Nordson Corporation QUICK REFERENCE MANUAL P/N 1121655_01 Freedomt Hot Melt Adhesive ystem afety General Warnings and Cautions WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. WARNING: Always wear heat-protective clothing, safety goggles (ANI Z87.1-1989 or equivalent), and safety gloves when working withhotmeltequipment. WARNING: Risk of burns. Failure to relieve system pressure before performing maintenanceorrepairscancausehot adhesive to spray from a connecting point. Relieve system pressure as instructed in this and all related documentation. ystem-pecific Warnings and Cautions WARNING: Risk of personal injury. Ensure that connecting cables and hoses are properly routed to prevent electrical and trip hazards. Refer to the hose manual for hose installation guidelines. WARNING: Risk of personal injury or equipment damage. Ensure that the Freedom melter is properly secured at the installation location to prevent injury or damage that could result if the melter falls or is tipped over. Refer to the system installation guide. 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. CAUTION: Obtain and read the Material afety Data heets for all materials used. 1
Description The Freedom hot melt adhesive system is an adhesive melting, transfer, and dispensing system that offers users: Freedom from mounting limitations Freedom from manual adhesive filling Freedom from confusing controls and diagnostics Freedom from excessive adhesive use Freedom from downtime due to char and contamination The important characteristics of the Freedom system are briefly described here. For more detailed information, refer to the melter manual. Touchscreen Controls The system is controlled through a user-friendly color touchscreen control system, called Optixt,thatall users can effectively operate. The Optix control system includes: a color-coded (green, red, or yellow) status indication that indicates system health easy setup of inputs/outputs text-based indications for system problems a system inventory and component identification function that shows what components are connected and provides their part numbers for easy reordering Integrated Fill ystem The Freedom system includes an integrated fill system. The melter reservoir stores only 1.1 kg (2.5 lb) of molten adhesive. olid adhesive stored in an adhesive bin is automatically transferred to the melter as needed. Easy to ervice The melter's internal components can be accessed entirely from the front, without removing the melter from its mount. martmelttechnology When the mart Melt technology is enabled, the melter's internal zones automatically switch off when the integrated fill system has not activated for a user-specified amount of time. The system continues to maintain ready status until a fill signal is generated. EcoBead Technology ystems that include the EcoBead technology can provide adhesives savings of up to 60% while still maintaining full adhesive bond integrity. The EcoBead technology is enabled by using the touchscreen to choose the desired adhesive savings and to select a pre-programmed adhesive pattern. Figure 1 Component Details screen (accessed through the ystem Inventory screen) 2
Key Melter Components Cyclone assembly Control system touchscreen Fill system power cable connection Air pressure adjustment screw Air pressure gauge Cyclone exhaust filter Adhesive filter Compressed air supply input Hydraulics assembly (pump, hopper, grid, reservoir) Hydraulics cover release Controls cover Hydraulics cover Audible alarm Main power switch Melter mounting brackets Controls cover release Hose hydraulic connectors Hose electrical connectors Input power cable clamp 3
Control ystem etup Use the touchscreen and the following sections of this manual to view or change control system settings: Navigation describes the control system Menu tructure a diagram of the control system menus Control ystem ettings tables that show all editable settings and their default values NOTE: The melter manual provides task-oriented setup procedures. Navigation All control system screens are accessed through two primary screens: thehomescreen the Master Controls screen Master Controls creen The Master Controls screen is used to: switch the heater control on or off switch the pump on or off switch the standby on or off switch the scheduler on or off enable or disable the fill system access the ettings and ystem screens NOTE: The ettings screens include operational values that are frequently changed. The ystem screens include global and more advanced melter settings that are typically not frequently changed. Home creen TheHomescreenisusedto: enable/disable zones, enter individual zone temperature setpoints, and create/modify zone names start/stop the pump, change the auto pump setting, and purge the melter view the fill system status (ready/not ready) view the status of the following: heater control on/off, pump on/off, password protection, system ready, recipes access the Master Controls screen Figure 3 Master Controls screen (accessed through the Home screen) Figure 2 Home screen 4
