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Nordson freedom Product Manual

Hot melt adhesive system
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Freedomt Hot Melt
Adhesive System
Software version 2.672
Customer Product Manual
Part 1123087_02
Issued 3/14
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

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  • Page 1 Software version 2.672 Customer Product Manual Part 1123087_02 Issued 3/14 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...
  • Page 2 ContourCoat, CPX, cSelect, Cyclo‐Kinetic, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, e.dot+, E‐Nordson, Equalizer, EquiBead, FillEasy, Fill Sentry, Flow Coat, Fluxplus, Freedom, Get Green With Blue, G‐Net, Genius, G‐Site, IntelliJet, iON, Iso‐Flex, iTrend, Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros, MiniEdge, Minimeter, Multifill, MultiScan, Myritex, Nano, OmniScan, OptiMix, OptiStroke,...

  • Page 3: Table Of Contents

    ......... 2‐12 Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 4 ....3‐49 Control System Setup and Initial System Startup ....3‐54 E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 5 ........4‐62 Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 6 ... . . 6‐11 Reverting Back to a Previous Firmware Version ....6‐12 E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 7 ........7‐60 Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 8 8‐54 Replacing the Fill System Pneumatic Control Assembly ..8‐56 Replacing the Adhesive Transfer Hose Cuff Assembly ..8‐58 E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 9 ..........9‐52 Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 10 Master Controls: System Screen ......B‐4 E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 11: Safety

    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. Issued 10-11 E 3/2014 Nordson Corporation...

  • Page 12: Responsibilities Of The Equipment Owner

    Provide appropriate emergency and first aid equipment. Conduct safety inspections to ensure required practices are being followed. Re‐evaluate safety practices and procedures whenever changes are made to the process or equipment. Issued 10−11 E 3/2014 Nordson Corporation...

  • Page 13: User Qualifications

    Do not modify the equipment. Do not use incompatible materials or unapproved auxiliary devices. Contact your Nordson representative if you have any questions on material compatibility or the use of non‐standard auxiliary devices. Issued 10-11 E 3/2014 Nordson Corporation...

  • Page 14: Instructions And Safety Messages

    Familiarize yourself with the location and meaning of the safety warning labels and tags affixed to the equipment. Refer to Safety Labels and Tags at the end of this section. If you are unsure of how to use the equipment, contact your Nordson representative for assistance. Installation Practices Install the equipment in accordance with the instructions provided in this document and in the documentation provided with auxiliary devices.

  • Page 15: Maintenance And Repair Practices

    Read and comply with the manufacturer's instructions and the MSDS supplied with equipment cleaning compounds. NOTE: MSDSs for cleaning compounds that are sold by Nordson are available at www.nordson.com or by calling your Nordson representative. Confirm the correct operation of all safety devices before placing the equipment back into operation.

  • Page 16: Equipment Shutdown

    2. Disconnect the input signal wiring to the applicator solenoid valve(s). 3. Reduce the air pressure to the applicator solenoid valve(s) to zero; then relieve the residual air pressure between the regulator and the applicator. Issued 10−11 E 3/2014 Nordson Corporation...

  • Page 17: General Safety Warnings And Cautions

    General Safety Warnings and Cautions Table 1‐1 contains the general safety warnings and cautions that apply to Nordson hot melt and cold adhesive equipment. Review the table and carefully read all of the warnings or cautions that apply to the type of equipment described in this manual.
  • Page 18 WARNING! Risk of fire or explosion! Nordson adhesive equipment is not rated for use in explosive environments and has not been certified for the ATEX directive or as nonincendive. In addition, this equipment HM, CA, PC should not be used with solvent‐based adhesives that can create an...
  • Page 19 CAUTION! Nordson hot melt equipment is factory tested with Nordson Type R fluid that contains polyester adipate plasticizer. Certain hot melt materials can react with Type R fluid and form a solid gum that can clog the equipment.

  • Page 20: Other Safety Precautions

    3. Do NOT attempt to remove the solidified hot melt from your skin. 4. In case of severe burns, treat for shock. 5. Seek expert medical attention immediately. Give the MSDS for the hot melt to the medical personnel providing treatment. Issued 10−11 E 3/2014 Nordson Corporation...
  • Page 21 1-11 Safety This page intentionally left blank. Issued 10-11 E 3/2014 Nordson Corporation...

  • Page 22: Safety Labels And Tags

    Table 1‐2 provides an illustration of the hazard identification symbols that appear on each safety label and tag, the meaning of the symbol, or the exact wording of any safety message. Figure 1‐1 Safety labels and tags Issued 10−11 E 3/2014 Nordson Corporation...
  • Page 23 TAG, WARNING, HOT ADHESIVE, VERTICAL 1100252 1100254 TAG, CAUTION, HOT SURFACE TAG, WARNING, HOT ADH/HYD PRESS 1100256 1122129 TAG, WARNING, DO NOT THROW TRASH TAG, WARNING, DO NOT TIP OVER (multi-feed bins only) 1122762 Issued 10-11 E 3/2014 Nordson Corporation...
  • Page 24 1-14 Safety Issued 10−11 E 3/2014 Nordson Corporation...

  • Page 25: Description

    Section 2 Description Introduction This manual describes the installation and use of the Freedom hot melt adhesive system. The Freedom system is a complete adhesive melting, transfer, and dispensing system that includes the Freedom melter along with Freedom hoses and applicators.

  • Page 26: Touchscreen Controls

    System part number: 440383-C Applicator Serial number: BN2013-54 Install Date: 12/03/2013 Applicator LCD Module P/N: 1121533 DuraBlue Main Board P/N: 1078624 DuraBlue Expansion Board P/N: 12/03/2013 Figure 2‐2 System Inventory and System Configuration screens E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 27: Integrated Fill System

    Description Integrated Fill System The Freedom system includes an integrated fill system. The melter reservoir stores only 1.1 kg (2.5 lb) of molten adhesive. The fill system automatically transfers solid adhesive stored in an adhesive bin to the melter as needed.

  • Page 28: Other Sources Of Information

    The installation guide shipped with the melter provides a visual quick‐reference for installing the melter. Online Support Visit http://emanuals.nordson.com/adhesives/software/ to download melter firmware updates and software utilities. Online Documentation Visit www.emanuals.nordson.com/adhesives to download product manuals and instruction sheets. E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 29: Limitations Of Use

    The adhesive melter may be used only to melt and convey suitable materials (e.g., thermoplastic hot melt adhesives). Any other use is considered to be unintended. Nordson will not be liable for personal injury or property damage resulting from unintended use.

  • Page 30: Residual Risks

    Risk of damage to cables/lines belonging to the customer if they were installed such that they come into contact with hot or rotating parts Risk of safety valve malfunction due to hardened or charred material E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 31: Melter Identification

    The model and part number are indicated on the equipment identification plate that is located on the top of the melter. Figure 2-3 Equipment identification plate Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 32: Key Components

    11. Hydraulics cover 3. Transfer hose solenoid harness 8. Hydraulics cover release 12. Controls cover connection 9. Hydraulic assembly (includes 4. Pump air pressure adjustment screw pump, hopper, grid, and reservoir) 5. Pump air pressure gauge E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 33 4. Strain relief for input/output wiring 7. Strain relief for applicator input wiring 2. Main power switch 5. Cable clamp for AC power cord 8. Hose hydraulic ports 3. Controls cover release 6. Hose electrical connections Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 34 11. Transfer hose pump 8. Sequencer (required only for 4. Transfer pump inlet systems that include multiple 5. Transfer pump air input melters and one or more multi‐feed adhesive storage bins) E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 35: Modes Of Operation

    If the fill system is inactive for a user‐specified amount of time, the Smart Melt capability reduces the grid temperature to the user‐specified temperature setpoint. Fault The melter alerts the operator when an abnormal event occurs. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 36: Optional Equipment

    Quick‐disconnect harness kit that allows the quick disconnect of transfer hose solenoid harnesses at the adhesive storage bin Refer to Section 9, Parts, for a complete list of optional equipment. E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 37: Installation

    The instructions provided in this section are intended to be used by personnel who have experience in the following subjects: Hot melt application processes Industrial power and control wiring Industrial mechanical installation practices Basic process control and instrumentation Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 38: Melter Installation

    Does not cause the operator to be under the melter during normal operation Is away from areas with strong drafts or where sudden temperature changes occur Does not expose the melter to excessive vibration E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 39 Installation 254 mm (10 in.) Figure 3‐1 Hose and cable routing clearance requirement Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 40: Verify The Contents Of The Ship-With Kit

    7‐position, 1-7 3. Jumper, 3/N/PE, AC 400-230 V 7. Fuse, time-lag, 2 A 11. Terminal block connector, 4. Jumper, 200-240 V, 1‐phase 8. Fuse, 5.00, very-fast-acting, 250 V 7‐position, 8-14 12. Male pneumatic adaptor E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 41 3‐position, 5.08 mm, female 15. Terminal block connector, 12‐position, 20. Suppressor, ferrite,18 mm diameter no key in position 3 23. Tag sheet, CE translations 16. Bottom support knob, M5 24. Nut, hex, flange, M6 Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 42: Mount The Melter

    1. Remove the corrugated cover from the shipping pallet. 2. See Figure 3‐4. Remove the M5 screw, washer, and nut that secure the melter's bottom mounting bracket to the shipping bracket. Figure 3‐4 Location of the M5 screw, washer, and nut E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 43 Location of the main mounting bracket 4. Continue to the correct procedure for your installation: Mounting the Melter on a Vertical Surface Mounting the Melter on the Floor Stand Mounting the Melter on the Bench Stand Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 44: Mounting The Melter On A Vertical Surface

    Installation Mounting the Melter on a Vertical Surface CAUTION! Risk of equipment damage. A Freedom hot melt system with four hoses weighs approximately 68 kg (150 lb). Nordson Corporation recommends selecting a mounting location that will support a system weight of at least 113 kg (250 lb).
  • Page 45 5. Lift the melter vertically off the shipping pallet and position it on the mounting bracket. 6. Using the M5 bottom support knob from the ship‐with kit, fasten the melter bottom bracket to the mounting surface. Figure 3-7 Installing the melter on the mounting bracket Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 46: Mounting The Melter On The Floor Stand

    BE INSTALLED ON THIS SURFACE Figure 3‐8 Melter floor stand mounting hole pattern in [mm] in. Note: In the next step, the melter mounting bracket is installed at the location shown in Figure 3‐8. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 47 2. See Figure 3‐9. Use the M6 screws, lock washers, and hex nuts from the ship‐with kit to install the mounting bracket on the floor stand. Figure 3‐9 Installing the mounting bracket on the floor stand (shown with optional casters) Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 48 3. See Figure 3‐10. With one person on each side of the melter, make sure each person grasps each handle with one hand. 4. Lift the melter vertically and position it on the mounting bracket. Figure 3-10 Installing the melter on the floor stand E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 49 Lock the casters after moving is complete. 6. Make sure the floor stand is on a level surface and that the casters are locked. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 50: Mounting The Melter On The Bench Stand

    NOTE: The bench stand is ordered separately. Refer to Optional Accessories in Section 9, Parts, for the part number. CAUTION! Risk of equipment damage. A Freedom hot melt system with four hoses weighs approximately 68 kg (150 lb). Nordson Corporation recommends a selecting a mounting location that will support a system weight of at least 113 kg (250 lb).
  • Page 51 4. Use the customer‐supplied bolts and associated hardware to bolt the stand to the mounting surface. Figure 3‐13 Installing the mounting bracket on the bench stand and bolting the bench stand to the mounting surface (typical installation shown) Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 52 5. See Figure 3‐14. With one person on each side of the melter, make sure each person grasps each handle with one hand. 6. Lift the melter vertically and position it on the mounting bracket. Figure 3-14 Installing the melter on the bench stand E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 53 Installation 7. See Figure 3‐15. Using the M5 bottom support knob from the ship‐with kit, fasten the melter bottom bracket to the stand. Figure 3‐15 Securing the melter bottom bracket on the bench stand Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 54 3-18 Installation This page intentionally left blank. E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 55: Configure The Electrical Service

