Nordson FoamMix Flex, Customer Product Manual

Page 1: ...Manual Part 1129048_01 Issued 12 20 NORDSON CORPORATION DULUTH GEORGIA USA www nordson com This document contains important safety information Be sure to read and follow all safety information in this...

Page 2: ...atic Signature stylized Slautterback Smart Coat Smart Gun SolderPlus Spectrum Speed Coat StediFlo Stratablend SureBead Sure Coat SureWrap Symphony Tip Seal TRAK Tribomatic Trilogy TrueBlue TrueCoat Tu...

Page 3: ...and Cautions 7 Other Safety Precautions 11 First Aid 11 System Overview 12 System Equipment 14 Advanced Foaming Station 14 ProMeter VDK Controller 15 ProMeter VDK Dispensing Module 16 Bulk Melters 16...

Page 4: ...wmeters Configuration Screen 46 Sealant Flowmeter Configuration Screen 48 Pressure Sensors Configuration Screen Group 49 Unloader Screen Group 54 AltaPail Versa Drum Main Screen 54 AltaPail Versa Drum...

Page 5: ...aming Station 81 Alarm Screen Messages 82 VDK Dispensing Module or Controller 82 FoamMix Flex Foaming Station 83 Bulk Melters Unloaders 84 Parts Lists 85 Cable Assemblies 85 Drive Assembly 86 Mixer As...

Page 6: ...Table of Contents iv Part 1129048_01 E 2020 Nordson Corporation...

Page 7: ...vided in this document can result in personal injury including death or damage to equipment or property Safety Alert Symbols The following safety alert symbol and signal words are used throughout this...

Page 8: ...ith governing regulations Contact the authority having jurisdiction for information S Maintain safety information including the safety labels affixed to the equipment in readable condition Instruction...

Page 9: ...heir job function S are physically capable of performing their job function and are not under the influence of any substance that degrades their mental capacity or physical capabilities Applicable Ind...

Page 10: ...e with the ATEX directive nor as nonincendive and should not be installed in potentially explosive environments S Ensure that the processing characteristics of the material will not create a hazardous...

Page 11: ...ent S Perform scheduled maintenance activities at the intervals described in this document S Relieve system hydraulic and pneumatic pressure before servicing the equipment S De energize the equipment...

Page 12: ...e levels of shut down are Relieving System Hydraulic Pressure Completely relieve system hydraulic pressure before breaking any hydraulic connection or seal Refer to the melter specific product manual...

Page 13: ...troller timer PLC etc 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 pressur...

Page 14: ...equipment are met Failure to comply with SDS requirements can cause personal injury including death HM WARNING Reactive material Never clean any aluminum component or flush Nordson equipment with halo...

Page 15: ...solenoid valve s can result in personal injury HM CA PC WARNING Risk of electrocution Even when switched off and electrically isolated at the disconnect switch or circuit breaker the equipment may sti...

Page 16: ...N Some Nordson melters are specifically designed to process polyurethane reactive PUR hot melt Attempting to process PUR in equipment not specifically designed for this purpose can damage the equipmen...

Page 17: ...Suspend dispensing hand held applicators by their proper suspension point First Aid If molten hot melt comes in contact with your skin 1 Do NOT attempt to remove the molten hot melt from your skin 2 I...

Page 18: ...ge to the equipment This manual provides information about the installation connection and setup of the FoamMix Flex System The following Nordson equipment is required to form the advanced foaming sys...

Page 19: ...6 Figure 1 Complete advanced foaming system 1 Bulk Unloaders 2 FoamMix Flex foaming station 3 ProMeter VDK dispensing module 4 FoamMix Flex VDK controller 5 Nitrogen tank customer supplied 6 FoamMix F...

Page 20: ...foaming station is intended to be used S for processing UV RTV silicone S in conjunction with a bulk melter S for generating foamed UV RTV silicone that will be discharged from a ProMeter VDK dispensi...