Control ystem etup (contd) Menu tructure 5
Control ystem etup (contd) Control ystem ettings Home creen Button/Menu Item Default Grid Adjust et Point 175 _C (350 _F) Manifold Adjust et Point 175 _C (350 _F) Fill Fill Enabled Pump Auto Pump On Applicator Adjust et Point 175 _C (350 _F) Create/Modify Name Applicator 1: Zone 1B Applicator 2: Zone 2B Applicator 3: Zone 3B Applicator 4: Zone 4B EcoBead ettings (for all applicators) Adhesive savings: 30 % Pattern: 9 Tolerance: 10 Beads Per Pattern: 1 Hose Adjust et Point 175 _C (350 _F) Create/Modify Name Hose 1: Zone 1A Hose 2: Zone 2A Hose 3: Zone 3A Hose 4: Zone 4A Master Controls: ettings creen Button/Menu Item Default Temperature Global Temperature Change +/- 1 ( C or F) NOTE: Used to reduce the temperature of all active zones in increments of one temperature unit. Global etpoint mart Melt Temperature 175 _C (350 _F) 15 _C(25_F) NOTE: If the fill system is inactive for a user-specified amount of time, the mart Melt feature reduces the internal zone temperatures by the number of degrees entered for this setting. Temperature Limits martmelttime Overtemperature: 15 _C(25_F) Undertemperature: 25 _C(50_F) 10 (minutes) Fill Fill Flutter Delay 5 (seconds) Overfill Delay Alert to Default Delay Time Audible Fill Alarm 60 (seconds) 4 (minutes) Enabled Continued... 6
Control ystem etup (contd) Control ystem ettings (contd) Master Controls: ettings creen (contd.) Button/Menu Item Default Inputs Input 1 Automatic tandby (input 1 only) Input 2 Input 3 Input 4 tandby Heater Control External Zone 1A/1B NOTE: The following additional values are available for inputs 1-4: Disabled, tandby, Heater Control, Pump Control, External Zone 2A/2B, Fill Enable/Disable. Ready Delay 0(minutes) tandby Automatic tandby Disabled Auto Exit tandby Time Disabled Auto tandby tart Time 0(minutes) Auto Heaters Off Time 60 (minutes) Auto Exit tandby Time 0(minutes) tandby Temperature 50 _C (100 _F) Outputs Output 1 ystem Ready Output 2 Output 3 Fault Tank Low NOTE: The following additional values are available for outputs 1-3: Disabled, ystem Ready, Melt Ready, Fill Ready, Ready Pump On, Fill Active, Fill Overfill Alarm, Fill Fault, Tank Low, Alert, Fault, ervice Reminder. Master Controls: ystem creen Button/Menu Default Optional ettings Formats/Units Date: mm/dd/yy Time: 12 Temperature: _C Date: yy/mm/dd, dd/mm/yy Time: 24 Temperature: _F Date/Time Date/time defined at factory User-specified date/time ervice Interval 500 (hours) 0-8760 (hours) cheduler No events defined Minimum: 2 events per day Maximum: 12 events per day Password Create/Modify: 1-65535 High security level: 1000 Medium security level: 2000 Low security level: 3000 Timeout: 1 (minute) 1-60 (minutes) et ecurity Level: No Password High Protection Medium Low Display Brightness/Contrast: 75/75 (percent) 30, 60, 75, 100 (percent) creen aver Delay: 5 (minutes) 1-120 (minutes) Administration Lockout Communication: Off On Language English CE languages (with software upgrade) 7
Operation tarting the ystem witch the melter on. The Home screen appears. The system is ready for normal operation when: the ystem tatus button indicates Ready/OK (green) all enabled zones reach setpoint temperature the Fill button indicates Ready the Pump button indicates Ready thereadydelaytime(ifused)haselapsed NOTE: The fill system and mart Melt are automatically enabled by default. Monitoring and Adjusting the Pump Air Pressure CAUTION: Do not force the air pressure adjustment screw beyond its normal range of adjustment. Doing so will damage the pneumatic assembly. Use a 5-mm hex key to turn the air pressure adjustment screw (located next to the pressure gauge) to adjust the pump air pressure. The air pressure gauge located on the front of the melter indicates the air pressure that is supplied to the pump. NOTE: The minimum pump air pressure is 0.7 bar (10 psi). Operating the melter with the air pressure set to less than 0.7 bar (10 psi) can cause the pump to function erratically. Figure 4 Location of the main power switch tarting/topping the Pump 1. FromtheHomescreen,touchPump. 2. Touch Pump Control to switch on/off the pump. Figure 6 Location of the air pressure adjustment screw (requires a 5-mm hex key) Figure 5 Location of the Pump Control button 8