    200-240, 1‐phase or 3 phase 4 hoses/applicators: 27-29 2 hoses/applicators: 20 400/230, 1‐phase or 3‐phase 4 hoses/applicators: 29 2. Remove the controls cover. Refer to Removing or Installing Covers in Section 6, Maintenance, as needed. Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 56 3. Strip approximately 15 cm (6 in.) of jacketing from the power cord and route it through the cable clamp (3). NOTE: If maximum protection from splashed liquids is required, Nordson Corporation recommends the following: Use liquid‐tight conduit and fittings, or If a jacketed, multi‐cable conductor is used, replace the supplied...
  • Page 57 3-21 Installation PE/G Figure 3-16 Connecting the power cord and ground wire 1. Expansion board 3. Cable clamp for power cord 4. Ground connection 2. Terminal block XT1 Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 58 Typical voltage plugs (plugs with and without the neutral If the electrical service was configured correctly, the melter touchscreen lead shown) indicates “System Status: Off” when power is supplied to the melter. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 59 3-23 Installation P/N 232617 P/N 227567 P/N 227569 P/N 227568 Figure 3-17 Connecting a voltage plug Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 60: Connect The Driver, Pattern Controller, Or Timer Wiring

    NOTE: Nordson Corporation recommends the EPC-15 or EPC-30 pattern controllers, or any Nordson pattern controller designed to send a 24 VDC, non-spiking output. 1. Make sure the driver/pattern controller/timer meets the specifications shown in Table 3‐3.
  • Page 61 Chassis Figure 3‐18 Connecting the driver, pattern controller, or timer wiring to terminal block X4 on the hose interface board 1. Terminal block X4 2. Strain relief for input/output wiring 3. Hose interface board Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 62: Connect Applicator Signal Wiring

    If an applicator has more than one independently fired solenoid valve, continue to the next step to connect the additional solenoid valve signals to the hose interface board inside the melter. See Figures 3‐19 to 3‐22 for diagrams of typical applicator signal connection setups. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 63 Hose 1 Sol. Applicator 1 Hose 2 Sol. Applicator 2 Sol. Hose 3 Applicator 3 Sol. Hose 4 Applicator 4 Figure 3‐19 Typical applicator signal wiring connection: one solenoid valve per applicator Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 64 Sol. Sol. Applicator 1 Hose 2 Sol. Applicator 2 Sol. Hose 3 Applicator 3 Sol. Hose 4 Applicator 4 Figure 3‐20 Typical applicator signal wiring connection: multiple solenoid valves on an applicator, common actuation E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 65 Figure 3‐21 Typical applicator signal wiring connection: two solenoid valves on an applicator, independent actuation Melter Hose interface board Driver, pattern controller, or timer Hose 1 Sol. Sol. Sol. Sol. Applicator 1 Figure 3‐22 Typical applicator signal wiring connection: four solenoid valves on an applicator, independent actuation Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 66 SL‐16 strain relief (2) on the bottom of the melter. NOTE: To achieve the best electrical noise immunity in an industrial environment, Nordson Corporation recommends shielded, twisted wire. NOTE: A solenoid valve‐to‐hose interface board cable is available. Refer to Optional Accessories in Section 9, Parts.
  • Page 67 Hose/applicator 4 - out Chassis Figure 3‐23 Connecting the applicator signal wiring to terminal block X1 on the hose interface board 1. Terminal block X1 2. Strain relief for applicator signal 3. Hose interface board wiring Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 68: Connect Inputs/Outputs (Optional)

    P/N 277908 and to terminal 14 on connector P/N 277909. NOTE: Connector P/N 277909 (terminals 8-14) is physically keyed to prevent it from being used in place of connector P/N 277908 (terminals 1-7). E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 69 2. Terminal block XT7 3. Strain relief for input/output wiring Note: If input 4 is used, wiring must be connected to terminal 7 on connector P/N 277908 and to terminal 14 on connector P/N 277909. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 70: Connect A Fill System Status Output (Optional)

    NO contact for the 24 VDC signal. 3. Plug the connector into terminal TB1 (2) on the fill board (3). 4. Reinstall the controls cover. Refer to Removing or Installing Covers in Section 6, Maintenance, as needed. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 71 Installation COM (common) NO (normally open) NC (normally closed) Figure 3‐25 Connecting a fill system status output 1. Connector P/N 266903 3. Fill board 4. Strain relief for input/output wiring 2. Terminal block TB1 Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 72: Connect An Air Supply To The Melter

    G¼ fitting in the air filter inlet. NPT pipe thread Remove the existing 8‐mm ( ‐in.) fitting and install the ¼ NPT‐to‐G¼ BSPP male adapter fitting (P/N 1034145) from the ship‐with kit in the air filter inlet. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 73 3-37 Installation NOTE: Nordson Corporation recommends installing an isolation valve in the plant air supply line just before the melter. 4. Open the plant air supply to the melter. 5. Turn the pump air pressure adjustment screw clockwise to set the melter's operating air pressure (the pressure supplied to the pump) to 1.4 bar (20 psi).
  • Page 74 3-38 Installation This page intentionally left blank. E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 75: Connect Hoses And Applicators

    3-39 Installation Connect Hoses and Applicators The Freedom melter supports the connection of up to four Freedom hose/applicator pairs. Each hose/applicator receptacle supports the connection of one hose/applicator pair. WARNING! Risk of fire or equipment damage. Before connecting hoses and...
  • Page 76 See Figure 3‐28. Make sure the hose solenoid valve cable is properly connected to the applicator solenoid valve. Refer to the user's guide provided with each Nordson hose. The guide contains important information about routing and installing the hose. Save all of the plugs that were removed from the hose ports. A plug will need to be reinstalled into a hose port if a hose is later removed.
  • Page 77 Manifold guard installed Manifold guard removed Figure 3‐27 Location of hose connections (bottom view of melter) 1. Manifold guards 3. Hose 1 ports 5. Engraved hose port number 2. Manifold (guards removed) 4. Hose Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 78 To connect applicators Observe the following guidelines: Refer to Appendix A, Calculating Melter Power Requirements, for information about how to calculate the power required by Nordson applicators. See Figure 3‐28. Make sure the applicator cordset is properly connected to the hose cordset.

  • Page 79: Remove The Shipping Bolt

    The bolt was required for shipping purposes only. NOTE: Do not reinstall the hydraulics cover. It needs to stay removed for the fill system installation procedures. Figure 3‐29 Removing the shipping bolt Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 80: Fill System Installation

    NOTE: To disconnect the hose, turn the retaining ring counterclockwise. 3. Reinstall the hydraulics cover. Connecting the adhesive transfer hose to the cyclone Figure 3‐30 1. Cyclone upper body 3. Adhesive transfer hose retaining ring 2. Adhesive transfer hose cuff E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 81 Quick‐disconnect transfer hose solenoid harness 3. Connect the transfer hose to the venturi pump (8) and then place the pump in the adhesive inlet on the bin. 4. Secure the hose inside the U‐shaped bracket (11). Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 82 2. Use customer‐supplied 12 mm OD air tubing to connect an air supply to the ¼ NPT air input fitting (10) on the storage bin. NOTE: The air supply must be capable of supplying 25 scfm and a minimum of 4.5 bar (65 psi). E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 83 3. Standard transfer hose solenoid 7. Venturi pump air input bracket harness 8. Venturi pump installed in adhesive 4. Transfer hose solenoid harness inlet on the bin connection on melter 9. Pneumatic control kit Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 84 3-48 Installation This page intentionally left blank. E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 85: Connect To A Multi-Feed Adhesive Storage Bin

    L1, L2/N, and PE/G terminals (3). d.. Reinstall the sequencer touch guard and cover. Figure 3‐32 Connecting a power supply to the sequencer 1. Cover 4. Power supply cable strain relief 2. Touch guard 3. Power supply terminals Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 86 4. See Figure 3‐35. Connect the transfer hose solenoid harness (1) to the transfer hose solenoid harness connection on the melter (4). Adjust or Melter Sequencer remove cables ties as needed. Standard transfer hose solenoid harness E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 87 NOTE: If you want to convert from standard sequencer solenoid harnesses to quick‐disconnect sequencer solenoid harnesses, refer Applying a numbered label to a standard sequencer solenoid to Section 9, Parts, to order a quick‐disconnect sequencer. harness Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 88 2. Use customer‐supplied 12 mm OD air tubing to connect an air supply to the ¼ NPT air input fitting (6) on the bin. NOTE: The air supply must be capable of supplying 25 scfm and a minimum of 4.5 bar (65 psi). E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 89 8. Ground screw on pump box 3. Adhesive transfer hose 9. Quick‐disconnect adapter harness 4. Transfer hose solenoid harness 10. Venturi pump installed in adhesive connection on melter inlet on the bin 5. Sequencer solenoid harness Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 90: Control System Setup And Initial System Startup

    Perform the initial (first-time) system startup procedure In particular, make sure you have entered the correct temperature setpoints for the heated zones before you perform the initial system startup procedure, which includes the initial calibration of the level sensor. E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 91: Setup

    NOTE: Changed settings are permanently stored approximately every two minutes. If the system is switched off within two minutes after a setting is changed, the change may not be saved. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 92: About Heated Components

    Default Name Applicator 1 Zone 1B Applicator 2 Zone 2B Applicator 3 Zone 3B Applicator 4 Zone 4B Hose 1 Zone 1A Hose 2 Zone 2A Hose 3 Zone 3A Hose 4 Zone 4A E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 93: About The Control System

    All control system screens are accessed through the following primary screens: Home screen Master Controls screen Settings screen System screen Refer to Menu Structure for a diagram of the control system screen hierarchy. Melter touchscreen Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 94: Home Screen

    Heaters: On Ready/OK Nothing Loaded Password: Disabled Pump, heaters, System System Status System Data Recipe button and password Inventory indication button and status status indications button indication Figure 4-1 Home screen buttons and indications E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 95: Master Controls Screen

    Scheduler 175_C 175_C Standby: Off Scheduler: Off Pump: On System Status: Recipes: System Status: Recipes: Refill Heaters: On Ready/OK Nothing Loaded Ready/OK Password: Disabled Nothing Loaded Enabled Settings System Figure 4-2 Master Controls screen Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 96: Settings Screen

    Zone 4A 175_C Standby 175_C Scheduler 175_C Standby: Off Scheduler: Off System Status: Recipes: Refill Ready/OK Nothing Loaded Enabled Settings System Settings Done Temperature Ready Delay Home Fill Standby Input Output Figure 4‐3 Settings screen E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 97: System Screen

    175_C 175_C Standby: Off Scheduler: Off System Status: Recipes: Refill Ready/OK Nothing Loaded Enabled Settings System System Done Formats/Units Password Home Date/Time Display 12/03/2013 04:440 Service Interval Administration Scheduler Language Figure 4‐4 System screen Part 1123087_02 E 3/2014 Nordson Corporation...
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  • Page 99: Menu Structure

    Create/ Brightness/ System Service Recipes Modify Contrast Reset Reminder Custom Lockout Screen Saver Display/Save Service Timeout Communication Delay Diagnostics Alert (on/off) Set Security Calibrate Reset Display System Level Screen Password Data Wipe Engineering Display E 3/2014 Nordson Corporation Part 1123087_02...
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  • Page 101 4-11 Setup This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 102: Control System Setup Procedures

    Recipes: Ready/OK Adjust Setpoint Create/Modify Name Nothing Loaded Pump: On Recipes: System Status: Heaters: On 175_C Ready/OK Nothing Loaded Password: Disabled EcoBead Settings Figure 4‐5 Accessing an external zone screen (Zone 1B screen shown) E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 103 NOTE: The grid setpoint cannot be more than 15 °C (30 °F) lower than the manifold setpoint. NOTE: The manifold setpoint cannot be more than 15 °C (30 °F) higher than the grid setpoint. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 104: Modifying Applicator Or Hose Zone Names

    Applicator 2: Zone 2B visible characters zone Applicator 3: Zone 3B Applicator 4: Zone 4B Hose 1: Zone 1A Hose 2: Zone 2A Hose 3: Zone 3A Hose 4: Zone 4A E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 105 4-15 Setup This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 106: Setting Up The Ecobead Capability

