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ProBlue Flex
Nordson ProBlue Flex User Manual
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ProBlue
Flex
Adhesive
Melter
with
BBconn
Controls
Core
Customer
Product
Manual
Part
1128350_02
Issued
06/20
NORDSON
CORPORATION
ï‚·
DULUTH,
GEORGIA
ï‚·
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.
2
Table of Contents
Default Chapter
3
Table of Contents
3
Safety
15
Safety Alert Symbols
15
Responsibilities of the Equipment Owner
16
Safety Information
16
Instructions, Requirements, and Standards
16
User Qualifications
17
Applicable Industry Safety Practices
17
Intended Use of the Equipment
17
Instructions and Safety Messages
18
Installation Practices
18
Operating Practices
18
Maintenance and Repair Practices
19
Equipment Safety Information
19
Equipment Shutdown
20
Relieving System Hydraulic Pressure
20
De-Energizing the System
20
Disabling the Applicators
20
General Safety Warnings and Cautions
21
Other Safety Precautions
24
First Aid
24
Safety Labels and Tags
25
Description
27
Key Components
28
Melter User Interface
29
Product Description
30
Intended Use
31
Limitations of Use
31
Electromagnetic Compatibility (EMC)
31
Residual Risks
32
Experience of Installation Personnel
32
Theory of Operation
33
Functional Blocks
34
Low Voltage Controller (LVC)
34
Power Distribution and Control
35
DC Power Supply
35
Temperature Control Modules
35
User Interface(S)
36
Adhesive Level Sensor
36
Optional Functional Blocks
36
How the Blocks Operate as a System
37
Melter Configuration Codes
38
Melter Identification
39
Other Sources of Information
40
Installation Guide
40
User Interface Quick Reference Guide
40
Problue Flex Manuals and Service Kit Instruction Sheets
40
Installation
41
Overview
41
Quick-Start
42
Additional Information
42
Experience of Installation Personnel
42
Melter Installation
43
Installation Tasks
43
Installation Requirements
44
Melter Clearances
44
Ventilation
46
Electrical Power
46
Compressed Air
47
Melter Mounting Considerations
48
Unpack the Melter
49
Contents of the Installation Kit
49
Customer-Supplied Materials
50
Mount the Melter
50
Removing the Melter from the Sub-Base
51
Mounting the Melter
55
Connecting Incoming Power
56
Configure the Electrical Service
57
Melter Power Requirements
57
Kg Tank (T04, X04)
57
Kg and 10 Kg Tank (T07, X07, T10, X10)
58
Kg/Hr MOD (M07, Z07)
58
Kg/Hr MOD (M14, Z14)
59
Kg Tank (T15, X15)
59
Kg/Hr MOD (M21, Z21)
60
Connecting Power Cables
61
Connect a Pump Control Signal
65
Connecting Power to the Solenoid Valve
66
Single Acting Pump Operation Notes
67
Connect a Compressed Air Supply
68
Connect Hoses and Applicators
71
Connecting the Hoses
71
Connecting the Applicators
74
Set up the Melter
75
Using the OLED User Interface
75
Set up the Melter Inputs and Outputs (I/O)
76
I/O Connections
76
Input Parameters
77
Output Parameters
78
Install Optional Accessories
80
Basic Melter Operation
81
Operator Level Tasks
81
Additional Information
81
Melter Operation
82
Filling the Melter Tank
82
Starting the Melter for the First Time
84
OLED User Interface
85
Commissioning Setup Wizard
85
Describing the Home Screen
87
Navigation Controls
88
Master Controls
90
System LED Indicators
91
System Status Chart
92
Toggle Switch
93
Shutting down the Melter
94
Maintenance
95
Relieving System Pressure
96
Locking out External Communications
97
Cleaning the Melter
97
Servicing the Pump
98
Supplies
98
Lubricating the Pump
99
Service Kit
99
Replacing the Filter
99
Draining the Tank
