Nordson Corporation OPERATOR S CARD P/N 052644A VL400 Melters Safety WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. WARNING: Obtain and read the Material Safety Data Sheets for all materials used. WARNING: Risk of equipment damage, personal injury, or death. Failure to disconnect and lock out electrical power before performing maintenance or repairs can cause electrical shock or inadvertant triggering of the applicator. Disconnect and lock out electrical power as instructed in this and all related documentation. WARNING: Always wear heat-protective clothing, safety goggles (ANSI Z87.-989 or equivalent), and safety gloves when working with hot melt equipment. WARNING: Risk of burns. Failure to relieve system pressure before performing maintenance or repairs can cause hot adhesive to spray from a connecting point. Relieve system pressure as instructed in this and all related documentation. Introduction The Nordson VL400 (Value Line) melter is designed to deliver precisely metered amounts of thermoplastic hot melt adhesive to nonwoven products at a consistent temperature. A hot melt system has three major equipment groups: the melter, the hoses, and the applicators. The melter melts adhesive and maintains it at the operating or standby temperatures you program uses a Vista temperature controller to control the operating temperatures of up to 4 heated zones, including 2 internal zones (the grid and tank or reservoir) and 2 external zones (hoses and applicators) controls two pump motors pumps one or two metered streams of adhesive through hoses to adhesive-dispensing applicators when in the gear-to-line mode, adjusts adhesive output as the production line speed changes Flexible, electrically heated hoses transfer the adhesive from the melter to electrically heated, pressure-fed applicators, where the adhesive is applied to the product. Nordson offers a wide variety of pressure-fed applicators in single- and multi-module configurations. The key parts of a VL400 melter are shown in Figures and 2. 4-VL400-OC-0
Introduction (contd) 0 2 9 8 7 6 5 Figure Key parts of a VL40 melter. Vista control panel 2. Motor controls 3. Main disconnect switch 4. Pump motor 5. Manifold 6. Drain valve 7. Hose port 8. Manifold filter 4 9. Circulation control valve 0. Electrical receptacles. Tank lid 3 4200002C 0 2 9 8 7 6 5 3 Figure 2 Key parts of a VL430 melter. Vista control panel 2. Motor controls 3. Main disconnect switch 4. Pump motor 5. Manifold 6. Drain valve 7. Hose port 8. Manifold filter 4 9. Circulation control valve 0. Electrical receptacles. Tank lid 44200003C 4-VL400-OC-0 2
Startup and Shutdown Starting the Melter NOTE: See Figure 5 for the Vista control panel components and Figure 6 for the motor control panel components.. If the melter is programmed to start automatically, go to step 5. The clock must be on for the automatic startup function to work. 2. Place the main disconnect switch in the ON position. 3. Place the Vista POWER switch in the ON position. 4. If the auto-energize heaters feature is disabled, press the HEATERS key to turn the heaters on. The HEATERS light will turn on. 5. Ensure that no warning or fault exists the operating temperature setpoints are correct there is enough adhesive in the tank or hopper (refer to Adding Adhesive) 6. Wait for the READY light on the Vista control panel to turn on. NOTE: If the system-ready time delay feature is enabled, the multipurpose display will show the number of minutes remaining until the system will be ready for operation. 7. To run the system in the manual mode: a. If the PUMP light on the Vista control panel is not on, press the PUMP key. b. Push the motor start/stop switches to the off (O) position. c. Place the gear-to-line/manual switches in the HAND (manual) position. d. Set the motor speed dials to 0. e. Push the motor start/stop switches to the on (I) position. f. Set the motor speed dials to the desired speed. To run the system in the gear-to-line mode: a. If the PUMP light on the Vista control panel is not on, press the PUMP key. b. Place the gear-to-line/manual switches in the G position. c. Push the motor start/stop switches to the on (I) position. The pumps will start when the production line starts and provides the line-speed input signal. d. If necessary, use the motor speed dials to trim the pump output. 8. Enable the applicators and start the production line. Adding Adhesive. Open the tank or hopper lid and check the adhesive level. 2. Refill the tank or hopper before the adhesive level drops below 50%. Add adhesive to within 25 mm ( in.) of the top of the tank or hopper. 3. Close the tank or hopper lid. Shutting Down the Melter. Stop the production line. 2. Stop the pumps by pushing the motor start/stop switches to the off (O) position. 3. Place a drain pan under all applicator dispensing modules and trigger the applicators to relieve system pressure. 4. Disable the applicators. 5. If the melter is programmed to stop automatically, skip the rest of this procedure. 6. Press the HEATERS key on the Vista control panel to turn the heaters off. The HEATERS light will turn off. 7. Place the main disconnect switch on the melter in the OFF position. 3 4-VL400-OC-0