    NOTE: Selecting Follow Mode (the default) disables the EcoBead capability. EcoBead Settings 30% | Pattern 8 EcoBead Settings Done Zone 1B Cancel Basic Settings Adhesive Savings: Help Beads per Pattern: Bead Pattern: Follow Mode Figure 4‐7 EcoBead Settings screen E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 107 Patterns for other adhesive savings selections will appear slightly different. Follow Mode Example of current bead pattern based on Adhesive Savings and Bead Pattern selections Figure 4‐8 EcoBead Settings screen and EcoBead help screen Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 108 (100%-20%-20%=60%). Follow Mode Disables the EcoBead capability. Enabled — When Follow Mode is enabled, no EcoBead settings are used; instead, the adhesive pattern is controlled by the driver, pattern controller, or timer input signal. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 109 30% Adhesive Savings, Bead Pattern 8 30% Adhesive Savings, Bead Pattern 9 Figure 4‐9 Bead patterns used to achieve 30% adhesive savings Note: The bead patterns for 40%, 50%, and 60% adhesive savings are similar to these patterns. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 110: Selecting The Auto Pump Setting

    Table 4‐5 Auto Pump Default Setting Button Description Default Setting Optional Setting Auto Pump Switches On or Off the automatic pump startup function. If Auto Pump is On, the pump automatically starts when all zones reach their setpoint temperatures. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 111 4-21 Setup This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 112: Entering Or Modifying A Global Temperature Setpoint

    To enter a specific temperature setpoint for an individual zone, refer to Modifying Temperature Setpoints for Individual Zones. NOTE: Nordson Corporation recommends calibrating the level sensor whenever the grid (or global) temperature setpoint is changed by more than 25 °C (50 °F). Refer to Calibrating the Level Sensor in Section 7, Troubleshooting.
  • Page 113 Global Temperature Reduces or increases the +/-1 °C (+/-1 °F) — Change temperature setpoint of all enabled and heated zones by increments of +/- 1 degree NOTE: Global Temperature Change does not affect disabled zones. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 114: Setting Up The Smart Melt Capability

    6.. Touch Smart Melt to enable the Smart Melt capability. 7.. Touch Done. Temperature Done Smart Melt Home Enabled Global Setpoint Global Temperature Change 175_C Smart Melt Setpoint Smart Melt Time 175_C 175_C Temperature Limits 175_C Figure 4‐12 Temperature screen E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 115 Smart Melt Time Specifies how long the fill 10 (minutes) 5-60 (minutes) system can remain inactive before the control system reduces the grid temperature by the number of degrees entered for Smart Melt Temperature Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 116: Modifying Temperature Limits

    Specifies the number of Overtemperature: 50-60 °C degrees a heated zone can 15 °C (25 °F) (10-110 °F) increase or decrease from its Undertemperature: setpoint temperature before a 25 °C (50 °F) temperature alert occurs E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 117 4-27 Setup This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 118: Entering Fill Settings

    Fill Flutter Delay Alert to Fault Delay Time Home 5 sec. 4 min. Overfill Delay Fill Level Graph 60 sec. Fill Calibration Manual Call for fill Audible Fill Alarm Enabled Figure 4‐14 Fill Settings screen E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 119 Alert to Fault Delay Specifies the amount of time that 4 (minutes) 1-20 (minutes) Time can elapse after an alert is generated (due to the Overfill Delay time being exceeded) before a fault is generated Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 120: Entering A Ready Delay

    2.. Touch Ready Delay and use the keypad to enter the desired value. Refer to Table 4‐10 for default and optional settings. Master Controls 3.. Touch Done. Settings Ready Delay Ready Delay Done Cancel Min. Home Figure 4‐15 Ready Delay screen E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 121 NOTE: The melter can perform a warm start if it is switched on when the zone temperatures are within 27 °C (50 °F) of their setpoint temperatures. In this case, the Ready Delay is bypassed. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 122: Entering Standby Settings

    Auto Exit Standby enter an Auto Exit Time elapses. Standby Time setting and enable Auto Exit Standby Time. Refer to Manual Standby/Auto Exit Standby Time Setup in this section. Continued... E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 123 When a Standby Event is Refer to Setting Up the entered using the Scheduler in this section. Scheduler, the system enters standby at the Enter Standby time. The system automatically exits standby at the Exit Standby Time. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 124: Standby Temp Delta Setup

    50 _C (100 _F) 5-190 _C Standby Temp Delta Specifies the number of degrees (10-350 _F) from the setpoint temperature by which the system reduces heated zones when the system enters the standby mode E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 125 4-35 Setup This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 126: Zone Standby Setup

    5.. Touch Done. Zone Standby Zone Standby Done Zone Standby Home Zone Standby Time 60 min. Individual zone standby is activated by monitoring applicator‐specific signals on the EcoBead board. Figure 4‐17 Zone Standby screen E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 127 Zone Standby Time, the hose/applicator pair enters zone standby. NOTE: When all hose/applicator zones enter zone standby, the system switches to automatic standby. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 128: Manual Standby/Auto Exit Standby Time Setup

    Specifies the amount of time to 0 (minutes) 0-180 (minutes) elapse after the system enters manual standby before the system automatically exits manual standby. To enable this function, change Auto Exit Standby Time to Enabled. E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 129: Automatic Standby/Auto Heaters Off Time Setup

    5.. Touch Automatic Standby to enable Automatic Standby. Settings 6.. Touch Done. Standby Automatic Standby Automatic Standby Done Automatic Standby Home Enabled Auto Standby Start Time 60 min. Auto Heaters Off Time 60 min. Figure 4‐19 Automatic Standby screen Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 130 Automatic Standby to enabled. Auto Heaters Off Time Specifies the amount of time that 60 (minutes) 0-1440 (minutes) must elapse after the system enters automatic standby before the heaters automatically shut off E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 131 4-41 Setup This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 132: Setting Up Inputs/Outputs

    System Ready System Ready Home Home Input 4 Pump Control Output 2 Output 2 Fault Fault Output 3 Output 3 Ready - Pump On Ready - Pump On Figure 4‐20 Input and Output screens E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 133 Alert provides an output signal when a potential fault is detected. If both Fault and Alert are used, then both a fault output and an alert output signal will be present when a fault is generated. When this control option condition occurs, contacts open. Contacts are normally open when power is off. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 134: Selecting The Date, Time, And Temperature Unit Formats

    Time: Temperature Figure 4‐21 Formats/Units screen Table 4‐18 Formats/Units Default and Optional Settings Item Default Setting Optional Settings Date format mm/dd/yy yy/mm/dd, dd/mm/yy Time format Temperature format C (degrees) F (degrees) E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 135: Setting The Date/Time/Day Of Week

    NOTE: The system does not automatically adjust for seasonal time changes or leap years. 3.. Touch Done. Date/Time Date/Time Settings Done Cancel Date: 12/03/13 Home Time: 14:40 Day of Week: Tuesday Figure 4‐22 Date/Time Settings screen Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 136: Entering A Service Reminder

    Service interval refers to the number of hours the heaters have been on. To customize the text that appears on the service reminder pop‐up, refer to the next procedure, Entering a Custom Service Alert. E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 137: Entering A Custom Service Alert

    Controls displayed when the value entered for Service Reminder is reached. 3.. Touch Done. System Service Interval Custom Service Alert Custom Service Alert Done Cancel Home 123 … Figure 4‐24 Custom Service Alert screen Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 138: Entering The Touchscreen Screen Saver Delay

    Table 4‐20 Screen Saver Delay Default and Optional Settings Button Description Default Setting Optional Settings Screen Saver Delay Specifies the amount of time of no 5 (minutes) 1-120 (minutes) user interaction with the touchscreen before the screen saver appears E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 139 4-49 Setup This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 140: Setting Up Password Protection

    When password protection is enabled, the Home screen indicates Password: Enabled and the Enter Password—Level [#] pop-up screen appears for password‐protected tasks. Password Done Create / Modify Home Help Timeout 5 min. Set Security Level Figure 4‐26 Password screen E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 141 Set Security Level Enables password protection No Password Protection Level 1 (high) when a security level is Level 2 (medium) selected. Refer to Table 4‐22 for an Level 3 (low) explanation of the security levels. Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 142 Enter a Service Reminder interval or clear a Custom Service Alert message Create Custom Service Alert message NOTE A: Level 1 (high) security includes Level 2 (medium) and Level 3 (low) functions; Level 2 (medium) security includes Level 3 (low) functions. Continued... E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 143 Scheduler On/Off Refill On/Off Auto Pump On/Off Bypass Ready Delay Change Language Change Date/Time/Day-of-week values Display (Brightness/Contrast, Screen Saver Delay, Calibrate Screen, Wipe Display) Display/Save Diagnostics/diagnostic file write to SD card View System Inventory/component details Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 144: Setting Up The Scheduler

    Date/Time and enter the correct value(s). System NOTE: The system does not automatically adjust for seasonal time changes or leap years. Scheduler Scheduler Cancel Current System Settings: Tuesday 12/03/13 14:40 Home Change Date/Time Done Figure 4-27 Scheduler screen E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 145 13:00 Done Cancel Turn Heaters On: Cancel Heat Enter Standby: 13:01 18:30 06:00 Home 0:30 Home Turn Heaters Off: Exit Standby: 18:00 13:30 Figure 4-28 Using the Scheduler to add heat and/or standby events Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 146 4-56 Setup To switch On the Scheduler To switch On the Scheduler, touch Home > Master Controls > Scheduler. Home Master Controls Scheduler Scheduler On E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 147 4-57 Setup This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 148: Using Recipes

    NOTE: You can also touch Recipes on the Home screen. Master Controls 2.. Refer to Table 4‐23 to manage recipes. System Administration Recipes Recipes Next Load or Delete a Recipe Back Home Do not use a Recipe Save Recipe Figure 4‐29 Recipes screen E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 149 1. Enter the correct melter settings for the recipe you want recipe to modify. 2. Touch Save Recipe and enter the exact same recipe name. The system unloads the currently loaded recipe, saves the new settings, and automatically loads the modified recipe. Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 150 Zone Standby Time value Auto Exit Standby Time (enabled or disabled) Auto Exit Standby Time value Standby Temp Delta Zone Standby (On or Off) Pump Information Pump (On or Off) Auto Pump (On or Off) E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 151: Selecting The Language Setting

    System Language Language Done Home Figure 4‐30 Language screen Table 4‐25 Language Default and Optional Settings Button Description Default Setting Optional Settings Language Specifies the control English CE languages (with system language software upgrade) Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 152: Initial System Startup

    Zone 4B Zone 2A Zone 4A Pump Control Purge 175_C 175_C 175_C 175_C Pump: Off Pump: On System Status: Recipes: Heaters: On Ready/OK Auto Pump Nothing Loaded Password: Disabled Figure 4‐31 Accessing the Pump screen E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 153 5.. Wait until the System Status indication shows Ready/OK. Pump: Off System Status: Recipes: Heaters: On Ready/OK Nothing Loaded Password: Disabled System Status indication Figure 4‐33 Location of the System Status indication on the Home screen Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 154 Refer to the manual for a detailed fill calibration procedure. Press the Empty Calibrate button below to set the empty level of the unit. Calibrate Level Sensor Empty Figure 4‐34 Fill Calibration screen E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 155 It can take several fill cycles to satisfy the level sensor. After the melter is properly filled, the system will work normally to maintain the proper adhesive level. Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 156 Disconnect and lock out power to the system before performing any activity under the melter when it is operating. 6.. Start the production line and test the system. When the system is running properly, refer to Section 5, Operation, for daily operating procedures. E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 157: Operation

    The hot melt system includes two groups of heated components that are referred to as internal and external heated zones. The internal heated zones are the Grid Manifold The external heated zones are the Hoses Applicators Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 158 Default Name Applicator 1 Zone 1B Applicator 2 Zone 2B Applicator 3 Zone 3B Applicator 4 Zone 4B Hose 1 Zone 1A Hose 2 Zone 2A Hose 3 Zone 3A Hose 4 Zone 4A E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 159: Filling The Adhesive Storage Bin

    Refer to Limitations of Use in Section 2, Description, for information about hot melt materials that should not be used in Freedom melters. The melter is equipped with a level sensor. When the level sensor detects a low level of adhesive in the grid, it calls for adhesive to activate the fill system.