100
Cleaning the Tank
102
Troubleshooting
103
About this Section
103
Safety
103
Troubleshooting Checklist
104
Overview
104
AC Power
104
DC Power
104
Level
104
Fill
105
Lid Switch
105
Temperature Control
105
Pump, Pneumatics and Pressure Control
106
User Interface
106
Standard I/O
106
Usb
107
Clock/Scheduler
107
Communications
107
Remote Color Touchscreen (if Used)
107
Software
107
Melters with 480V Transformer Base
108
Other Options, Accessories, Upgrades, Future Product Enhancements
108
400/480 Volt Melters
108
About Built-In Diagnostics
109
About Nordnet
110
Troubleshooting Nordnet
110
Electrical Box - Internal Board Connections
111
Identifying Electrical Components
112
Melter Pneumatic Flow Control
118
Pressure Control and Pump Compatibility
119
Troubleshoot the Melter
122
Checking the Melt or Manifold RTD
122
Checking the Operation of the Thermostats
122
Removing the Level Sensor, Melt RTD, or Melt Thermostat
123
Remove Melter Panels
123
Access the Components
124
Removing the Manifold RTD
126
Checking the Operation of the Power Relay
126
Checking the Operation of the Tank, Grid, or Manifold TRIAC
127
Checking the Resistance of the Tank, Grid, and Manifold Heaters
127
Troubleshoot the Fill System
131
Fill Time Limit
131
Fill System Troubleshooting Table
132
Calibrating the Level Sensor
133
Cleaning Adhesive bin Blockage
133
Technical Data
135
General Specifications
135
Pump Specifications
136
Melter Specifications
137
4, 7, 10 Kg Tank Melters
137
And 14 Kg MOD Melters
137
A and B Chassis for 240V and 480V Melters
137
Electrical Specifications
138
Melter Power Requirements
138
Kg Tank (T04, X04)
138
Kg and 10 Kg Tank (T07, X07, T10, X10)
139
Kg/Hr MOD (M07, Z07)
139
Kg/Hr MOD (M14, Z14)
140
Kg Tank (T15, X15)
140
Kg/Hr MOD (M21, Z21)
141
Discrete I/O
141
Standard Remote Input/Output
141
Communication
142
Pressure Management
142
Fill System Specifications
143
Melter Dimensions
144
Melter Sub-Base Dimensions
147
Wiring Diagram - Electrical Box Enclosure Layout
148
Wiring Diagram - Input Power
149
Wiring Diagram - Power Distribution
150
Wiring Diagram - Power Distribution Expansion Board
151
Wiring Diagram - Low Voltage Control Board
152
Wiring Diagram - Melt and Manifold (Melt on Demand)
155
Wiring Diagram - Hoses and Applicators
156
Wiring Diagram - 4 Channel Power Module #2
158
Wiring Diagram - TB3 Variations
159
Wiring Diagram - Light Tower
160
Wiring Diagram - Legacy Inputs/Outputs
161
Wiring Diagram - Chassis Ground
162
Wiring Diagram - Hose/Applicator Expansion Base
163
Wiring Diagram - Hose/Applicator Ground Tree
164
Wiring Diagram - Hose/Applicator Expansion Power Module #3
165
Wiring Diagram - Hose/Applicator Expansion Power Module #4
166
Wiring Diagram - Adhesive Tracking Board
167
Parts
169
Using the Illustrated Parts Lists
169
Problue Flex Melter Assembly
170
Melt on Demand Melter
184
Additional Tank Components
187
Manifold Modules
188
Filter Manifold for Double Acting Pumps
192
Filter Manifold for Single Acting Pumps
194
Hose Manifold
196
Pump Parts
197
Manifold Heater Module
198
Heater Plate Parts
200
Lid Module
202
Fill Lid Module
204
Electrical Cabinet Assembly
206
Blank Hose/Applicator Module
209
4/6 Channel Hose/Applicator Module
209
OLED Electrical Enclosure Door
210
OEM Electrical Enclosure Door
211
Heater Harness
212
Standard Double Acting Regulator
213
Double Acting Regulator with Transducer
214
Standard Double Acting Remote Run up Regulator
215
P1 Single Acting Pneumatic Panel Assembly Service Kit
216