System Pressure Relief and Manifold Filter Maintenance Relieving System Pressure System pressure must be relieved before you can safely proceed with many maintenance, troubleshooting, and repair procedures. Follow this procedure whenever you need to relieve system pressure. NOTE: If you have a two-stream system, relieve pressure in both streams at the same time. Cleaning or Replacing a Manifold Filter Screen Clean or replace the manifold filter screen(s) as needed. If, as you are performing this procedure, you notice that a filter screen is damaged, replace it.. Relieve system pressure. 2. See Figure 4. Unscrew the filter from the manifold and disassemble it. WARNING: Risk of burns. Failure to relieve system pressure before performing maintenance or repairs can cause hot adhesive to spray from a connecting point. Always wear heat-protective clothing, safety goggles (ANSI Z87.-989 or equivalent), and safety gloves when working with hot melt equipment.. Stop the pumps and place the system in the manual mode. 2. If applicable, heat the system to application temperature. 3. Place drain pans under the melter manifold drain valves, the applicator drain valves (if applicable), and the applicator nozzles or dies. 2 ÎÎÎ Figure 4 Manifold filter components. Bung 4. Screen 2. O-ring 5. Screw 3. Tube 3 4 5 69000004C 4. See Figure 3. Open all melter and applicator (if applicable) drain valves. 3. Inspect the filter screen. If there are any dents, tears, or blockages in the screen, obtain a new screen and skip to the next step. If the filter screen is damaged, clean it using one of the cleaning methods described in the maintenance section of the melter manual. Apply O-ring lubricant to a new O-ring and reassemble the filter. 4. Apply anti-seize lubricant to the filter threads. 5. With the system at application temperature, install the filter in the manifold. Figure 3 Opening a melter drain valve 40500009C 5. Trigger the applicator dispensing modules. 6. Close all drain valves. 6. Use one of the following methods to purge air from the adhesive stream for which the filter screen was cleaned or replaced: Remove the supply hose fitting and allow adhesive to drain from the hose port until the air is purged (this is the quickest method). If the applicator that the adhesive stream supplies has a drain valve, open the applicator drain valve and allow adhesive to drain from the applicator until the air is purged. 4-VL400-OC-0 4
Vista Control Panel 2 8 3 7 6 4 5 6 7 8 9 0 5 2 Figure 5 Vista control panel. Zone indicator lights 2. STANDBY and SETPOINT lights 3. SYSTEM SETTINGS light 4. Up arrow key (system settings) 5. Down arrow key (system settings) 6. Right arrow key (system settings) 7. INTERVAL and 2 lights 4 3 8. POWER switch 9. Clock control lights 0. System control keys. System control lights 2. Up arrow key (selector display) 3. Up arrow key (multipurpose display) 4. Selector display 5. Multipurpose display 6. FAULT light 7. READY light 8. Actual temperature display 9. Down arrow key (multipurpose display) 20. Enter key 60400020C 5 4-VL400-OC-0
Vista Control System Programming Procedures NOTE: See Figure 5 for the location of the displays, keys, and lights on the Vista control panel. Monitoring/Scanning Zone Temperatures Press the MONITOR/SCAN key to toggle between the monitor and scan modes. In the scan mode. the system scans each zone and displays the zone temperatures in sequence. In the monitor mode, the system displays the temperature of the zone currently selected. Turning the Heaters On or Off Press the HEATERS key to turn all the active zone heaters on or off. The HEATERS light turns on when the heaters are on. The melter can be programmed to automatically turn the heaters on or off. Refer to Setting Heaters On/Off or Enter/Exit Standby Times. Entering/Exiting Standby Press the STANDBY key to take the melter into or out of the standby mode. The STANDBY light turns on when the melter is in the standby mode. The melter can be programmed to automatically enter/exit the standby mode. Refer to Setting Heaters On/Off or Enter/Exit Standby Times. Changing System Settings. Press the up or down arrow keys next to the SYSTEM SETTINGS light until the light turns on. 2. Press the up arrow key under the selector display until the number of the feature you want to change appears in the display. Refer to Vista Control System Settings for feature numbers and descriptions. NOTE: To move through the feature numbers in increments of 0, press the right arrow key near the SYSTEM SETTINGS key. 3. Press the up or down arrow keys under the multipurpose display to change the setting. Refer to Vista Control System Settings for the default and optional settings for each feature. 