Freedom Adhesive System

404 Pages·2015·11.44 MB·English

(cid:2)
Freedom Hot Melt
Adhesive System
Software version 2.674
Customer Product Manual
Part 1124684_01
Issued 8/15
This document contains important safety information
Be sure to read and follow all safety information in this
document and any other related documentation.
NORDSON CORPORATION  DULUTH, GEORGIA  USA
www.nordson.com
For CE Declaration, refer to equipment documentation.
Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General information
about Nordson can be found on the Internet using the following address: http://www.nordson.com.
Address all correspondence to:
Nordson Corporation
Attn: Customer Service
11475 Lakefield Drive
Duluth, GA 30097
Notice
This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2013.
No(cid:2)part(cid:2)of(cid:2)this(cid:2)document may be photocopied, reproduced, or translated to another language without the prior written
consent of Nordson(cid:2)Corporation. The(cid:2)information(cid:2)contained in this publication is subject to change without notice.
Trademarks
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Cross‐Cut, CrystallCut, cScan+, Dage, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber, DuraPail, Dura‐Screen,
Durasystem, Easy(cid:2)Coat, Easymelt, Easymove Plus, Ecodry, Econo‐Coat, e.dot, EFD, Eliminator, Emerald, Encore, Equatherm, ESP,
e-stylized, ETI‐stylized, Excel 2000, Fibrijet, Fillmaster, FlexiCoat, Flex‐O‐Coat, Flow Sentry, Fluidmove, FoamMelt, FoalMelt - stylized,
FoamMix, Freedom, Fulfill, GreenUV, HDLV, Heli‐flow, Horizon, Hot Shot, iControl, iDry, iFlow, Isocoil, Isocore, Iso‐Flo, iTrax, Kinetix,
KISS, Lean(cid:2)Cell, Little(cid:2)Squirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, MicroCoat, MicroMark, Micromedics,
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Nordson and Arc, OptiMix, Optimum, Package of Values, Paragon, Pattern View, PermaFlo, PICO, PicoDot, Plasmod, Poly-Check,
Porous(cid:2)Coat, PowderGrid, Powderware, Precisecoat, PrintPlus, Prism, ProBlue, Prodigy, Pro‐Flo, Program‐A‐Bead, Program‐A‐Shot,
Program‐A‐Stream, Program‐A‐Swirl, ProLink, Pro‐Meter, Pro‐Stream, Pulsar, Quantum, RBX, Rhino, Saturn, Saturn with rings,
Scoreguard, Sealant Equipment & Engineering, Inc, SEE and design, See‐Flo, Seal Sentry, Select(cid:2)Charge, Select(cid:2)Coat, Select Cure,
Servo‐Flo, Shot‐A‐Matic, Signature, Signature - stylized, Slautterback, Smart‐Coat, Smart-Gun, SolderPlus, Spectrum, Speed‐Coat,
StediFlo, Stratablend, SureBead, Sure Coat, Sure‐Max, SureWrap, TAH, Tip-Seal, Tracking(cid:2)Plus, TRAK, Trends, Tribomatic, Trilogy,
TrueBlue, TrueCoat, Tubesetter, Ultra, UpTime, u‐TAH, Value Plastics, Vantage, VersaBlue, Versa‐Coat, VersaDrum, VersaPail,
VersaPUR, Versa‐Screen, Versa‐Spray,VP Quick-Fit, VP Quick-Fit, VP Quick-Fit stylized, VP stylized, Watermark,
When you expect more., Xaloy, Xaloy - stylized, X-Plane, and YesTech are registered trademarks of Nordson Corporation.
