FoamMix Series Processor - Nordsonemanuals.nordson.com/adhesives/English_Manuals/1052254.pdf ·...

NORDSON CORPORATION DULUTH, GEORGIA USAwww.nordson.com

FoamMixSeries ProcessorConfiguration III

Customer Product ManualPart 1052254B

Issued 05/06

Part 1052254B � 2006 Nordson CorporationAll rights reserved

For CE Declaration, refer to melter manual.

Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General informationabout Nordson can be found on the Internet using the following address: http://www.nordson.com.

Address all correspondence to:

Nordson CorporationAttn: Customer Service11475 Lakefield Drive

Duluth, GA 30097

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2005.No part of this document may be photocopied, reproduced, or translated to another language without the prior written

consent of Nordson Corporation. The information contained in this publication is subject to change without notice.

Trademarks

AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, CleanSleeve, CleanSpray,ColorMax, Control Coat, Coolwave, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, DuraBlue, Durafiber, Dura-Screen, Durasystem, Easy Coat,Easymove Plus, Ecodry, Econo-Coat, e.dot, EFD, e stylized, ETI, Excel 2000, Fillmaster, FlexiCoat, Flexi-Spray, Flex-O-Coat, Flow Sentry, Fluidmove,FoamMelt, FoamMix, Heli-flow, Helix, Horizon, Hot Shot, iControl, iFlow, Isocoil, Isocore, Iso-Flo, iTRAX, Kinetix, Little Squirt, LogiComm, Magnastatic,

March, MEG, Meltex, Microcoat, Micromark, MicroSet, Millennium, Mini Squirt, Mountaingate, MultiScan, Nordson, OptiMix, Package of Values, Pattern View, PermaFlo, Plasmod, Porous Coat, PowderGrid, Powderware, Printplus, Prism, ProBlue, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, RBX,

Rhino, Saturn, Scoreguard, Seal Sentry, Select Charge, Select Coat, Select Cure, Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat,SureBead, Sure Clean, Sure Coat, Sure-Max, TRAK, Tracking Plus, Trends, Tribomatic, Ultra, Ultrasaver, UpTime, Vantage, Veritec, VersaBlue, Versa-Coat, Versa-Screen, Versa-Spray, Walcom, Watermark, and When you expect more. are registered trademarks of Nordson Corporation.

Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AquaCure, ATS, Auto-Flo, AutoScan, Best Choice, Blue Series, Check Mate,Classicblue, Colo-on-Demand, Controlled Fiberization, Control Weave, CPX, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraDrum, DuraPail,

Easy Clean, EasyOn, Eclipse, E-Nordson, EquiBead, ESP, Fill Sentry, G−Net, G−Site, HDLV, iON, Iso-Flex, iTrend, Lacquer Cure, Lean Cell, Maverick,Maxima, MicroFin, MicroMax, MiniBlue, MiniEdge, Minimeter, Multifil, Myritex, OptiStroke, PatternPro, PCI, Powder Pilot, Powercure, Primarc,

Process Sentry, Prodigy, Pulse Spray, Quad Cure, Ready Coat, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit, Sure Brand, SureMix, SureSeal, Sure Wrap, Swirl Coat, Tempus, ThruWave, Trade Plus,

TrueBlue, Ultrasmart, Universal, VersaDrum, VersaPail, Vista, Web Cure, and 2 Rings (Design) are trademarks of Nordson Corporation.

Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes, could lead to violation of the owners’ rights.

Table of Contents i

Part 1052254B� 2006 Nordson Corporation

Table of Contents

Safety 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Alert Symbols 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Responsibilities of the Equipment Owner 1-2 . . . . . . . . . . . . . . . . . . . . . . .

Safety Information 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instructions, Requirements, and Standards 1-2 . . . . . . . . . . . . . . . . . .User Qualifications 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applicable Industry Safety Practices 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use of the Equipment 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instructions and Safety Messages 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . .Installation Practices 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Practices 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance and Repair Practices 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Safety Information 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Equipment Shutdown 1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving System Hydraulic Pressure 1-5 . . . . . . . . . . . . . . . . . . . . .De-energizing the System 1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disabling the Guns 1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Safety Warnings and Cautions 1-6 . . . . . . . . . . . . . . . . . . . . . .Other Safety Precautions 1-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .First Aid 1-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Description 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Basic Operation 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Theory of Operation 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Metering System 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gas Pressure Regulator 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dryer/filter 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gas Control Valve 2-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Pressure Regulator 2-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Pressure Check Valve 2-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Check Valve 2-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sealant/Hydraulic System 2-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Reducing Regulator 2-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sealant Flow Meter 2-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mixer System 2-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil System 2-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pump 2-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Circuit 2-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Circuit 2-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cooling System 2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chiller 2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cooling Jackets 2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature control system 2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsii

Part 1052254B � 2006 Nordson Corporation

Installation 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unpacking 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steps 8 through 10 – Units Equipped with Chiller 3-4 . . . . . . . . . . .All Units: 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Units Equipped with Chiller 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Programming System Parameters 4-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Program−Password 4-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Program−Mixer 4-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Program−Mixer−Ratio 4-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Program−Mixer−Pressure Units 4-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Program−Mixer−Accel 4-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Program−Mixer−Time Const 4-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Program−Temp 4-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Program−Temp−Setpoints (Heated Units Only) 4-14 . . . . . . . . . . . . . . . .Program−Temp−Setpoints−Zones (Heated Units Only) 4-14 . . . . . . . . .Program−Temp−Setpoints−Setall (Heated Units Only) 4-15 . . . . . . . . .Program−Temp−Setpoints−Setback (Heated Units Only) 4-15 . . . . . . .Program−Temp−Setpoints−Shutdown (Heated Units Only) 4-15 . . . . . .Program−Temp−Zone−Shutdown−Zone (Heated Units) 4-16 . . . . . . . .Program−Temp−Shutdown (Unheated Units) 4-16 . . . . . . . . . . . . . . . . .Program−Temp−Setpoints−Shutdown−Sealant (Heated Units Only) . . . . .4-16 Program−Temp−Startup (Heated Units Only) 4-17 . . . . . . . . . . . . . . . . .Program−Temp−Startup−Seq−Start (Heated Units Only) 4-17 . . . . . . .Program−Temp−Startup−Delay (Heated Units Only) 4-18 . . . . . . . . . . .Program−Temp−Units (All Units) 4-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . .Program−Temp−Labels (Heated Units Only) 4-18 . . . . . . . . . . . . . . . . . .Program−Temp−Gains (Heated Units Only) 4-19 . . . . . . . . . . . . . . . . . . .Adjusting Gains (Heated Units Only) 4-20 . . . . . . . . . . . . . . . . . . . . . . . . .Program−Motor 4-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Program−Motor−Speed 4-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Program−Motor−Setback 4-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Program−Motor−Setback Speed 4-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . .Program−Motor−Setback Delay 4-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Program−Clock (Heated Units Only) 4-23 . . . . . . . . . . . . . . . . . . . . . . . . .Program−Clock−Time (Heated Units Only) 4-23 . . . . . . . . . . . . . . . . . . .Program−Clock−Time−Time of Day (Heated Units Only) 4-24 . . . . . . . .Program−Clock−Time−Date (Heated Units Only) 4-24 . . . . . . . . . . . . . .Program−Clock−Time−Format (Heated Units Only) 4-24 . . . . . . . . . . . .Program−Clock−Schedule (Heated Units Only) 4-24 . . . . . . . . . . . . . . .Program−Clock−Schedule−View (Heated Units Only) 4-25 . . . . . . . . . .Program−Clock−Schedule−Add (Heated Units Only) 4-25 . . . . . . . . . . .Program−Clock−Schedule−Delete (Heated Units Only) 4-26 . . . . . . . . .Program−Clock−Schedule−Clear All (Heated Units Only) 4-27 . . . . . . .

Table of Contents iii


Startup Mode of Operation 4-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setback Mode of Operation 4-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shutdown Mode of Operation 4-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual Mode of Operation 4-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual−Temp (Heated Units Only) 4-30 . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Motor 4-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Gas−Flow 4-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Displ 4-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual−Displ−Sealant/Gas−Mixer 4-32 . . . . . . . . . . . . . . . . . . . . . . . .Manual−Displ−Sealant 4-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Disp−Oil 4-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Disp−Motor 4-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Displ−Gas−Supply 4-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Displ−Flmtr 4-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Displ−Temp 4-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Set the Oil Pressure 4-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Set Normal Operating Pressure 4-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Set the High Pressure Oil Circuit 4-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction of Sealant into the FoamMix Unit 4-36 . . . . . . . . . . . . . . . . . . .Set the Mixer Gas Pressure 4-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .View System Parameters 4-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mixer−View 4-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mixer−Review 4-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mixer−Ratio 4-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mixer−Flow 4-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mixer−Flmtr 4-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mixer−Pressure 4-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mixer−Pressure−Sealant/Gas−Mixer 4-40 . . . . . . . . . . . . . . . . . . . . . . . . .Mixer−Pressure−Gas−Supply 4-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mixer−Pressure−Oil 4-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temp−View 4-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heated units: 4-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unheated units: 4-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temp−Review 4-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heated units: 4-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heated units: 4-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unheated units: 4-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unheated units: 4-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heated units: 4-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heated and unheated units: 4-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heated units: 4-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heated units: 4-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heated units: 4-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heated and unheated units: 4-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temp−Zone 4-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temp−Setback (Heated Units Only) 4-43 . . . . . . . . . . . . . . . . . . . . . . . . .Temp−Shutdown 4-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temp−Shutdown−Zone (Heated Units Only) 4-44 . . . . . . . . . . . . . . . . . .Temp−Shutdown−Sealant (Heated Units Only) 4-44 . . . . . . . . . . . . . . . .Temp−Startup−Seq (Heated Units Only) 4-44 . . . . . . . . . . . . . . . . . . . . . .Temp−Startup−Delay (Heated Units Only) 4-44 . . . . . . . . . . . . . . . . . . . .Motor−View 4-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor−Review 4-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor−Speed 4-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor−Setback 4-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clock−View (Heated Units Only) 4-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsiv


Daily Operating Procedures 4-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unheated units (no temperature channels) 4-47 . . . . . . . . . . . . . . . . . . .

System shutdown 4-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Start−up 4-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heated units (with temperature channels) 4-47 . . . . . . . . . . . . . . . . . . . .System shutdown: 4-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System start−up 4-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Precautions 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Maintenance 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Periodic maintenance schedule 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance Procedures 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspect Hydraulic, Gas and Electrical Connections 5-2 . . . . . . . . . .Check and Replacing Gear Reducer Oil 5-3 . . . . . . . . . . . . . . . . . . .Check and Replacing Oil in the Reservoir 5-3 . . . . . . . . . . . . . . . . . .Replace the Gas Dryer Cartridge 5-4 . . . . . . . . . . . . . . . . . . . . . . . . .Replace the gas filter 5-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FoamMix System Diagnostics 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual−Diag 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Diag−Temp−Heater−Enter 6-3 . . . . . . . . . . . . . . . . . . . . . . . . . .Temperature Channel Identification 6-4 . . . . . . . . . . . . . . . . . . . . . . . . .Temperature channel locations 6-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Diag−Temp−RTD 6-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Diag−Temp−Short 6-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Diag−Temp−Current 6-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Diag−Temp−Aux−Out 6-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Diag−FoamMix 6-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Diag−FoamMix−Inputs 6-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Diag−FoamMix−Outputs 6-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Diag−I/O 6-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Diag−I/O−Inputs 6-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Diag−I/O−Outputs 6-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Diag−Display 6-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Diag−Key 6-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Diag−PROM 6-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual−Diag−RAM 6-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FoamMix system faults 6-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Major faults 6-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Minor faults 6-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fault messages 6-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Other error message 6-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents v


Using the Troubleshooting Flowchart 6-22 . . . . . . . . . . . . . . . . . . . . . . . . . . .Ratio Control Parameters Out of Range 6-23 . . . . . . . . . . . . . . . . . . . . .T.1.1 6-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .T.1 6-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Density Reduction Changes 6-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .T.2 6-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Low Oil Pressure 6-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .T.3 6-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No Gas Flow Indication 6-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .T.4 6-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Line Frequency Interrupts not Detected (Unheated Units Only) 6-31 .T.5 6-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Open Heater 6-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .T.6 6-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Open Heater Troubleshooting 6-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DP.1 − Check FoamMix Printed Circuit Board 6-37 . . . . . . . . . . . . . . . .DP.2 − Check the I/O Board 6-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using the Illustrated Parts Tables 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heated System Controller 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unheated System Controller 7-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard Oil System 7-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .High Pressure Oil System 7-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard Pressure Gas Supply System 7-14 . . . . . . . . . . . . . . . . . . . . .High Pressure Gas Supply System 7-18 . . . . . . . . . . . . . . . . . . . . . . . . .Unheated Sealant System 7-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heated Sealant System 7-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heated HP Sealant System 7-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Polyamide Sealant System 7-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Parts Drawings Foldou. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .t 31

Table of Contentsvi


## TABSHEET ##

Safety

Safety 1-1

A1EN−01−[XX−SAFE]−10� 2006 Nordson Corporation Issued 4-02

Section 1Safety

Read this section before using the equipment. This section containsrecommendations and practices applicable to the safe installation,operation, and maintenance (hereafter referred to as “use”) of the productdescribed in this document (hereafter referred to as “equipment”).Additional safety information, in the form of task-specific safety alertmessages, appears as appropriate throughout this document.

WARNING: Failure to follow the safety messages, recommendations, andhazard avoidance procedures provided in this document can result inpersonal injury, including death, or damage to equipment or property.

Safety Alert Symbols The following safety alert symbol and signal words are used throughout thisdocument to alert the reader to personal safety hazards or to identifyconditions that may result in damage to equipment or property. Comply withall safety information that follows the signal word.

WARNING: Indicates a potentially hazardous situation that, if not avoided,can result in serious personal injury, including death.

CAUTION: Indicates a potentially hazardous situation that, if not avoided,can result in minor or moderate personal injury.

CAUTION: (Used without the safety alert symbol) Indicates a potentiallyhazardous situation that, if not avoided, can result in damage to equipmentor property.

Safety1-2

A1EN−01−[XX−SAFE]−10 � 2006 Nordson CorporationIssued 4-02

Responsibilities of the Equipment Owner Equipment owners are responsible for managing safety information,ensuring that all instructions and regulatory requirements for use of theequipment are met, and for qualifying all potential users.

Safety Information � Research and evaluate safety information from all applicable sources,

including the owner-specific safety policy, best industry practices,governing regulations, material manufacturer’s product information, andthis document.

� Make safety information available to equipment users in accordancewith governing regulations. Contact the authority having jurisdiction forinformation.

� Maintain safety information, including the safety labels affixed to theequipment, in readable condition.

Instructions, Requirements, and Standards � Ensure that the equipment is used in accordance with the information

provided in this document, governing codes and regulations, and bestindustry practices.

� If applicable, receive approval from your facility’s engineering or safetydepartment, or other similar function within your organization, beforeinstalling or operating the equipment for the first time.

� Provide appropriate emergency and first aid equipment.

� Conduct safety inspections to ensure required practices are beingfollowed.

� Re-evaluate safety practices and procedures whenever changes aremade to the process or equipment.

User Qualifications Equipment owners are responsible for ensuring that users:

� receive safety training appropriate to their job function as directed bygoverning regulations and best industry practices

� are familiar with the equipment owner’s safety and accidentprevention policies and procedures

� receive, equipment- and task-specific training from another qualifiedindividual

NOTE: Nordson can provide equipment-specific installation,operation, and maintenance training. Contact your Nordsonrepresentative for information

� possess industry- and trade-specific skills and a level of experienceappropriate to their job function

Safety 1-3


� are physically capable of performing their job function and are notunder the influence of any substance that degrades their mentalcapacity or physical capabilities

Applicable Industry Safety Practices The following safety practices apply to the use of the equipment in themanner described in this document. The information provided here is notmeant to include all possible safety practices, but represents the best safetypractices for equipment of similar hazard potential used in similar industries.

Intended Use of the Equipment � Use the equipment only for the purposes described and within the limits

specified in this document.

� Do not modify the equipment.

� Do not use incompatible materials or unapproved auxiliary devices.Contact your Nordson representative if you have any questions onmaterial compatibility or the use of non-standard auxiliary devices.

Instructions and Safety Messages � Read and follow the instructions provided in this document and other

referenced documents.

� Familiarize yourself with the location and meaning of the safety warninglabels and tags affixed to the equipment. Refer to Safety Labels andTags at the end of this section.