4. Press the enter key to save the setting. 5. Press the MONITOR/SCAN key to exit the system settings mode. Changing Temperature Settings. Press the up or down arrow keys next to the SYSTEM SETTINGS light until the SETPOINT (for operating temperature setpoints) or STANDBY (for standby temperature setpoints) light turns on. The INTERNAL light will turn on. 2. If you wish to change a hose or applicator zone temperature, press the right arrow key next to the SYSTEM SETTINGS light until the HOSE or GUN light turns on. 3. Press the up arrow key under the selector display until the number for the zone you wish to change appears in the display. Refer to Table. NOTE: If you wish to change all internal, hose, or applicator zones to the same temperature, use zone number 0 (set all). 4. Press the up or down arrow keys under the multipurpose display to change the temperature. 5. Press the enter key to save the setting. 6. Press the MONITOR/SCAN key to exit the temperature setting mode. Zone Number (See Note A) Table Zone Numbers INTERNAL light is on Zone selected when the... HOSE light is on (See Note B) GUN light is on 0 Set All Set All Set All Tank or Hose Applicator Reservoir 2 Grid Hose 2 Applicator 2 3 Hose 3 Applicator 3 4 Hose 4 Applicator 4 5 Hose 5 Applicator 5 6 Hose 6 Applicator 6 NOTE A: For example, if the selector display shows a number 3 and the GUN (applicator) light is on, then the selected zone is Applicator 3. B: If you have heated-air zones, the zone number that appears in the selector display will be one of the hose or applicator zone numbers. 4-VL400-OC-0 6
Vista Control System Programming Procedures (contd) NOTE: See Figure 5 for the location of the displays, keys, and lights on the Vista control panel. 7. Press the MONITOR/SCAN key to exit the heaters on/off or enter/exit standby setting mode. Setting the Clock. Press the up or down arrow keys next to the SYSTEMS SETTINGS light until the SET TIME light turns on. 2. Press the up arrow key under the selector display until the correct day code is shown (=Monday, 2=Tuesday, and so on); then press enter. 3. Press the up or down arrow key under the multipurpose display until the correct hour is shown in the left side of the display; then press enter. 4. Press the up or down arrow key under the multipurpose display until the correct minutes are shown on the right side of the display; then press enter. 5. Press the MONITOR/SCAN key to exit the clock-setting mode. Setting Heaters On/Off or Enter/Exit Standby Times. Press the up or down arrow keys next to the SYSTEM SETTINGS light until the HEATERS ON, HEATERS OFF, ENTER STANDBY, or EXIT STANDBY light turns on. 2. Press the right arrow key (under the up/down arrow keys) until the INTERVAL or INTERVAL 2 light turns on. You can program two sets of times for each feature (heaters on/off or enter/exit standby). 3. Press the up arrow key under the selector display until the correct day code is shown (=Monday, 2=Tuesday, and so on); then press enter. 4. Press the up or down arrow key under the multipurpose display until the correct hour is shown in the left side of the display; then press enter. If you wish to delete a time, press the key until four dashes appear in the display; then press enter and skip to step 7. 5. Press the up or down arrow key under the multipurpose display until the correct minutes are shown on the right side of the display; then press enter. 6. Repeat steps 5 for each interval time you wish to program. Using the Automatic Functions If you want the automatic, clock-related functions to occur (heaters on/off and enter/exit standby), press the CLOCK key to turn the clock on. The CLOCK light turns on when the clock is on. Checking the Warning or Fault Log. Press the up or down arrow keys next to the SYSTEMS SETTINGS light until the light turns on. 2. Press the up arrow key under the selector display until feature number 35, 36, 37, (first, second, and third most recent warnings) or 26, 27, or 28 (first, second, and third most recent faults) appears. 3. The multipurpose display will show two numbers: one that represents the affected zone and one that represents the type of warning or fault that occurred. Refer to Table 2. Table 2 Warning/Fault Log Numbers (See Note) Warning Number Fault Number Meaning Not used 0 No fault Not used Zone below operating temperature setpoint 2 2 Open RTD 3 3 Shorted RTD 4 4 Zone out of band (warning) or overtemperature (fault) Not used 5 Defective control board Not used 6 Brownout occurred NOTE: The first number in the multipurpose display represents the affected zone: 0 = tank or reservoir, = grid, 2 7 = hoses 6, and 8 3 = applicators 6. Remember that if you have heated-air zones, that zone number will be represented as one of the hose or applicator zone numbers. The second number in the multipurpose display represents the warning or fault number. 7 4-VL400-OC-0