Accubar, Active Nozzle, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AltaSlot, Alta Spray, ATS, Auto‐Flo, AutoScan,
Axiom, Best Choice, Blue Series, Bravura, CanPro, Champion, Check Mate, ClassicBlue, Classic IX, Clean(cid:2)Coat, Cobalt, Concert,
Controlled Fiberization, Control(cid:2)Weave, ContourCoat, CPX, cSelect, Cyclo‐Kinetic, DispensLink, Dry Cure, DuraBraid, DuraCoat,
DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, EdgeControl, e.dot+, E‐Nordson, Equalizer, EquiBead, FillEasy, Fill(cid:2)Sentry,
FlexSeam, Flow Coat, FluxPlus, Genius, Get Green With Blue, G‐Net, G‐Site, IntelliJet, iON, Iso‐Flex, iTrend, Lacquer Cure, Maxima,
Mesa, MicroFin, MicroMax, Mikros, MiniEdge, Minimeter, MiniPUR, Multifill, MultiScan, Myritex, Nano, OmniScan, OptiStroke, Optix,
Partnership+Plus, PatternJet, PatternPro, PCI, PharmaLok, Pinnacle, Powder(cid:2)Pilot, Powder Port, Powercure, Process Sentry,
Pulse Spray, PURBlue, PUReOne, PURJet, Ready Coat, RediCoat, RollVIA, Royal Blue, Select(cid:2)Series, Sensomatic, Shaftshield,
SheetAire, Smart, Smartfil, SolidBlue, Spectral, SpeedKing, Spray Works, StediTherm, StrokeControl, Summit, SureFoam, Sure(cid:2)Mix,
SureSeal, Swirl(cid:2)Coat, ThruWave, Trade(cid:2)Plus, Trio, TruFlow, Ultra FoamMix, UltraMax, Ultrasaver, Ultrasmart, Unity, UNITYMotion,
Universal, ValueMate, Versa, VersaPUR, Vista, Web Cure, and 2(cid:2)Rings (Design) are(cid:2)trademarks of Nordson(cid:2)Corporation.
Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes,
could lead to violation of the owners' rights.
Buna-N is a registered trademark of Pittway Corps.
Loctite is a registered trademark of Loctite Corporation.
Never Seez is a registered trademark of Bostik Inc.
Torx is a registered trademark of Textron Inc.
Part 1124684_01 (cid:2) 2015 Nordson Corporation
All rights reserved
Table of Contents i
Table of Contents
Safety ..................................................... 1-1
Safety Alert Symbols ......................................... 1‐1
Responsibilities of the Equipment Owner ....................... 1‐2
Safety Information ........................................ 1‐2
Instructions, Requirements, and Standards ................... 1‐2
User Qualifications ........................................ 1‐3
Applicable Industry Safety Practices ........................... 1‐3
Intended Use of the Equipment ............................. 1‐3
Instructions and Safety Messages ........................... 1‐4
Installation Practices ...................................... 1‐4
Operating Practices ....................................... 1‐4
Maintenance and Repair Practices .......................... 1‐5
Equipment Safety Information ................................. 1‐5
Equipment Shutdown ..................................... 1‐6
Relieving System Hydraulic Pressure ..................... 1‐6
De‐energizing the System ............................... 1‐6
Disabling the Applicators ................................ 1‐6
General Safety Warnings and Cautions....................... 1‐7
Other Safety Precautions .................................. 1‐10
First Aid .................................................. 1‐10
Safety Labels and Tags ...................................... 1‐12
Description ................................................ 2-1
Introduction ................................................ 2‐1
Touchscreen Controls ..................................... 2‐2
Integrated Fill System ..................................... 2‐3
Easy to Service ........................................... 2‐3
Smart Melt Capability ...................................... 2‐3
EcoBead Capability ....................................... 2‐3
Other Sources of Information ................................. 2‐4
Installation Guide ......................................... 2‐4
Online Support ........................................... 2‐4
Online Documentation ..................................... 2‐4
Limitations of Use ........................................... 2‐5
Intended Use ............................................. 2‐5
Electromagnetic Compatibility (EMC) ........................ 2‐5
Examples of Unintended Use ............................... 2‐5
Residual Risks ........................................... 2‐6
Melter Identification ......................................... 2‐7
Key Components ........................................... 2‐8
Modes of Operation ......................................... 2‐11
Heating (Normal Mode) .................................... 2‐11
Standby ................................................. 2‐11
Smart Melt ............................................... 2‐11
Fault .................................................... 2‐11
Optional Equipment ......................................... 2‐12
(cid:2) 2015 Nordson Corporation Part 1124684_01
ii Table of Contents
Installation ................................................. 3-1
Overview .................................................. 3‐1
Experience of Installation Personnel ............................ 3‐1
Melter Installation ........................................... 3‐2
Obtain Customer‐Supplied Materials ........................ 3‐2
Select the Installation Location .............................. 3‐2
Verify the Contents of the Ship‐With Kit ...................... 3‐4
Mount the Melter ......................................... 3‐6
Unpacking the Melter ................................... 3‐6
Mounting the Melter on a Vertical Surface .................. 3‐8
Mounting the Melter on the Floor Stand .................... 3‐10
Mounting the Melter on the Bench Stand ................... 3‐14
Configure the Electrical Service ............................. 3‐19
Connect the Driver, Pattern Controller, or Timer Wiring ......... 3‐24