� If you are unsure of how to use the equipment, contact your Nordsonrepresentative for assistance.

Installation Practices � Install the equipment in accordance with the instructions provided in this

document and in the documentation provided with auxiliary devices.

� Ensure that the equipment is rated for the environment in which it will beused and that the processing characteristics of the material will notcreate a hazardous environment. Refer to the Material Safety DataSheet (MSDS) for the material.

� If the required installation configuration does not match the installationinstructions, contact your Nordson representative for assistance.

� Position the equipment for safe operation. Observe the requirements forclearance between the equipment and other objects.

� Install lockable power disconnects to isolate the equipment and allindependently powered auxiliary devices from their power sources.

� Properly ground all equipment. Contact your local building codeenforcement agency for specific requirements.

� Ensure that fuses of the correct type and rating are installed in fusedequipment.

Safety1-4


� Contact the authority having jurisdiction to determine the requirement forinstallation permits or inspections.

Operating Practices � Familiarize yourself with the location and operation of all safety devices

and indicators.

� Confirm that the equipment, including all safety devices (guards,interlocks, etc.), is in good working order and that the requiredenvironmental conditions exist.

� Use the personal protective equipment (PPE) specified for each task.Refer to Equipment Safety Information or the material manufacturer’sinstructions and MSDS for PPE requirements.

� Do not use equipment that is malfunctioning or shows signs of apotential malfunction.

Maintenance and Repair Practices � Perform scheduled maintenance activities at the intervals described in

this document.

� Relieve system hydraulic and pneumatic pressure before servicing theequipment.

� De-energize the equipment and all auxiliary devices before servicing theequipment.

� Use only new factory-authorized refurbished or replacement parts.

� Read and comply with the manufacturer’s instructions and the MSDSsupplied with equipment cleaning compounds.

NOTE: MSDSs for cleaning compounds that are sold by Nordson areavailable at www.nordson.com or by calling your Nordsonrepresentative.

� Confirm the correct operation of all safety devices before placing theequipment back into operation.

� Dispose of waste cleaning compounds and residual process materialsaccording to governing regulations. Refer to the applicable MSDS orcontact the authority having jurisdiction for information.

� Keep equipment safety warning labels clean. Replace worn ordamaged labels.

Equipment Safety Information This equipment safety information is applicable to the following types ofNordson equipment:

� hot melt and cold adhesive application equipment and all relatedaccessories

� pattern controllers, timers, detection and verification systems, and allother optional process control devices

Safety 1-5


Equipment Shutdown To safely complete many of the procedures described in this document, theequipment must first be shut down. The level of shut down required variesby the type of equipment in use and the procedure being completed. If required, shut down instructions are specified at the start of theprocedure. The levels of shut down are:

Relieving System Hydraulic Pressure Completely relieve system hydraulic pressure before breaking any hydraulicconnection or seal. Refer to the melter-specific product manual forinstructions on relieving system hydraulic pressure.

De-energizing the System Isolate the system (melter, hoses, guns, and optional devices) from allpower sources before accessing any unprotected high-voltage wiring orconnection point.

1. Turn off the equipment and all auxiliary devices connected to theequipment (system).

2. To prevent the equipment from being accidentally energized, lock andtag the disconnect switch(es) or circuit breaker(s) that provide inputelectrical power to the equipment and optional devices.

NOTE: Government regulations and industry standards dictate specificrequirements for the isolation of hazardous energy sources. Refer tothe appropriate regulation or standard.

Disabling the Guns All electrical or mechanical devices that provide an activation signal to theguns, gun solenoid valve(s), or the melter pump must be disabled beforework can be performed on or around a gun that is connected to apressurized system.

1. Turn off or disconnect the gun triggering device (pattern controller, timer,PLC, etc.).

2. Disconnect the input signal wiring to the gun solenoid valve(s).

3. Reduce the air pressure to the gun solenoid valve(s) to zero; thenrelieve the residual air pressure between the regulator and the gun.

Safety1-6


General Safety Warnings and Cautions Table 1-1 contains the general safety warnings and cautions that apply toNordson hot melt and cold adhesive equipment. Review the table andcarefully read all of the warnings or cautions that apply to the type ofequipment described in this manual.

Equipment types are designated in Table 1-1 as follows:

HM = Hot melt (melters, hoses, guns, etc.)

PC = Process control

CA = Cold adhesive (dispensing pumps, pressurized container, andguns)

Table 1-1General Safety Warnings and Cautions

EquipmentType Warning or Caution

HM

WARNING: Hazardous vapors! Before processing any polyurethanereactive (PUR) hot melt or solvent-based material through acompatible Nordson melter, read and comply with the material’sMSDS. Ensure that the material’s processing temperature andflashpoints will not be exceeded and that all requirements for safehandling, ventilation, first aid, and personal protective equipment aremet. Failure to comply with MSDS requirements can cause personalinjury, including death.

HM

WARNING: Reactive material! Never clean any aluminum componentor flush Nordson equipment with halogenated hydrocarbon fluids.Nordson melters and guns contain aluminum components that mayreact violently with halogenated hydrocarbons. The use ofhalogenated hydrocarbon compounds in Nordson equipment cancause personal injury, including death.

HM, CA

WARNING: System pressurized! Relieve system hydraulic pressurebefore breaking any hydraulic connection or seal. Failure to relievethe system hydraulic pressure can result in the uncontrolled release ofhot melt or cold adhesive, causing personal injury.

HM

WARNING: Molten material! Wear eye or face protection, clothingthat protects exposed skin, and heat-protective gloves when servicingequipment that contains molten hot melt. Even when solidified, hotmelt can still cause burns. Failure to wear appropriate personalprotective equipment can result in personal injury.

Continued...

Safety 1-7


General Safety Warnings and Cautions (contd)

Table 1-1General Safety Warnings and Cautions (contd)


HM, PC

WARNING: Equipment starts automatically! Remote triggeringdevices are used to control automatic hot melt guns. Before workingon or near an operating gun, disable the gun’s triggering device andremove the air supply to the gun’s solenoid valve(s). Failure todisable the gun’s triggering device and remove the supply of air to thesolenoid valve(s) can result in personal injury.

HM, CA, PC

WARNING: Risk of electrocution! Even when switched off andelectrically isolated at the disconnect switch or circuit breaker, theequipment may still be connected to energized auxiliary devices.De-energize and electrically isolate all auxiliary devices beforeservicing the equipment. Failure to properly isolate electrical power toauxiliary equipment before servicing the equipment can result inpersonal injury, including death.

CA

WARNING: Risk of fire or explosion! Nordson cold adhesiveequipment is not rated for use in explosive environments and shouldnot be used with solvent-based adhesives that can create anexplosive atmosphere when processed. Refer to the MSDS for theadhesive to determine its processing characteristics and limitations.The use of incompatible solvent-based adhesives or the improperprocessing of solvent-based adhesives can result in personal injury,including death.

HM, CA, PC

WARNING: Allow only personnel with appropriate training andexperience to operate or service the equipment. The use of untrainedor inexperienced personnel to operate or service the equipment canresult in injury, including death, to themselves and others and candamage to the equipment.

Continued...

Safety1-8



HM

CAUTION: Hot surfaces! Avoid contact with the hot metal surfacesof guns, hoses, and certain components of the melter. If contact cannot be avoided, wear heat-protective gloves and clothing whenworking around heated equipment. Failure to avoid contact with hotmetal surfaces can result in personal injury.

HM

CAUTION: Some Nordson melters are specifically designed toprocess polyurethane reactive (PUR) hot melt. Attempting to processPUR in equipment not specifically designed for this purpose candamage the equipment and cause premature reaction of the hot melt.If you are unsure of the equipment’s ability to process PUR, contactyour Nordson representative for assistance.

HM, CA

CAUTION: Before using any cleaning or flushing compound on or inthe equipment, read and comply with the manufacturer’s instructionsand the MSDS supplied with the compound. Some cleaningcompounds can react unpredictably with hot melt or cold adhesive,resulting in damage to the equipment.

HM

CAUTION: Nordson hot melt equipment is factory tested withNordson Type R fluid that contains polyester adipate plasticizer.Certain hot melt materials can react with Type R fluid and form a solidgum that can clog the equipment. Before using the equipment,confirm that the hot melt is compatible with Type R fluid.

Other Safety Precautions � Do not use an open flame to heat hot melt system components.

� Check high pressure hoses daily for signs of excessive wear, damage,or leaks.

� Never point a dispensing handgun at yourself or others.

� Suspend dispensing handguns 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. Immediately soak the affected area in clean, cold water until the hot melta has cooled.

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 hotmelt to the medical personnel providing treatment.

## TABSHEET ##

Descrip

tion

Description 2-1


Section 2Description

General Description The Nordson FoamMix Configuration III processor uses microprocessorbased electronics to control the mechanical mixing of a flowable sealantwith precisely metered quantities of inert gas to provide a foam of uniformdensity. A complete, integrated system can be assembled to dispense thisfoamed material onto a substrate for producing closed-cell foam gaskets,eliminating the need for die-cut and foam-type gaskets.

FoamMix offers the following standard features:

� Microprocessor based controller with EPROM-based software andnonvolatile memory for all operator-programmed set points

� Expandable card-rack circuit board configuration

� Operator interface through a menu-driven, two-1-line-by-40-characterliquid crystal display (LCD) and tactile membrane keypad panel for easeof programming and daily operation

� Full system diagnostics that activate automatic alarm and shutdownfunctions

� Remote signal output with user-ready connections for system ready andpump interlock

� Display of system functions including: mix ratio, material and gas flowrates, system pressures, system temperatures, motor speed andcurrent, system operation mode, and diagnostic messages

� Selectable Celsius/Fahrenheit, bar/psi display

� Sequential heater start-up capability (units with temperature control)

Description2-2


General Description (contd)

� Seven-day clock for automatic system activation (units with temperaturecontrol)

� Selectable 12 hour/24 hour display (units with temperature control)

� Variable speed mixer drive motor

� Corrosion-resistant material construction

� Gas dryer (�5ppm H20) and filter (�7 micron) with replaceablecartridges

� Removable sheet metal enclosures

� Operator-adjusted, low-temperature setback mode (units withtemperature control)

� High-viscosity polymer sealant material processing capability.

� Integral chiller option (not available on high temperature units) to provideactive cooling of the mixer barrel for shear-sensitive materials. Thisreduces temperature fluctuations of the sealant due to mix energy.

In addition, the following optional features are available for FoamMix:

� Up to 12 external temperature channels to control hose and guntemperatures, and other auxiliary equipment

Description 2-3


Specifications Parameter Specification

Exterior dimensions

� Height

� Depth

� Width

� 193 cm (76 in.)

� 99 cm (39 in.)

� 102 cm (40 in.)

Weight 410 kg (900 lb)

Electrical requirements 240 VAC (+5%, −10%), 50/60 Hz, 3�

Maximum 15 A unheated systemmaximum 35 A heated system

Air supply (for oil system pump) 4.8 bar (60−120 psi) dry, filtered air

Gas supply

� Low pressure system

� High pressure system

Nitrogen, dry grade

� Maximum 90 par (1300 psi) working pressure

� maximum 207 bar (3000 psi) working pressure

Material Pressure

� Low pressure system

� High pressure system

� Maximum 83 par (1200 psi) working pressure

� maximum 207 bar (3000 psi) working pressure

Heating elements (heated systems only)

� Regulator

� Flow meter

� Heated union

� Mixer (3 zones)

� Cartridge heaters (2)


� Band heater (1)


Temperature range

� Operating

� Ambient

� 38−204 �C (100−400 �F) (heated systems only)

� 0−50 �C (32−122 �F)

Humidity Up to 90% relative (non-condensing)

Maximum continuous delivery rate Up to 45 kg/hr (100 lb/hr)

Viscosity range 1000−10,000 cps

Material density reduction Up to 80% (material dependent) (�5% accuracy)

Controller

� Type

� Temperature control method (heated systems)

� Temperature sensors

� Temperature control channels

� Proprietary microprocessor

� PID

� Nickle RTD (120 ohm)

� 18 controlled zones (12 external − heatedsystems), 2 monitoring zones)

Temperature stability �1 �C (�2 �F)

Noise level �76 dB (measured 1 m [3.3 ft] from unit)

Display 3 line, 40 character LED

Operator interface Pressure sensitive, membrane panel

Description2-4


Basic Operation A simple block diagram of the FoamMix unit is shown in Figure 2-1.FoamMix is a standalone unit that accepts a solid (nonfoamed) sealantmaterial supplied at its input from an external source. A flow meter monitorsthe amount of sealant being supplied to the unit. An inert gas (usuallynitrogen) is mechanically combined, under pressure, with the sealant. Gasinput into the sealant is governed by a microprocessor-based controller.The controller receives input from the flowmeter, which then releases gasbased on the amount of sealant being supplied.

An integral pressure-reducing regulator maintains constant sealant pressuresupplied from the external source. This ensures proper control of gasinjection into the mixer and smooth flow of the material through the flowmeter. The combined material is deposited onto a substrate through anozzle and exposed to atmospheric pressure. The gas expands, producinga foamed material.

Description 2-5


MICROPROCESSOR-BASED CONTROLLER NITROGENBOTTLE

GASCONTROL

VALVE

BULK

DELIVERYSYSTEM

SEALANTFLOW

METERMIXER

SEALANT

PRESSURE

REGULATOR

Figure 2-1 FoamMix System Block Diagram

Description2-6


Theory of Operation The system can be broken down into six major subsystems:

� Gas metering system

� Sealant/hydraulic system

� Mixer system

� Oil system

� Cooling system (if installed)

� Temperature control system (if applicable)

The primary subsystems are the gas metering, sealant/hydraulic and mixersystems, since they are responsible for the density control and foamingprocesses. The remaining subsystems are auxiliary support systems formaintaining proper sealant properties and protecting sensitive machinecomponents. All of these individual subsystems are controlled andmonitored by the process controller.

Gas Metering System Responsible for injecting a precise volume of inert gas into the sealant forproper density reduction. Components include:

Gas Pressure Regulator Sets the manifold mixer gas pressure using a pressure transducer. Thispressure must be greater than the static mixer sealant pressure (monitoredby a transducer located at the mixer) for gas to be injected into the sealant.

Dryer/filter Insures �5 ppm H2O and removes particulate of �7 microns. This allowsthe use of industrial-grade gases while protecting against excess moistureentering the sealant − important when using moisture-curing materials andpreventing clogging of downstream components.

Description 2-7


Gas Control Valve A thermal mass flow meter and control valve that governs the flow of gasinto the mixer. An analog electrical signal received from the controlleractivates the valve. The valve also transmits a signal back to the controllerindicating actual gas flow. The controller compensates for the differencebetween actual and desired flow.

Back Pressure Regulator Controls the pressure drop across the gas control valve to maintain thecalibrated accuracy of the valve. This regulator maintains a constant 2 bar(30 psid) regardless of the gas flow or upstream pressure.

Back Pressure Check Valve Relieves pressure from the back pressure regulator dome if the differentialbetween the inlet and dome exceeds 20 bar (300 psig).

Check Valve Prevents sealant from entering the gas system if the sealant pressureexceeds the mixer gas pressure.

Sealant/Hydraulic System Consists of the pressure reducing regulator and the flow meter.

Pressure Reducing Regulator Maintains constant sealant pressure in the mixer. Because this is anonventing regulator, pressure reduction by the regulator requires openingthe gun to relieve pressure.

Sealant Flow Meter A positive displacement device that transmits pulses at a frequency inproportion to the flow rate of the sealant. This data is then used to meterappropriate amounts of gas.

Description2-8


Mixer System A low shear mechanical mixer assembly combines gas and sealant. Avariable speed DC motor, gear reducer and mixer shaft control the mixingprocess.

Motor speed is programmed as a percentage of maximum speed(20%−100%) with 100% being approximately 1,750 rpm. Gear reducers areavailable in either 25:1, 7.5:1 or 5:1 speed reduction. Optimum mixer speedis dependent on flow rates and sealant characteristics.

Pressure transducers monitor oil and sealant pressure. Oil pressure mustalways be higher than sealant pressure to prevent sealant from leaking pastthe mechanical face seals and into the bearings. If oil and sealant pressureare equal, the controller sounds an alarm and shuts the system down.Higher oil pressure also keeps the faces of the seals well lubricated,increasing their life and reducing heat/friction.

RTDs (resistance temperature detectors) monitor oil and sealanttemperatures to ensure that they do not exceed the limits oftemperature-sensitive sealant materials.