Vista Control System Settings Feature No. Feature Description Default Setting Optional Settings 0 Password Establishes the password. Password enable Enables/disables the password requirement. When this feature is on, operators can view programmed settings but cannot change them. To 0 (off) 0 (off) (on) change settings, the password must be entered. 2 System-ready time delay Allows you to specify an amount of additional time for the adhesive in the system to melt after all zones have reached their setpoint temperatures. At the end of the time delay, the READY light turns on. 8 (minutes) 0 60 (minutes) 3 Overtemperature setpoint 4 Celsius/ Fahrenheit display 5 Global temperature band 6 9 Individual temperature bands (See Note E) 20 Sequential or simultaneous startup Allows you to specify the maximum temperature any zone can reach before the system initiates a fault condition. This setting should be at least 4 C (25 F) above the highest operating temperature setpoint. The system will not allow you to set the overtemperature setpoint lower than this, or the operating temperature setpoint higher (see Note B). Allows you to display temperature in Celsius or Fahrenheit degrees. Allows you to specify the degree to which the temperature of any zone may deviate before the system indicates an out-of-band warning (see Note C). Allows you to specify the degree to which the temperature of an individual zone may deviate before the system indicates a warning (see Note D). Allows you to specify whether the system will perform a sequential startup (internal and hose zones heat first, then applicator zones) or a simultaneous startup (all zones heat at once). Allows you to display the heater proportioning (a flashing INTERNAL, HOSE, or GUN light). 28/425 (C/F) F (Fahrenheit) 7/30 (C/F) 7/30 (C/F) (sequential) 2 Display heater proportioning 0 (no display) 22 System warning Allows you to toggle the warning output contact to or power-on/off alert remotely located operators that a system (system status warning has occurred or that the power is on. warning) NOTE A: For the password, refer to the melter manual. The password cannot be changed. 52 246/25 475 (C/F) F (Fahrenheit) C (Celsius) 6 28/0 50 (C/F) 6 28/0 50 (C/F) 0 (simultaneous) (sequential) 0 (no display) (show display) 0 (power on) (system warning) B: The overtemperature setpoint should be at least 42 C (75 F) below the flash point temperature of the adhesive. Refer to the adhesive s MSDS for the flash point temperature. C: If you enter a setpoint that is higher than the tank or reservoir temperature setpoint, the pump will start when the tank or reservoir reaches its temperature setpoint. D: If you enter a new setpoint for this feature, the new setpoint is immediately entered for the individual zones (Features 6 9). However, it is not saved as the setpoint for Feature 5. Feature 5 always returns to the default setpoint of 6 C (0 F). E: Feature 6=tank or reservoir, Feature 7=grid, Features 8 3=hoses 6, Features 4 9=applicators 6. Continued on next page 4-VL400-OC-0 8
Vista Control System Settings (contd) Feature Feature No. 23 System ready or pump on/off status 25 Auto-energize heaters Description Allows you to toggle the system-ready output contact to alert remotely located operators that the system is ready (up to temperature) or that the pump is on. Enables/disables the auto-energize heaters feature. If this feature is on, the system turns all heaters on automatically when melter is turned on. However, if you have programmed the system to turn all heaters on and off automatically using the clock function, your clock settings override the auto-energize heaters feature. If the auto-energize heaters feature is off, you must turn the heaters on manually, or allow any clock settings you have programmed to turn the the heaters on or off. 26 Heater run time Allows you to display the total time (in hours) that the heaters have been running. 