Connect Applicator Signal Wiring ........................... 3‐26
Connect Inputs/Outputs (Optional) .......................... 3‐32
Connect a Fill System Status Output (Optional) ............... 3‐34
Connect an Air Supply to the Melter ......................... 3‐36
Connect Hoses and Applicators ............................. 3‐39
Remove the Shipping Bolt ................................. 3‐43
Fill System Installation ....................................... 3‐44
Connect to a Single‐Feed Adhesive Storage Bin .............. 3‐44
Connect to a Multi-Feed Adhesive Storage Bin ................ 3‐49
Control System Setup and Initial System Startup ................. 3‐55
Setup ...................................................... 4-1
Introduction ................................................ 4‐1
About Heated Components ................................... 4‐2
About the Control System .................................... 4‐3
Home Screen ............................................ 4‐4
Master Controls Screen .................................... 4‐5
Settings Screen .......................................... 4‐6
System Screen ........................................... 4‐7
Menu Structure ........................................... 4‐9
Control System Setup Procedures ............................. D‐12
Modifying Temperature Setpoints for Individual Zones ......... D‐12
Modifying Applicator or Hose Zone Names ................... D‐14
Setting Up the EcoBead Capability .......................... D‐16
Selecting the Auto Pump Setting ............................ D‐20
Entering or Modifying a Global Temperature Setpoint .......... D‐22
Setting Up the Smart Melt Capability ........................ D‐24
Modifying Temperature Limits .............................. D‐26
Entering Fill Settings ...................................... D‐29
Entering a Ready Delay .................................... D‐31
Entering Standby Settings ................................. D‐33
Standby Temp Delta Setup .............................. D‐35
Zone Standby Setup .................................... D‐37
Manual Standby/Auto Exit Standby Time Setup ............. D‐39
Automatic Standby/Auto Heaters Off Time Setup ........... D‐40
Setting Up Inputs/Outputs .................................. D‐43
Selecting the Date, Time, and Temperature Unit Formats ....... D‐45
Setting the Date/Time/Day of Week ......................... D‐46
Entering a Service Reminder ............................... D‐47
Part 1124684_01 (cid:2) 2015 Nordson Corporation
Table of Contents iii
Entering a Custom Service Alert ............................ D‐48
Entering the Touchscreen Screen Saver Delay ................ D‐49
Setting Up Password Protection ............................ D‐51
Setting Up the Scheduler .................................. D‐55
Using Recipes ............................................ D‐59
Selecting the Language Setting ............................. D‐62
Initial System Startup ........................................ D‐63
Operation .................................................. 5-1
Introduction ................................................ 5‐1
About Heated Components ................................... 5‐1
Filling the Adhesive Storage Bin ............................... 5‐3
Starting the System .......................................... 5‐4
Monitoring the System ....................................... 5‐6
On/Off Button Colors ...................................... 5‐6
General System Status .................................... 5‐8
Fill System Status ......................................... 5‐10
Heated Zone Status ....................................... 5‐12
Pump Status ............................................. 5‐14
Starting/Stopping the Pump ................................... 5‐16
Monitoring and Adjusting the Pump Air Pressure ................. 5‐17
Enabling/Disabling Zones or Changing Temperature Setpoints .... 5‐18
Switching On/Off Standby .................................... 5‐20
Switching On/Off Manual Standby ........................... 5‐20
Switching Off Automatic Standby ........................... 5‐20
Switching Off Zone Standby ................................ 5‐20
Switching On/Off Heaters, Scheduler, or Refill ................... 5‐22
Enabling/Disabling the EcoBead Capability ..................... 5‐23
Clearing or Resetting Alerts/Faults ............................. 5‐24
Resetting the Service Interval ................................. 5‐26
Shutting Down .............................................. 5‐28
Maintenance ............................................... 6-1
Preventive Maintenance Schedule ............................. 6‐1
Cleaning the Touchscreen .................................... 6‐2
Relieving System Pressure ................................... 6‐3
Removing or Installing Covers ................................ 6‐4
Replacing the Adhesive Filter ................................. 6‐6
Replacing the Cyclone Exhaust Filter .......................... 6‐8
Upgrading the Firmware ...................................... 6‐9
Upgrading the Firmware by Installing a New Customer SD Card . 6‐9
Upgrading the Firmware Electronically (File Only) ............. 6‐11
Reverting Back to a Previous Firmware Version................ 6‐12
(cid:2) 2015 Nordson Corporation Part 1124684_01
iv Table of Contents
Troubleshooting............................................ 7-1
About This Section .......................................... 7‐1
Safety...................................................... 7‐1
Control System Troubleshooting Aids .......................... 7‐2
Displaying System Data ................................... 7‐2
Resetting the System ...................................... 7‐4