Mechanical face seals have many advantages over standard shaft lip seals:

� No shaft and/or sleeve wear

� Little or no leakage

� Automatic wear adjustment

� Low maintenance

� Reduced friction and heat generation

� Long life

Description 2-9


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Description2-10


Oil System Provides and maintains pressure in the oil chamber (bearing housing) toprotect the mechanical face seals. It also lubricates the tapered rollerbearings located in the oil chamber.

Oil Pump An air-operated unit that pressurizes oil in the oil chamber at a pressureratio of 36:1.

Air Circuit Shop air supplies the oil pump. Two air pressure regulators are used: onefor normal operation (low pressure) and another for a fault condition whenthe sealant pressure approaches the shop air pressure. Oil pressure mustbe greater than 13.8 bar (200 psig) above sealant pressure. If not, the unitautomatically shifts (via the solenoid valve) to the high pressure circuit ,setat (3000 psig). This prevents sealant from getting between the hardenedsurfaces of the face seals.

Oil Circuit Oil is circulated through the oil chamber by a pumping ring located on theoutboard face seal. As the shaft rotates, the pumping ring displaces a smallvolume of oil and starts the circulation. The circulation cools the seal facesand bearings, and avoids hot spots in the oil chamber. If the systemrequires service, oil pressure must be relieved by opening the manual bleedvalve.

Oil pressure is monitored by a pressure transducer located in the oil circuit.Temperature is monitored by a RTD also located in the oil chamber.

The pressure relief valve is set to open at a set range between 151.7−172.4bar (2,200−2,500 psi). When a pressure fault occurs, the oil pump willgenerate 206.8 bar (3,000 psi), causing the relief valve to open. Therestrictor upstream of the relief valve maintains 206.8 bar (3,000 psi) oilpressure until the fault is corrected and cleared.

Description 2-11


Cooling SystemCools and/or conditions the temperature of sealant in critical applications. ARTD located at the output end of the mixer housing monitors sealanttemperature. The RTD signals the controller, which opens a solenoid valvethat releases coolant. A chiller or, if desired, external connections areprovided to circulate customer-supplied coolant.

ChillerA circulating bath-type chiller with a preset bath temperature of −10 �C(14 �F). Glycol is used as the coolant.

Cooling JacketsLocated on the mixer housing. Combination heating and cooling jackets areavailable for applications requiring strict temperature control of the sealant.

NOTE: This option is not available on heated units.

Temperature control systemThe control system monitors and regulates temperature in the sealantregulator, flow meter, mixer and applicable manifolds. Temperaturechannels are also available for external auxiliary equipment, as well ashoses and guns. Heater control is accomplished through pulse widthmodulation and a Proportioned Integral Derivative (PID) control algorithm.

Temperature can be monitored and adjusted at the controller operatorinterface and keypad. Temperature readout of the actual and set−pointtemperatures are in either degrees Fahrenheit (�F) or degrees Celsius (�C).

At power-up, the software performs a vacant/connected channelconfiguration test. If both the RTD and heater are missing from a channel,that channel is labeled as “vacant.” A previously vacant channel that isconnected while the controller is running will not be recognized until thecontroller is rebooted.

The FoamMix system may be operated in either a low temperature(unheated) mode, warm (32 − 121 �C [90 − 250 �F]) (heated) mode, or hightemperature (121 − 204 �C [250 − 400 �F]) (heated) mode. Zones areindividually heated and controlled. On unheated units, no zones areheated; on heated units, all zones are heated. External temperaturechannels and the chiller/cooling lines are options that maximize temperatureconditioning flexibility.

NOTE: Maximum “per-program” temperature setting is 232 �C (450 �F).

Description2-12


Temperature control system(contd)The software menu structure is responsive to the temperature range of thespecific FoamMix system. This “auto-configuration” shows the operatoronly those menus and displays relevant to a specific subsystem in aFoamMix unit. For instance, a system with no temperature control will notdisplay menus relating to programming or viewing auto-start times orsetback temperatures. Likewise, setback mode is non−functional in asystem without temperature channels.

In a temperature−controlled system, only connected temperature channelswill be displayed in the status menus. In a heated system, set-points maybe programmed for vacant channels.

At power up, diagnostic tests detect vacant channels. In an unheatedsystem, both temperature monitoring channels are required; therefore, if aRTD is open, a fault will be generated.

In a heated system, the heaters are also tested. Combining the heater andRTD tests, the software performs the vacant/connected configuration check.

The power up test also includes checking the RTDs and heaters for openedand shorted connections.

A second diagnostics test (heated systems only) runs once every 30seconds as long as the controller is powered; it tests for shorted triacs, andregisters an overtemperature fault if detected.

A third test (heated systems only) runs while the controller is activelycontrolling temperature zones. Once every 30 seconds, a single zone istested for the opened heater condition. Therefore, the frequency of theopened heater test for a given channel is equal to (30 seconds) x (the totalnumber of heater channels connected.)

Heated systems only: The auto start, auto setback and auto shutdownfeatures enable the operator to initiate a specified activity at a programmedtime. The system is capable of storing a total of 30 programmed times,which are identified by time-of-day, day-of-week and type (start, setback orshutdown). These times, once programmed, will remain in controllermemory until cleared by the operator.

A CLOCK key and associated LED are located on the keyboard. Pressingthe CLOCK key toggles the system between the auto-enabled and -disabledstates. The clock LED must be on to use the auto features. When thecontroller reaches a programmed auto time (and the CLOCK key isactivated), the auto function is enabled.

Description 2-13


An auto function may not be activated while in the Manual mode. If an autotime occurs while programming a set point, the auto action will be delayeduntil the set point is programmed.

Following an auto start execution, if more than two hours have passed sincethe system ready condition was set, and no sealant flow has been detectedsince that time, and the system has remained in Ready mode, the systemthen automatically goes in Setback mode. Otherwise, the effect of autostart is exactly like that of pressing the STARTUP key.

In heated systems, a sequential startup feature is provided. This featuremay be disabled by the operator. Sequential startup operates as follows:

� Zone Group A = Hoses

� Zone Group B = Regulator, Flow meter, Mixer

� Zone Group C = Options

� Zone Group D = Gun

1. Start Zone Group A.

2. Wait for last zone in Group A to reach 80% of set point.

3. Start Zone Group B.

4. Wait for last zone in Group B to reach 80% of set point.

5. Start Zone Group C.

6. Wait for last zone in Group C to reach 80% of set point.

7. Start Zone Group D.

8. Wait for last zone to reach 1 �C (5 �F) below set point.

9. Wait for programmable temperature ready delay.

10. Start mixer startup sequence.

If the sequential start is disabled, the controller starts all heating zones atonce, waits until all zones are within 5 �F of set point, then begins thetemperature ready delay and mixer startup sequence shown above.

In heated systems, the sequential/non−sequential cold startup sequencecan be bypassed if the system has previously been heated up totemperature. This is referred to as a “warm start.” On a normal sequentialor non−sequential cold start, a “hot” flag is set following the temperatureready delay. That flag is then checked on subsequent startup to determineif warm start may be used. The flag is cleared if any zone dips below 80%of set point at any time.

Description2-14


## TABSHEET ##

Installatio

n

Installation 3-1


Section 3Installation

WARNING: Allow only qualified personnel to perform the following tasks.Follow the safety instructions in this document and all other relateddocumentation.

UnpackingThe unit is shipped with the control cabinet laying on top of the mixer baseunit; the entire unit assembly is bolted to a pallet.

1. Remove the FoamMix unit from the pallet before removing the controllerfrom the base.

2. Remove the controller from the base.

3. Locate the appropriate mounting hardware for attaching the controller tothe base. The hardware includes the following:

Part Description Quantity984707 Nut, MB 4983417 Washer, oversized, MB 8983404 Lockwasher, MB 4982049 Screw, hex head, MC X 25 mm 4920069 Coolant, glycol (units with chiller only) 2 gal.

4. After unpacking, inspect the unit for damage. Report any damage to aNordson representative.

Installation3-2


Installation

FLOWMETERENCODER

642 psi

OIL PRESSURE

64

psi

HIGH

864

barpsi1bar=0,1MPa

PRESSURESUPPLY

OPERATINGOIL PRESSURE

864

2barpsi

Figure 3-1 FoamMix System Block Diagram (typical set-up shown)

1. Install the main (input) power line per Figure 3-2, noting the appropriateconnection for the applicable voltage.

Installation 3-3


A B C

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Installation3-4


Installation (contd)

2. Install the gas line from the gas source to the mixer gas supply inlet.The connection at the inlet is 1/4 in. NPTF.

NOTE: DO NOT USE PTFE TAPE OR PIPE DOPE ON THE THREADS.The mating thread is brass and sealing can be done without dope or tape.Also, dope or tape can clog gas lines and sensitive valves in the FoamMixunit.

3. Connect the shop air supply to the 1/4 in. NPTF air inlet.

4. Connect sealant hoses per system diagram (shipped separately fromthis manual).

Steps 8 through 10 – Units Equipped with Chiller5. Locate container of glycol shipped with unit.

6. Remove chiller tank cover.

7. Pour glycol into the chiller tank until the level reaches the top mark.

CAUTION: Do not overfill!

All Units:Refer to Operation for instructions on charging the system with gas andsealant, and programming system parameters.

Units Equipped with Chiller After the unit begins operation, add additional glycol to the chiller tank untilthe level again reaches the top mark. This is to compensate for glycolpumped downstream into the hoses and cooling jackets.

## TABSHEET ##

Op

eration

Operation 4-1


Section 4Operation


IntroductionThis section contains information concerning the setup and operation of theFoamMix system. FoamMix may be operated in either unheated (roomtemperature) mode or heated (warm or high temperature) mode.

The letters XXXXXXXX on a display represent either the STARTUP,SHUTDOWN, SETBACK or MANUAL mode of operation. The lettersYYYYYY represent the selected channel.

FoamMix is designed to operate through separate modes:

� STARTUP mode (AUTO key) initiates temperature and mixer startupsequences and operates the control functions.

� SHUTDOWN mode (OFF key) stops the FoamMix process and is ineffect when the system is not in operation.

� SETBACK mode (SETBACK key) (heated units only) is similar to theSHUTDOWN mode, except that temperature zones are maintained atthe setback temperature setting rather than being disabled.

� MANUAL mode (MANUAL key) includes self−diagnostic tests andmenus for controlling and monitoring system components.

System set points may be programmed while operating in the STARTUP,SETBACK (heated units only) or SHUTDOWN mode. A password isrequired to access the programming menu in order to establish set points.A separate service password is required for programming related to serviceand system configuration.

The system logs process faults. Pressing the FAULT key displays faults inany mode of operation and at any time. Upon exiting the fault display, thepreviously viewed menu is displayed.

Operation4-2


Introduction (contd)NOTE: Perform initial system startup only in the following sequence:

1. Programming System Parameters

2. Setting Oil Pressure

3. Introduction of Sealant into the Unit

4. Setting Mixer Gas Pressure

Figures 4-1 and 4-2 illustrate the software modes of heated and unheatedFoamMix systems operation with the general capability of each mode.

FOAMMIX

SYSTEM

STARTUP MODE

NORMAL OPERATION

SHUTDOWN MODE

SHUT DOWN SYSTEM

SETBACK MODE

TEMPERATURE SETBACK

MANUAL MODE

MANUAL OPERATION

AND DIAGNOSTICS

Figure 4-1 Heated FoamMix System Software Modes

FOAMMIX

SYSTEM

STARTUP MODE

NORMAL OPERATION

SHUTDOWN MODE

SHUT DOWN SYSTEM

MANUAL MODE

MANUAL OPERATION

AND DIAGNOSTICS

Figure 4-2 Unheated FoamMix System Software Modes

Operation 4-3


Figures 4-3 and 4-4 illustrate the general effects within the FoamMix systemwhen a mode change is initiated, as well as specific changes to systemoperation when entering a different mode.

STARTUP SHUTDOWN

SYSTEM READY OFF

SETBACK MANUAL

MODE CHANGE

GAS OUTPUT ZEROPURGE OFF

RATIO CONTROL OFFMOTOR OFF

SEQUENTIAL STARTSTOPPED

TEMP CHANNELS OFFINITIATE TEMPERATURE

AND MIXER STARTUPTEMP CHANNELS OFF

SYSTEM READY OFFTEMP CHANNELS TO

SETBACK TEMP

SYSTEM READY OFF

TEMP CHANNELS OFF

Figure 4-3 Heated FoamMix System Software Mode Change

STARTUP SHUTDOWN

SYSTEM READY OFF

MANUAL

MODE CHANGE

GAS OUTPUT ZEROPURGE OFF

RATIO CONTROL OFFMOTOR OFF

INITIATE MIXER STARTUP SYSTEM READY OFF

Figure 4-4 Unheated FoamMix System Software Mode Change

Operation4-4


Introduction (contd)Figures 4-5 and 4-6 illustrate the overall, operator-interface capabilities ofthe FoamMix controller. For each mode of operation, main menus displayprocesses that can be be accessed when in that particular mode. Note thatthe MIXER, TEMP, MOTOR and CLOCK (heated units only) main menusare for viewing only. The PROGRAM main menu can be accessed forprogramming at any time while in the STARTUP, SHUTDOWN or SETBACK(heated units only) modes. The PASSWORD display within the PROGRAMmain menu is designed for use by Nordson service personnel only. The setof menus contained in the boxes-in MANUAL mode portion of both figures ispassword protected. The operator must enter a password before any menucan be accessed.

Operation 4-5


X

Figure 4-5 Heated FoamMix Controller Tree Menu

Operation4-6


Introduction (contd)

X

Figure 4-6 Unheated FoamMix Controller Tree Menu

Operation 4-7


Figure 4-7 shows the FoamMix controller keypad for unheated and heatedunits.

ON OFF MANAUAL SETBACK

1

2

3

!PURGE FAULT CLOCK

FAULT

INCREASE

DECREASE

ENTERPREVIOUS NEXT

ESC

Figure 4-7 Heated FoamMix Controller Keypad

ON Key – Places the system in the STARTUP mode of operation. Wheninitiated, STARTUP will be shown on the display.

OFF Key – Places the system in SHUTDOWN mode. After pressing thiskey, SHUTDOWN will immediately appear on the display. Note that this keyis functional when the system is in a Major fault condition.

SETBACK Key – (Heated units only) Places the system in the SETBACKmode of operation.

MANUAL Key – Places the system in the MANUAL mode of operation.After pressing this key, MANUAL will immediately appear on the display.Note that this key is functional when the system is in a Major fault condition.

1,2,3 Keys – Used to enter the 1-to-5 digit password.

Operation4-8


Introduction (contd)ENTER Key – Places operator-generated information, values and set pointsinto the controller memory.

ESC Key – Removes the existing display and returns the display to the toplevel menu.

INCREASE, DECREASE Keys – Used to enter numerical values within thePROGRAM menu.

PREVIOUS, NEXT Keys – Enable the operator to access the previous andnext displays or messages in relation to the display or message currentlybeing viewed.

PURGE Key – Places the unit in the PURGE condition.

PURGE Indicator – Illuminates when the system is in the PURGE process.

CLOCK Key – (Heated units only) Actives the unit’s CLOCK function.

CLOCK Indicator – (Heated units only) Illuminates when the CLOCK key ispressed, indicating that the CLOCK function is activated.

FAULT Key – Pressing this key acknowledges a FAULT condition. This, inturn, permits the operator to correct the condition and reestablish theFAULT−monitoring function.

FAULT Indicator – Will flash when the system enters a Major or Minor faultcondition. Refer to Troubleshooting for a listing of conditions that willactivate this indicator.

Operation 4-9


Programming System ParametersIf selecting PROGRAM from the main menu produces a request for apassword, select the default password of “1111.” The display below (heatedunit in this case) will be shown:

PROGRAM XXXXXXXX(MIXER TEMP MOTOR CLOCK PASSWORD)

All programming and system configuration will take place through themenus that follow in this section.

Use the INCREASE and DECREASE keys to enter numerical values. Pressthe ENTER key to save programmed values. If EXIT is pressed instead ofENTER, the value will not be saved and the previous value will remain ineffect.

Program−PasswordTo change the password, select PASSWORD within the PROGRAM menu.The display below will be shown:

PROGRAM PASSWORD XXXXXXXXCHANGE PASSWORD? (NO YES)

Selecting NO will return the display to the top level PROGRAM menu.Selecting YES will produce the display below and permit the entering ofpassword information:

PROGRAM PASSWORD XXXXXXXXENTER CURRENT PASSWORD

The password can be a series of one to five digits, created by using the 1,2and 3 keys on the keypad. The default password is “1111.” If only theENTER key is pressed with no numbers or keys preceding it, the passwordis disabled and the system will no longer ask for it when the MANUAL modeor PROGRAM menu is requested. To regain the PROGRAM PASSWORDfunction, press the ENTER key at the display below for the currentpassword.

