Nordson FoamMelt FIT25 Adhesive Foam Melter User Manual

Nordson FoamMelt FIT25 Adhesive Foam Melter

System Components

The system components enable programming of system operating values and provide feedback for monitored components. All system operating values are stored in non-volatile memory. Therefore, values are entered only once.

Control Components

Refer to Table 2-1 and see Figure 2-1 below and Figure 2-2 on page 2-4 for a description of the FM FIT25 melter’s major control components.

Electrical Components

Refer to Table 2-2 and Figure 2-3 below, Figure 2-4 on page 2-6, and Figure 2-5 on page 2-7 to view a layout of the electrical panel components.

Figure 2-4: 240 VAC back panel:

Tank and Drive Assembly

Refer to Table 2-3 and see Figure 2-6 for information on the major components of the tank and drive assembly.

Manifold Assembly

Refer to Table 2-4 and see Figure 2-7 for information on the major components of the manifold assembly.

Density Controller Block Assembly

Refer to Table 2-5 and see Figure 2-8 for information on the major components of the Density controller block assembly.

Operating Modes

The FM FIT25 melter has three operating modes: startup, operating, and standby.

Startup Mode

During a sequential startup, when the clock timer or an operator turns the system on, the tank and hoses begin to heat first. After the temperatures of the tank and hoses are all within 19.5 °C or 35.1 °F of their setpoint temperatures, the applicators start to heat. When the tank, hoses, and applicators are within 3 °C or 5.4 °F of their setpoint temperatures, a time delay begins. The adjustable time delay provides additional time for the material in the tank to melt. At the end of the time delay, the green READY indicator turns on, indicating that the system is ready for operation. You can program the system so the pump starts automatically, either when the READY indicator turns on or when the tank reaches the temperature you specified. Or you can program the system so the pump must be started manually. The capability to heat all zones simultaneously is also available.

Operating Mode

While the system is operating, the melter uses PID power modulation to the heaters and nickel RTDs to maintain the temperature of each heated zone.

Standby Mode

When you place the melter in Standby mode, the control system disables the pump and reduces the temperature of all heating zones to the standby temperature setpoints you have selected. Use the Standby mode to keep the material warm when normal operation must be interrupted for a while. The lower temperature reduces char formation and conserves energy.

HMI Control Assembly

The HMI control assembly includes a 10” touch panel and controller that provides a single user-friendly machine interface for system status, settings, and control.

1. Touch panel
2. Console

Home Screen

The Home screen consists of three major components.

Functional Tiles

The Home screen is divided into several functional tiles. Refer to Table 2-7 and see Figure 2-11 on page 2-15 for a description of all the tiles on the Home screen.

Status Bar: The Status bar provides a quick summary of the system status. Refer to Table 2-8 and see Figure 2-12 for information regarding the status indicators on the status bar.

System Operation
The FAULT, READY, and DISABLED indicators indicate whether the system is prepared for operation.

FAULT
The red FAULT light turns on to indicate a fault or warning within the corresponding system component.

READY
The green READY light turns on to indicate that the corresponding system component is ready to operate and that no faults exist.

DISABLED
The gray DISABLED light indicates that the corresponding system component is disabled and not ready. The corresponding system component must be enabled, or all setting requirements cannot switch to the READY status.

Display Tiles

The display tiles on the Home screen provide detailed information about the system status.s

• When running the system, a display tile shows the status of each temperature zone.
• When configuring the system, a display tile shows the current system settings.

Refer to Table 2-9 below and see Figure 2-13 on page 2-19 for information on all the display tiles on the Home screen.

Quick Navigation Bar

The Quick Navigation bar lets you navigate to and customize all of the system components to fit the specific needs of each application. Refer to Table 2-10 and Figure 2-14 for information on all the components of the Quick Navigation bar.

Theory of Operation

The FM FIT25 melter uses a process that combines hot melt material with an inert gas to produce a foam of uniform density.
There are four stages in the FoamMelt process, as shown in the table below.

Melting Stage

The warm hopper, the heated grid and reservoir, melt pellets, slats, or other forms of solid hot melt material. The heating components of the grid and reservoir are controlled independently.

Mixing Stage

After being melted, the hot melt material is fed into a constant displacement, two-stage gear pump where it is mixed with an inert gas (commonly industrial-grade carbon dioxide or nitrogen). The two-stage gear pump is similar to a pair of gear pumps that are stacked one on top of the other in a single housing. The top portion of the pump draws a measured amount of molten hot melt material into the pump. The larger volume bottom portion of the pump creates a vacuum that helps draw in the gas. As the gas and molten hot melt material move toward the pump discharge port, hydraulic pressure in the pump increases, forcing the gas into solution with the molten hot melt material. A series of slots cut into the plates above and below the second-stage gear teeth also helps mix the gas with molten hot melt material.