Page 21: ...es whether the last amount of material dispensed was within customer specified limits and therefore it can also be operated in the volume mode or the flow mode S In the volume mode the output signal i...

Page 22: ...y a bulk melter FoamMix FoamMelt or by any other positive pressure material supply system Figure 4 Pro Meter VDK dispensing module Bulk Melters Up to two Nordson bulk melters may be used in this syste...

Page 23: ...ent that makes up the FoamMix Flex foaming system needs to be purchased separately S FoamMix Flex foaming station S ProMeter VDK dispensing module S ProMeter VDK controller S Bulk melter unloader S Ni...

Page 24: ...t the Equipment For details on how to mount the equipment refer to the following product manuals S AltaPail II bulk melter S Pro Meter VDK dispensing module S Pro Meter VDK controller S FoamMix Flex f...

Page 25: ...as two adjustment knobs the stainless steel knob is factory set and locked DO NOT adjust this knob or foam quality will be adversely affected NOTE If the Nordson pressure regulator is used with your s...

Page 26: ...at meets the following requirements to the controller Voltage Electrical Service Line 240 VAC single phase 25 A 3 3 mm2 12 AWG 90 _C 194 _F 3 Route the electrical service wiring through the strain rel...

Page 27: ...Connector Type Cable Connector Type 1 Trigger Volume Interface 1 9 Sealant Flow Meter 2 2 Digital Analog Interface 1 10 Gas Control Valve 3 Pressure Transducer 1 11 Melter 1 Motor Enable 4 Applicator...

Page 28: ...to VDK controller connections Cable Connector Details Purpose A Cable is connected internally from the VDK dispensing module to the VDK controller servo drive Motor power B Encoder 3 Cable is connecte...

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Page 30: ...Gas Pressure connection on the FoamMix Flex foaming station to the VDK controller 7 Cable is connected from the Sealant Flow Meter connection on the FoamMix Flex foaming station to the VDK controller...

Page 31: ...the FoamMix Flex unit electrical compartment can result in personal injury including death The FoamMix Flex foaming station requires an output signal from the bulk melter in order to operate Standard...

Page 32: ...tations from a single melter each unit must be connected to a discreet bulk melter output 6 Route the signal cable over to the FoamMix Flex foaming station 7 Run the end of the signal cable through th...

Page 33: ...FoamMix Flex Foaming System 27 Part 1129048_01 E 2020 Nordson Corporation Figure 9 120V unit signal cable connection Figure 10 240V unit signal cable connection...

Page 34: ...est fit your manufacturing process Main Screen The components on the Main screen let you navigate various screens for setting up and operating the FoamMix Foaming system 1 2 3 4 VDK MOTOR RUNNING MIXE...

Page 35: ...atus area consists of the following components 1 2 5 6 4 STATUS TEXT AREA MIXER U1 U2 VDK 3 M Figure 12 Status area components Item Component Function 1 Status Symbol and Color Displays the system sta...

Page 36: ...s Text State Description OFF System is not functioning NOT READY Bulk Unloader 1 and or 2 is in ready state Bulk Unloader 1 EMPTY Bulk Unloader 1 and or 2 is empty COLLECTIVE FAULT Pump has stopped be...

Page 37: ...ick Navigation area can display any of the following navigation buttons Quick Navigation Button Function AUTO MAN Opens the One Shot AUTO MANUAL screen for all system components Config Opens the Syste...

Page 38: ...FoamMix status NOTE If you are already inside a screen group this area is used to navigate between the screen in the respective group The active screen will be highlighted in white M MOTOR RUNNING MIX...

Page 39: ...ays an overview of the system and values for main process variables For all other screens it displays settings and process variables VDK MOTOR RUNNING MIXER U1 U2 VDK Advanced FoamMix Version DV1 M NN...

Page 40: ...en buttons change color depending on the equipment state Bulk Melter 1 and 2 The button colors shown in the following table describe the different states of the bulk melter Button Color State Black In...