Operation4-10


Program−Password(contd)If the current password is correctly entered, the display below is shown.Enter the new password.

PROGRAM PASSWORD XXXXXXXXENTER NEW PASSWORD

After entering the new password, the following display is shown whichrequests that the new password be entered again for verification. Enter thenew password again.

PROGRAM PASSWORD XXXXXXXXRE−ENTER NEW PASSWORD TO VERIFY

If the new password is entered correctly the second time, it will be storedand the following acknowledgement will be shown.

PROGRAM PASSWORD XXXXXXXXNEW PASSWORD IN EFFECT – PRESS EXIT

If the current password was not entered, the following display is shown.

PROGRAM PASSWORD XXXXXXXXINCORRECT CURRENT PASSWORD – PRESS EXIT

Program−MixerWhen the EXIT key is pressed, the display returns to the top levelPROGRAM menu.

At the PROGRAM MIXER level indicated below, the ratio set point, pressureunits, gas flow meter acceleration or sealant flow averaging time may beprogrammed.

PROGRAM MIXER XXXXXXXX(RATIO PRESSURE UNITS ACCEL TIME CONST)

Operation 4-11


Program−Mixer−RatioAt the display shown here, the gas ratio index value can be entered. Thisvalue is to be programmed in the range of 0.0 (OFF) to 10.0 in 0.1increments. No units are associated with this value. The default value isOFF. Refer to the Gas Ratio Index Set point Relationship table, followingthe display below, which indicates the relationship between: Ratio Setting,Theoretical Density and % of Gas to Sealant.

NOTE: The Theoretical Density Reduction is eight times the Ratio Setting.Note also that the actual density reduction may differ from the theoretical.

PROGRAM MIXER XXXXXXXXGAS RATIO INDEX SETPOINT = ____.___

Table 4-1 GAS RATIO INDEX SETPOINT RELATIONSHIP

Ratio Setting Theoretical Density (%) % of Gas to Sealant

0.2 1.60 1.63

0.4 3.20 3.31

0.6 4.80 5.04

0.8 6.40 6.84

1.0 8.0 8.70

1.2 9.60 10.62

1.4 11.20 12.61

1.6 12.80 14.68

1.8 14.40 16.82

2.0 16.00 19.05

2.2 17.60 21.36

2.4 19.20 23.76

2.6 20.80 26.26

2.8 22.40 28.87

3.0 24.00 31.58

3.2 25.60 34.41

3.4 27.20 37.36

3.6 28.80 40.45

3.8 30.40 43.68

4.0 32.00 47.06

4.2 33.60 50.60

4.4 35.20 54.32

Continued...

Operation4-12


Program−Mixer−Ratio(contd)

Ratio Setting Theoretical Density (%) % of Gas to Sealant

4.6 36.80 58.23

4.8 38.40 62.34

5.0 40.00 66.67

5.2 41.60 71.32

5.4 43.20 76.06

5.6 44.80 81.16

5.8 46.40 86.57

6.0 48.00 92.31

6.2 49.60 98.41

6.4 51.20 104.92

6.6 52.80 111.86

6.8 54.40 119.30

7.0 56.00 127.27

7.2 57.60 135.85

7.4 59.20 145.10

7.6 60.80 155.10

7.8 62.40 165.96

8.0 64.00 177.78

8.2 65.60 190.70

8.4 67.20 204.88

8.6 68.80 220.51

8.8 70.40 237.84

9.0 72.00 257.14

9.2 73.60 278.79

9.4 75.20 303.23

9.6 76.80 331.03

9.8 79.40 362.96

10.0 80.00 400.00

Operation 4-13


Program−Mixer−Pressure UnitsPressure units are indicated as either PSI or BAR. If BAR is not selected,the display will automatically indicate the pressure units in PSI.

PROGRAM MIXER XXXXXXXXXPRESSURE UNITS: (PSI BAR)

Program−Mixer−AccelProgram the limit on the acceleration of the command to the gas controlvalve. This range is 0.1−10.0 V/sec. A setting of 10.0 V/sec representsmaximum acceleration and response. The default setting is 0.1 V/sec.

PROGRAM MIXER XXXXXXXXGAS METER ACCEL LIMIT=_____ _____ V/SEC

Program−Mixer−Time ConstProgram the averaging time for sealant flow. The available range forprogramming is 5−30 seconds. The default setting is 30 seconds. Higheraveraging times will slow valve response, however, the valve and displaywill be more stable.

PROGRAM MIXER XXXXXXXXSEALANT FLOW AVERAGING TIME = _____SEC

Program−TempHeated units: the following functions are available for use: temperature setpoints may be programmed, the sequential start feature may be activated ordisabled, temperature units may be set, and the temperature ready delaymay be programmed.

PROGRAM TEMP XXXXXXXX(SETPOINTS STARTUP UNITS LABELS GAINS)

Unheated units: the following functions are available for use: shutdowntemperature set points, chiller set points (if installed) or temperature units.

PROGRAM TEMP XXXXXXXX(SHUTDOWN CHILLER UNITS)

Operation4-14


Program−Temp−Setpoints (Heated Units Only)The following functions are available for use at this level: individualtemperature zones may be programmed, all zones may be set to a singlevalue, the setback temperature differential may be set or the shutdowntemperature may be set. If installed, the high and low temperaturethresholds for chiller operation are programmed.

PROGRAM TEMP SETPOINTS XXXXXXXX(ZONES SETALL SETBACK SHUTDOWN CHILLER)

Program−Temp−Setpoints−Zones (Heated Units Only)Choosing to program individual temperature zone set points at theSETPOINTS display will produce the following display:

PROGRAM TEMP SETPOINTS XXXXXXXXYYYYYY SETPOINT=________F

Use the INCREASE and DECREASE keys to adjust setpoints. Pressing theENTER key stores the value and automatically advances the display to thenext zone. Press the NEXT or PREVIOUS key to skip over a particularsetpoint and move to the next or previous zone. When programming for thelast zone is complete, the display will advance to the first zone. Press thePREVIOUS key at this point to return the display to the last zone.

To end the programming of individual zones, press the EXIT key. For warmunits, the temperature range for programming zones is 32 − 135 �C(90 − 275 �F) with the default temperature value being 52 �C (125 �F). Forhigh temperature units, the temperature range for programming zones is121 − 177 �C (250 − 350 �F) with the default temperature of 121 �C(250 �F). Temperature set points are programmed in 1� (F or C)increments. A non-programmable, overtemp temperature differential setpoint (17 �C [30 �F] above set point for warm units and 28 �C [50 �F] aboveset point for high temperature units) is used for all temperature zones.

NOTE: Individual zone set points may not be programmed to a valuegreater than the programmed shutdown temperature minus the overtempdifferential value. Individual zone programming limits will automatically bedecreased to prevent the entering of an invalid value.

Operation 4-15


Program−Temp−Setpoints−Setall (Heated Units Only)The SETALL feature, within the PROGRAM TEMP SETPOINTS menu, setsall temperature zone set points to a single value. When SETALL isselected, the display here is shown:

PROGRAM TEMP SETPOINTS XXXXXXXXSET ALL CHANGES=__________F

When activated, the programming start point will always be the lowestpossible set point temperature for the temperature range currentlyprogrammed. This value is the same as the default setting for alltemperature zones. Pressing the ENTER key will set all temperature zonesto the selected value. Pressing the EXIT key will stop the SETALL session,resulting in no change to the set points. Temperature set points within theSETALL function are programmed in 1� (F or C) increments.

NOTE: The SETALL temperature set point may not be programmed to avalue greater than the programmed shutdown temperature minus theovertemp differential value. SETALL programming limits will automaticallybe decreased to the lowest limit of all zones to prevent entering an invalidvalue in any zones.

Program−Temp−Setpoints−Setback (Heated Units Only)SETBACK permits a temperature input less than the SETPOINT for timeswhen the FoamMix is not in use. All temperature zones are controlled totheir respective set points minus the setback differential. The SETBACKtemperature may be programmed in the range of 0 − 66 �C (0 − 150 �F) in1� (F or C) increments with the default value being 0 �F/C.

PROGRAM TEMP SETPOINTS XXXXXXXXSETBACK TEMP=SETPOINT LESS _________F

Program−Temp−Setpoints−Shutdown (Heated Units Only)When SHUTDOWN is selected from the PROGRAM TEMP SETPOINTSmenu, the display below is are shown:

PROGRAM TEMP SETPOINTS XXXXXXXX(ZONE SEALANT

Either the normal SHUTDOWN temperature or the sealant zoneSHUTDOWN temperature may be programmed at this point.

Operation4-16


Program−Temp−Zone−Shutdown−Zone (Heated Units)

Program−Temp−Shutdown (Unheated Units)Choosing to program the normal SHUTDOWN temperature will produce thefollowing displays (heated unit above, room temp unit below):

PROGRAMTEMP SETOINTS SHUTDOWN XXXXXXXXSHUTDOWN TEMP=_________F

PROGRAM TEMP XXXXXXXXSHUTDOWN TEMP=_________F

A single SHUTDOWN temperature may be programmed for the sealantzone on room temp units for all zones except the sealant zone on heatedunits. Programming in 1� (F or C) increments may be performed in therange of 43 − 66 �C (110 −150 �F) on unheated units, 49 − 152 �C(120 − 305 �F) on warm units and 149 − 204 �C (300 − 400 �F) on hightemperature units. The default value is 43 �C (110 �F) on unheated units,68 �C (155 �F) on warm units and 149 �C (300 �F) on high temperatureunits.

NOTE: (Heated units only) SHUTDOWN temperature may not beprogrammed to a value less than the established SETPOINT temperatureplus the overtemp differential value for any zone. SHUTDOWNprogramming limits will automatically be decreased to the highest value ofall zones plus the overtemp differential value to prevent the entering invalidvalues.

Program−Temp−Setpoints−Shutdown−Sealant (Heated Units Only)Choosing the sealant zone SHUTDOWN temperature option will producethe display below:

PROGRAM TEMP SETPOINTS SHUTDOWN XXXXXXXXSEALANT SHUTDOWN TEMP=________F

A separate SHUTDOWN temperature may be programmed for the sealantzone. Programming in 1� (F or C) increments may be performed in therange of 49 − 152 �C (120 − 305 �F) on warm units and 300 − 400 �F(149 − 204 �C) on high temperature units. The default value is 68 �C(155 �F) on warm units and 149 �C (300 �F) on high temperature units.

Operation 4-17


Program−Temp−Startup (Heated Units Only)Selecting STARTUP from the PROGRAM TEMP menu produces thefollowing display:

PROGRAM TEMP STARTUP XXXXXXXX(SEQ−START DELAY)

The SEQUENTIAL START or the READY DELAY may be programmed.

Program−Temp−Startup−Seq−Start (Heated Units Only)The sequential temperature startup feature may be ENABLED orDISABLED at the displays shown below:

PROGRAM TEMP STARTUP XXXXXXXXSEQUENTIAL START: (ENABLED DISABLE)

PROGRAM TEMP STARTUP XXXXXXXXSEQUENTIAL START: (DISABLED ENABLE)

An ENABLED sequential start allows for the material expansion withoutcreating excessive pressures in the system. The SEQUENTIAL STARTdefault is the ENABLED state.

Zone group designations are as follows:

� Zone Group A= Hoses

� Zone Group B= Regulator, Flow meter, Mixer

� Zone Group C = Options

� Zone Group D = Gun

When the sequential start feature is ENABLED, the sequence oftemperature zone heating during system startup is as follows:

1. Zone Group A begins heating.

2. After Zone Group A reaches 80% of its set point temperature. ZoneGroup B begins heating.

3. After Zone Group B reaches 80% of its set point temperature, ZoneGroup C begins heating.

4. After Zone Group C reaches 80% of its set point temperature, ZoneGroup D begins heating.

5. When the last zone is within 5 �F of reaching its set point, thetemperature ready delay begins.

6. When the delay expires, the motor startup sequence begins.

Operation4-18


Program−Temp−Startup−Delay (Heated Units Only)Selecting DELAY from the PROGRAM TEMP STARTUP menu produces thefollowing display:

PROGRAM TEMP STARTUP XXXXXXXXTEMPERATURE READY DELAY =________MIN

The TEMPERATURE READY DELAY time may be programmed in therange of 0 – 60 minutes. The default time value is 5 minutes.

Program−Temp−Units (All Units)Choosing UNITS from the PROGRAM TEMP menu permits systemtemperatures to be viewed and programmed in either �F or �C at thedisplays below. The default value is �C.

PROGRAM TEMP XXXXXXXXTEMPERATURE UNITS: (�C OR �F)

PROGRAM TEMP XXXXXXXXTEMPERATURE UNITS: (�F OR �C)

Program−Temp−Labels (Heated Units Only)This feature allows the operator to assign names to the temperaturechannels in a heated system instead of retaining the system−assigneddefaults. Each channel name may be up to six characters long with thefollowing options available:

� All 26 upper−case alphabetic characters

� Numerals 0 through 9

� The dash (“−“) character

� The empty space (“”)

Spaces at the end of the label will be deleted by the system. Use the rightand left arrow keys to move the cursor from one character to the next. Usethe up and down arrow keys to scroll through the list of available characters.Pressing the ENTER key saves the programmed label and advances theoperator to the next channel. Pressing EXIT ignores changes made to thelast displayed channel and exits the LABELS menu.

The menu for this function is shown below:

PROGRAM TEMP XXXXXXXXENTER CHANNEL NAME:XXXXXX

Operation 4-19


Program−Temp−Gains (Heated Units Only)This feature allows the operator to program specific PID control parametersto provide ultimate flexibility and temperature control. ThePROGRAM−TEMP−GAINS menu is show below:

PROGRAM TEMP GAINS XXXXXXXX(NIRE CHAN2 CHAN4 CHAN5 CHAN6 CHAN7)

Pressing MORE causes similar screens to display channels 8 through 18.

NOTE: There are no gain settings for channels 1 and 3, since these aremonitor−only channels and are unavailable for operator input.

Press ENTER to select a channel and see the next menu (YYYYY is equalto the selected channel label):

PROGRAM TEMP GAINS YYYYY XXXXXXXX(KPN KPD KIN KID KDN KDD ILO IHI ERR)

In all cases, the following three values must be programmed:

� Proportional Gain: Set by entering the numerator term (KPN) anddenominator term (KPD). The net gain is then determined by:

KP=KPN/KPD

The proportional term controls the response speed (i.e., how quicklythe zone reaches the desired set point.)

� Integral Gain: Set by entering a numerator term (KIN) and denominatorterm (KID). The total gain is then determined by:

KI=KIN/KID

The integral term (sometimes referred to as “reset”) corrects foractual temperature offset from the set point which is caused by theproportional output. If the integral term is set improperly, the actualtemperature will oscillate, i.e., become unstable.

� Derivative Gain: Set by entering a numerator term (KDN) anddenominator term (KDD). The actual gain is then determined by:

KD=KDN/KDD

The derivative term reduces or totally eliminates overshoot(temperature exceeding set point). If this is set improperly, thesystem will either act sluggish (react slowly to a change), or react tooquickly, causing considerable temperature overshoot.

Operation4-20


Program−Temp−Gains (Heated Units Only)(contd)The remaining terms to be programmed include ILO (Integral Low Limit) andIHI (Integral High Limit), and ERR (Maximum Error):

� ILO/IHI – Defines a band width range when the integral control term (KI)is turned on.

� ERR – Defines a maximum error (degrees x 100) that can occur beforethe heaters are turned full on (100% power) or turned off (0% power).Inside this range, the normal proportioning algorithm is in effect asdefined by the KP term.

Adjusting Gains (Heated Units Only)All of these terms must be set properly in order for a temperature system towork properly.