P2 Single Acting Pneumatic Panel Assembly Service Kit
216
Standard Single Acting Regulator Module with Gauge
217
Standard Single Acting Regulator Module with Transducer
218
Lid Switch Module
219
Lid Switch Replacement Parts
220
Enclosure Module
222
Kg/7 MOD/14 MOD Enclosure Module
222
Electrical Cables and Fuses
226
Ship-With Kit
228
Service Kits
229
E-Box Enclosure Service Kits
229
Assorted Jumper Harness Pack Kit
229
OLED Electrical Door Service Kit
229
OEM Electrical Door Service Kit
229
E-Box Knockout Service Kit
229
E-Box Full Replacement Service Kit
230
LVC Replacement Service Kit
230
Power Supply Service Kit
230
Power Distribution Replacement Service Kit
230
4-Channel Hose/Applicator Module Service Kit
231
Temperature Control Module Service Kit
231
4-Channel Hose/Applicator Blank Service Kit
231
Power Distribution Expansion Service Kit
231
15 Amp Fuse Service Kit
232
Pump Service Kits
233
Pump Replacement Service Kit
233
Pump Service Kit
233
High Output Double Acting Pump Replacement Service Kit
234
High Output Double Acting Pump Service Kit
235
Single Acting High Output Pump Replacement Service Kit
235
Single Acting High Output Pump Service Kit
236
Low Viscosity Pump Replacement Service Kit
236
Low Viscosity Pump Service Kit
237
Low Pressure Pump Replacement Service Kit
237
Low Pressure Pump Service Kit
238
Low Pressure/Low Viscosity Pump Replacement Service Kit
238
Low Pressure Low Viscosity Pump Service Kit
239
Magnetic Actuator Service Kit
240
Air Valve Assembly Service Kit
240
Magnetic Fork Service Kit
240
Airline Service Kit
240
Pump and PDV Fittings Service Kit
241
Single Acting Airline , P1 and P2 Service Kit
241
Lid Service Kits
241
Lid Switch Service Kit
241
Fill Lid Filter Service Kit
241
FF Inlet Tube Service Kit
242
Size a Replacement Lid Service Kit
242
Size B Replacement Lid Service Kit
242
Size a Fill Lid Replacement Service Kit
242
Size B Fill Lid Replacement Service Kit
243
Tank Service Kits
243
4/7Kg and 7/14 Kg/Hr MOD Level Sensor Service Kit
243
10 Kg Level Sensor Service Kit
243
Kg 230V Tank Service Kit
244
Kg 400/480V Tank Service Kit
245
Grid/Hopper Service Kits
246
MOD 7 Kg, 700W, 230V Grid/Hopper Service Kit
246
MOD 14 Kg, 1200W, 230V Grid/Hopper Service Kit
246
MOD 7 Kg, 700W, 400/480V Grid/Hopper Service Kit
247
MOD 14 Kg, 1200W, 400/480V Grid/Hopper Service Kit
247
Manifold Service Kits
248
Standard Hose Manifold Service Kit
248
Manifold Filter Service Kit
248
Manifold Center Service Kit
248
Single Acting Pump Manifold Filter Service Kit
249
Heater Service Kits
249
480V, 2500W Heater Block Service Kit
249
480V, 1000W Heater Block Service Kit
250
Enclosure Service Kits
251
Mounting Plate (Sub-Base) Service Kit
251
Kg Tank and 7/14 MOD
251
Mounting Plate (Sub-Base) Service Kit, 7/10 Kg Tank
251
Insulation Service Kits
252
Kg Tank Insulation Service Kit
252
MOD Insulation Service Kit
252
Manifold Insulation Service Kits
253
Standard Manifold Kit Guard Service Kit
253
Manifold Insulation Service Kit
253
MOD Manifold Insulation Service Kit
253
Upgrade Kits
254
Fill Upgrade Kit, Size a
254
Fill Upgrade Kit, Size B
254
To 6 H/A Expansion Kit
255
To 4 H/A Expansion Kit
255
Legacy I/O Kit
256
External USB Kit
256
Size a Tank Lock Kit
256
Size B Tank Lock Kit
257
MOD 14, 1200W, 400/480V Kit
257
MOD 7, 700W, 400/480V Kit
257
MOD 14, 1200W, 200/240V Kit
257
MOD 7, 700W, 200/240V Kit
258
App Module Upgrade Kit
258
Pneumatic Assembly P2 Upgrade Kit
258
Pneumatic Assembly P3 Upgrade Kit
259
Spare Parts List
260