27 Fault log (most recent fault) 28 Fault log (second most recent fault) 29 Fault log (third most recent fault) 35 Warning log (most recent warning) 36 Warning log (second most recent warning) 37 Warning log (third most recent warning) NOTE A: Allows you to display the cause of the most recent system fault. Refer to Checking the Warning or Fault Log. Allows you to display the cause of the second most recent system fault. Refer to Checking the Warning or Fault Log. Allows you to display the cause of the third most recent system fault. Refer to Checking the Warning or Fault Log. Allows you to display the cause of the most recent system warning. Refer to Checking the Warning or Fault Log. Allows you to display the cause of the second most recent system warning. Refer to Checking the Warning or Fault Log. Allows you to display the cause of the third most recent system warning. Refer to Checking the Warning or Fault Log. Features 26 29 and 35 37 are always on. There is no default setting. Default Setting (system ready) (on) Optional Settings 0 (pump on) (ready) 0 (off) (on) 9 4-VL400-OC-0
Motor Control System Operation NOTE: Refer to Starting the Melter earlier in this operator s card for information on operating the pumps in the manual or gear-to-line mode. Item No. in Figure 6 Control Motor start/stop switch 2 Motor speed dial 3 Gear-to-line/manual switch Function This switch is used to manually start and stop the pump. It is operable only when the melter has reached the system-ready condition. If a remote motor start/stop switch is used, this switch must be in the off (O) position. To install a remote motor start/stop switch, refer to Connecting Input/Output Wiring in Section 3, Installation. This dial is used to control the motor speed in either the manual or gear-to-line mode. This switch is used to place the melter in either the manual or gear-to-line mode. To set up the melter to operate in the gear-to-line mode, refer to Installing a Line-Speed Signal Generator and Connecting Input/Output Wiring in Section 3, Installation, and (if applicable) to Setting Up the Gear-to-Line for Nonstandard Signal Inputs in this section. 4 RPM readout This display shows the RPM of the selected pump. 5 RPM readout selector switch This switch is used to select the pump RPM to be displayed in the RPM readout. 4 2 3 5 Figure 6 Motor control panel 4200006C 4-VL400-OC-0 0
Spare Parts and Supplies To order parts, call the Nordson Customer Service Center or your local Nordson representative. Refer to the VL400 melter manual for a more comprehensive spare parts list and a complete set of parts lists and illustrations. Component Part Description Tank 23027 Thermostat, open-on-rise, 26 in. leads 0572 RTD Manifold (single-stream) 94030 O-ring, Viton,.750 x.875 x 0.063 in. (between manifold and tank) 288977 Valve, pressure relief 945032 O-ring, Viton, 3 / 8 in. tube 365246 Valve, circulation control 9400 O-ring, Viton, 0.239 ID x 0.070 W in. 9409 O-ring, Viton, 0.83 x 0.939 x 0.063 in. 945039 O-ring, Viton, 3 / 4 in. tube 47883 Manifold filter assembly, in/out 47884 Screen, manifold filter, 0.006 in. mesh 9420 O-ring, Viton,.000 x.88 x 0.094 in. 27484 Valve, drain 945037 O-ring Viton, in. tube Manifold (dual-stream) 94390 O-ring, Buna N, 2.87 x 2.375 x 0.093 in. (between manifold and tank) 803762 O-ring, -35, Viton,.925 ID x 0.03 W in., BR 27609 Valve, pressure relief 945032 O-ring, Viton, 3 / 8 in. tube 365246 Valve, circulation control 9400 O-ring, Viton, 0.239 ID x 0.070 W in. 9409 O-ring, Viton, 0.83 x 0.939 x 0.063 in. 945039 O-ring, Viton, 3 / 4 in. tube 47883 Manifold filter assembly, in/out 47884 Screen, manifold filter, 0.006 in. mesh 9420 O-ring, Viton,.000 x.88 x 0.094 in. 27484 Valve, drain 779673 O-ring, grad/hopper/extension 945037 O-ring, Viton, in. tube Pump 25436 Pump, PR2M,.8 cc/rev/stream, single-stream 254279 Pump, PR25M2, 7.0 cc/rev/stream, single-stream 253843 O-ring, 8.0 x.5 mm (2 required) 25383 Packing ring 25384 Bushing 29997 Pump, PU22M,.7 cc/rev/stream, dual-stream 253843 O-ring, 8.0 x.5 mm (2 required) 252595 O-ring, 0.0 x.5 mm (2 required) 25383 Packing ring 25384 Bushing Drive system 342 Motor, AC gear, 7 / 8 hp, 230/460 VAC, 3, 2480 rpm, 27: reduction 779604 Coupling Continued... 4-VL400-OC-0
Spare Parts and Supplies (contd) Component Part Description Electrical system 234428 Service kit, control assembly, Vista 234427 Repair kit, power board, Vista 93949 Fuse, Vista power board, 25 A, VAC (2 required) 30904 Fuse, Vista power board, A, 250 VAC (2 required) 939683 Fuse, Vista power board, 6.3 A, 250 VAC (8 required) 234429 Service kit, control board, Vista 234426 Service kit, display board, Vista 234424 Service kit, firmware, Vista 04629 Drive, motor, 230 VAC, hp, 77702 Circuit breaker, 230 440 V, 6 A 777604 Relay, motor drive enable, 24 VDC, DPDT 777603 Fan, with wiring harness Hoses 39672 Repair kit, hose cordset connector Issued 8/04 Original copyright date 2004. Nordson and the Nordson logo are registered trademarks of Nordson Corporation. Vista is a trademark of Nordson Corporation. Viton is a registered trademark of E.I. DuPont de Nemours & Co. 4-VL400-OC-0 2