Page 41: ...ration ProMeter VDK Dispensing Module The button colors shown in the following table describe the different states of the VDK dispensing module Button Color State Black Inactive System off Green Ready...

Page 42: ...on Mixer The button colors shown in the following table describe the different states of the advanced foaming station Button Color State Black Inactive System off Green Running Yellow A warning specif...

Page 43: ...29048_01 E 2020 Nordson Corporation Nitrogen Tank The button colors shown in the following table describe the different states of the nitrogen tank Button Color State Black Inactive Green Ready Yellow...

Page 44: ...e VDK controller Start the System 1 See Figure 15 Place the MAIN DISCONNECT switch in the ON position 2 When ready for operation push the SYSTEM ON button to activate the control circuits and allow ac...

Page 45: ...n displays automatically if no unloader was configured for the system If you want to change the type and or number of connected unloaders you can access this screen from the main configuration screen...

Page 46: ...FoamMix Version DV1 VDK s s AUTO MAN MIXER GAS All Automatic All Manual Not enough access rights M A A A A Figure 17 AUTO MAN screen Item Component Function 1 AUTO MAN Touch this button on the Main sc...

Page 47: ...Log In Log Out screen Item Component Function 1 User item 5 Fig 11 Touch this button on the Main screen to access the Log In Log Out screen 2 Touch this button to access the Main screen 3 Log In Touch...

Page 48: ...em status and the VDK dispensing module advanced foaming station and nitrogen tank screen settings S User account E Engineer This user account allows full access to the available menu screens The user...

Page 49: ...button to access these options System Configuration Screen Touch the System Config button to access options that let you view or change the system configuration 1 3 2 6 4 5 Status MOTOR RUNNING MIXER...

Page 50: ...e the output mode Flow Volume 3 Foam Density View or change the desired foam density 4 VDK Pump Mode View or change the VDK Pump running mode Automatic On external line reference or Manual On set RPM...

Page 51: ...view 2 1 Shut Down Application MOTOR RUNNING MIXER U1 U2 VDK Advanced FoamMix Version DV1 M PanelView Setup PanelView Setup Screen Backlight Intensity Figure 20 PanelView Setup screen Item Component F...

Page 52: ...x Version DV1 M PanelView Setup Flowmeter Config Pressure Sensors Config Configure Gas Flowmeter Flowmeter Config VDK Pump Flow System Config Configure Sealant Flowmeter Sealant Flow Feedback Figure 2...

Page 53: ...w Low Limit cc min Raw Analog Input Flow Zero Offset cc min Status must read System Ready to zero flowmeter Figure 22 Gas Flowmeter Configuration screen Item Component Function 1 Zero Gas Flowmeter To...

Page 54: ...wmeter NNN N Status must read System Ready to zero flowmeter NNN N Sealant Flowmeter Raw Analog Input Flow Zero Offset Sealant Flowmeter Limits MIN MAX Sealant Flowmeter Config Figure 23 Sealant Flowm...

Page 55: ...se options Sealant Input Transducer Configuration Screen Touch the Sealant Input Transducer button on the Pressure Sensors Configuration screen to view or change the sealant input transducer configura...

Page 56: ...ferential pressure for the PID controller NOTE If the Unloader speed is PID controlled to maintain a sealant pressure setpoint and the actual pressure value deviates with more than these deltas an ala...

Page 57: ...n DV1 M Sealant Input Transducer NNN N VDK Transducer Minimum Delta Gas Transducer Range End Gas Actual Pressure Mpa Mpa Mpa Gas Input Transducer Mixer Transducer Gas Input Transducer Figure 25 Gas In...

Page 58: ...s MOTOR RUNNING MIXER U2 VDK U1 Advanced FoamMix Version DV1 M Sealant Input Transducer NNN N VDK Transducer Mixer Transducer Range End Mixer Actual Pressure Mpa Mpa Gas Input Transducer Mixer Transdu...