Basic Spare Parts Service Kit
260
Basic Expanded Spare Parts Service Kit
260
Pneumatic Filter Service Kit
260
Pneumatic Filter and Bulkhead Bracket Service Kit
261
Flex RTD Replacement Service Kit
261
Pneumatic Transducer Service Kit
261
Drain Chute Replacement Service Kit
261
Drain Valve Replacement Service Kit
262
Wireway Cover Service Kit
262
P4/P7/P10 Pressure Discharge Valve Service Kit
262
100 Mesh Saturn Filter Service Kit
262
Pneumatic Panel Assembly Service Kit
263
P2 Pneumatic Panel Assembly Service Kit
263
P3 Pneumatic Panel Assembly Service Kit
263
Thermostat Service Kit
263
Single Acting P1 Pneumatic Assembly Service Kit
264
Single Acting P2 Pneumatic Assembly Service Kit
264
General Parts
265
Problue Flex Common Hardware
265
Problue Flex Jumper Pack, 3/PE, 200/240V
266
Problue Flex Jumper Pack, 3/N/PE, 200/400V
266
Problue Flex Jumper Pack, 1/N/PE, 200/240V, 25
266
Problue Flex Jumper Pack, 3/PE, 200/240V, 10
266
Problue Flex Jumper Pack, 1/PE, 200/240V, 10
266
Problue Flex Assorted Jumper Pack
267
Hydraulics Fittings,90 Degree
267
Hydraulics Fittings, 90 Degree, 25
267
Hydraulics Fittings, 45 Degree
267
Hydraulics Fittings, 45 Degree, 25
267
Hydraulics Fittings Straight, 10
268
Hydraulics Fittings Straight
268
Calculating Melter Power Requirements
269
Appendix A
269
Appendix B
273
Appendix B SP Pump Diagnostics and Repair
273
Introduction
273
Available Pump Options
273
Pump Function
274
Double Acting Pump
274
Pump Isolation Valve
275
Pressure Discharge Valve
275
Single Acting Pump
275
Pump Diagnostics
276
Double Acting Pump Diagnostics
276
Single Acting Pump Diagnostics
278
Pump Disassembly and Reassembly
280
Melter Preparation
280
Required Tools and Materials
280
Tools
280
Service Parts
281
Supplies
281
Remove the Pump from the Melter (All Pumps
282
Remove the Actuator Assembly (Double Acting Pumps Only
285
Remove the Magnetic Actuator Assembly (Double Acting Pumps Only
285
Remove the Air Valve Assembly (Double Acting Pumps Only
286
Special Reassembly Instructions
286
Remove the Shifter Fork (Double Acting Pumps Only
287
Special Reassembly Instructions
287
Remove the Cylinder Head and Cylinder (All Pumps
287
Remove the Piston Cups (All Pumps
288
Special Reassembly Instructions
288
Remove the Siphon Check Valve Assembly and Hydraulic Piston Assembly (All Pumps
288
Remove the Pressure Check Valve for Double Acting Pumps
289
Special Reassembly Instructions
289
Remove the Pressure Check Valve for Single Acting Pumps
289
Replace the Hydraulic Piston Seal (All Pumps
290
Installing the Pump (All Pumps
291
Standard Double Acting Pump Assembly Parts List
292
High Output Double Acting Pump Assembly Parts List
294
Low Viscosity Double Acting Pump Assembly Parts List
296
Low Pressure Double Acting Pump Assembly Parts List
298
Low Pressure/Low Viscosity Double Acting Pump Assembly Parts List
300
High Output Single Acting Pump Assembly Parts List
302
Actuator Assembly Parts List
304
Piston Assembly Hydraulics Parts List
306
High Output Double Acting Hydraulic Piston Assembly
307
Low Viscosity Double Acting Hydraulic Piston Assembly
308
Appendix C the Bbconn Cloud
309
Web Address
309
List of Browsers
309
Key Functions
309
Importing and Exporting Files
310
Appendix D
311
Appendix D Adhesive Tracking System
311
Overview
311
Intended Use
312
Unintended Use
312
Theory of Operation
313
Technical Data
315
Specifications
315
Useful Calculations and Conversion Formulas
316
Specific Gravity Calculation
316
K-Factor Calculation
316
Conversions
317
