Some events occur quickly Look at the seconds in t...

Page 126: ...has exceeded normal variation The Fill System is disabled S Check the sensor cable between the refill board and the sensor at both ends S If problem persists replace level sensor and or level sensor...

Page 127: ...adhesive Level in adhesive storage bin S Check for clogged adhesive in adhesive storage bin hose or transfer pump S Check for clogged exhaust air filter S Check for low transfer pump air pressure Stop...

Page 128: ...ssure below detectable range Pressure input indicates the pressure is below the sensing range Check air supply to the system for disconnected air input or leaking airline Alert Pressure Control Valve...

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