Page 59: ...er Range End VDK Actual Pressure Gas Input Transducer Mixer Transducer VDK Transducer VDK Transducer Mpa Mpa Mpa VDK Minimum Pressure Figure 27 VDK Pressure Transducer Configuration screen Item Compon...

Page 60: ...il Versa Drum button on the Main screen to view or change options for the AltaPail and Versa Drum melters NOTE If two AltaPail Versa Drum unloaders are connected a second unloader button is visible in...

Page 61: ...w or change the operating mode of the unloader S Manual S Auto PID 3 Control Type View or change the unloader control type S ON Active on pressure control S OFF Not controlled S Low Level The unloader...

Page 62: ...Derivative Gain bar bar Auto PID Config NNN N PID Proportional Gain UNLD Level Low Delay 7 min Figure 29 AltaPail Versa Drum Auto PID Configuration screen Item Component Function 1 Actual Pressure Vie...

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Page 64: ...tton on the main screen to view or change the Rhino settings 1 2 5 3 4 Status MOTOR RUNNING MIXER U2 VDK U1 Advanced FoamMix Version DV1 M Rhino 1 Rhino 1 Operating mode Control Type Rhino Checkout Pa...

Page 65: ...abled 2 Operating Mode View or change the operating mode of the unloader S Manual S Auto PID 3 Control Type View the control type of the unloader S ON Active on pressure control S OFF Not controlled S...

Page 66: ...ed Press Build Complete Unit Connected Platen Lowered Press Build Complete Rhino Checkout Page Figure 31 Rhino Checkout screen Item Component Function 1 Melter Interface Used Touch this check box butt...

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Page 68: ...creen Touch the FoamMix Main Status button on the Mixer main screen to view the status of the FoamMix mixer 1 2 3 4 5 Sealant Flow Gas Flow Press Min Delta Pressure Delta Mixer Status cc min cc min Mp...

Page 69: ...sealant flow if the sealant flowmeter is present 2 Gas Flow View the gas flow 3 Press Min Delta View the minimum delta between sealant and gas pressure 4 Pressure Delta View the pressure delta and sta...

Page 70: ...view or change the mixer motor configuration 1 2 3 4 MANUAL MOTOR RUNNING MIXER U1 U2 VDK Advanced FoamMix Version DV1 M Configuration Actual Speed Diagnostics NNNN Drv FAULT FoamMix Main Status Mixer...

Page 71: ...f delay of the mixer motor after the VDK pump stops S Enable Status View or change the current status as follows S Disabled S Enabled S Running S Drive fault S Operating Mode View or change the dive o...

Page 72: ...ual Setpoint FoamMix Main Status Mixer Motor Config Foam Config Operating Mode Minimum Delta I P Output Foam Config Mpa NNN N Gas Ratio NO NOT ALI ATICI Figure 34 Foam Configuration screen Item Compon...

Page 73: ...Main Drive Setup VDK Main Reset Total KG VDK Pressure Volume Flow OK Mpa NNN RPM NNNN N Not enough access rights MOTOR RUNNING U1 U2 MIXER VDK Total Flow Figure 35 VDK Main screen Item Component Func...

Page 74: ...e Analog Output Config Drive Analog Reference Config Drive Speed Feedback Config Press to Purge Not enough access rights Figure 36 VDK Drive Setup Screen Item Component Function 1 Flow Rate View the a...

Page 75: ...Config Drive Speed Feedback Config Pump Config SSSSSSSSSSSSSSSSSSSSSSSSSSSS s s Maximum View Limit Pump Size cc rev Figure 37 VDK Pump Configuration screen Item Component Function 1 Pump Size cc rev...

Page 76: ...ec Applicator ON delay Drive Analog Output Config Drive Analog Reference Config Drive Speed Feedback Config SSSSSSSSSSSSSSSSSSSSSSSSSSSS Flow Analog Out Scaling in CC min Drive Analog Output Config se...