Displaying Diagnostics (the Event Log) ...................... 7‐5
Obtaining Event Log and Diagnostic Files .................... 7‐6
About the EventLog.csv File .............................. 7‐9
About the Diagnostic.nor File ............................. 7‐9
Resetting the Passwords .................................. 7‐10
Adjusting the Touchscreen Brightness/Contrast ............... 7‐11
Locking Out Communication ............................... 7‐12
Calibrating the Touchscreen ................................ 7‐13
Melter Troubleshooting ...................................... 7‐14
About Melter Alerts/Faults .................................. 7‐14
Heated Zone Alerts/Faults ................................. 7‐14
Melter Alerts ............................................. 7‐15
Melter Faults ............................................. 7‐15
Touchscreen Troubleshooting Table ......................... 7‐19
Melter Troubleshooting Table ............................... 7‐19
EcoBead Capability Troubleshooting Table ................... 7‐22
Fill System Troubleshooting .................................. 7‐23
About Fill System Alerts/Faults ............................. 7‐23
Fill System Alerts ......................................... 7‐24
Fill System Faults ......................................... 7‐25
Fill System Troubleshooting Table .......................... 7‐26
Fill System Troubleshooting Procedures ..................... 7‐28
Displaying the Fill Level Graph ........................... 7‐28
Using Manual Call for Fill................................. 7‐29
Calibrating the Level Sensor ............................. 7‐30
Clearing Adhesive Bin Blockage .......................... 7‐37
Cleaning the Cyclone Exhaust Tube ...................... 7‐38
Circuit Board Component Tables .............................. 7‐40
Main Board .............................................. 7‐40
Hose Interface Board ...................................... 7‐43
EcoBead Board .......................................... 7‐52
Fill Board ................................................ 7‐54
Power Module Board ...................................... 7‐57
Expansion Board ......................................... 7‐58
CPU/LCD Board .......................................... 7‐59
Power Supply Board ...................................... 7‐60
Part 1124684_01 (cid:2) 2015 Nordson Corporation
Table of Contents v
Repair ..................................................... 8-1
Purging the Melter ........................................... 8‐2
Tilting Open the Hydraulics Assembly .......................... 8‐4
Melter Repair Procedures .................................... 8‐6
Replacing an RTD or Thermostat ........................... 8‐6
Replacing the Level Sensor Cable .......................... 8‐10
Replacing the Level Sensor Board .......................... 8‐14
Replacing a Circuit Board .................................. 8‐17
Replacing the Main Board Fuses ............................ 8‐20
Replacing the Pneumatic Control Assembly .................. 8‐21
Replacing the Tilt Switch ................................... 8‐26
Replacing the Touchscreen Assembly ....................... 8‐30
Replacing a Cyclone Assembly Component .................. 8‐33
Replacing the Pump ....................................... 8‐38
Replacing a Hydraulics Assembly Component ................ 8‐44
Replacing the Internal SD Card ............................. 8‐49
Fill System Repair Procedures ................................ 8‐52
Replacing the Transfer Pump or Transfer Pump O‐Rings ....... 8‐52
Replacing the Vibrator ..................................... 8‐54
Replacing the Fill System Pneumatic Control Assembly ........ 8‐56
Replacing the Adhesive Transfer Hose Cuff Assembly ......... 8‐58
Parts ...................................................... 9-1
Using the Illustrated Parts Lists ................................ 9‐1
Viewing the System Inventory ................................. 9‐2
Melter Parts Lists ........................................... 9‐3
Melter Assemblies ........................................ 9‐3
Chassis and Controls Assembly ............................ 9‐7
Hydraulics Assembly ...................................... 9‐14
Pump ................................................... 9‐16
Pump Hydraulic Piston .................................... 9‐19
Pump Shifter ............................................. 9‐20
Manifold ................................................. 9‐22
Grid/Hopper ............................................. 9‐24
Reservoir ................................................ 9‐26
Cyclone Assembly ........................................ 9‐28
Air Filter Assembly ........................................ 9‐30
Melter Wall Mounting Bracket .............................. 9‐31
Fill System Parts Lists ....................................... 9‐32
Single‐Feed Adhesive Storage Bin .......................... 9‐32
Multi‐Feed Adhesive Storage Bin ........................... 9‐34
Adhesive Transfer Hose ................................... 9‐37
Standard Transfer Hoses ................................ 9‐37
Quick‐Disconnect Transfer Hoses ........................ 9‐38
Quick Disconnect Adhesive Transfer Hose Parts ............ 9‐40
Coupling Assembly, Pump Box ............................. 9‐42
Transfer Hose Pump Parts ................................. 9‐43
Transfer Hose Solenoid Harness ............................ 9‐44
Standard Harnesses .................................... 9‐44
Quick‐Disconnect Harnesses ............................ 9‐45
Sequencer ............................................... 9‐46
(cid:2) 2015 Nordson Corporation Part 1124684_01
vi Table of Contents
Parts contd.