Operation (contd) Enabling/Disabling Heated Zones or Changing Temperature etpoints Touch any zone button to: enable or disable the zone adjust the temperature setpoint NOTE: Nordson Corporation recommends that users NOT disable the internal zones (grid and manifold). witching On/Off Heaters, tandby, cheduler, or Refill The melter heater control, standby, scheduler, and refill functions are controlled through the Master Controls screen. 1. From the Home screen, touch Master Controls. 2. Touch the appropriate button to manually switch on/off or enable/disable the following: Heater Control tandby Pump Control cheduler Refill A green radio button indicates on; a white radio button indicates off. 3. Touch Done. Figure 7 Applicator 1 screen (accessed through the Home screen) NOTE: The fill system is automatically enabled by default when the system status is Ready/OK. The fill system is automatically disabled whenever Heater Control is switched off. NOTE: If a fault occurs, Pump Control and Heater Control are automatically switched off. Figure 8 Master Controls screen (accessed through the Home screen) 9
Operation (contd) Monitoring The ystem The screen saver appears after 5 minutes (the default) of no user interaction with the touchscreen. The screen saver is a full screen version of the ystem tatus button on the Home screen, shown below. The Home screen appears when you touch anywhere on the screen. Refer to ystem tatus Button Indications on the next page for an explanation of all system status indications. hutting Down witch off the melter. Figure 10 Location of the main power switch Figure 9 ystem status button as a screen saver 10
Operation (contd) ystem tatus Button Indications Button Color Heaters Pump Description ystem tatus Ready\OK Dark green On On All enabled heated zones are at setpoint temperature. ystem tatus Ready\Low Level ystem tatus Ready\ervice ystem ystem tatus tatus Heating Heaters Fill: Off Ready ystem ystem tatus tatus Heat: Heaters Ready Off Fill: Off ystem tatus Heat: Off Fill: Ready ystem ystem tatus tatus Heat: Heaters Off Off Fill: Off ystem tatus Heating Fill Off ystem tatus Ready Delay Dark green Dark green Light green Light green Light green Light green Light green Light blue On On ame as Ready/OK, but the adhesive level in the hopper is below normal; check the adhesive supply. On On ame as Ready/OK, but a component requires regularly scheduled service. On On/Off The system is heating all enabled zones to their setpoint temperatures. Refill is enabled. On On/Off Heated zones are at setpoint temperature but Refill is disabled. Off On/Off Heated zones are at setpoint temperature and the pump is ready, but Heater Control is off. NOTE: This could be the result of a zone or pump fault. Off On/Off Heated zones are at setpoint temperature but Heater Control is off and Refill is disabled. On Off The system is heating all enabled zones to their setpoint temperatures. On Off Although all enabled zones are at setpoint temperature, Ready/OK status is delayed until the Ready Delay time has elapsed. ystem tatus tandby Mode Blue On Off The system has been manually or automatically placed into tandby mode. ystem tatus Alert ystem tatus Fault Yellow On On The melter continues to operate normally, but some functions may not be available. The system requires service. Red Off Off A system fault condition has been detected. Pump Control and Heater Control are switched off. 11
ervice Recommended Maintenance Thefollowingtabledescribesthepreventivemaintenance and other service tasks required to keep the system operating within specified limits and to prevent equipment malfunctions. Task Frequency Reference Replace the adhesive filter As needed When changing the type or grade of adhesive Replacing the Adhesive Filter Replace the cyclone exhaust filter As needed Replacing the Cyclone Exhaust Filter Relieving ystem Pressure WARNING: Before disconnecting any hydraulic fitting or opening any pressurized port, always complete this procedure to safely relieve hydraulic pressure. 1. FromtheHomescreen,touchPump. Purging the ystem Use the Purge button to pump all adhesive from the melter as needed. The fill system is automatically disabled during a purge. From the Home screen, touch Pump > Purge.To stop the purge, touch Purge again. 2. Touch Pump Control to switch off the pump. 3. Trigger the applicators until adhesive no longer flows from the applicators. Figure 12 Location of the Purge button Figure 11 Location of the Pump Control button 12
ervice (contd) Replacing the Adhesive Filter Toremovetheadhesivefilter: 1. Relieve system pressure. Refer to Relieving ystem Pressure. 2. Remove the hydraulics cover. 3. Usea13-mmwrenchoranadjustablewrenchto close the shutoff valve. Replacing the Adhesive Filter (contd.) To install the adhesive filter: 1. Confirm that the O-ring on the new filter is in good condition. 2. Thread the filter into the manifold and then tighten the filter to 4.5 Nm(40in.-lb). 3. Open the shutoff valve. 4. Reinstall the hydraulics cover and restore the system to normal operation. Closed Open Replacing the Cyclone Exhaust Filter 1. From the Home screen, touch Master Controls > Refill to disable the fill system. 2. Remove the cyclone exhaust filter cover (1) by turning the fasteners on the top and bottom of the filter cover one quarter-turn counterclockwise. 3. Replace the old filter (2) with a new one. 4. Reinstall the filter cover, enable the fill system, and restore the system to normal operation. 2 Figure 13 Location of the shutoff valve 4. Use an 8-mm hex wrench or an adjustable wrench to loosen (counterclockwise) and then remove the filter, taking care to keep adhesive from dripping onto the assembly. 1 Figure 15 Replacing the cyclone exhaust filter Figure 14 Removing the adhesive filter 13