The units are shipped with default values set for each channel as noted inthe following table:

Table 4-2 GAS RATIO INDEX SETPOINT RELATIONSHIP

Channel Name KPN KPD KIN KID KDN KDD ILO IHI ERR

2 REGLTR 2 1 1 2 100 1 1 100 500

4 FLWMT 100 1 1 8 10 1 1 100 500

5 UNION 25 1 1 10 4 1 1 100 500

6 MIX−IN 100 1 1 6 8 1 1 100 500

7 MIX−BODY 100 1 1 6 8 1 1 100 500

8 MIX−OUT 50 1 1 6 10 1 1 100 500

9 OPT−1_ 50 1 1 9 5 3 1 100 500

10 OPT−2_ 50 1 1 12 5 3 1 100 500

11 OPT−3_ 50 1 1 9 5 3 1 100 500

12 OPT−4_ 50 1 1 12 5 3 1 100 500

13 OPT−5_ 50 1 1 10 5 3 1 100 500

14 OPT−6_ 50 1 1 10 5 3 1 100 500

15 OPT−1_ 50 1 1 10 5 3 1 100 500

16 OPT−2_ 50 1 1 10 5 3 1 100 500

17 OPT−3_ 50 1 1 10 5 3 1 100 500

18 OPT−4_ 50 1 1 10 5 3 1 100 500

19 OPT−5_ 50 1 1 10 5 3 1 100 500

20 OPT−6_ 50 1 1 10 5 3 1 100 500

Operation 4-21


In most cases, these values should not require change. If values do requireadjustment, use the following procedure:

1. Set the derivative gain (KD) and integral gain (KI) to 0. Set theproportional gain (KP) to a very low number such as 1.

2. Begin heating the unit and slowly increase the proportional gain (KP)until the steady state error is 1−2 �C (2−4 �F).

3. Slowly increase the integral gain (KI) until the steady state error is 1.

4. Begin dynamic testing with a cold start, and monitor the dynamicresponse of the unit for temperature overshoot.

5. If temperature overshoot occurs, slowly increase the derivative gain(KD) until the overshoot is reduced to an acceptable limit.

6. If there is no temperature overshoot and the response time is too slow,increase the proportional gain (KP) to obtain the desired response.

This procedure is repetitious and may take time to accomplish.

If this procedure does not obtain acceptable results, contact a Nordsonrepresentative.

Program−MotorThe following display appears at the PROGRAM MOTOR level ofprogramming:

PROGRAM MOTOR XXXXXXXX(SPEED SETBACK)

The motor SPEED set point or motor SETBACK speed may be selected atthis point.

Operation4-22


Program−Motor−SpeedSelecting SPEED from the PROGRAM MOTOR display permits theprogramming of the MOTOR SPEED SETPOINT, as shown at the displaybelow:

PROGRAM MOTOR SPEED XXXXXXXXMOTOR SPEED SETPOINT=________%

This set point is programmed in the range of 20−100% of full scale, in 1%increments. The default value is 20%.

NOTE: With the 7.5:1 speed reducer, the mixer shaft rotates at � 50−250RPM (corresponding to the 20−100% of full scale set point range.) The 5:1speed reducer allows the mixer shaft rotation at � 70−350 RPM and the25:1 speed reducer allows mixer shaft rotation at � 14−70 RPM.

Program−Motor−SetbackChoosing SETBACK from the PROGRAM MOTOR main menu permits theselection of programming the SPEED or DELAY of the MOTOR SETBACK,as shown in the following display:

PROGRAM MOTOR SPEED XXXXXXXXX(SPEED DELAY)

Program−Motor−Setback SpeedSelecting SPEED from the PROGRAM MOTOR SETBACK menu permitsthe programming of the MOTOR SETBACK SPEED, as shown in thefollowing display:

PROGRAM MOTOR XXXXXXXXXMOTOR SETBACK SPEED=_________%

The MOTOR SETBACK SPEED can be programmed as OFF or from 20%of the maximum motor speed to 100% of the MOTOR SPEED SETPOINT.

Operation 4-23


Program−Motor−Setback DelaySelecting DELAY from the PROGRAM MOTOR SETBACK menu permitsthe programming of the MOTOR SETBACK DELAY, as shown in thefollowing display:

PROGRAM MOTOR XXXXXXXXXMOTOR SETBACK DELAY=________SEC

This setting is programmed in the range of 5 – 300 seconds, in 5 secondsincrements. The default value is 30 seconds. This feature provides forautomatic shutdown or speed reduction of the motor if sealant flow is notdetected by the flow meter within the specified MOTOR SETBACK DELAYtime period.

Program−Clock (Heated Units Only)The following display appears at the PROGRAM CLOCK level ofprogramming:

PROGRAM CLOCK XXXXXXXX(TIME SCHEDULE)

At this display, either current time and time format (TIME) or scheduled autotimes (SCHEDULE) may be selected for programming.

Program−Clock−Time (Heated Units Only)Selecting TIME to program current time and time format produces thedisplay below:

PROGRAM CLOCK TIME XXXXXXXX(TIME OF DAY DAY FORMAT)

Three values must be set in relation to current time: TIME OF DAY, DAY ofweek and time FORMAT (12HR or 24 HR).

Operation4-24


Program−Clock−Time−Time of Day (Heated Units Only)Use the INCREASE and DECREASE keys to set the TIME OF DAY, asused in programming other numerical values. If the 12 HR DAY time formatis in effect, the hours displayed on the menu below will scroll from 0−12using AM and PM. With the 24 HR DAY time format in effect, the hours willscroll from 0−24 with no AM or PM label.

PROGRAM CLOCK TIME XXXXXXXXTIME OF DAY = _____:_____AM

Program−Clock−Time−Date (Heated Units Only)The following menu is used to select the current DATE:

PROGRAM CLOCK TIME XXXXXXXXDATE=XX/XX/XX

The software has a built−in calendar that will recognize the proper day ofthe week based on the actual date.

Program−Clock−Time−Format (Heated Units Only)The menus below are used to select the TIME FORMAT. The default forTIME FORMAT is the 12 HR format.

PROGRAM CLOCK TIME XXXXXXXXTIME FORMAT:12 HR 24 HR)

PROGRAM CLOCK TIME XXXXXXXXTIME FORMAT: (24 HR 12 HR

Program−Clock−Schedule (Heated Units Only)The display below is shown when SCHEDULE is selected from thePROGRAM CLOCK menu. The following options are available at this level:VIEW AUTO times, ADD AUTO times, DELETE individual programmedAUTO times or CLEAR ALL programmed AUTO times.

PROGRAM CLOCK SCHEDULE XXXXXXXX(VIEW ADD DELETE CLEAR ALL)

Operation 4-25


Program−Clock−Schedule−View (Heated Units Only)The following displays operate exactly like the CLOCK displays selectedfrom the main menu. Refer to the description for the PROGRAM−CLOCKlevel and related displays in this section for information which will assist inproceeding through the following displays.

PROGRAM CLOCK SCHEDULE XXXXXXXXPROGRAMMED STARTUP day ____:____AM

PROGRAM CLOCK SCHEDULE XXXXXXXXPROGRAMMED SETBACK day ____:____AM

PROGRAM CLOCK SCHEDULE XXXXXXXXPROGRAMMED SHUTDOWN day ___:___AM

PROGRAM CLOCK SCHEDULE XXXXXXXXNO PROGRAMMED AUTO TIMES

Program−Clock−Schedule−Add (Heated Units Only)Selecting ADD from the PROGRAM CLOCK SCHEDULE menu producesthe following display:

PROGRAM CLOCK SCHEDULE XXXXXXXXAUTO TYPE: (START SETBACK SHUTDOWN)

Program a new AUTO TYPE of event time. Selecting an AUTO TYPE fromthe previous display and pressing the ENTER key produces the displaybelow, where the startup time is to be entered using the INCREASE andDECREASE keys:

PROGRAM CLOCK SCHEDULE XXXXXXXXENTER TIME ____:____AM

If the EXIT key rather than the ENTER key is pressed, the AUTO TYPEselection will not be stored. After pressing the ENTER key to store theAUTO TYPE event time, the following display is shown.

PROGRAM CLOCK SCHEDULE XXXXXXXXDAY: (SUN MON TUE WED THU FRI SAT)

Operation4-26


Program−Clock−Schedule−Add (Heated Units Only)(contd)At this level, a day of the week must be chosen for the selected AUTOTYPE. Pressing the EXIT key before pressing the ENTER key will not storethe displayed time and will return the display to the previous menu. If themaximum number of Auto times (40) had been previously programmed, thefollowing display will be shown when selecting the ADD menu. Pressing theEXIT key will return the display to the previous menu. One or moreprogrammed times will have to be deleted before programming any newtimes.

PROGRAM CLOCK SCHEDULE XXXXXXXXMAX NUMBER OF AUTO TIMES PROGRAMMED

Program−Clock−Schedule−Delete (Heated Units Only)Selecting DELETE from the PROGRAM CLOCK SCHEDULE menu, willproduce one of the following displays if any AUTO times are programmed:

PROGRAM CLOCK SCHEDULE XXXXXXXXDELETE STARTUP day ____:____AM? (NO YES)

PROGRAM CLOCK SCHEDULE XXXXXXXXDELETE SETBACK day ____:____AM? (NO YES)

PROGRAM CLOCK SCHEDULE XXXXXXXXDELETE SHUTDOWN day____:____AM? (NO YES)

For each programmed time, a decision must be made as to whether todelete that time or continue to the next programmed time. Selecting eitherNO or YES will advance the display to the next programmed time. Thedisplay will continue to advance until all times are deleted. Pressing EXITends the DELETE sequence. If no AUTO times are programmed, or if allprogrammed times have been deleted, the display below is shown:

PROGRAM CLOCK SCHEDULE XXXXXXXXNO PROGRAMMED AUTO TIMES

Operation 4-27


Program−Clock−Schedule−Clear All (Heated Units Only)At this level all programmed AUTO times can be detected. Selecting NOwill return the display to the previous menu.

PROGRAM CLOCK SCHEDULE XXXXXXXXCLEAR ALL PROGRAMMED TIMES? (NO YES)

Selecting YES to delete all programmed times will produce the followingacknowledgement at the display below:

PROGRAM CLOCK SCHEDULE XXXXXXXXALL AUTO TIMES CLEARED – PRESS EXIT

Startup Mode of OperationSTARTUP is engaged by pressing the AUTO key (all units) or by theenabled AUTO STARTUP feature (heated units). When initiated, thefollowing display is shown:

STARTUP(MIXER TEMP MOTOR CLOCK PROGRAM)

In heated units, this display will continue to be shown until all channelsreach application temperature and other startup procedures are completed.During this time, the second line on the display may be used for viewing orprogramming system parameters. In unheated units, this display (minus theCLOCK feature) will be shown briefly until the startup procedures arecompleted.

The READY display is shown after all startup procedures have beensuccessfully completed and the motor has been started. This coincides withthe enabling of the system ready output. This READY display (minusCLOCK in unheated units) is the top level menu during normal operation.

READY(MIXER TEMP MOTOR CLOCK PROGRAM)

NOTE: If PDL is installed, a different menu display is shown. See Section10 for details.

Operation4-28


Setback Mode of OperationSETBACK mode is entered by either pressing the SETBACK key or by theAUTO SETBACK feature. When the SETBACK mode is initiated, thefollowing display is shown:

SETBACK(MIXER TEMP MOTOR CLOCK PROGRAM)

Shutdown Mode of OperationSHUTDOWN may be engaged in one of the following possible ways: onpower−up of the system; by pressing the OFF key while in another mode ofoperation; upon entering a major fault condition; or by the AUTOSHUTDOWN feature (heated units).

If the SHUTDOWN mode was entered by pressing the OFF key, AUTOSHUTDOWN or by entering a major fault condition, the following display(minus CLOCK in unheated units) will be shown immediately:

SHUTDOWN(MIXER TEMP MOTOR CLOCK PROGRAM)

Otherwise on power-up, it will be shown following completion of the internal,self-diagnostic tests. This display is the main menu for the SHUTDOWNmode.

If a major fault has occurred, it is only possible to enter the MANUAL modeof operation. Otherwise, any of the other modes of operation (SETBACK,STARTUP and MANUAL) may be entered by pressing the appropriate modekey.

Upon power-up of the system, the following message is displayed forseveral seconds. During this time, the set of self-diagnostic tests will beinitiated.

FoamMix System Vx.xxCOPYRIGHT 1990 NORDSON CORP

Operation 4-29


One of the self−tests performed on power-up is a CRC check of the serviceprogram data. Failure of this test indicates that faulty data was admitted tothe NVRAM (non−volatile RAM) device. This can only be corrected byobtaining the service password and reprogramming the correct values forthe service-programmable parameters.

The message below will be displayed in the event of failure of this test:

FoamMix System Vx.xxFATAL ERROR−SYSTEM CRC−CALL SERVICE

If incorrect data is detected in the user−programmable area of NVRAMduring power−up self−tests, default values for set points will be loaded intoVRAM and the message be loaded into NVRAM and the message belowwill be displayed.

FoamMix System Vx.xxDEFAULTS SET – PROGRAM YOUR SYSTEM

At this point, pressing the EXIT key will continue the controller power−upsequence.

Another test is performed on power−up to determine if the necessaryboards are present in the system. The following boards must be present forthe system to operate (board switch settings are in parentheses):

� 1 temperature board (#0)

� 1 I/O board (#0)

� 1 FoamMix board (#0)

If one or more required boards is not installed, a message will be displayed.The following displays indicate each message for the corresponding board.To correct this error condition, the controller must be powered−down andthe appropriate board(s) installed.

***FATAL ERROR***FOAMMIX BOARD # NOT FOUND

***FATAL ERROR***IO BOARD # NOT FOUND

***FATAL ERROR***TEMP BOARD # NOT FOUND

Operation4-30


Manual Mode of OperationMANUAL mode may be accessed by pressing the MANUAL key (if thepassword is not disabled) and then entering the correct password at theprompt as shown here:

MANUALENTER PASSWORD

The following displays (minus TEMP in unheated units) will be shown at thattime. These displays are the MANUAL main menu. When the MANUALmode is entered, temperature channels are turned off (heated units), outputto the gas flow meter is turned off and the motor is stopped. When leavingthe MANUAL mode by pressing one of the other mode keys, outputs arereturned to those same states (i.e., output to gas flow meter is turned offand motor is stopped).

MANUAL(MORE TEMP MOTOR GAS−FLOW)

MANUAL(MORE CHILLER DISPL DIAG)

Refer to Section 6 – Troubleshooting for detailed information concerningsystem diagnostic (DIAG) functions.

Note that the MANUAL mode is the only mode other than the SHUTDOWNmode which may be entered after a major fault condition occurs.

Manual−Temp (Heated Units Only)Selecting TEMP from the MANUAL main menu produces the followingdisplay:

TEMP MANUALTEMPERATURE CHANNELS:(OFF ON SETBACK)

Three optional selections are available from this display. Choosing OFFfrom this display will turn all temperature channels off. Choosing ON willestablish the setpoint temperature for all channels. Choosing SETBACK willestablish the setback temperature for all channels. The default selectionupon entering this display is OFF. When the EXIT key is pressed to leavethis menu, the temperature control selected remains in effect until it isaltered or the mode of operation is changed.

Operation 4-31


Manual−MotorSelecting MOTOR from the MANUAL main menu produces the followingdisplay:

CURRENT= A MANUALMOTOR SPEED SETPOINT= %

Motor current is indicated on the top line of the display. The second linedisplays the motor speed set point, which is initially set to zero. The motorspeed set point may be altered from 0 –100% by using the INCREASE andDECREASE keys. When the EXIT key is pressed to leave the displaybelow, the motor control remains at the speed selected until it is altered orthe mode of operation is changed.

NOTE: The set point selected under the MANUAL mode does not affect thenormal operation set point stored in the unit’s memory.

Manual−Gas−FlowSelecting GAS−FLOW from the MANUAL main menu produces thefollowing display:

ACTUAL GAS FLOW= _________SCCM MANUALGAS FLOW COMMAND=____.____

The top line of the display indicates actual gas flow. The second lineindicates the gas flow set point, which is initially set to zero. Gas flow maybe altered from 0.0−1.0 (representing zero to full scale) by using theINCREASE and DECREASE keys. When the EXIT key is pressed to leavethis display, gas flow remains at the selected rate until it is altered or themode of operation is changed.

NOTE: The set point entered for the MANUAL mode does not affect thenormal operation ratio set point stored in the unit’s memory.

Operation4-32


Manual−DisplSelecting DISPL from the MANUAL main menu produces the followingdisplay:

DISPLAY MANUAL(MORE SEALANT/GAS−MIXER SLNT OIL MOTOR)

DISPLAY MANUAL(MORE GAS−SUPPLY FLMTR TEMP)

From this menu, gas and sealant pressure (SEALANT/GAS−MIXER),sealant flow and pressure combined on one display (SLNT), oil pressure(OIL), motor speed (MOTOR), gas supply pressure (GAS−SUPPLY), zonetemperatures (TEMP) or the current sealant flow meter counter value maybe selected for viewing.

Manual−Displ−Sealant/Gas−MixerSelecting SEALANT/GAS−MIXER from the DISPLAY menu produces thedisplay below. At this level, sealant and mixer gas pressure may be viewed.