Page 77: ...MOTOR RUNNING MIXER U1 U2 VDK Advanced FoamMix Version DV1 M Drive Setup Pump Config Reverse Analog Ref Signal Polarity Drive Analog Output Config Drive Analog Reference Config SSSSSSSSSSSSSSSSSSSSSS...

Page 78: ...rection Drive Analog Output Config Drive Analog Reference Config SSSSSSSSSSSSSSSSSSSSSSSSSSSS Drive Speed Feedback Config NNN N Drive Speed Feedback Config RPM Feedback Scaling Factor Step 1 Stop Driv...

Page 79: ...NNNNNN NNN MOTOR RUNNING MIXER U1 U2 VDK NNNN N NNNN N NNNN N NNNN N NNNN N NNNN N NNNN N NNNN N NNNN NN NNNN Advanced FoamMix Version DV1 M Acc Status FoamMix VDK Status VDK SureFoam FoamMix Status R...

Page 80: ...NNN Advanced FoamMix Version DV1 M Acc Status FoamMix VDK Status Accumulated Acc Status Error Flow acc Gas Flow acc Ratio Current Gas Flow Applied Ratio VDK Flow cc min Figure 42 Accumulator Status sc...

Page 81: ...ble switch is in the ON position Bulk Melter Unloader PID Mode Prior to dispensing material the Bulk melter unloader supply system must be placed into Automatic PID control 1 Power on the Bulk melter...

Page 82: ...ng processed the system may need to be purged for several minutes Adjust Foam Density The FoamMix Flex foaming system is capable of significantly reducing silicone density Foam density is a function o...

Page 83: ...Run or Purge the system for a period of time that will ensure the VDK supply hose will be filled with the material at the new Gas Ratio 6 Weigh the dispensed adhesive 7 To increase the density of the...

Page 84: ...ming station Recommended Maintenance Schedule This is a recommended schedule for maintaining the Pro Meter VDK controller Activity Interval Clean air filters on cooling fan and vent Monthly Replace th...

Page 85: ...side of the FoamMix Flex assembly where the gas valve and gas transducer are located 2 Remove the M6 socket head cap screw 3 that secures the side panel to the manifold stabilizer with a 5 mm Allen wr...

Page 86: ...scratch the surface of the gas check valve stem seat area and cause seal failure 1 Wipe the exterior surface of the check valve assembly 2 to remove excess adhesive 2 Remove the hex nut guide and spri...

Page 87: ...n 1 Loss of foamed silicone No gas supply Check nitrogen tank pressure and regulator position Incorrect pressure differential between the gas inlet pressure and the silicone outlet pressure Ensure tha...

Page 88: ...Data is Out of Range Warning Edit the last entered data point and correct the new data to be within the operational range PLC Low Battery Alarm Warning Replace the PLC battery VDK Low Pressure Fault F...

Page 89: ...OFF Fault Place the Mixer Enable switch located on the controller door into the ON 1 position Mixer Motor is Not in Automatic Mode Fault On the SureFoam Configuration page place the mixer into Auto m...

Page 90: ...k Melter Unloader 1 Pail Low Warning Bulk Melter Unloader 1 Pail Empty Warning Bulk Melter Unloader 2 Pail Low Warning Bulk Melter Unloader 2 Pail Empty Warning Bulk Melter Unloader 1 Not Ready Warnin...

Page 91: ...nections refer to Connect the FoamMix Flex Foaming System Part Description Quantity 1510490 CABLE ASSY SFA MIXER GAS VALVE 5M 9DSUB 1 1515090 CABLE SFA MIXER GAS XDCR FOAMMIX 1 1513588 CABLE SERVO LEN...

Page 92: ...ING TAPERED ROLLER 1 98x1 00x 56 1 4 1513051 BLOCK SERVO DRIVE HEAT ISOLATION 1 5 982034 SCR SKT M6X50 BL 4 6 982046 SCR HEX CAP M5X14 BL 8 7 1512888 ADAPTER DRIVE SHAFT FOAMMIX 1 8 1515062 REDUCER SE...