Troubleshooting Alerts/Faults If an alert/fault appears, investigate and correct the situation that caused the alert/fault and then clear the alert/fault. The control system will continue to generate the alert/fault condition until the situation is resolved. Touchscreen Problems Problem Possible Cause Corrective Action 1. Touchscreen buttons not working Touchscreen not properly calibrated Calibrate the touchscreen. Touch Master Controls > ystem > Display > Calibrate creen. If you cannot access the Calibrate creen button, cycle the power and calibrate the screen as indicated on restart screens. 2. Touchscreen blank Cable disconnected Open the electrical enclosure and ensure that the power cable (the one with a green housing) is properly connected to the display/cpu board. Fill ystem Problems Problem Possible Cause Corrective Action 1. ystem overfilled Level sensor not calibrated properly Level sensor ground wire not properly connected Level sensor cable not properly connected Level sensor failure Refill board not working Adhesive bin solenoid stuck open Recalibrate the sensor at application temperature with the tank empty. Refer to Calibrating the Level ensor in the service section of the melter manual. Connect the sensor ground wire or replace the triaxial cable. Inspect the sensor cable connections. Ensure that the fitting is tightened to 1.1 Nm(10in.-lb). Replace the sensor. Replace the refill board. Clean or replace the solenoid. Continued... 14
Troubleshooting (contd) Fill ystem Problems (contd) Problem Possible Cause Corrective Action 2. ystem underfilled No adhesive Add adhesive to the bin. No power Fill system communication cable loose No or low air pressure Failed air pressure regulator Clogged cyclone exhaust filter Overfill time limit too short Foreign or incorrect material in bin Adhesive bridging in bin Vibrator failure Transfer hose blocked Adhesive bin pump blocked Adhesive bin solenoid failure Failed refill board Level sensor not calibrated properly Connect power. Ensure that the fill system communication cable is securely connected to the melter and the adhesive bin. Ensure that enough air pressure and air flow is available. Replace the regulator. Clean or replace the cyclone exhaust filter. Refer to Replacing the Cyclone Exhaust Filter under ervice. Adjust the time limit setting. Inspect the material in the bin for contamination. Dislodge the adhesive. Replace the vibrator. Clear the blockage from the hose. Reroute the hose if a hose blockage problem persists. Disconnect the adhesive transfer hose from the adhesive bin and and clear the blockage from the pump. Clean or replace solenoid. Replace the refill board. Recalibrate the sensor at application temperature with the tank empty. Refertothelevelsensorcalibration procedure in the service section of the melter manual. 15
ervice Kits NOTE: Refer to the parts section of the melter manual for comprehensive parts lists and illustrations. Assemblies Part Description Hydraulic 1121523 ERVICE KIT, PITON PUMP 1121528 ERVICE KIT, REERVOIR AEMBLY 1121529 ERVICE KIT, MANIFOLD AEMBLY 1121530 ERVICE KIT, GRID AEMBLY 1121527 ERVICE KIT, PREURE DICHARGE VALVE 1028305 FILTER, ATURN, MELTER, 100 MEH Electrical 1121531 ERVICE KIT, RTD (GRID/REERVOIR) 1028321 ERVICE KIT, THERMOTAT, 500F, OOR 1121538 ERVICE KIT, FILL ENOR 1121539 ERVICE KIT, FILL ENOR CABLE 1078624 ERVICE KIT, DURABLUE, MAIN, PCA 1031203 ERVICE KIT, DURABLUE, FUE, MAIN BOARD 1121534 ERVICE KIT, FILL CONTROL BOARD 1121535 ERVICE KIT, HGIB 1121536 ERVICE KIT, TITCHING BOARD 1121540 ERVICE KIT, 24V POWER UPPLY 1031201 ERVICE KIT, DURABLUE EXPANION 1087152 ERVICE KIT, HOE/APPLICATOR POWER MODULE 1121545 ERVICE KIT, HYDRAULIC HINGE WITCH Pneumatic 1121524 ERVICE KIT, PNEUMATIC CONTROL AEMBLY 1121526 ERVICE KIT, FILL AIR VENT FILTER Control system 1121533 ERVICE KIT, TOUCHCREEN AEMBLY 1121537 ERVICE KIT, D CARD FOR OFTWARE UPDATE Fill system 1121546 ERVICE KIT, FILL PUMP 1121556 ERVICE KIT, CYCLONE AEMBLY 1121548 ERVICE KIT, FILL VIBRATOR AEMBLY 1121549 ERVICE KIT, FILL CONTROL OLENOID 1121110 AY,TRANFERHOE,4M,FREEDOOM 1121111 AY,TRANFERHOE,9M,FREEDOOM 1121112 AY, TRANFER HOE, 18 M, FREEDOOM 1121555 ERVICE KIT, MAIN VACUUM HOE AND FITTING Issued 2/13 Original copyright date 2013. Nordson and the Nordson logo are registered trademarks of Nordson Corporation. Freedom and Optix are trademarks of Nordson Corporation. 16