Optional Accessories ........................................ 9‐50
Adhesive Storage Bin Grates ............................... 9‐50
Air Flush Kit .............................................. 9‐50
Air Gauge ............................................... 9‐51
Applicator Solenoid Valve‐to‐Melter Cables .................. 9‐51
Hose‐to‐Applicator Fittings ................................. 9‐52
Melter Stands and Castors ................................. 9‐53
Solenoid Harness Quick‐Disconnect Kits ..................... 9‐54
Service Kits ................................................ 9‐55
Technical Data ............................................. 10-1
General Specifications ....................................... 10‐1
Electrical Specifications ...................................... 10‐1
Heater Specifications ........................................ 10‐2
Pump Specifications ......................................... 10‐2
Fill Specifications ........................................... 10‐3
EcoBead Capability Specifications ............................. 10‐4
Dimensions ................................................ 10‐6
Hydraulic Flow Diagrams ..................................... 10‐13
Wiring Diagrams ............................................ 10‐16
System Schematic .......................................... 10‐19
Calculating Melter Power Requirements...................... A-1
Control System Settings .................................... B-1
Home Screen ............................................... B‐1
Master Controls: Settings Screen .............................. B‐2
Master Controls: System Screen .............................. B‐4
Part 1124684_01 (cid:2) 2015 Nordson Corporation
Safety 1-1
Section 1
Safety
Read this section before using the equipment. This section contains
recommendations and practices applicable to the safe installation, operation,
and maintenance (hereafter referred to as “use”) of the product described in
this document (hereafter referred to as “equipment”). Additional safety
information, in the form of task‐specific safety alert messages, appears as
appropriate throughout this document.
WARNING! Failure to follow the safety messages, recommendations, and
hazard avoidance procedures provided in this 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 to alert the reader to personal safety hazards or to identify
conditions that may result in damage to equipment or property. Comply with
all safety information that follows the signal word.
WARNING! Indicates a potentially hazardous situation that, if not avoided,
can result in serious personal injury, including death.
CAUTION! Indicates a potentially hazardous situation that, if not avoided,
can result in minor or moderate personal injury.
CAUTION! (Used without the safety alert symbol) Indicates a potentially
hazardous situation that, if not avoided, can result in damage to equipment or
property.
(cid:2) 2015 Nordson Corporation Issued 10-11
1-2 Safety
Responsibilities of the Equipment Owner
Equipment owners are responsible for managing safety information, ensuring
that all instructions and regulatory requirements for use of the equipment are
met, and for qualifying all potential users.
Safety Information
(cid:3)
Research and evaluate safety information from all applicable sources,
including the owner‐specific safety policy, best industry practices,
governing regulations, material manufacturer's product information, and
this document.
(cid:3)
Make safety information available to equipment users in accordance with
governing regulations. Contact the authority having jurisdiction for
information.
(cid:3)
Maintain safety information, including the safety labels affixed to the
equipment, in readable condition.
Instructions, Requirements, and Standards
(cid:3)
Ensure that the equipment is used in accordance with the information
provided in this document, governing codes and regulations, and best
industry practices.
(cid:3)
If applicable, receive approval from your facility's engineering or safety
department, or other similar function within your organization, before
installing or operating the equipment for the first time.
(cid:3)
Provide appropriate emergency and first aid equipment.
(cid:3)
Conduct safety inspections to ensure required practices are being
followed.
(cid:3)
Re‐evaluate safety practices and procedures whenever changes are
made to the process or equipment.
Issued 10−11 (cid:2) 2015 Nordson Corporation