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Page 94: ...Y SFA MIXER GAS VALVE 5M 9DSUB 1 17 1514891 TRANSDUCER ASSY PRESSURE GAS 1 18 1512721 BLOCK GAS PRESSURE TRANSDUCER 1 19 972047 FITTING TUBE 9 16X7 16 O RING 1 20 985409 PIN DOWEL 250X 500 H G 1 21 97...

Page 95: ...8 973299 PLUG O RING STR THD 3 8 24 3 59 1514938 MANIFOLD FOAMMIX FLEX 1 60 972034 CONNECTOR 37DEG STR THD 1 97 1 61 130633 CONNECTOR 8 SAE M 3 4T 37S 1 62 1090202 TUBEFTG CONN 10MMT 1 4NPT PUSHIN BRA...

Page 96: ...ly contd 2X 2X 2X SEE BOTTOM VIEW ON SHEET 2 FOR MOUNTING HOLE PATTERN 2X 2 1 63 4 3 5 6 7 9 8 60 61 62 64 65 69 67 6 66 25 70 68 13 12 11 14 10 15 16 19 18 17 9 8 7 6 26 20 21 53 58 59 9 54 8 57 24 2...

Page 97: ...X 313 10408 1 4 1108372 S LUBRICANT O RING NSF H1 FOOD GRADE 4L 1 5 940101 S O RING VITON BLK 239ID X 070W BR 1 6 945036 S BACK UP RING SINGLE 1 4 X 3 8 1 7 1514983 S BODY CHECK VALVE GAS FOAMMIX 1 8...

Page 98: ...27 SWITCH DISCONNECT 3P 40A A B 1 19 171229 KNOB DISCONNECT YELLOW RED A B 1 20 1502419 POWER SUPPLY 24VDC 2 1A 50W 1 21 1512281 CIRCUIT BREAKER 2P 480V 25A UL489 1 22 7174249 FAN 230VAC 55M3 H SK3238...

Page 99: ...1 10 02 11 03 12 04 13 05 14 06 15 07 COM 0 N C COM 1 N C V V 00 08 09 01 10 02 11 03 12 04 13 05 14 06 15 07 COM 0 COM 1 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 4 6 5 3 32 12 31 84 2 66 82 8 7 26 24 77 85 86...

Page 100: ...OF PANEL LABEL S SHOWN ARE ON INSIDE OF PANEL 0 35 22 65 3X 2X 38 81 72 34 37 81 75 56 54 36 13 9 23 37 34 89 90 37 34 19 18 4X 47 48 54 55 56 81 36 54 56 75 81 34 37 80 46 45 36 72 81 37 34 72 71 73...

Page 101: ...1 58 ITEM NUMBER RESERVED 59 1123690 TERMINAL DIN JUMPER 41POS CUT TO LENGTH 1 60 1504522 BLOCK TERMINAL 2P DIODE 4 61 171656 DIODE GENP 1N4007 1KV 1A AXL 11 62 1123691 SUPPRESSOR EMI CLAMP FERRITE 13...

Page 102: ...EM NUMBER RESERVED 84 1095205 CIRCUIT BREAKER 2 POLE 15A UL489 1 85 1513332 MOTOR CONTROL SRV 240V 1PH 1 1kW PROG 1 86 1513331 MODULE COMM ENET IP DRV 8400 TL 1 87 1513333 CLAMP WIRE SHIELD 4 15MM 1 8...

Page 103: ...2UNF ROHS 1514982 VALVE ASSY CHECK GAS FOAMMIX 1511876 VALVE GAS 250 SCCM 1500 PSI 1514891 TRANSDUCER ASSY PRESSURE GAS 1510208 SEAL ROTARY 5 8 ID WITH FLANGE 1123460 CONTROLLER MOTORCNTL SERVO DRIVE...

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