DISPLAY MANUALSEALANT=____PSI MIXER GAS=____PSI

Manual−Displ−SealantSelecting SLNT from the DISPLAY menu produces the display below. Atthis level, sealant flow and pressure may be viewed.

DISPLAY MANUALSEALANT FLOW=___CCPM PRESSURE=___PSI

Manual−Disp−OilSelecting OIL from the DISPLAY menu produces the display below. At thislevel, oil pressure may be viewed.

DISPLAY MANUALOIL PRESSURE=_____PSI

Operation 4-33


Manual−Disp−MotorSelecting MOTOR from the DISPLAY menu produces the display below. Atthis level, motor speed may be viewed.

DISPLAY MANUALMOTOR SPEED=_________%

Manual−Displ−Gas−SupplySelecting GAS−SUPPLY from the DISPLAY menu produces the displaybelow. At this level, gas supply pressure may be viewed.

DISPLAY MANUALGAS SUPPLY PRESSURE =_______PSI

Manual−Displ−FlmtrAt the MANUAL DISPLAY FLOWMETER level, the operator views thecurrent value of the 16−bit sealant flow meter input counter. The cursor isset on the CLEAR option, and by pressing ENTER, the operator clears thiscounter. When the counter reaches a value of 65535, it rolls over to 0 onthe next input count. Pressing EXIT leaves this menu.

DISPLAY MANUALSEALANT FLMTR COUNTS=XXXXX (CLEAR)

Manual−Displ−TempSelecting TEMP from the DISPLAY menu produces the display below. Atthis level, actual and/or set point temperatures may be viewed for differentzones, using the NEXT and PREVIOUS keys.

DISPLAY MANUALYYYYYY SETPOINT=____F ACTUAL=_____F

The display below will be shown for any zone which as no establishedtemperature set point.

DISPLAY MANUALNO YYYYYY SETPOINT ACTUAL=______F

Operation4-34


Set the Oil PressureCAUTION: This procedure must be followed to ensure proper charging ofthe oil system prior to the introduction of sealant into the system. Failure toproperly adjust the oil pressure may result in seal failure.

1. Select the MANUAL mode of system operation at the controller. Thefollowing menu will be displayed:

MANUAL(MORE TEMP MOTOR GAS−FLOW)

2. Select MORE from the menu. The following display (includingCHILLER, if installed) will appear.

MANUAL(MORE CHILLER DISPL DIAG)

3. Select DISPL from the menu. The following display will be produced.

DISPLAY MANUAL(MORE SEALANT/GAS−MIXER SLNT OIL MOTOR

4. Select OIL from the menu. The following display will be produced, fromwhich OIL PRESSURE may be viewed.

DISPLAY MANUALOIL PRESSURE=_____________PSI

Set Normal Operating Pressure1. Using the oil pump air regulator, slowly increase air pressure while

monitoring the OIL PRESSURE display. Adjust the oil pressure to1,800−2,000 psig (124−138 bar). This will correspond to 55 psig (4 bar)air pressure which can be read on the OPERATING PRESSURE gauge.

2. As air pressure is increased, the oil pump will begin to cycle. When thepump stops cycling, the maximum hydraulic pressure has been reachedfor a given input air pressure.

3. Slowly open the manual needle valve so the pump cycles approximately20 times per minute to purge air from the system. Run the system forabout five minutes, then close the valve.

Operation 4-35


NOTE: If the pump continues to cycle after the valve is closed:

a. Check for oil leaks.

b. Ensure that the oil pressure is below the relief valve setting of about2,400 psig (165 bar).

Set the High Pressure Oil Circuit1. Locate the oil pump high pressure air regulator mounted to the left rear

of the air circuit panel.

2. Adjust the air pressure to approximately 85 psig (6 bar). This willcorrespond to about 3,000 psig (207 bar) oil pressure.

CAUTION: The HIGH PRESSURE circuit must be set properly. The unitwill automatically switch to the high pressure if sealant pressure gets within200 psig (14 bar) of the oil pressure. This will protect the mechanical faceseals from damage.

3. Test the unit as follows:

a. Slowly open the manual needle valve until the pump begins to cycle.Do NOT allow the pump to cycle more than 20 times per minute.

b. Decrease normal oil operating pressure by decreasing air pressure.

c. When oil pressure gets within 200 psig (14 bar) of the sealantpressure, the HIGH PRESSURE circuit will be activated, a MAJORFAULT will occur and the high oil pressure can be read on thedisplay (app. 207 bar [3,000 psig]).

d. Clear the FAULT by increasing the setting of the normal operatingpressure to the original setting, close the needle valve andacknowledging the FAULT on the operator panel.

e. The oil pressure will decrease to just below the relief valve settingand hold constant.

CAUTION: The oil system check valve maintains pressure in the bearinghousing for a short period of time even if air pressure is lost. This ensurespositive pressure from the bearing housing to the mixer housing to preventsealant leakage and possible seal damage. To reduce or relieve pressurefor maintenance or other purposes, the manual needle valve must beopened. This should be done only after the oil pump air regulator is set tozero and the mixer sealant pressure has been completely relieved.

WARNING: To avoid personal injury, refer to the applicable maintenanceprocedure within Preventive Maintenance for the proper method of reducingoil pressure.

Operation4-36


Introduction of Sealant into the FoamMix UnitAt this point of system startup, all programming of system parameters andthe setting of oil pressure should be completed.

1. Enter STARTUP mode by pressing the AUTO key. The display below(minus CLOCK in unheated units) will be shown. Note that theDATALOG and SERIAL options will be displayed only if the data-loggingoption is installed.

STARTUP(MIXER TEMP MOTOR CLOCK DATALOG)

STARTUP(MORE SERIAL PROGRAM)

2. The message displayed will remain while the system waits for otherstartup procedures to be completed (and for all zones to reachapplication temperature in heated units). During this time, systemparameters may be viewed or programmed by using the menu on thesecond line of the display.

3. The READY display shown below (minus CLOCK in unheated units)appears after all startup procedures have been successfully completedand the motor has been started. This coincides with the enabling of theSYSTEM READY output. The READY display is the top level shownduring normal system operation.

STARTUP(MIXER TEMP MOTOR CLOCK DATALOG)

STARTUP(MORE SERIAL PROGRAM)

4. Sealant inlet pressure should be adjusted at the pump to provide apressure higher than what is required for the desired applicationpressure and flow rate.

CAUTION: DO NOT EXCEED THE OIL PRESSURE SETTING! Thesealant application pressure should be adjusted with the pressure reducingregulator in the FoamMix unit.

Operation 4-37


NOTE: The pressure reducing regulator is not a self−relieving regulator. Toreduce the sealant pressure, the system gun must be triggered to relievedownstream pressure as the pressure setting is adjusted.

Sealant pressure can be monitored by selecting MIXER from the mainmenu as indicated below. At this level, a variety of mixer−related valuesmay be viewed. The resulting sequence of displays is for viewing only. Toalter set points, PROGRAM must be selected at the main menu level.

MIXER XXXXXXXX(REVIEW RATIO FLOW FLMTR PRESSURE)

At the MIXER PRESSURE level indicated at the next display, sealant andmixer gas pressures may be observed by selecting SEALANT/GAS−MIXERfrom the menu. The second display is utilized for monitoring indicatedpressures.

MIXER PRESSURE XXXXXXXX(SEALANT/GAS−MIXER GAS−SUPPLY OIL)

MIXER PRESSURE XXXXXXXXSEALANT=_____PSI MIXER GAS=______PSI

5. Initial sealant pressure should be set as follows:

a. Start with the process regulator fully closed (screw full−outcounterclockwise).

b. Adjust the pump air pressure for the desired sealant input pressure.This should be 300 – 400 psi (21−28 bar) above the desired mixersealant pressure, but not to exceed the oil pressure setting.

c. Slowly open the sealant regulator by turning the adjustment screwclockwise. Once sealant flow starts, open the gun to allow sealantflow to purge the system of air. Adjust the pressure while sealant isflowing.

CAUTION: Sealant pressure higher than oil pressure will damage themechanical face seals.

6. Upon obtaining proper sealant pressure and/or flow, close the gun andobserve the sealant static pressure. This pressure must not exceed theoil pressure. While observing the sealant pressure rise, be prepared tolower sealant pressure and/or allow an increase in oil pressure so as toprevent damage to the seals. If sealant pressure exceeds oil pressure,increase oil pressure until it exceeds 200 psi (14 bar) differential.

Operation4-38


Set the Mixer Gas Pressure1. Select the MANUAL mode of operation at the controller.

2. Select the MANUAL−DISPL−SEALANT/GAS MIXER display shownbelow:

DISPLAY MANUALSEALANT=____PSI MIXER GAS=____PSI

3. While monitoring mixer gas pressure, slowly increase the pressure tothe desired setting. Note that the maximum mixer gas pressure is 1,500psi (103 bar). Higher pressures will activate the pressure relief valve. Ifthe relief valve opens, decrease the pressure until the valve closes.

NOTE: Set the gas mixer pressure to 200 psi (14 bar) higher than thesealant pressure to ensure that gas is injected into the mixer.

CAUTION: If the pressure is increased too rapidly, the diaphragm in theback pressure regulator will be susceptible to damage due to an excessivepressure differential between the inlet port and dome port.

View System Parameters

Mixer−ViewSelecting MIXER from the main menu produces the display below.

MIXER XXXXXXXX(REVIEW RATIO FLOW FLMTR PRESSURE)

From this display, several mixer−related vales may be viewed. Thesevalues and their respective displays are for viewing only. In order to changeset points and values, PROGRAM must be selected from the main menu.

Operation 4-39


Mixer−ReviewSelecting REVIEW from the MIXER menu produces the following displays.Each set point for GAS RATIO INDEX, SEALANT/GAS FLOW,SEALANT/GAS−MIXER PRESSURE, GAS SUPPLY PRESSURE, and OILPRESSURE is displayed for several seconds.

MIXER REVIEW XXXXXXXXGAS RATIO INDEX SETPOINT=____.____

MIXER REVIEW XXXXXXXXSEALANT FLOW=__CCPMGAS FLOW=__SCCM

MIXER REVIEW XXXXXXXXSEALANT=____PSI MIXER GAS=_______PSI

MIXER REVIEW XXXXXXXXGAS SUPPLY PRESSURE=______PSI

MIXER REVIEW XXXXXXXXOIL PRESSURE=______PSI

Mixer−RatioSelecting RATIO from the MIXER menu produces the following display,indicating the GAS RATIO INDEX SETPOINT.

MIXER XXXXXXXXGAS RATIO INDEX SETPOINT=____.____

Mixer−FlowAt the MIXER FLOW level, values for SEALANT and GAS FLOW may beobserved at the display below. The value for SEALANT FLOW is acalculated value. The GAS FLOW displayed is the actual gas flow from thegas metering device.

MIXER XXXXXXXXSEALANT FLOW__CCPM GAS FLOW=__SCCM

Operation4-40


Mixer−FlmtrAt the MIXER FLMTR level, the operator views the current value of the16−bit sealant flow meter input counter. The cursor is set on the CLEARoption, and by pressing ACCEPT, the operator clears this counter. Whenthe counter reaches a value of 65535, it rolls over on to 0 on the next inputcount. Pressing EXIT leaves this menu.

MIXER FLMTR XXXXXXXXSEALANT FLMTR COUNTS−XXXXX (CLEAR)

Mixer−PressureSelecting PRESSURE from the MIXER menu produces the followingdisplay. Existing pressures for SEALANT/GAS−MIXER, GAS SUPPLY andOIL may be selected for viewing at this level.

MIXER PRESSURE XXXXXXXX(SEALANT/GAS−MIXER GAS SUPPLY OIL)

Mixer−Pressure−Sealant/Gas−MixerSelecting SEALANT/GAS−MIXER from the MIXER PRESSURE display willindicate the SEALANT and MIXER GAS pressures at the display below.

MIXER PRESSURE XXXXXXXXSEALANT=___PSI MIXER GAS=_____PSI

Mixer−Pressure−Gas−SupplySelecting GAS−SUPPLY from the MIXER PRESSURE display shows theGAS SUPPLY PRESSURE at the display below.

MIXER PRESSURE XXXXXXXXGAS SUPPLY PRESSURE = _______PSI

Operation 4-41


Mixer−Pressure−OilSelecting OIL from the MIXER PRESSURE display will indicate the OILPRESSURE at the display below.

MIXER PRESSURE XXXXXXXXOIL PRESSURE=_________PSI

Temp−ViewSelecting TEMP from the main menu enables the viewing of severaltemperature−related values. These values and their respective displays arefor viewing only. To change set points and values, PROGRAM must beselected from one of the main menus shown here (chiller option displayed ifinstalled):

Heated units:

TEMP XXXXXXXX(MORE REVIEW ZONE SETBACK SHUTDOWN)

Unheated units:

TEMP XXXXXXXX(MORE STARTUP CHILLER)

TEMP XXXXXXXX(REVIEW ZONES SHUTDOWN CHILLER)

Temp−ReviewSelecting REVIEW from the TEMP menu produces the displays shown onthe following page.

Note that in heated units, TEMP REVIEW scans all temperature zone(TEMP ZONE), temperature setback differential (SETBACK TEMP),shutdown temperature (SHUTDOWN TEMP, SEALANT SHUTDOWNTEMP), and ready delay(TEMPERATURE READY DELAY) set points aswell as the status of the SEQUENTIAL STARTUP feature (DIS/ENABLED).

In unheated units, TEMP REVIEW scans the system for SEALANTSETPOINT, OIL SETPOINT, SHUTDOWN TEMP AND CHILLERSETPOINTS (if installed).

In all units, each display is shown for several seconds before proceeding tothe next display.

Operation4-42


Heated units:

TEMP REVIEW XXXXXXXXYYYYYY SETPOINT=___F ACTUAL=____F

Heated units:

TEMP REVIEW XXXXXXXXNO YYYYYY SETPOINT ACTUAL=____F

Unheated units:

TEMP REVIEW XXXXXXXXNO SEALANT SETPOINT ACTUAL=_____F

Unheated units:

TEMP REVIEW XXXXXXXXNO OIL SETPOINT ACTUAL=______F

Heated units:

TEMP REVIEW XXXXXXXXSETBACK TEMP=SETPOINT LESS_____F

Heated and unheated units:

TEMP REVIEW XXXXXXXXSHUTDOWN TEMP=______F

Heated units:

TEMP REVIEW XXXXXXXXSEALANT SHUTDOWN TEMP=______F

Heated units:

TEMP REVIEW XXXXXXXXSEQUENTIAL STARTUP IS DIS/ENABLED

Heated units:

TEMP REVIEW XXXXXXXXTEMPERATURE READY DELAY=_____MIN

Heated and unheated units:

TEMP REVIEW XXXXXXXXCHILLER ACTIVATE RANGE=____F TO _____F

Operation 4-43


Temp−ZoneSelecting ZONE from the TEMP menu enables the viewing of individualtemperature zone set points and actual temperatures. Moving through thezones is accomplished through the use of the NEXT and PREVIOUS keys.

(Heated units only) The following display is an example of a display that willbe shown for a control zone.

TEMP XXXXXXXXYYYYYY SETPOINT=____F ACTUAL=______F

(All units) The following display is an example of a display that will be shownfor a monitor−only zone.

TEMP XXXXXXXXNo YYYYYYY SETPONT ACTUAL=______F

Temp−Setback (Heated Units Only)Selecting SETBACK from the TEMP menu produces the display below. TheSETBACK temperature is shown in degrees less than the set pointtemperature.

TEMP XXXXXXXXSETBACK TEMP=SETPOINT LESS ________F

Temp−ShutdownSelecting SHUTDOWN from the TEMP menu produces the display below.

� (Unheated units only) This screen displays the sealant and oil shutdowntemperatures.

TEMP SHUTDOWN XXXXXXXXSHUTDOWN TEMP=_______F

� (Heated units only) At this level, either the standard ZONE shutdowntemperature valve or SEALANT shutdown temperature value may beselected for viewing.

TEMP SHUTDOWN XXXXXXXX(ZONE SEALANT)

Operation4-44


Temp−Shutdown−Zone (Heated Units Only)Selecting ZONE from the TEMP SHUTDOWN display produces thefollowing display. This display indicates the standard programmedshutdown temperature.

TEMP SHUTDOWN XXXXXXXXSHUTDOWN TEMP=________F

Temp−Shutdown−Sealant (Heated Units Only)Selecting the SEALANT from the TEMP SHUTDOWN display produces thefollowing display. This display indicates the programmed sealant shutdowntemperature.