  • Page 160: Starting The System

    System Status indication shows Ready/OK. Pump: Off System Status: Recipes: Heaters: On Ready/OK Nothing Loaded Password: Disabled System Status indication Figure 5‐1 Location of the System Status indication on the Home screen E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 161 NOTES: When the pump is On, it attempts to pump even if the system status is not Ready/OK. Nordson Corporation recommends not starting the pump until the system status is Ready/OK. By default, the fill system and Smart Melt capability are automatically enabled.

  • Page 162: Monitoring The System

    Figure 5‐3 Home screen buttons and indications On/Off Button Colors Table 5‐2 shows the meaning of the on/off button color indications. Table 5‐2 What the Button Colors Indicate Button Color Description Green White E 3/2014 Nordson Corporation Part 1123087_02...
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  • Page 164: General System Status

    Zone 4B Zone 4A 175_C 175_C 175_C 175_C Pump: On System Status: Recipes: Heaters: On Ready/OK Nothing Loaded Password: Disabled System Status : Ready / OK Figure 5‐4 System status button as a screen saver E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 165 The melter continues to operate normally, but some functions may not System Status Alert be available. The system requires service. A system fault condition has been System Status detected. Pump Control and Heater Fault Control are switched Off. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 166: Fill System Status

    Waiting for The fill system is enabled but the system has not reached Fill Status Ready Ready/OK status. Waiting for heat Light green Waiting for The fill system is transferring adhesive. Fill Status Ready Filling E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 167 5-11 Operation This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 168: Heated Zone Status

    (refer to Connect indicates that EcoBead Inputs/Outputs (Optional) in is not enabled Section 3, Installation, and to Setting Up Inputs/Outputs in Section 4, Setup) Figure 5‐6 Heated zone button indications E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 169 Fault The zone is enabled, but the system has detected a fault Zone 1A condition. Fault NOTE: When a fault occurs, Heater Control and Pump Control are switched Off. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 170: Pump Status

    The system status is Ready/OK and the pump is On. Pump NOTE: When the pump is On, it attempts to pump even if the system status is not Ready/OK. Nordson Corporation recommends not starting the pump until the system status is Ready/OK.
  • Page 171 Light green Auto Pump is On and is waiting for the system to reach Auto Pump Ready/OK status, but the Pump Control button was toggled to On, so the pump is pumping. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 172: Starting/Stopping The Pump

    NOTE: When the pump is On, it attempts to pump even if the system status is not Ready/OK. Nordson Corporation recommends not starting the pump until the system status is Ready/OK.

  • Page 173: Monitoring And Adjusting The Pump Air Pressure

    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. Air pressure adjustment screw (requires a 5‐mm hex key) Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 174: Enabling/Disabling Zones Or Changing Temperature Setpoints

    System Status: Recipes: Ready/OK Adjust Setpoint Create/Modify Name Nothing Loaded Pump: On Recipes: System Status: Heaters: On 175_C Ready/OK Nothing Loaded Password: Disabled EcoBead Settings Figure 5-9 Enabling/disabling a zone or changing a temperature setpoint E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 175 5-19 Operation This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 176: Switching On/Off Standby

    Heater Control to toggle Heater Control Off and back On. This re‐enables all applicator or hose zones that entered zone standby. Refer to Table 5‐2 for the meaning of the button colors. 2. Touch Done. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 177 175_C Standby: Off Scheduler: Off Pump: On System Status: Recipes: Recipes: System Status: Refill Heaters: On Ready/OK Ready/OK Nothing Loaded Password: Disabled Nothing Loaded Enabled Settings System Figure 5‐10 Accessing the Master Controls screen Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 178: Switching On/Off Heaters, Scheduler, Or Refill

    175_C Standby: Off Scheduler: Off Pump: On System Status: Recipes: System Status: Recipes: Refill Heaters: On Ready/OK Nothing Loaded Ready/OK Password: Disabled Nothing Loaded Disabled Settings System Figure 5‐11 Accessing the Master Controls screen E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 179: Enabling/Disabling The Ecobead Capability

    Freedom systems using the EcoBead capability can provide adhesive savings of up to 60% while still maintaining full adhesive bond integrity. As the Freedom system operates, the control system learns the adhesive application pattern. When enabled, the EcoBead capability switches the signal to the applicator to produce a stitched adhesive pattern, resulting in the user‐specified amount of adhesive savings.

  • Page 180: Clearing Or Resetting Alerts/Faults

    Zone 4B Zone 2A Zone 4A ues to work, but maintenance may be required. 175_C 175_C 175_C 175_C Pump: On System Status: Recipes: Heaters: On Ready/OK Nothing Loaded Password: Disabled Figure 5‐13 Typical Fault message E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 181 5-25 Operation This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 182: Resetting The Service Interval

    The System Status button continues to indicate Ready/Service. Clear Closes the pop-up message and resets the service reminder counter back to 0 (zero) hours. Nordson Corporation recommends choosing this selection after the required service has been performed. Master Controls Fill Status...
  • Page 183 Master Controls the service interval counter back to 0 (zero) hours. 3. Touch Done. System Service Interval Service Reminder Done Cancel hours. Home Clear Service Reminder Custom Service Alert Figure 5‐15 Service Reminder screen Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 184: Shutting Down

    5-28 Operation Shutting Down Switch the melter off. Melter power switch E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 185: Maintenance

    Replacing the Adhesive Filter As needed When changing the type or grade of adhesive Replacing the cyclone exhaust As needed Replacing the Cyclone Exhaust filter Filter Upgrading the firmware As needed Upgrading the Firmware Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 186: Cleaning The Touchscreen

    Wipe Display locks the touchscreen for 30 seconds, allowing you to clear Controls dust from the screen without accidentally changing a setting. System Display Display Done Brightness/Contrast Home Screen Saver Delay Calibrate Screen Wipe Display E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 187: Relieving System Pressure

    Zone 4B Zone 2A Zone 4A 175_C 175_C 175_C 175_C Pump: On Pump: On Recipes: System Status: Auto Pump Heaters: On Ready/OK Nothing Loaded Password: Disabled Figure 6‐1 Location of the Pump Control button Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 188: Removing Or Installing Covers

    Note: The controls cover release is located on the left side of the melter. To install a cover Insert the cover pins into the slots on the top brackets and push the bottom of the cover onto the chassis. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 189 Maintenance This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 190: Replacing The Adhesive Filter

    Master 4. See Figure 6‐3. Use a 13-mm wrench or an adjustable wrench to close Controls the shutoff valve. Refill Disabled Closed Open Figure 6‐3 Location of the shutoff valve E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 191 2. Thread the filter into the manifold and then tighten the filter to 4.5 NSm (40 in.‐lb). 3. Open the shutoff valve. 4. Reinstall the hydraulics cover and restore the system to normal operation. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 192: Replacing The Cyclone Exhaust Filter

    4. Reinstall the filter cover, enable the fill system, and restore the system to normal operation. Figure 6‐5 Replacing the cyclone exhaust filter 1. Cyclone exhaust filter cover 2. Filter E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 193: Upgrading The Firmware

    Maintenance Upgrading the Firmware There are two methods for upgrading the firmware. Nordson Corporation Contents of the firmware upgrade may provide the new firmware preinstalled on a new customer SD card or as service kit: an electronic file only. You will need the following items: SD card service kit 3‐mm hex key...
  • Page 194 SD card. A pop‐up shows the file transfer progress. Automatically reboots the melter when the upgrade is complete (usually in about 10 minutes) NOTE: Nordson Corporation recommends copying the *.dat files to another backup storage media in case an SD card is damaged. E 3/2014 Nordson Corporation...

  • Page 195: Upgrading The Firmware Electronically (File Only)

    SD card. A pop‐up shows the file transfer progress. Automatically reboots the melter when the upgrade is complete (usually in about 10 minutes) NOTE: Nordson Corporation recommends copying the *.dat files to another backup storage media in case an SD card is damaged. Part 1123087_02...

  • Page 196: Reverting Back To A Previous Firmware Version

    The system automatically detects a new *.dat file and does the following: Performs the downgrade Copies the current *.dat file to the \backup directory on the internal SD card Automatically reboots the melter when the upgrade is complete (usually in about 10 minutes) E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 197: Troubleshooting

    This troubleshooting section covers only the most common problems you may encounter. If you cannot solve the problem with the information provided here, contact your Nordson representative. This section is organized as follows: Control System Troubleshooting Aids—includes procedures for using the control system to obtain system diagnostic information and solve common control system issues.

  • Page 198: Control System Troubleshooting Aids

    Time in Standby (hours): 350 Smart Melt Time (hours): 200 Fill Cycle Count: 4455 Time Length of Last Fill (sec): 2 Time Between Last Two Fills (sec): 580 Figure 7‐1 System Data, screen 1 E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 199 Troubleshooting System Data Done Home CPU Board Version: 2.655 Fill Board Software Version: 22 Hose Interface Board Version: 1.27 EcoBead Board Version: 2.3 Figure 7‐2 System Data, screen 2 Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 200: Resetting The System

    Table 7‐1 Levels of System Reset Button Description Parameters only Resets editable parameters such as setpoints, but leaves custom zone names intact Parameters and Resets all editable parameters, including custom names custom zone names E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 201: Displaying Diagnostics (The Event Log)

    Refer to the next procedure, Obtaining Event Log and Diagnostics Files to obtain event log and diagnostic files that you can view on a computer and email to your Nordson Representative. 1. From the Home screen, touch Master Controls > System >...

  • Page 202: Obtaining Event Log And Diagnostic Files

    Obtain a csv version of the event log, allowing you to easily view the file in most any spreadsheet program. Refer to About the EventLog.csv File. Obtain a diagnostic file that you can send to your Nordson service representative to help resolve melter issues. Refer to About the Diagnostic.nor File.
  • Page 203 Loosen, but do not remove, the screws on the underside of the touchscreen assembly. b.. Lift up the entire panel and tilt the top of the panel away from the melter. Figure 7‐6 Location of the touchscreen assembly screws Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 204 Tighten the screws loosened previously. 6. Restore power to the system and switch the melter on. 7. Refer to About the Eventlog.csv File and to About the Diagnostic.nor File for information on how to use these files. E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 205: About The Eventlog.csv File

    The diagnostic.nor file includes event log data and additional embedded melter software and hardware data to help your Nordson Representative resolve melter issues. If you cannot resolve a troubleshooting issue, Nordson Corporation recommends emailing the diagnostic.nor file to your Nordson Representative.

  • Page 206: Resetting The Passwords

    NOTE: You must know the Medium (Level 2) password to perform a password reset. If the neither the default Level 2 password (2000) or the master password (1225) works, contact your Nordson Representative for assistance. 1. From the Home screen, touch Master Controls > System >...

  • Page 207: Adjusting The Touchscreen Brightness/Contrast

    Wipe Display Figure 7‐9 Display screen Table 7‐2 Brightness/Contrast Default and Optional Settings Button Description Default Setting Optional Settings Brightness/Contrast Enhances the visibility and 75/75 (percent) 30, 60, 75, 100 readability of the touchscreen (percent) Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 208: Locking Out Communication

    Use Lockout Communications to prevent unexpected operational changes from any remote source (such as the standard inputs) from being communicated to the melter control system. Nordson Corporation recommends using Lockout Communication when it is necessary to perform service procedures inside the melter that require the power to remain on.

  • Page 209: Calibrating The Touchscreen

    +, allow at least 5 seconds for the software to respond. System NOTE: Use caution when calibrating the touchscreen because the calibration can easily be skewed. Nordson Corporation recommends using a stylus or the eraser end of a pencil when calibrating the touchscreen.