Gas Modulation

The gas (carbon dioxide or nitrogen) is supplied to the unit from a user-supplied gas cylinder equipped with a regulator. The gas flows through a pressure switch that activates an LED indicator if the supply pressure falls below 2.04 bar (30 psi). The gas passes from the pressure switch through a pressure regulator and gauge that controls the input gas pressure to the pump. An electric modulation (solenoid) valve controls the gas flow in response to system requirements. The gas then passes through a check valve located just before the manifold; this eliminates the possibility of material backflow into the gas line.
The solenoid valve is controlled by the density controller/filter. Turning the density control knob clockwise adds more gas to the solution.

Holding/Discharging Stage

• As the hot melt solution leaves the pump and enters the manifold, hydraulic pressure is measured by a pressure transducer and displayed on the operator control panel.
• The hot melt solution flows from the manifold through the density controller/ filter assembly, into supply hoses, and out to the automatic or hand-operated extrusion applicator(s). Unused solution recirculates through the return hose(s) connected to the return port in the manifold. This prevents the hot melt solution from separating and improves its consistency.
• As the hot melt solution enters the return port in the manifold, it passes through a pressure control valve.
• Hydraulic overpressure protection is provided by a pressure relief valve mounted in the manifold. If hydraulic pressure reaches 85 bar, ±7 bar (1,250 psi, ±100 psi), the valve redirects the solution into the reservoir.
• The hydraulic pressure is automatically controlled to maintain a setpoint selected by an operator using a touchscreen.

System Diagram

See Figure 2-15 in the section that follows for a diagram of the FM FIT25 standard melter density controller system.

System Diagram – Standard

Installation

Introduction

This section describes how to install the FM FIT25 melter and its components. Refer to the manuals that came with the hoses, applicators, and encoder for installation instructions for those products.

Unpacking

Refer to the FM FIT25 instruction sheet for details on unpacking the melter. Unpack carefully and check for damage caused during transport. Save pallets, angle brackets, and boxes for later use, or dispose of them properly according to local regulations. All hoses and applicators are shipped in separate containers.

Inspection

Perform the following steps to inspect the melt.er

1. Inspect all surfaces for dents, scratches, cracks, corrosion, and other physical damage.
2. Inspect the hoses for broken connectors, tears in the outer cover, and other damage.
3. Inspect all fasteners and mechanical connections for tightness.

Installation Requirements

Read the following before installing your melter:

• “Location”
•  “Wiring” on page 3-3
• “Hose/Applicator Power” on page 3-3

Other requirements and recommendations are provided in the installation procedures.

Location

Carefully select the location for the melter and its associated applicators and hoses. Follow these guidelines when choosing a location. Make certain:

• There is enough room to open the tank lid, open the electrical enclosure, remove the filter assembly, remove the pump enclosure, and make electrical connections for the hoses
• An operator can access all controls
• Maintenance personnel have room to service and repair the melter
• Installers can route the hoses without bending them
• The mounting surface can support the weight of the melter when the melter is filled with adhesive; refer to the section “Specifications” on page 10-1
• The mounting surface is le.vel
• The drain valve projects over the edge of the mounting surface, and there is at least 15 cm (6 in.) for draining adhesive.

Wiring

Follow these guidelines when installing wiring to the melter:

• Allow enough room to route your electrical service line to the melter.
• Route wires away from AC power lines, solenoid output lines, and electrical equipment such as motors, contacts, and relays.
• Make connections with the minimum length of wire needed. A long wire can act as an antenna for electrical noise.

Hose/Applicator Power

The power requirements of your hoses and applicators must be determined to make sure that you do not overload the melter. If your Nordson representative has not already checked to see that your melter can support all of the hoses and applicators you plan to install, or if you need to add new hoses, you must calculate your hose/applicator power requirements now. If you need help with this procedure, contact your Nordson Corporation representative.

Hoses

The FM FIT25 melter requires supply and return hoses to circulate the solution from the manifold to the applicators and back to the manifold. Refer to the instructions that are shipped with each hose for additional information on how to install the hose properly.

Perform the steps that follow to install the supply hoses.

1. See Figure 3-1 to determine the proper hose and applicator configuration for your melter. A plus (+) sign indicates a hydraulic supply port; a minus (-) sign indicates a hydraulic return port. Squares indicate electrical connections.
   1. One applicator
   2. Two applicators
   3. Two applicators
   4. Hand-held applicator
2. Remove the plug from an appropriate supply port in the manifold.
3. Apply anti-seize lubricant to the connector threads and o-ring lubricant to the O-rings on the connector.
4. Install the connector to the supply port. Tighten the connector to 9.5–13.6 N•m to create an effective seal.
5. Connect the supply hose to the connector in the manifold.
6. Connect the hose electrical plug to one of the electrical sockets on the melter.
7. Route the hose from the manifold to the applicator if the hose is being connected to an applicator. Follow the procedures in your applicator manual for instructions on connecting hoses to applicators.
8. Repeat steps 2 through 7 if your melter requires an additional supply hose.