TEMP SHUTDOWN XXXXXXXXSEALANT SHUTDOWN TEMP=________F

Temp−Startup−Seq (Heated Units Only)Selecting SEQ from the TEMP STARTUP SEQ menu produces one of thetwo displays shown below. The first display indicates that the sequentialstartup feature is disabled, while the second display indicates that thesequential startup is enabled.

TEMP XXXXXXXXSEQUENTIAL STARTUP IS DISABLED

TEMP XXXXXXXXSEQUENTIAL STARTUP IS ENABLED

Temp−Startup−Delay (Heated Units Only)The following display indicates the length of the TEMPERATURE READYDELAY.

TEMP STARTUP XXXXXXXXTEMPERATURE READY DELAY =_______MIN

TEMP REVIEW XXXXXXXXCHILLER ACTIVE RANGE ____F TO _____F

Operation 4-45


Motor−ViewSelecting MOTOR from the main menu produces the display below. At thislevel, motor−related values pertaining to motor speed and setback delaymay be selected for viewing. These values and their respective displaysare for viewing purposes only. In order to change set points and values,PROGRAM must be selected from the main menu.

MOTOR XXXXXXXX(REVIEW SPEED SETBACK)

Motor−ReviewSelecting REVIEW from the MOTOR menu produces the following displays.The MOTOR REVIEW menu scans MOTOR SPEED, MOTOR SETBACKSPEED and MOTOR SETBACK DELAY, displaying each for severalseconds.

MOTOR REVIEW XXXXXXXXMOTOR SPEED=______% CURRENT=_____A

MOTOR REVIEW XXXXXXXXMOTOR SETBACK SPEED=______%

MOTOR REVIEW XXXXXXXXMOTOR SETBACK DELAY=______SEC

Motor−SpeedSelecting SPEED from the MOTOR menu produces the display below. Thisdisplay indicates both the controller MOTOR SPEED output and motorcurrent. MOTOR SPEED is shown in percent of full scale. MotorCURRENT is shown in amps.

MOTOR XXXXXXXXMOTOR SPEED=_____% CURRENT=_______A

Motor−SetbackSelecting SETBACK from the MOTOR main menu produces the followingdisplay. At this level, the SPEED or DELAY of the MOTOR SETBACK maybe selected for viewing.

MOTOR SETBACK XXXXXXXX(SPEED DELAY)

Operation4-46


Motor−Setback−Speed

Selecting SPEED from the MOTOR SETBACK menu produces the displaybelow. This display indicates the programmed MOTOR SETBACK SPEED,shown as percent of full scale.

MOTOR SETBACK XXXXXXXXMOTOR SETBACK SPEED=_____%

Motor−Setback−Delay

Selecting DELAY from the MOTOR SETBACK menu produces the followingdisplay. This display indicates the programmed MOTOR SETBACK DELAYin seconds. If no sealant flow has been detected within this programmedtime, the motor speed will be set to the MOTOR SETBACK SPEED untilflow is again detected.

MOTOR SETBACK XXXXXXXXMOTOR SETBACK DELAY=_____SEC

Clock−View (Heated Units Only)Selecting CLOCK from the main menu produces the following set ofdisplays. These displays indicate the programmed AUTO times. At thislevel, PROGRAMMED STARTUP, SETBACK and SHUTDOWN times maybe viewed by using the NEXT and PREVIOUS keys.

CLOCK CURRENT: day ____:____AM XXXXXXXXPROGRAMMED STARTUP day _____:_____AM

CLOCK CURRENT: day ____:____AM XXXXXXXXPROGRAMMED SETBACK day _____:_____AM

CLOCK CURRENT: day ____:____AM XXXXXXXXPROGRAMMED SHUTDOWN day _____:_____AM

If no AUTO times have been programmed, the display below is shown.

CLOCK CURRENT: day ____:____AM XXXXXXXXNO PROGRAMMED AUTO TIMES

The displays above are for viewing programmed times only. If programmedAUTO times are to be added or deleted, PROGRAM must be selected fromthe main menu.

Operation 4-47


Daily Operating Procedures

Unheated units (no temperature channels)

System shutdown1. Press the OFF button on the keypad to place the unit in the

SHUTDOWN mode.

2. Remove air pressure to shut down the sealant pump. This will preventexcess sealant pressure and damage to the seals should the SealantPressure Regulator fail.

3. Leave the gas supply and air supply pressures to the unit as is. Do notdisconnect or reduce the gas or air supply pressures. If gas supplypressure to the unit should increase, the system relief valves will ventpressures to the atmosphere.

System Start−up1. Press the ON button on the keypad to place the unit in START−UP

mode.

2. Apply air pressure to start the sealant delivery pump.

3. If the system pressure was not maintained during shutdown period,sealant left over in the mixer and downstream hoses should be purgedprior to beginning operation. This will prevent spitting due to gasemission from solution at lower pressures.

Heated units (with temperature channels)

System shutdown:There are a number of ways in which to shut down a heated system,depending on such things as the length of shutdown period, the type ofsealant feed (pump) and type of sealant itself. In all cases, be aware ofpotential problems associated with sealant contraction due to cooling andexpansion during heating.

WARNING: Sealant may contract or expand due to cooling or heating andcould damage equipment and injure personnel.

1. Remove the air supply from the sealant pump.

Operation4-48


Heated units (with temperature channels)(contd)

CAUTION: Never place the FoamMix unit in the SHUTDOWN mode whilethe pump is operating. As the sealant cools and contracts within thesystem, the pump will continue to deliver material into voids created bysealant contraction. When the system is again heated, the sealant withinthe system will try to expand, creating excess pressures in the system.

2. Shut off the temperature control for the sealant pump and allow it tocool.

3. Shut down the FoamMix unit.

4. When the CLOCK function is used for automatic shutdown or setback,the pump clock must also be utilized and synchronized with theFoamMix clock.

5. Leave the gas and air supply pressures to the unit as is.

System start−up1. Press the ON button on the keypad to place the unit in START−UP

mode. Allow the unit to heat up before starting the pump heating cycle.

2. Begin the pump heating.

3. Begin normal operation only when both the FoamMix unit and pumpreach the SYSTEM READY state.

4. If the system has been in SHUTDOWN mode for an extended period oftime, the sealant that was resident in the mixer and downstream hosesmust be purged period to beginning operation. This will avoid splittingdue to gases coming out of solution at the lower pressures.

NOTE: Some materials may require an extended soak time (30 minutes ormore) at temperature and pressure to get back into solution in the hoses.

## TABSHEET ##

Main

tenan

ce

Maintenance 5-1


Section 5Maintenance


IntroductionThis section outlines the preventive maintenance procedures that Nordsonrecommends for the FoamMix processor. These procedures includeperiodic inspections, cleaning and general guidelines to keeping theequipment in the proper working order.

Safety Precautions

WARNING: Halogenated hydrocarbon solvents are dangerous when usedto clean components in a pressurized fluid system. The use of halogenatedhydrocarbons in this system could result in an explosion. Refer to Section 1of this manual (Safety Summary) for further details.

WARNING: To prevent serious personnel injury from material underpressure, always relieve system pressure before breaking any hydraulicconnections. To relieve system pressure, shut off pump and trigger all guns.

CAUTION: Never heat system components with a torch or an open flameof any kind. If it is necessary to heat components for maintenance or repair,use an electric oven with forced air circulation or a flameless electric heatgun. Do not heat plastic parts above 450 �F (230 �C).

Maintenance5-2


General MaintenanceMixer cabinet covers should be attached at all times to prevent accidentalcontact with electrical and/or heated components, and to keep the unit freeof dust, etc.

Periodic maintenance scheduleThe table below shows the periodic maintenance schedule for the FoamMixunit. Specific instructions for performing the various procedures will befound following the table.

Interval Procedure

Weekly (40 hrs) Visually inspect all hydraulic, gas and electrical connections; repair/replaceas necessary.

Monthly (250 hrs) Replace gas dryer cartridge and gas filter.

Semi−annually (1,000 hrs) Thoroughly inspect for gas line leaks utilizing leak detector fluid(P/N 900300).

Replace gear reducer oil.

Check oil reservoir level.

Check chiller (if installed) cooling fluid level.

Replace sealant check valve.

Annually (2,000 hrs) Replace oil in the pressurized oil system.

Replace chiller cooling fluid (if installed).

Check flowmeter calibration (See Troubleshooting, DP.2).

Maintenance Procedures

Inspect Hydraulic, Gas and Electrical Connections1. Visually inspect hydraulic connections and fittings for leaks and damage.

Inspect hoses for kinks, fraying and cuts.

2. Visually inspect all gas tubing for bends, kinks and other damage.

3. Visually inspect electrical connections to the hoses for fraying, brokenwires or damaged connections. Check connections to heaters andtransducers.

4. If gas leaks are suspected, all joints and connections must bethoroughly inspected using a leak detector fluid (Nordson P/N 900300).Since the gas volume is normally very low, the area being inspectedshould be thoroughly wetted and sufficient time given to detect bubbles.The procedure may need to be repeated to detect the leaks.

Maintenance 5-3


Check and Replacing Gear Reducer Oil1. Oil level should be up to the bottom of this plug hole.

2. If the level falls below this point, add replacement oil (P/N 139877 orAGMA – 8 equivalent), then replace the oil level plug and proceed withnormal operation.

3. To replace oil, remove the oil level plug, then:

a. Place a shallow container under the gear reducer.

b. Remove the drain plug in the bottom of the gear reducer housing.

c. After all the oil is drained, reinstall the drain plug in the gear reducerhousing and refill the reducer until the oil level is up to the bottom ofthe oil level plug hole.

d. Reinstall the oil level plus and proceed with normal operation.Dispose of the drained oil in a safe and legal manner.

Check and Replacing Oil in the Reservoir1. The oil level can be checked visually by removing the mixer access

cover and observing the oil level through the transparent reservoir.

2. If oil must be added, remove the oil fill port located on the top of thereservoir cap. This can be done without de−pressurizing the system.

3. Fill the reservoir with oil, P/N 1046197.

Maintenance5-4


Replace the Gas Dryer Cartridge1. Close the gas pressure regulator.

2. Disconnect the external nitrogen supply and verify that the gas supplypressure and mixer gas pressure are zero (0) psi on the displays:

a. MANUAL−DISPLAY−GAS−SUPPLY

b. MANUAL−DISPLAY−SEALANT/GAS−MIXER.

3. Remove the four (4) flange screws using a 6 mm Allen wrench.

4. Remove the dryer cartridge cover.

5. Discard and replace the O-ring. DO NOT APPLY O-RING LUBRICANT.

6. Discard and replace the dryer cartridge.

7. Install the cartridge cover and torque the four (4) flange screws to 100in.−lbs.

8. Slowly apply pressure and check for leaks using leak detector fluid(P/N 900300).

9. If necessary, reset mixer gas pressure as described in Operation.

Replace the gas filter1. Close the gas pressure regulator.

2. Disconnect the external nitrogen supply and verify that the gas supplypressure and mixer gas pressure are zero (0) psi on the displays:

a. MANUAL−DISPLAY−GAS−SUPPLY.

b. MANUAL−DISPLAY−SEALANT/GAS−MIXER.

3. Remove the filter plug from the manifold.

4. Discard and replace the O-ring on the plug. DO NOT APPLY O-RINGLUBRICANT.

5. Remove the spring.

6. Discard and replace the filter.

7. Install the spring and plug.

8. Slowly apply pressure and check for leaks using leak detector fluid(P/N 900300).

9. Reset mixer gas pressure as described in Operation.

## TABSHEET ##

Trou

blesh

oo

ting

Troubleshooting 6-1


Section 6Troubleshooting


This section contains troubleshooting procedures. These procedures coveronly the most common problems that you may encounter. If you cannotsolve the problem with the information given here, contact your localNordson representative for help.

The following troubleshooting information presents specific problems, eachfollowed by a listing of possible causes. Obvious causes of malfunction,such as broken wires and missing fasteners, are not considered part ofequipment and troubleshooting. These type of failures should be correctedduring routine preventive maintenance procedures, unless the failurepresents an immediate hazard to equipment or personnel.

The letters XXXXXXXX on a display represent either the STARTUP,SHUTDOWN, SETBACK or MANUAL mode of operation. The lettersYYYYYY represent the selected channel.

WARNING: Before attempting any troubleshooting procedure, refer toSafety for a comprehensive listing of safety-related issues concerning theFoamMix unit.

WARNING: To avoid the spraying of oil or process material or the releaseof a pressurized gas or hydraulic oil, do not loosen any hydraulic orpneumatic fittings or connections without first relieving system hydraulic orpneumatic pressure in the individual systems.

NOTE: The following procedures assume that all external support systemsare functional. Before performing a troubleshooting procedure, ensure thatthe cause of the problem is not external to the FoamMix unit.

Troubleshooting6-2


FoamMix System DiagnosticsThe following information concerning the FoamMix system can be accessedthrough the use of the controller keypad. The MANUAL main menu mustfirst be selected, followed by the selection of DIAG from that menu. At thispoint, various diagnostic functions are available, as described in thefollowing set of displays.

Selecting DIAG from the MANUAL main menu produces the followingdisplay. From this menu, any of the following diagnostic tests may bechosen to be executed: temperature board test (TMP), FoamMix board test(FMX), I/O board test (IO), display test (DSPL), keyboard test (KEY), PROMtest (PROM), or RAM test (RAM).

DIAGNOSTICS MANUAL(TMP FMX IO DISPL KEY PROM RAM)

Manual−DiagSelecting TMP from the DIAG menu produces the display below. Thisdisplay can be used to test a temperature board (card). Initially, the cardnumber (switch setting) must be entered for the card to be tested.

DIAGNOSTICS MANUALENTER CARD # TO TEST (0−15):

If the card number selected is not installed, the message below will bedisplayed.

DIAGNOSTICS MANUALCARD NOT INSTALLED – PRESS EXIT

If the card number selected is installed, the display below is shown.

DIAGNOSTICS TEMP MANUAL(HEATER RTD SHORT CURRENT AUX−OUT)

The previous display presents the following test options from which aselection is to be made:

� Control Heater Outputs (HEATER)� Examine RTD Inputs (RTD)� Check for Shorted RTD’s (SHORT)� Attempt to Detect Current Flow from Heater(s) (CURRENT)� Control Auxiliary Outputs (AUX−OUT)

Troubleshooting 6-3


Manual−Diag−Temp−Heater−EnterSelecting HEATER from the DIAGNOSTICS TEMP menu produces thefollowing display.

DIAGNOSTICS TEMP MANUALENTER HEATER OUTPUT: 00000000

In order to run the heater circuit output test, the eight binary digits (bits)corresponding to the eight heater circuit outputs must be individually set. Azero (0) indicates that a heater will be turned off, while a one (1) indicates aheater will be turned on. The cursor, which is moved using the NEXT andPREVIOUS keys, indicates the digit currently being edited. Each bit is setor toggled using the INCREASE and DECREASE keys. When all bits havebeen set to the desired values, pressing ENTER will output the data to theheater(s).

Refer to the Temperature Channel Identification table, the TemperatureChannel Location table and Power Module Diagnostics chart to identifysystem parameters, including channels, boards and zone groups.

NOTE: When a heater is turned on, it receives full power with notemperature control. Do NOT leave heaters on for an extended period oftime, as overheating and equipment damage may occur.

WARNING: In order to observe LED and neon operation, the electricalcabinet must be open. Observe and follow all normal electrical safetyprecautions when working on or near energized electrical components ofthe FoamMix system. Failure to observe and follow proper precautions mayresult in personal injury or death.

With the heater on (receiving full power), perform this test:

1. Select DIAGNOSTICS−TEMP−CURRENT. Turning on just onetemperature zone at a time is an effective way of detecting bad heatersor wiring. If current is detected, the heater and wiring is acceptable. Ifno current is detected, then there is a problem with the heater or wiring.

2. While referring to the Power Module Diagnostics Chart, observe theLEDs and neons on the power module. Depending on the status ofthese indicators, the channel is either operating or not operating.

Troubleshooting6-4


Temperature Channel Identification

BoardGroups

ChannelNumber

ChannelName

Mnemonic Board ID,Channel

Zone Group HeaterChannel

Resistance(Heated/Hi

Temp Units)

0 1 Oil OIL 0030,0 Montr only —

0 2 Regulator REGLTR 0030,1 Zone B 192/192

0 3 Sealant SEALNT 0030,2 Montr only —

0 4 Flowmeter FLWMTR 0030,3 Zone B 192/192

0 5 Union UNION 0030,4 Zone B 384/384

0 6 Mix−in MIX−IN 0030,5 Zone D 82/41

0 7 Mix−body MIX−BODY 0030,6 Zone C —

0 8 Mix−out MIX−OUT 0030,7 Zone D 192/165

1 9 Option − 1 OPT−1 0031,0 Zone C









2 18 Option − 10 OPT−10 0032,1 Zone C

2 19 Option − 11 OPT−11 0032,2 Zone C

2 20 Option − 12 OPT−12 0032,3 Zone C

NOTE A: Channels 1 and 3 apply to all units.