  • Page 210: Melter Troubleshooting

    RTD resistance too high (loose Check the connections. Repair or replace Internal or external open connector, damaged wiring, or failed the damaged wiring or RTD or replace the RTD on [zone name] RTD) device containing the RTD. E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 211: Melter Alerts

    If the fault persists, replace the main board, the ribbon cable, or the touchscreen assembly. Refer to Replacing a Circuit Board or Replacing the Touchscreen Assembly in Section 8, Repair. Continued... Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 212 Check the cable connections. If the disconnected interface board disconnected cables appear correct, try cycling the power. If the fault persists, replace the boards. Refer to Replacing a Circuit Board in Section 8, Repair. Continued... E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 213 SD card. Refer to Replacing the Internal SD Card in Section 8, Repair. If the fault still persists, replace the CPU/LCD board by replacing the touchscreen assembly. Refer to Replacing the Touchscreen Assembly in Section 8, Repair. Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 214 7-18 Troubleshooting Melter Faults (contd) 1 (internal SD card 2 (customer SD card) Figure 7‐12 Location of the internal and customer SD cards 1. Internal SD card 2. Customer SD card 3. Touchscreen assembly E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 215: Touchscreen Troubleshooting Table

    Refer to Replacing a Circuit Board in Section 8, Repair. Loose or disconnected harness Check all harness connections. Incorrect voltage plug installed Check the electrical installation. Refer to Configure the Electrical Service in Section 3, Installation. Continued... Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 216 NOTE A: The pump should make two regularly spaced exhaust sounds. If you hear two exhaust sounds followed by a pause, the pump is stroking erratically (the hydraulic shaft is moving faster in one direction than the other). Continued... E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 217 Replace the fork. Shifter fork bent or damaged Clean or replace the magnet Magnet assembly dirty or assembly. damaged Replace the bumper assembly. Bumper assembly dirty or damaged Replace the fork. Shifter fork magnet loose Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 218: Ecobead Capability Troubleshooting Table

    (variation in timing). To maintain a stitched output, signal jitter must not exceed 10 percent. Noise interfering with signal Check cables and connections for electrical noise that may be interfering with the signal. Route cables away from noise sources. E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 219: Fill System Troubleshooting

    Alert to Fault Delay Time, the control system generates a fault. When a fill fault occurs, Pump Control is switched Off, but Heater Control remains On. Refer to Fill System Troubleshooting Table to troubleshoot fill system problems. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 220: Fill System Alerts

    Return the hydraulic section to the upright and locked position. Fill alert Duration of a fill exceeded amount of time Refer to Fill System Troubleshooting entered for Overfill Delay Table in this section. E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 221: Fill System Faults

    Replace the level sensor cable. Refer to Replacing the Level Sensor Cable in Section 8, Repair. Fill sensor circuit Fill board failed Replace the fill board. Refer to Replacing a Circuit Board in Section 8, Repair. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 222: Fill System Troubleshooting Table

    When air is not flowing (static) to the pump and vibrator When air is flowing (dynamic) to the pump and vibrator Make sure the difference between the two readings does not exceed 0.7 bar (10 psi). Continued... E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 223 Cleaning the Cyclone Exhaust Tube later in this section. Air pressure too high Reduce the air pressure to the adhesive bin such that it is just high enough for reliable operation. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 224: Fill System Troubleshooting Procedures

    Alert to Fault Delay Time Home 4 min. 5 sec. Overfill Delay Fill Level Graph 60 sec. Fill Level Graph Administration Fill Calibration Language Audible Fill Alarm Enabled Done Figure 7‐13 Fill Level Graph screen E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 225: Using Manual Call For Fill

    Warning! Use of the Manual Call to Fill function overrides normal operation and can result in an overfill situation with adhesive entering the exhaust section of the melter. Never operate system with filter or filter cover removed. Activate Cancel Figure 7‐14 Manually activating the fill system Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 226: Calibrating The Level Sensor

    1. Heat the system to operating temperature. The system status must be Ready/OK to calibrate the level sensor. 2. From the Home screen, touch Master Controls > Refill to disable the fill system. Master Controls Refill Disabled E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 227 Zone 2B Zone 4B Zone 2A Zone 4A 175_C 175_C 175_C 175_C Pump: Off Pump: On System Status: Auto Pump Recipes: Heaters: On Ready/OK Nothing Loaded Password: Disabled Figure 7‐15 Accessing the Pump Control button Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 228 Zone 2B Zone 4B Zone 2A Zone 4A 175_C 175_C 175_C 175_C Pump: On Pump: On Recipes: System Status: Auto Pump Heaters: On Ready/OK Nothing Loaded Password: Disabled Figure 7‐16 Accessing the Purge button E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 229 See Figure 7‐17. Pull the spring-loaded pin to release the assembly and carefully tilt it open. Figure 7‐17 Location of the spring‐loaded pin used to tilt open the hydraulics assembly Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 230 2. See Figure 7‐18. Disconnect the adhesive transfer hose from the cyclone upper body by turning the retaining ring counterclockwise and then sliding the hose cuff away from the cyclone upper body. Figure 7‐18 Location of the cyclone upper body E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 231 To close the hydraulics assembly and To calibrate the level sensor. Figure 7‐19 Verifying that the grid fin tips are visible 1. Cyclone base fasteners 2. Grid fin tips Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 232 Refer to the manual for a detailed fill calibration procedure. Press the Empty Calibrate button below to set Fill Calibration the empty level of the unit. Calibrate Level Sensor Empty Figure 7‐20 Fill Calibration screen E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 233: Clearing Adhesive Bin Blockage

    19 mm (¾ in.) to break up the blockage. Controls 4. Reconnect the hose and restore the system to normal operation. Refill Disabled Figure 7‐21 Using a rod to remove adhesive bin blockage Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 234: Cleaning The Cyclone Exhaust Tube

    3. Clear any adhesive from the filter and exhaust tube. Controls 4. Reinstall the filter and cover and restore the system to normal operation. Refill Disabled Figure 7‐22 Cyclone exhaust filter components 1. Cyclone exhaust filter cover 2. Filter E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 235 7-39 Troubleshooting This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 236: Circuit Board Component Tables

    Manifold heater (5 A, 250 V, fast-acting, 5 x 20 mm) F7/F8 — Hose/applicator 1 heaters (6.3 A, 250 V, 5 x 20 mm) F9/F10 — Hose/applicator 2 heaters (6.3 A, 250 V, 5 x 20 mm) F11/F12 — Not used Continued... E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 237 High-voltage and control voltage out to hose/applicator 1 Input/output High-voltage and control voltage out to hose/applicator 2 Input Switch closure from melter control switch Test Points Contact +5 VDC out of low-voltage power supply Contact Circuit common of low-voltage power supply Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 238 7-42 Troubleshooting Main Board (contd) Figure 7‐23 Main board components E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 239: Hose Interface Board

    Verify proper applied Off when no connection applicator signal is Remove/replace hose present interface board If green when applicator signal should not be present, verify proper connection Continued... Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 240 Verify output is not May flash red at shorted applicator Remove/replace hose switch-off interface board If always green: Verify proper connection Remove/replace hose interface board If always red: Verify proper connection Remove/replace hose interface board Continued... E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 241 Verify proper applied Off when no connection applicator signal is Remove/replace hose present interface board If green when applicator signal should not be present, verify proper connection Continued... Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 242 Verify output is not May flash red at shorted applicator Remove/replace hose switch-off interface board If always green: Verify proper connection Remove/replace hose interface board If always red: Verify proper connection Remove/replace hose interface board Continued... E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 243 (should be green Remove/replace hose most of the time) interface board Red when all applicator outputs are forced off, when melter is not ready, and during software upgrades Continued... Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 244 Refer to Table 7‐5 to identify the communications packet sequences. DS17 Component ID power— Green Verify hose interface indicates that power is on board power LED is green Remove/replace hose interface board E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 245 4 flashes: task watchdog reset occurred 8 flashes: unknown fault Yellow flash sequences 1 flash: unauthenticated device present (alerts) 2 flashes: task stack near limit 3 flashes: shorted device present 8 flashes: unknown fault Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 246 7-50 Troubleshooting Hose Interface Board (contd) DS12 DS10 DS14 Figure 7‐24 Hose interface board components E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 247 7-51 Troubleshooting This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 248: Ecobead Board

    Too much jitter in input signal— resolve signal issues if possible Noisy input—check cables and connections Always off: output Verify connection never active between EcoBead board and hose interface board Remove/replace EcoBead board Remove/replace hose interface board E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 249 7-53 Troubleshooting Figure 7‐25 EcoBead board components Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 250: Fill Board

    Downstream Green when fill board — Power LED has been assigned a NordBus address; power has been switched on to the next downstream device E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 251 If the alert persists, replace the level sensor, level sensor cable, and/or the fill board. 6 flashes: Check the NordBus cable. If the alert persists, communications replace the NordBus cable and/or the fill board. heartbeat warning Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 252 7-56 Troubleshooting Fill Board (contd) Figure 7‐26 Fill board components E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 253: Power Module Board

    AC power present at module for hose 3 Neon (Orange) AC power present at module for applicator 3 Fuses F1/F2 and F3/F4 — 6.3 A, 250 V, Fast‐acting, 5 x 20 mm Figure 7‐27 Power module board components Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 254: Expansion Board

    Bi-directional input and 20-position ribbon cable connection for cable to power module output Bi-directional input and 34-position ribbon cable connection for cable to main board and CPU/LCD output board Figure 7‐28 Expansion board components E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 255: Cpu/Lcd Board

    Table 7-11 CPU/LCD Board Designation Type Description Connection Points Input/output Data to/from fill board Input/output Data to/from main board and expansion board Input 24 VDC input to CPU/LCD board Figure 7‐29 CPU/LCD board components Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 256: Power Supply Board

    7-60 Troubleshooting Power Supply Board See Figure 7‐30. Table 7-12 Power Supply Board Designation Type Description Connection Points Input AC power input Output 24 VDC output Figure 7‐30 Power supply board components E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 257 EcoBead board Power supply board Melter (covers removed) Manifold and reservoir RTDs and thermostats; level sensor board Main board Expansion Hose electrical board connections Hose interface board Figure 7‐31 Melter circuit boards and electrical connections E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 258 7-62 Troubleshooting This page intentionally left blank. E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 259: Repair

    Have the required tools, supplies, and replacement parts on hand. They are listed at the beginning of each service procedure. Refer to Section 9, Parts, for component part numbers. Relieve system pressure and/or lockout communications as appropriate before performing any service activity. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 260: Purging The Melter

    Zone 2B Zone 2A Zone 4B Zone 4A 175_C 175_C 175_C 175_C Pump: On Pump: On System Status: Auto Pump Recipes: Heaters: On Ready/OK Nothing Loaded Password: Disabled Figure 8‐1 Accessing the Purge button E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 261 Repair This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 262: Tilting Open The Hydraulics Assembly

    Section 6, Maintenance, as needed. 3. See Figure 8‐2. Pull the spring-loaded pin to release the assembly and carefully tilt it open. Refill Disabled Figure 8‐2 Location of the spring‐loaded pin used to tilt open the hydraulics assembly E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 263 2. When the assembly is upright, allow the spring‐loaded pin to automatically catch the assembly. 3. Make sure the insulation is securely wrapped around the hydraulics assembly. 4. Reinstall the hydraulics cover and enable the fill system. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 264: Melter Repair Procedures

    1. Switch off the melter and disconnect and lock out input power to the melter. 2. Remove the hydraulics cover. Refer to Removing or Installing Covers in Section 6, Maintenance, as needed. 3. Open the insulation around the hydraulics assembly. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 265 Figure 8‐3 Replacing an RTD or a thermostat 1. Grid RTD retaining clip 4. Manifold thermostat (covered by boot) 2. Grid thermostat (covered by boot) 5. Bulkhead harness connection 3. Manifold RTD retaining clip Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 266 3. Plug the bulkhead harness connector into the BHRX1 connection. 4. Continue to the next procedure to replace a thermostat, or close the hydraulics assembly insulation, reinstall the hydraulics cover, and restore the system to normal operation. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 267 Figure 8‐5 Replacing an RTD or a thermostat 1. Grid RTD retaining clip 4. Manifold thermostat (covered by boot) 2. Grid thermostat (covered by boot) 5. Bulkhead harness connection 3. Manifold RTD retaining clip Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 268: Replacing The Level Sensor Cable