I/O Declarations on the ATS Board
318
Flow Meter Assembly Parts Lists
320
Flow Meter and Sensor Parts
320
Flow Meter Parts
322
ATS Service Kits
324
ATS Upgrade Kit
324
ATS Hose Manifold Kit
324
ATS PCA Kit
325
Inductive Sensor Cable Kit
325
ATS Manifold Guard Kit
325
ATS Service Kit
326
Appendix E Optional Accessories
327
Available Accessories
327
Air Pressure Relief Valve
328
Air Pressure Relief Valve Kit
328
Wi-Fi Module
329
Wi-Fi Module Service Kit
329
Light Tower
330
Light Tower Board and Light Tower Service Kit
331
Light Tower Board Only Service Kit
331
Communication Cards
332
Profibus Communication Service Kit
332
Ethercat Communication Service Kit
332
CC Link Communication Service Kit
332
Devicenet Communication Service Kit
333
Powerlink Communication Service Kit
333
CC Link IE Communication Service Kit
333
Remote Touchscreen User Interface
334
PB Touchscreen Service Kit (Comes with 5M Communication Harness
334
5 M Communication Cable
335
10 M Communication Cable
335
Remote Touchscreen T50 Service Kit
335
Fulfill System
336
Dimensions
336
Adhesive Storage bin Dimensions
337
Fulfill System Specifications
339
Single-Feed Adhesive Storage bin
340
Multi-Feed Adhesive Storage bin
342
Sequencer
344
Adhesive Transfer Hose Parts
348
Adhesive bin Pump Parts
350
Suction Lance Kit
352
Transfer Hose Solenoid Harnesses
354
Quick Disconnect Kits (Optional
355
Service Kits
356
Field Install Kits
356
Appendix F
357
Appendix F Problue Flex 400/480 Volt Transformer
357
Overview
357
Intended Use
358
Unintended Use
358
Transformer Function
358
Installation
359
Installation Tasks
359
Transformer Sizing
360
Clearances
362
Ship-With Kit Components
364
Preparing the Transformer for Installation
365
Mounting the Transformer on the Parent Machine
367
Connecting Electrical Service to the Transformer
368
Preparing the 400/480V Melter for Installation on the Transformer
370
Sub-Base Removal
371
Mounting the 400/480V Melter on the Transformer
374
Connecting Transformer to the Melter
374
Troubleshooting
376
Parts
378
KVA 480V Transformer Assembly, Size a
378
KVA 480V Transformer Assembly, Size B
380
Transformer PCA Tray Assembly
381
KVA 480V Transformer Top Assembly, Sizes a and B
382
Ship-With Kit
383
KVA Transformer PCA Service Kit
383
KVA 400/480V Transformer Service Kit
383
Transformer Solid State Relay Service Kit
384
Transformer 8A Fuse Service Kit
384
Transformer 10A Fuse Service Kit
384
Wiring Diagrams
385
Appendix G
389
Appendix G Hose/Applicator Expansion Base
389
Overview
389
Safety
390
Intended Use
390
Unintended Use
390
Melter Firmware Requirements
390
Installation
390
Installation Clearances
391
Power Requirements
392
Removing the Melter from the Sub-Base
392
Mounting the Expansion Base to the Sub-Base
395
Mounting the Melter to the Expansion Base
396
Connecting Expansion Base and Sub-Base Wiring to the Melter
398
Using Melter with Expansion Base in a Water Wash Environment
400
Troubleshooting
401
General Troubleshooting
401
Troubleshooting Specific to Expansion Base
402
Expansion Base Circuit Board Indicators
403
I/O Declarations for the 4 Channel Temperature Control Expansion Board
404
Block Diagrams
405
Expansion Base Selection
407
240 Voltage - Legacy and Standard Warmup
407
Expansion Base Parts
410
Wiring Diagrams
412
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Nordson ProBlue Flex Specifications
General
Brand
Nordson
Model
ProBlue Flex
Category
Melting Machines
Language
English
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