1. First return port
2. Second return port
3. First supply port
4. Second supply port

Jumper Hoses Between Automatic Applicators

Perform the following steps to install jumper hoses between two automatic applicators.

1. Apply anti-seize lubricant to the threads of the hydraulic fitting on each applicator.
2. Follow the instructions in your applicator manual to connect the hose to the applicators.
3. Connect the hose electrical plug to one of the electrical sockets on the melter. NOTE: If the electrical cord for the jumper hose does not reach from the applicators to the melter, use a hose extension cord. Refer to the section “Parts” on page 9-1 for more information.
4. Repeat steps 1 through 3 if your melter requires an additional jumper hose.

Maintenance

Preventive Maintenance Schedule

Every machine that is a major component of a manufacturing process requires preventive maintenance to ensure safe, reliable performance. Every application has different factors that affect maintenance requirements. The schedule in Table 6-1 is based on moderate-to-severe operating conditions. Your application may require the maintenance procedures more or
less frequently. Keep a maintenance schedule and adjust the schedule as you define your application requirements. Some of the FM FIT25 melter’s components are wear items. Other components are prone to degradation in performance because of material buildup. In cases where component degradation affects the safety or performance of the melter, and quick troubleshooting may be difficult, Nordson Corporation recommends replacing components as preventive maintenance.

Checking the Hydraulic, Gas, and Electrical Connections

Use the following procedure to check the hydraulic, gas, and electrical connections.

1. Check the following hydraulic connections for leaks and damage:
   • all hose connections and fittings at the manifold,
   • all fittings between hoses and applicators
2. Check all hoses for cuts, kinks, and fraying.
3. Check all gas tubes for bends, kinks, or other damage.
4. Check all electrical connections to the hoses for fraying, broken wires, and damaged connectors.
5. Refer to the section “Parts” on page 9-1 to replace any damaged equipment.

Cleaning the Fan and Air Filter

Depending on dust accumulation, the filters (1 and 3) for the air inlet and outlet (4 and 5) must be cleaned (knocked out) or replaced.

1. Air filter, top air inlet
2. Fan
3. Air filter, bottom air inlet
4. Fan and filter
5. Air filter, air outlet

Installing Filter Cartridges

1. Apply high-temperature grease to all threads and o-rings.
2. Slide the filter cartridge into the filter bore and tighten slightly. Torque = 4.5 N•m / 40 in.-lb. NOTE: The dragged-in air must now be removed.
3. Place a container under the respective drain valve.
4. Use a screwdriver to turn the drain valve screw counterclockwise and open the valve.
5. Allow the pump to run and feed material until it comes out free of bubbles. NOTE: For information on locating the drain valve, see Figure 6-2 on page 6-7.
6. Use a screwdriver to turn the drain valve screw clockwise and close the valve.
7. Properly dispose of material according to local regulations.
8. Resume normal operations.

Resuming Normal Operation

Perform the following steps to resume normal operation after relieving system hydraulic pressure and performing maintenance.

1. Close the drain valve.
2. Install the applicator nozzle(s).
3. Touch the Master Controls button on the Home screen, and then touch the Global Heater button to turn on all of the heaters.
4. Ensure all symbols in the status area are green in color, which indicates that the system is ready.
5. Touch the Master Controls button and then touch the Pump button. The pump turns on. Adjust pump speed to suit your application needs. Refer to Figure 5-7 on page 5-8.
6. Touch the Gas On/Off button to turn on the gas.
7. Touch the Pressure tile and then enter the desired pressure for the application.
8. Allow the system to stabilize for 3-5 minutes before resuming normal operation.

Troubleshooting

Mechanical Troubleshooting

The following table provides general troubleshooting information for mechanical problems. You may need to refer to maintenance and disassembly procedures for additional troubleshooting information.

Pump Outlet Pressure Troubleshooting

Temperature Control Troubleshooting

The FM FIT25 melter was designed and tested for resistance to EMI that is typically present in heavy industrial applications. To protect the FM FIT25 melter from EMI, it is important that all enclosures are in good condition and properly installed and grounded. Failure to take these precautions may result in random faults and a melter shutdown.

Electrical Safety During Troubleshooting

Before performing troubleshooting activities inside the electrical enclosure, exhaust all methods of troubleshooting the problem with the electrical enclosure closed or with the power off. In general, perform troubleshooting activities as follows:

• Check the displays and lights for warnings, faults, and other status information.
• Check for continuity and grounding between system components (unit, applicators, hoses, and other equipment).
• Make sure the branch circuit disconnect switch is properly installed.
• Make sure the power supply is supplying the proper voltage.
• Prioritize troubleshooting activities to limit exposure to live power. Perform troubleshooting activities involving live power last.
• Understand the system electrically and mechanically before opening the electrical enclosure. Pay special attention to system power distribution and to I/O interfaces with other equipment.
• Identify and eliminate potential electrical shock hazards in the environment surrounding the melter.

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