    3. Open the insulation around the hydraulics assembly. 4. See Figure 8‐6. Pull the spring-loaded pin and carefully tilt open the hydraulics assembly. Figure 8‐6 Location of the spring‐loaded pin used to tilt open the hydraulics assembly E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 269 Loosen, but do not remove, the screws on the underside of the touchscreen assembly. b.. Lift up the entire panel and tilt the top of the panel away from the melter. Figure 8‐7 Location of the touchscreen assembly screws Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 270 5. Close the hydraulics assembly insulation, close the touchscreen assembly and tighten the screws, reinstall the controls and hydraulics covers, and restore the system to normal operation. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 271 3. Level sensor cable ground wire 4. Level sensor board end of the (connects to X3) (connects to the grid/hopper level sensor cable (connects assembly) to X1) 2. Level sensor cable ground wire (connects to the fill board) Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 272: Replacing The Level Sensor Board

    Section 6, Maintenance, as needed. 3. See Figure 8‐9. Pull the spring-loaded pin and carefully tilt open the hydraulics assembly. Figure 8‐9 Location of the spring‐loaded pin used to tilt open the hydraulics assembly E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 273 (4). 1.1 NSm (10 in.‐lb) Figure 8‐10 Replacing the level sensor board 1. Cyclone upper body 3. Cyclone base and gasket 4. Level sensor board and gasket 2. Cyclone base insulation blankets Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 274 6. Close the hydraulics assembly by pushing up on the pump and allowing the spring‐loaded pin to automatically catch the assembly. 7. Connect the adhesive transfer hose. 8. Reinstall the hydraulics cover and restore the system to normal operation. E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 275: Replacing A Circuit Board

    1. After noting their locations, disconnect all power and control cables from the board to be replaced. 2. Remove the screws and associated hardware that secure the board and then carefully remove the board from the melter. Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 276 6. If you replaced the fill board, calibrate the level sensor. Refer to Calibrating the Level Sensor in Section 7, Troubleshooting. 7. Reinstall the controls cover and restore the system to normal operation. Verify that the system operates normally. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 277 Note: See Figure 7‐31 for an alternate illustration of the board locations. Note: The CPU/LCD board on the touchscreen assembly is replaced by replacing the entire touchscreen assembly. Refer to Replacing the Touchscreen Assembly later in this section. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 278: Replacing The Main Board Fuses

    F5/F6 Manifold heater F5 and F6 F7/F8 Hose/applicator 1 heaters (Fast, 5 A, 250 VAC) F9/F10 Hose/applicator 2 heaters F7–F10 (2 spares provided) (6.3 A, 250 VAC) Figure 8‐12 Location of the main board fuses E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 279: Replacing The Pneumatic Control Assembly

    3. Remove the hydraulics cover. Refer to Removing or Installing Covers in Section 6, Maintenance, as needed. 4. See Figure 8‐13. Remove the cyclone exhaust cover and filter. Figure 8‐13 Removing the cyclone exhaust filter and cover 1. Cyclone exhaust filter cover 2. Filter Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 280 To remove the pneumatic control assembly 1. See Figure 8‐14. Remove the three screws that secure the plenum and pneumatic control assembly to the melter chassis. Figure 8‐14 Location of the screws that secure the pneumatic control assembly E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 281 Figure 8‐15 Replacing the pneumatic control assembly (port numbers enlarged for clarity) 1. Blue air line connected to port 1 3. Pneumatic control assembly 2. Yellow air line connected to port 2 Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 282 WARNING! Risk of personal injury. Do not operate the system without a properly installed cyclone exhaust filter and filter cover. 4. Reinstall the cyclone exhaust filter and cover. 5. Reinstall the hydraulics cover and restore the system to normal operation. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 283 8-25 Repair This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 284: Replacing The Tilt Switch

    2. Remove the two screws that secure the tilt switch harness (3) to the top pump bracket and remove the harness. 3. Disconnect the bulkhead harness connector from the top left side of the hydraulics enclosure (1). Pin removal tool Cable ties E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 285 8-27 Repair 1 (BHRX1) Figure 8‐16 Replacing the hydraulic tilt switch 1. Bulkhead harness connection 2. Tilt switch actuator 3. Tilt switch harness Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 286 2. See Figure 8‐16. Use the supplied screws to secure the new tilt switch actuator and harness to the melter chassis and top pump bracket. 3. Plug the bulkhead harness connector into the BHRX1 connection. 4. Reinstall the hydraulics cover and restore the system to normal operation. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 287 8-29 Repair This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 288: Replacing The Touchscreen Assembly

    1. See Figure 8‐18. Open the touchscreen assembly as follows: a.. Loosen, but do not remove, the screws on the underside of the touchscreen assembly. b.. Lift up the entire panel and tilt the top of the panel away from the melter. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 289 2. After noting their locations, disconnect all of the power and control cables connected to the touchscreen assembly. 3. See Figure 8‐19. Move the touchscreen assembly back to the upright position, remove the two screws loosened previously, and lift the touchscreen assembly away from the melter. Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 290 Tighten the touchscreen assembly screws (1). 5. Reinstall the controls cover and restore the system to normal operation. Figure 8‐19 Replacing the touchscreen assembly 1. Touchscreen assembly screws 2. Ground wire connection E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 291: Replacing A Cyclone Assembly Component

    5. See Figure 8‐20. Pull the spring-loaded pin and carefully tilt open the hydraulics assembly. Gasket, cyclone base to hopper Worm clamps Exhaust hose Figure 8‐20 Location of the spring‐loaded pin used to open the hydraulics assembly Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 292 (3) and exhaust hose (1) and then remove these components. Figure 8‐21 Replacing the cyclone assembly components 1. Exhaust hose 3. Cyclone upper body 5. Cyclone base 2. Worm clamp 4. Cyclone base insulation blankets 6. Gasket E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 293 (5) and disassemble the components shown in Figure 8‐22. Figure 8‐22 Cyclone assembly components 1. Exhaust hose 4. O‐ring 2. Exhaust hose worm clamp 5. Cyclone upper body 3. Exhaust tube 6. O‐ring Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 294 4. Close the hydraulics assembly by pushing up on the pump and allowing the spring‐loaded pin to automatically catch the assembly. 5. Connect the adhesive transfer hose. 6. Reinstall the hydraulics cover and restore the system to normal operation. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 295 8-37 Repair This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 296: Replacing The Pump

    4. See Figure 8‐23. Open the insulation and use a 13-mm wrench or an adjustable wrench to close the shutoff valve. Male elbow High temperature lubricant Closed Open O‐ring lubricant Figure 8‐23 Location of the shutoff valve E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 297 8-39 Repair 5. See Figure 8‐24. Pull the spring-loaded pin and carefully tilt open the hydraulics assembly. Figure 8‐24 Location of the spring‐loaded pin used to open the hydraulics assembly Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 298 (2) to the pump top bracket (3). Figure 8‐25 Location of the pump air inlet fitting, tilt switch, and pump bracket 1. Pump air inlet fitting 2. Tilt switch harness 3. Top pump bracket E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 299 4. See Figure 8‐27.Pull the pump (1) straight out of the manifold. If needed, insert a screwdriver into the slot (2) in the top of the manifold to pry the pump loose. Figure 8‐27 Removing the pump 1. Pump 2. Manifold slot Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 300 Place six drops of SP pump oil into the air inlet fitting (1). d.. Remove the pump lubrication tag (4). Figure 8‐28 Preparing the replacement pump for installation 1. Air inlet fitting 3. O‐rings 2. Plastic plug 4. Pump lubrication tag E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 301 5. Close the hydraulics assembly by pushing up on the pump and allowing the spring‐loaded pin to automatically catch the assembly. 6. Reinstall the hydraulics cover and restore the system to normal operation. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 302: Replacing A Hydraulics Assembly Component

    Figure 8‐29 Contents of the hydraulic assembly service kits 1. Pressure discharge valve service kit 3. Grid/hopper service kit 4. Reservoir service kit 2. Manifold service kit E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 303 4. Remove the hydraulics cover. Refer to Removing or Installing Covers in Section 6, Maintenance, as needed. 5. See Figure 8‐30. Pull the spring-loaded pin to tilt open the hydraulics assembly. Figure 8‐30 Location of the spring‐loaded pin used to open the hydraulics assembly Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 304 1. Bulkhead harness connection 4. Cyclone upper body 7. Hose connection location 2. Hydraulic tilt switch harness 5. Hydraulics assembly ground strap 8. Pressure discharge valve T‐fitting 3. Pneumatic assembly power cable 6. Level sensor cable connection E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 305 2. See Figure 8‐32. Remove the two screws that secure the hydraulics assembly to the melter chassis and then carefully remove the hydraulics assembly from the melter and place it on a suitable work surface. Figure 8‐32 Location of the hydraulics assembly securing screws Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 306 Level sensor cable and ground wire (6) Hoses (7) Air lines to the T‐fitting on the pressure discharge valve (8) 3. Close the insulation, reinstall the hydraulics cover, and restore the system to normal operation. E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 307: Replacing The Internal Sd Card

    Loosen, but do not remove, the screws on the underside of the touchscreen assembly. b.. Lift up the entire panel and tilt the top of the panel away from the melter. Figure 8‐33 Location of the touchscreen assembly screws Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 308 4. Remove the old customer SD card (2). The customer SD card is identified by a tag. 1 (internal SD card 2 (customer SD card) Figure 8‐34 Location of the internal and customer SD cards 1. Internal SD card 2. Customer SD card 3. Touchscreen assembly E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 309 Automatically reboots the melter when the upgrade is complete (usually in about 10 minutes) NOTE: Nordson Corporation recommends copying the *.dat files to another backup storage media in case an SD card is damaged. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 310: Fill System Repair Procedures

    3. Disconnect the air supply tubing from the pump outer section. O‐ring, 1.375 X 1.625 X 0.125 (3) 4. See Figure 8‐35. Use a pull and twist action to remove the pump assembly from the bin. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 311 9. Reconnect the compressed air supply line to the bin. 10. Enable the fill system and restore the system to normal operation. Figure 8-36 Transfer pump components 1. Pump inner section 2. O‐rings 3. Air jets 4. Pump outer section Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 312: Replacing The Vibrator

    5. Reconnect the air line tubing to the vibrator inlet and exhaust ports. 6. Reconnect the compressed air supply to the bin. 7. Enable the fill system and restore the system to normal operation. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 313 8-55 Repair Figure 8‐37 Vibrator components 1. Air inlet fitting 3. Exhaust fitting 2. Retaining nuts (obscured) 4. Vibrator Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 314: Replacing The Fill System Pneumatic Control Assembly

    2. Slide the pneumatic control assembly down and out of the retaining clip (2). 3. Loosen the screw on solenoid valve electrical connector (3) and disconnect the connector from the solenoid valve. 4. Disconnect all the air line tubing connected to the pneumatic control assembly. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 315 4. Secure the assembly with single retaining screw removed previously. 5. Connect the compressed air supply to the adhesive bin. 6. Enable the fill system and restore the system to normal operation. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 316: Replacing The Adhesive Transfer Hose Cuff Assembly

    Disconnect the hose by turning the retaining ring (2) counterclockwise and then sliding the hose cuff (1) away from the transfer pump outlet. Hose components Figure 8‐39 1. Hose cuff 2. Hose retaining ring E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 317 (3) in the screw holes on hose cuff. EXPLODED VIEW, HOSE CUFF Figure 8‐40 Transfer hose cuff assembly components 1. O‐ring 4. Retaining ring 2. Cuff 5. Hose 3. Self‐tapping screw Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 318 4. Reconnect both ends of the transfer hose solenoid harness. 5. Reinstall the hydraulics cover, enable the fill system, and restore the system to normal operation. Hose components Figure 8‐41 1. Hose cuff 3. Hose clamp 2. Hose retaining ring E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 319: Parts

    A dash in this column indicates that the item is an assembly. The number in the Part column is the Nordson part number you can use to order the part. A series of dashes indicates that the part is not saleable. In this case, you must order either the assembly in which the part is used or a service kit that includes the part.

  • Page 320: Viewing The System Inventory

    1078624 Hose‐Applicator Interface Board P/N: 1121535 DuraBlue Expansion Board P/N: 12/03/2013 EcoBead Board P/N: 1121536 Four Channel Power Module P/N:: 1087152 24‐V Power Supply P/N: 1121540 Figure 9‐1 System Inventory and System Configuration screens E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 321: Melter Parts Lists

    E: To replace this item, order service kit part 1121544. F: To replace this item, order service kit part 1121536. G: Refer to the installation section for the contents of the ship‐with kit. NS: Not Shown Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 322 Parts Melter Assemblies (contd) Figure 9‐2 Melter assemblies (1 of 3) E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 323 Parts Figure 9‐3 Melter assemblies (2 of 3) Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 324 Parts Melter Assemblies (contd) FILL HARNESS SLEEVING Figure 9‐4 Melter assemblies (3 of 3) E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 325: Chassis And Controls Assembly

    S CHASSIS,FREEDOM ‐ ‐ ‐ ‐ ‐ ‐ S BEZEL,TOUCH SCREEN,FREEDOM ‐ ‐ ‐ ‐ ‐ ‐ S ASSY, LCD MODULE, COMPLETE,FREEDOM ‐ ‐ ‐ ‐ ‐ ‐ S NUT,HEX,W/EXT TOOTH WASHER,M5,STL, 1052143 S BOARD, MAIN W/HT SINK ASSY, DURA/ALTA ‐...
  • Page 326 S FILTER,EXHAUST,7.38 X 4.50 X .50 ‐ ‐ ‐ ‐ ‐ ‐ S ASSY,FILTER COVER,FILL SYSTEM,DS1 1121673 S FITTING,BULKHEAD,8mm to 8mm 1121897 S CONN,REDUCER,8MM TO 6MM,RT 1121927 S TUBE,INLET TO REG,6MM,BLUE,FREEDOM 1121928 S TUBE,REG TO PUMP,6MM,PTFE,FREEDOM 1121363 S GASKET,BEZEL,TOUCHSCREEN,FREEDOM 1121364 S GASKET,REG,GAUGE,FREEDOM 1121365...
  • Page 327 J: To replace this item, order service kit part 1121556. This kit contains several cyclone assembly‐related components. K: To replace this item, order service kit part 1121526. L: To replace this item, order service kit part 1121539. NS: Not Shown Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 328 9-10 Parts Chassis and Controls Assembly (contd) Figure 9‐5 Chassis and controls assembly (1 of 3) E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 329 9-11 Parts Figure 9‐6 Chassis and controls assembly (2 of 3) Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 330 9-12 Parts Chassis and Controls Assembly (contd) 82 73 04 Figure 9‐7 Chassis and controls assembly (3 of 3) E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 331 9-13 Parts This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 332: Hydraulics Assembly

    S RESERVOIR ASSY, DS1 ‐ ‐ ‐ ‐ ‐ ‐ S INSULATION,HYDRAULIC ASSY,MAIN, 1121700 FREEDOM S ELBOW, MALE,6 MM TUBE X G 1/8 1023307 S TUBE,PDV TO PUMP,6MM,FREEDOM 1121403 S SCREW,PUMP RETAINER.FREEDOM 1121845 S SCR,SKT HD,M8 X 80MM,STNSTL 1121199 S HARNESS,BULKHEAD,RIGHT,FREEDOM...
  • Page 333 (PART OF ITEM 10) IS INSTALLED UNDER RETAINING PLUG PLATE BOOT INSULATOR BOOT ASSEMBLY IS PART OF ITEM 10 PUSH PLUGS FULLY INTO BOOTS. PUSH BOOTS OVER CERAMIC INSULATORS ON HEATERS. Figure 9‐8 Hydraulics assembly Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 334: Pump

    952100 S RETAINING RING,INT,100,PUSHON 986331 S HOUSING, PISTON PUMP,DS1 1121282 S SEAT, CHECK—PISTON PUMP 1121178 S DISC, CHECK LIMIT 1121179 S BRACKET, PUMP, FREEDOM 1121658 S LUBRICANT,O‐RING,NSF‐H1,FOOD GRADE 1108372 S LUBRICANT,NEVER‐SEEZ,NSF‐H1,FOOD 1108371 GRADE S ADHESIVE,LOCTITE 272,RED,HI TEMP,50ML 900470 NOTE A: Refer to Pump Hydraulic Piston later in this section.
  • Page 335 Parts TIGHTEN TO 2.8-3.5 NSM (25-31 IN.‐LB) 17 11 28 TIGHTEN TO 11.3-13.6 NSM (100-120 IN.‐LB) 11 28 TIGHTEN TO 2.8-3.5 NSM (25-31 IN.‐LB) 6 27 SECTION B-B Figure 9‐9 Pump (1 of 2) Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 336 9-18 Parts Pump (contd) 5 27 21 22 5 27 TIGHTEN TO 6.8-8.5 NSM (60-75 IN.‐LB) SECTION A-A DETAIL C DETAIL D DETAIL E Figure 9‐10 Pump (2 of 2) E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 337: Pump Hydraulic Piston

    1022658 PISTON ASSY,HYDRAULIC,PROBLUE — S PISTON,PUMP,15:1 1017229 S PIN,ROLL,.125X .500,STL,ZN 985302 S BALL,440SSTL,.375, 50 900000 S SEAT,BALL,PRESSURE 503709 S ADHESIVE,LOCTITE 272,RED,HI TEMP,50ML 900470 TIGHTEN TO 11.3-13.6 NSM (100-120 IN.‐LB) Figure 9‐11 Pump hydraulic piston Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 338: Pump Shifter

    S WASHER,PISTON SEAL,SP30 983445 TIGHTEN TO TIGHTEN TO 3.2-4.1 NSM 3.2-4.1 NSM (28-36 IN.‐LB) (28-36 IN.‐LB) TIGHTEN TO 1.8-2.3 NSM 2 11 (16-20 IN.‐LB) TIGHTEN TO 6.8-8.5 NSM (60-70 IN.‐LB) Figure 9‐12 Pump shifter E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 339 9-21 Parts This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 340: Manifold

    B: To replace this item, order service kit part 1121527. C: To replace this item, order service kit part 1028305. D: To replace a manifold or grid RTD, order service kit part 1121531. E: To replace this item, order service kit part 1122056. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 341 9-23 Parts TIGHTEN TO 10.2-11.3 NSM (90-100 IN.‐LB) TIGHTEN TO 3.4-4.2 NSM (30-37 IN.‐LB) Figure 9‐13 Manifold Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 342: Grid/Hopper

    NOTE A: To replace this item, order service kit part 1121530. B: To replace this item, order service kit part 1121538. C: To replace a manifold or grid RTD, order service kit part 1121531. D: To replace this item, order service kit part 1122056. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 343 9-25 Parts TIGHTEN TO 1.0-1.1 NSM (9-10 IN.‐LB) Figure 9‐14 Grid/hopper Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 344: Reservoir

    S SCR,SKT,M6 X 110,304SS,GR A2,PC 70 1120684 S BALL,440SSTL, .250,100 900037 S RETAINING RING,INT, 37,PUSHON 986503 S LUBRICANT,O‐RING,NSF‐H1,FOOD GRADE 1108372 S LUBRICANT,NEVER‐SEEZ,NSF‐H1,FOOD 1108371 GRADE NOTE A: To replace this item, order service kit part 1121528. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 345 9-27 Parts Figure 9‐15 Reservoir Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 346: Cyclone Assembly

    1121271 S WASHER,LK,M,EXT,M5,STEEL,ZN PL 983422 S GASKET,CYCLONE BASE TO HOPPER,DS1 1121221 S WIRE ASSY,BONDING,EMI,BRAIDED, 1121698 FREEDOM NOTE A: To replace this item, order service kit part 1121556. This kit contains several cyclone assembly‐related components. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 347 9-29 Parts 12 13 Figure 9‐16 Cyclone assembly Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 348: Air Filter Assembly

    S FILTER, PARTICULATE,1/4 BSPP‐G ‐ ‐ ‐ ‐ ‐ ‐ S FITTING,CONN,PUSH‐IN,8MM,G1/4 THD 1121296 S CONN,MALE,8MM T X 1/4UNI 971121 NOTE A: To replace this item, order service kit part 1121525. Figure 9‐17 Air filter assembly E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 349: Melter Wall Mounting Bracket

    Description Note 1121664 BRACKET, WALL MTG, FREEDOM NOTE A: The hardware used to secure this bracket to a mounting surface is provided in the ship‐with kit. Refer to the installation section for the contents of the ship‐with kit. Figure 9‐18 Melter wall mounting bracket...

  • Page 350: Fill System Parts Lists

    S S GROMMET,.438 ID X .75 OD,RUBBER 1091885 S S LUBRICANT,O-RING,NSF-H1,FOOD 1108372 GRADE,4L NOTE A: Pump box assemblies are available as a kit. For a single‐feed pump box kit, order part 1123015. B: To replace the solenoid, order service kit 1121549. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 351 9-33 Parts Figure 9‐19 Single‐feed adhesive storage bin parts Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 352: Multi‐Feed Adhesive Storage Bin

    S S BRACKET, SOLENOID SUPPORT 1121880 S S LUBRICANT,O-RING,NSF-H1,FOOD 1108372 GRADE,4L NOTE A: Pump box assemblies are available as a kit. For a multi‐feed pump box kit, order part 1123101. B: To replace the solenoid, order service kit 1123103. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 353 9-35 Parts Figure 9-20 Multi-feed adhesive storage bin parts Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 354 9-36 Parts This page intentionally left blank. E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 355: Adhesive Transfer Hose

    NOTE: To convert from a standard transfer hose solenoid harness to a quick‐disconnect harness, refer to Solenoid Harness Quick‐Disconnect Kits under Optional Accessories. Item Part Description Quantity Note — 1123047 ASSY,TRANSFER HOSE,4M,FREEDOM FF2 — — 1121111 ASSY,TRANSFER HOSE,9M,FREEDOM — — 1121112 ASSY,TRANSFER HOSE,18M,FREEDOM —...

  • Page 356: Quick‐Disconnect Transfer Hoses

    See Figure 9‐21. These transfer hoses include a quick‐disconnect transfer hose solenoid harness and a quick‐disconnect adapter harness for installation on the adhesive storage bin. Item Part Description Quantity Note — 1123375 KIT,ASSY,TRANSFER HOSE,4M QD,FREEDOM — — 1123373 KIT,ASSY,TRANSFER HOSE,9M QD,FREEDOM — — 1123374 KIT,ASSY,TRANSFER HOSE,18M QD,FREEDOM —...
  • Page 357 QTY VARIES ACCORDING TO HOSE LENGTH BIN END OF MELTER END OF HOSE ASSEMBLY HOSE ASSEMBLY EXPLODED VIEW, HOSE CUFF Figure 9‐21 Adhesive transfer hose parts (hose with standard transfer hose solenoid harness shown) Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 358: Transfer Hose Pump Parts

    Parts Transfer Hose Pump Parts See Figure 9‐22. Item Part Description Quantity Note — 1121546 SERVICE KIT,TRANSFER PUMP,FREEDOM — — 1121947 SERVICE KIT,HIGH FLOW,TRANSFER PUMP, — FREEDOM S PUMP ASSY, SOLIDS TRANSFER, — ‐ ‐ ‐ ‐ ‐ ‐ —...

  • Page 359: Transfer Hose Solenoid Harness

    Optional Accessories. Item Part Description Quantity Note — 1123088 CABLE,4M,FRDM,FF2,QUICK DISC — 1123089 CABLE,9M,FRDM,FF2,QUICK DISC — 1123090 CABLE,18M,FRDM,FF2,QUICK DISC WIRE COLOR BLACK WHITE GREEN RING ORANGE Figure 9‐23 Standard transfer hose solenoid harness Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 360: Quick-Disconnect Harnesses

    Quick‐Disconnect Harnesses See Figure 9‐24. Item Part Description Quantity Note — 1121344 CABLE ASSY,FILL,4M,DS1 — 1121345 CABLE ASSY,FILL,10M,FREEDOM — 1121346 CABLE ASSY,FILL,20M,FREEDOM WIRE POSITION COLOR VIOLET SLATE PINK Figure 9‐24 Quick‐disconnect transfer hose solenoid harness E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 361: Sequencer

    — — S CONTROL UNIT, 2­MELTER, SEQUENCER, — 1122855 FF2 (standard) S CONTROL UNIT, 4­MELTER, SEQUENCER, — 1122856 — FF2 (standard) S CONTROL UNIT,4-MELT,SEQ'R.,FREEDOM, — 1122924 — FF2 (quick‐disconnect) S CONTROL UNIT,2-MELT,SEQ'R.,FREEDOM, — 1122925 — FF2 (quick‐disconnect) S S BRACKET,CTL.BOX,SEQUENCER,FF2 1122398 S S ENCLOSURE,POLY,MACH.,2­POS,SEQ'R,...
  • Page 362 1122941 S S TBCONN,MSTB,3POS,5.08MM,FEM 226903 S S CONNECTOR,MC PLUG,6 POS 933751 S S TBCONN,8POS,3.81MM,MCVR1-5ST 305988 S S WASHER,FLAT,REG, 345913 S S WASHER, FLAT, REG, 345929 , ZN S S SPCLSCR,HEXHEADCAP, 1123477 -20,.75, NYLON, SLOTTED S S SPCLSCR,HEXHEADCAP, 1123478 -16,.75, NYLON, SLOTTED E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 363 9-45 Parts TERMINAL BLOCK FROM WIRE HARNESS (WIRES NOT SHOWN) Figure 9-25 Sequencer parts (1 of 2) Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 364 9-46 Parts Sequencer (contd) Figure 9-26 Sequencer parts (2 of 2) E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 365: Air Flush Kit

    9-47 Parts Optional Accessories To optimize the performance of your system, Nordson Corporation recommends the following optional accessories. Adhesive Storage Bin Grates See Figure 9‐27. The optional adhesive storage bin grate is installed on the top of the bin. Pouring packaged adhesive through the a grate sifts the adhesive and separates any clumps caused by the adhesive packaging process.

  • Page 366: Air Gauge

    KIT,CABLE,EXTENSION,SOL,M8,0.3M LG 1121989 KIT,CABLE,EXTENSION,SOL,M8,90DEG, 0.3 M LG 1121990 KIT,CABLE,SPLITTER,SOL,M8,1MTO2F,0.3M LG NOTE A: These extension and splitter cables can be used for additional routing configurations. AR: As Required NS: Not Shown Figure 9‐28 Solenoid valve‐to‐melter cables E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 367: Hose-To-Applicator Fittings

    972628 Straight fitting in. x 18 threads, with O‐ring 972647 45‐degree swivel fitting 37‐degree JIC, size 6 972646 90‐degree swivel fitting Figure 9‐29 Hose‐to‐applicator fittings 1. Straight fitting 2. 45‐degree fitting 3. 90‐degree fitting Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 368: Melter Stands And Castors

    KIT,FREEDOM,MOUNT,FLOOR,FIXED,DS1 (floor stand) 1121243 KIT,FREEDOM,BENCH SUPPORT,DS1 (bench stand) 1121234 KIT,FREEDOM,CASTER PLATE, DS1 (base plate with casters) 1122108 KIT,BASE PLATE,STAND,FREEDOM (base plate only) NOTE A: This kit includes a floor stand that can be bolted to the floor. B: The melter bench stand is height‐adjustable.

  • Page 369: Solenoid Harness Quick-Disconnect Kits

    Item Part Description Quantity Note — 1123112 KIT, HARNESS, FREEDOM QUICK DISC 4M — — 1123113 KIT, HARNESS, FREEDOM QUICK DISC 9M — — 1123114 KIT, HARNESS, FREEDOM QUICK DISC 18M —...

  • Page 370: Service Kits

    Fill System 1121526 SERVICE KIT, FILL EXHAUST FILTER, FREEDOM 1121546 SERVICE KIT, TRANSFER PUMP, FREEDOM 1121947 SERVICE KIT, HIGH FLOW, TRANSFER PUMP, FREEDOM 1121548 SERVICE KIT, VIBRATOR, FREEDOM 1121549 SERVICE KIT, PNEU. CONTROLS, BIN, FREEDOM 1123103 KIT, PNEU CTRL, MF ADH STR BIN, G3 (multi‐feed bins) 1121549 KIT, PNEU.
  • Page 371 Item Data Note Hose/applicator heating capacity 2 to 4 hose/applicator pairs 40-204 C (100-400 F) Control temperature range  0.5 C ( 1 F) Control temperature accuracy IP rating IP 54 Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 372: Technical Data

    0.7 bar (10 psi) Viscosity range 800-10,000 cps Pressure ratio 15:1 Air consumption at 415 kPa (60 psi) and maximum pump speed 46 l/min. (1.6 scfm) Displacement 7.20 ml/stroke ( 0.44 in /stroke) Maximum speed 90 strokes/min. E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 373: Fill Specifications

    Conditioning Dry, non‐lubricated ¼‐in. NPT female Inlet air connection ¼‐in. BSPP female G ¼ female Pump type Venturi Adhesive storage bin capacity 120 L (264 lb) or 240 L (528 lb) Enclosure rating IP54 Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 374: Ecobead Capability Specifications

    Control system functions Maximum operating frequency 150 Hz (9000 per minute) Minimum on time 5 ms Line speed sensor Not required Diagnostic and status LED Multiple indicators NOTE: Refer to Section 7, Troubleshooting, for detailed information. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 375 10-5 Technical Data This page intentionally left blank. Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 376: Dimensions

    Dimensions 886.6 mm (34.91 in.) 280.3 mm (11.03 in.) 839.9 mm (33.07 in.) 409.1 mm (16.11 in.) 525 mm (20.67 in.) 254 mm (10 in.) Figure 10-1 Melter dimensions [mm (in.)] (1 of 3) E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 377 (4.45 in.) 186.2 mm (7.33 in.) 549.3 mm (21.63 in.) 127 mm (5 in.) 68.9 mm (2.71 in.) 364 mm (14.33 in.) 317.5 mm (12.50 in.) Figure 10-2 Melter dimensions [mm (in.)] (2 of 3) Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 378 10-8 Technical Data Dimensions (contd) 390.5 mm (15.38 in.) FOR SERVICE 18 DEG Figure 10-3 Melter dimensions [mm (in.)] (3 of 3) E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 379 10-9 Technical Data 698.5 mm (27.5 in.) 838 mm (33 in.) 1423 mm (56 in.) Figure 10-4 Melter and floor stand dimensions Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 380 840 mm (33 in.) 679 mm (26.7 in.) Figure 10-5 Melter and bench stand dimensions Note: The bench stand is height‐adjustable by four 60.3‐mm (2.375‐in.) increments, for a 325-505.4 mm (12.8-19.9 in.) adjustment range. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 381 10-11 Technical Data 554 mm (21.8 in.) 480 mm (18.9 in.) 1400 mm (55.1 in.) 917 mm (36.1 in.) Figure 10-6 Single-feed adhesive storage bin dimensions and clearances Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 382 10-12 Technical Data Dimensions (contd) 667 mm (26.3 in.) 620 mm (25 in.) 1656 mm (65.2 in.) 688 mm (27 in.) Figure 10-7 Multi-feed adhesive storage bin dimensions and clearances E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 383: Hydraulic Flow Diagrams

    Hydraulic Flow Diagrams Weep return Pressure Level path dump valve sensor Pump Adhesive in Grid Filter Reservoir Check valve Shutoff valve Low pressure fluid Outlets High pressure fluid Figure 10‐8 Hydraulic flow path, pump down‐stroke Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 384 Hydraulic Flow Diagrams (contd) Level Weep return Pressure sensor path dump valve Pump Adhesive in Grid Filter Reservoir Check valve Shutoff valve Low pressure fluid Outlets High pressure fluid Figure 10‐9 Hydraulic flow path, pump up‐stroke E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 385 Weep return Pressure Level path dump valve sensor Pump Adhesive in Grid Filter Reservoir Check valve Shutoff valve Low pressure fluid Outlets High pressure fluid Figure 10‐10 Hydraulic flow path, pressure dump valve open Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 386: Wiring Diagrams

    GRID RTD MANIFOLD RTD MANIFOLD GROUND GRID RTD MANIFOLD RTD GRID GROUND GRID THERMOSTAT PUMP SOLENOID + TILT SWITCH MANIFOLD THERMOSTAT PUMP SOLENOID - TILT SWITCH Figure 10‐11 Bulkhead harness connector (BHRX1) pin positions E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 387 10-17 Technical Data WIRE COLOR BLACK WHITE GREEN RING ORANGE Figure 10‐12 Standard transfer hose solenoid harness pin positions WIRE POSITION COLOR VIOLET SLATE PINK Figure 10‐13 Quick‐disconnect transfer hose solenoid harness pin positions Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 388 10-18 Technical Data Wiring Diagrams (contd) Figure 10‐14 Sequencer wiring diagram E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 389: System Schematic

    10-19 Technical Data System Schematic A system schematic is provided on the next two pages. Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 390 10-20 Technical Data This page intentionally left blank. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 391 10-21 Technical Data Figure 7‐15 System schematic (1 of 2) E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 392 10-22 Technical Data Figure 7‐16 System schematic (2 of 2) E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 393: Calculating Melter Power Requirements

    Two hose/applicator pair maximum—The combined wattage of hose/applicator pairs 1 and 2 or hose/applicator pairs 3 and 4 If your Nordson representative has already calculated the hose/applicator power requirements and confirmed that the maximum allowable wattages will not be exceeded, then no further calculation is necessary. However, you should re‐evaluate the hose and applicator power requirements before you:...
  • Page 394 Table A‐2, then the configuration or position of the hose/applicator pairs must be rearranged, shorter hoses must be used, or lower power applicators must be used in order to reduce the power requirement. E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 395 Component Table A-1 Wattage Any single hose or applicator 1000 W Any hose/applicator pair 1200 W Sum of hose/applicator pairs 1 and 2 2000 W Sum of hose/applicator pairs 3 and 4 2000 W Part 1123087_02 E 3/2014 Nordson Corporation...
  • Page 396 Calculating Melter Power Requirements E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 397: Control System Settings

    Zone 3A, or Zone 4A 175 _C (350 _F) 40-204 _C (100-400 _F) Adjust Setpoint Create/Modify Name Hose 1: Zone 1A Limited to 10 visible Hose 2: Zone 2A characters Hose 3: Zone 3A Hose 4: Zone 4A Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 398: Master Controls: Settings Screen

    NOTE A: The first time the melter is switched on after a factory reset, Heater Control is Off. For all other times the melter is switched on, Heater Control is On, regardless of whether it was On or Off when the melter was switched off. Continued... E 3/2014 Nordson Corporation Part 1123087_02...
  • Page 399 Outputs Output 1 System Ready Disabled System Ready Melt Ready Fill Ready Output 2 Fault Ready—Pump On Fill Active Fill Overfill Alarm Fill Fault Output 3 Ready—Pump On Tank Low Alert Fault Service Reminder Part 1123087_02 E 3/2014 Nordson Corporation...

  • Page 400: Master Controls: System Screen

    Brightness 75 (percent) 30, 60, 75, 100 (percent) Contrast 75 (percent) 30, 60, 75, 100 (percent) Screen Saver Delay 5 (minutes) 1-120 (minutes) Administration Lockout Communication Language — English CE languages (with software upgrade) E 3/2014 Nordson Corporation Part 1123087_02...

  • Page 401: Ec Declaration Of Conformity

    The product specified conforms to the directives and standards described above. Technical File Contact: Dieter Ziesmer Nordson Engineering GmbH Gregory P. Merk, Senior Vice President Lilienthalstrasse 6 Adhesives Dispensing Systems 21337 Lueneburg GERMANY Date: 20 March 2014 Nordson Corporation S 28601 Clemens Road S Westlake, Ohio 1105311A05 DOC074R6...

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