B: Channels 1 through 8 apply to heated units option.

C: Channels 9 through 20 apply to units with external temperature channels option.

Troubleshooting 6-5


Temperature channel locations

ZoneDescription

TemperatureCard

ChannelNumber

Power Module DiagnosticDisplay Pos

Position onModule

Oil temperature 0 1 1 0000 0000 Top

Regulator 0 2 1 0000 0010 Upper Middle

SealantTemperature

0 3 1 0000 0100 Lower Middle

SealantFlowmeter

0 4 1 0000 1000 Bottom

Union 0 5 2 0001 0000 Top

Mix−in 0 6 2 0010 0000 Upper Middle

Mix−body 0 7 2 0100 0000 Lower Middle

Mix−out 0 8 2 1000 0000 Bottom

Option 1 1 9 3 0000 0001 Top

Option 2 1 10 3 0000 0010 Upper Middle

Option 3 1 11 3 0000 0100 Lower Middle

Option 4 1 12 3 0000 1000 Bottom

Option 5 1 13 4 0001 0000 Top



Option 8 1 16 4 1000 0000 Bottom

Option 9 2 17 5 0000 0001 Top



Option 12 2 20 5 0000 1000 Bottom

1. Channel descriptions are defaults.

2. Temperature card is identified by the position of the 16−position rotaryswitch on the front of the card.

3. Channel numbers are arbitrary.

4. Power modules are labeled from the top to bottom. Number 1 is at thetop.

5. This bit pattern is used in the MANUAL−DIAG−TEMP−HEATERdisplays. The position of the particular zone’s heater is represented bythe “X”. Note that channels 1 and 3 are monitor−only channels and donot have an associated heater.

Troubleshooting6-6


Temperature channel locations(contd)

Channel is On

Normal Operation

FAULT

1. Fuse Blown

2. Safety Relay Open

Channel is Emptyor

FAULTShorted Triac

Channel is OffNormal Operation

NEON

ON OFF

LED

ON

OFF

Manual−Diag−Temp−RTDSelecting RTD from the DIAGNOSTICS TEMP menu produces the displaybelow (heated unit shown). (In unheated units, the active channels fromwhich a selection is to be made are 0 and 2). To examine an RTD A/Dvalue, the channel number for that RTD must be entered. The channelnumbers are designated in the above tables.

DIAGNOSTIC TEMP MANUALENTER RTD CHANNEL (0−7):

After entering the desired channel number, the RTD input value will beshown, as indicated in the next display.

DIAGNOSTIC TEMP MANUALCH INPUT VALUE:

An RTD input value of 0−25 indicates a shorted sensor. A value of1012−1023 indicates an open sensor. A value of 26−1011 is the normaloperating range, representing 32−525F (0−274C). The RTD input valuewill continue to be displayed until the EXIT key is pressed.

Troubleshooting 6-7


Manual−Diag−Temp−ShortSelecting SHORT from the DIAGNOSTICS TEMP menu permits thescanning of channels 0 and 2 in unheated units and all eight channels of theselected board for shorted RTDs. The following displays indicate what isshown when the scanning process observes a good and shorted RTD.Scanning will continue until the EXIT key is pressed.

DIAGNOSTIC TEMP MANUALRTD OK, CHANNEL NO.:

DIAGNOSTIC TEMP MANUALRTD SHORTED, CHANNEL NO.:

Manual−Diag−Temp−CurrentSelecting CURRENT from the DIAGNOSTICS TEMP menu produces one ofthe following two displays as the unit attempts to detect current on thetemperature board. This monitoring is continually performed with thedisplay continually updated (if necessary) until the EXIT key is pressed.

DIAGNOSTIC TEMP MANUALCURRENT IS DETECTED

DIAGNOSTIC TEMP MANUALCURRENT IS NOT DETECTED

Manual−Diag−Temp−Aux−OutSelecting the AUX−OUT from the DIAGNOSTICS TEMP menu producesthe following display. To control the auxiliary outputs for a given board, thefour binary digits corresponding to the four outputs must be individuallytoggled. A zero (0) indicates that a relay will be opened. A one (1) closesthe relay. The cursor indicates the digit currently being edited. To move thecursor, use the NEXT and PREVIOUS keys. Each bit is toggled using theINCREASE or DECREASE key. After setting all bits to the desired values,press the ENTER key to output the selected values. Safety relays arelocated at the output bit zero (LSB, at right).

DIAGNOSTIC TEMP MANUALENTER AUXIL. CHANNEL OUTPUT: 0000

Manual−Diag−FoamMixSelecting FOAMMIX from the DIAG menu produces the following displaywhich can be used to test FoamMix board #0. Analog INPUTS orOUTPUTS may be chosen for testing at this point.

DIAGNOSTICS FOAMMIX MANUAL(INPUTS OUTPUTS)

Troubleshooting6-8


Manual−Diag−FoamMix−InputsSelecting INPUTS from the menu produces the display below.

DIAGNOSTICS FOAMMIX MANUALENTER INPUT CHANNEL (0−7):

To test analog units, the channel number (0−7) to be examined must beentered. Channel identification for the configured system is as follows:

ChannelNumber

Channel Description Scaling Range FoamMixBoard Revision Levels

116632 A, B, C, D

Scaling Range FoamMixBoard Revision Levels

116632 E and later

0 Oil Pressure 51−255 (0−5000 psi) 204−1023 0−5000 psi)

1 Sealant pressure 51−255 (0−5000 psi) 204−1023 0−5000 psi)

2 Mixer Gas pressure 51−255 (0−5000 psi) 204−1023 0−5000 psi)

3 Gas Control Valve Flow 00−255 (0−max flow) 00−1023 (0−max flow)

4 Motor Current 00−255 (0−20 amps) 00−1023 (0−20 amps)

5 Motor Speed 00−255 (0−1725 rpm) 00−255 (0−1725 rpm)

6 Gas Control Valve Reference 00−255 (0−max flow) 00−1023 (0−max flow)

7 Gas Supply Pressure 51−255 (0−5000 psi) 204−1023 (0−5000 psi)

After entering the channel number, the INPUT VALUE is indicated in thedisplay below. This value is displayed until the EXIT key is pressed.

DIAGNOSTIC FOAMMIX MANUALCH______INPUT VALUE:

Manual−Diag−FoamMix−OutputsSelecting OUTPUTS from the FOAMMIX menu produces the followingdisplay.

DIAGNOSTIC FOAMMIX MANUALENTER OUTPUT CHANNEL (0 OR 1):

To test analog outputs, the channel number must be entered. The selectedchannel is ramped in saw−tooth fashion from 0 to full scale in approximately25 seconds. Channel identification for the configured system is as follows:

� #0= motor speed – 0−5 MA

� #1= gas control valve 0−5 VDC

After entering the channel number, the following display is shown. Thisdisplay will continue to be shown until the EXIT key is pressed.

DIAGNOSTIC FOAMMIX MANUALRAMPING D/A OUTPUT CH_____

Troubleshooting 6-9


Manual−Diag−I/OSelecting I/O from the DIAG menu produces the following display which canbe used to test I/O board #0. Digital INPUTS or OUTPUTS may be chosenfor testing at this point.

DIAGNOSTICS I/O MANUAL(INPUTS OUTPUTS)

Manual−Diag−I/O−InputsSelecting INPUTS from the I/O menu produces the display below. Thevalue shown will be in the form of a bit pattern, with each bit correspondingto the state of one input. A value of one (1) indicates that the input is at alogic high state. A value of zero (0) indicates a low input.

DIAGNOSTICS I/O MANUALDIGITAL INPUT VALUE:XXXXXXX

Channel LED Label Function

1 D7 Motor Pre-start

3 D5 Oil Level Low Warning

4 D4 Oil Level Low Fault

6 D2 Future

7 D1 Future

Troubleshooting6-10


Manual−Diag−I/O−OutputsSelecting OUTPUTS from the I/O menu produces the following display.

DIAGNSTICS I/O MANUALENTER IO BOARD OUTPUT: 000000

To control the digital outputs, the eight binary digits corresponding to theeight outputs must be individually toggled. A zero (0) indicates that a relaywill be opened. A one (1) closes the relay. The cursor indicates the digitcurrently being edited. To move the cursor, use the NEXT and PREVIOUSkeys. Each bit is toggled using the INCREASE or DECREASE key. Aftersetting all bits to he desired values, press the ENTER key to output theselected values. Assignments in the system are as follows:

CAUTION: The low pressure oil pump solenoid should not be energized(closed) without first energizing (opening) the high pressure oil pumpsolenoid.

Channel LED Label Function

0 D16 Motor Start Relay

2 D14 Fault

3 D13 System Ready

5 D11 High pressure oil pump solenoid (Normally Closed)

7 D9 Pump Interlock

Manual−Diag−DisplaySelecting DISPLAY from the DIAG menu produces the following set ofdisplay test screens:

DIAGNOSTICS DISPLAY TEST MANUALVISUALLY INSPECT DISPLAY FUNCTIONS

DIAGNOSTICS DISPLAY TEST MANUALCURSON ON >X (X represents the cursor)

DIAGNOSTICS DISPLAY TEST MANUALCURSOR OFF>

DIAGNOSTICS DISPLAY TEST MANUALCLEAR DISPLAY/CURSOR HOME TEST FOLLOWS

X (X represents the cursor)

(solid blocks filling the entire display)(solid blocks filling the entire display)

Troubleshooting 6-11


DIAGNOSTICS DISPLAY TEST MANUALCHARACTER TEST FOLLOWS

! $ % & ’ ( ) * + , = . / 0 1 2 3 4 5 6 7 8 9 : ; ó ? @ABCDEFGHIJKLMNOPQRSTUVWXYZ[]

Abcdefghijklmnopqrstuvwxyz |

DIAGNOSTICS DISPLAY TEST MANUALPIXEL TEST FOLLOWS

**************************************************************************

##########################################################################

$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

OOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOO

RRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRR

DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD

SSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSS

OOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOO

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

DIAGNOSTICS DISPLAY TEST MANUAL ***TEST COMPLETE***

Troubleshooting6-12


Manual−Diag−KeySelecting KEY from the DIAG menu produces the display below. At thispoint, a particular key must be pressed as requested at the second line ofthe display.

DIAGNOSTICS KEYBOARD TEST MANUALPRESS ‘ ‘ KEY. . .

The next display will be shown if the correct key is pressed.

DIAGNOSTICS KEYBOARD TEST MANUALPRESS ‘ ‘ KEY . . .OK

The key test procedure will now ask for anther key to be pressed. Thisprocess continues until all keys are tested. If an incorrect key is pressed orthe keyboard is not functioning properly for a key, the following display isshown.

DIAGNOSTICS KEYBOARD TEST MANUALPRESS ‘ ‘ KEY . . . INCORRECT KEY

If a key is not pressed or no keys are recognized by the system, thefollowing display is shown.

DIAGNOSTICS KEYBOARD TEST MANUALPRESS ‘ ‘ KEY . . .NEVER SAW A KEY

Upon completion of the key test sequence; one of the two following displayswill be shown, depending on the status of the key tests.

DIAGNOSTICS KEYBOARD TEST MANUAL*** TEST PASSED ***

DIAGNOSTICS KEYBOARD TEST MANUAL*** TEST FAILED ***

Manual−Diag−PROMSelecting PROM from the DIAG menu permits the testing of a PROM.Testing a PROM results in the generation of a 16 bit CRC which iscompared to the value stored in the PROM. During this operation, thefollowing will be displayed.

DIAGNOSTICS PROM TEST MANUALCALCULATING CRC . . .

If the values are equal, the following message will be displayed until theEXIT key is pressed.

DIAGNOSTICS PROM TEST MANUAL*** TEST PASSED ***



If the calculated and stored values do not match, the following message willbe displayed and the system will lock up.

*** FATAL ERROR ***ROM FAILURE

Manual−Diag−RAMSelecting RAM from the DIAG menu permits the testing of all RAM in thesystem. During the test, the following will be displayed.

DIAGNOSTICS RAM TEST MANUALTEST IN PROGRESS

If the RAM test passes, the following will be displayed.

DIAGNOSTICS RAM TEST MANUAL*** TEST PASSED ***

If the RAM test fails, the system will lock up and one of the followingmessages will be displayed.

DIAGNOSTICS RAM TEST MANUALNON−VOLATILE RAM FAILURE

DIAGNOSTICS RAM TEST MANUALRAM FAILURE

FoamMix system faults

Major faultsThe following major fault conditions will cause system shutdown, open theREADY contact, flash the fault LED on the control panel and close the faultoutput contact:

� LOW OIL PRESSURE

� MOTOR OVERTEMPERATURE

� RATIO CONTROL PARAMETERS OUT OF FRAME

� NVRAM ERROR− DEFAULTS LOADED

� FATAL ERROR – SYSTEM CRC – CALL SERVICE

� LINE FREQUENCY INTERRUPTS NOT DETECTED

� CHANNEL ABOVE SHUTDOWN TEMPERATURE

� GAS SUPPLY PRESSURE TRANSDUCER FAULT

� OIL PRESSURE TRANSDUCER FAULT

� MIXER GAS PRESSURE TRANSDUCER FAULT

� SEALANT PRESSURE TRANSDUCER FAULT

Troubleshooting6-14


� CHANNEL OPEN HEATER

� CHANNEL SHORTED SENSOR

� CHANNEL OPEN SENSOR

� CHANNEL NOT CONNECTED

� SHORTED SSR

� SEALANT/OIL OVERTEMPERATURE

� LOW OIL LEVEL (FAULT)

Minor faultsThe following minor fault conditions will cause the fault LED to flash andclose the fault output contact.

� LOW GAS SUPPLY PRESSURE

� MOTOR AT CURRENT LIMIT

� CHANNEL OVERTEMPERATURE

� BATTERY FAILURE IN NVRAM/CLOCK DEVICE

� PDL RAM BOARD BATTERY LOW CONDITION

� LOW OIL LEVEL (WARNING)

Fault messagesThe following fault messages are a combination of the previously listedMajor and Minor faults. The FoamMix controller has the ability to detectsystem major problems and take corrective action. Two types of systemfaults can occur: Major and Minor. Major faults cause the system to enter ashutdown state, while Minor faults simply cause a warning message to belogged in the system. When a fault occurs, the FAULT LED begins flashingand the fault output is closed. Fault messages which have been logged intothe system may be viewed by pressing the FAULT key. After all faults havebeen viewed, the fault output is opened, the FAULT LED glowscontinuously, and the existing display is replaced by one of the two followingmessages:

*** FAULT DISPLAY ***TOTAL SYSTEM FAULTS:

*** FAULT DISPLAY ***NO FAULTS PRESENT IN THE SYSTEM

If there are faults logged in the system, they can be viewed by using thePREVIOUS or the NEXT keys to scroll through the messages.

Note that in order to clear a fault, the source of the fault must be correctedand, after viewing the fault message, the fault display must be exited.

The following is a listing of fault messages along with a description of theproblem. All pressures used in fault detection are averaged to avoid theerroneous logging of faults.



Troubleshooting charts are located later in this section.

The occurrence of the LOW OIL PRESSURE fault, as shown below,indicates that the oil pressure is less than the sum of the sealant pressureand 200 psi (13 bar).

*** FAULT DISPLAY ***LOW OIL PRESSURE

The occurrence of the LOW GAS SUPPLY PRESSURE fault, as shownbelow, indicates that the gas supply pressure is less than the sum of the gasmixer pressure and 200 psi (13 bar). This condition is a Minor fault and ischecked only during the mixer startup sequence.

*** FAULT DISPLAY ***LOW GAS SUPPLY PRESSURE

The occurrence of the MOTOR OVERTEMPERATURE fault, as shownbelow, indicates that the motor thermostat has tripped. This is a Major faultcondition.

*** FAULT DISPLAY ***MOTOR OVERTEMPERATURE

The occurrence of the RATIO CONTROL fault, as shown below, indicatesthat the control system could not supply the correct volume of gas tooperate at the programmed ratio. The fault is logged when the controlsystem error is greater than the magnitude of the error threshold. This isproportional to the programmed gas control valve and will be in the range of100−1000 cc. Possible causes for this fault condition include: incorrectlyprogrammed sealant or gas meter, ratio Index programmed too high per theactual expected sealant flow and gas control valve capacity, or the sealantflow is higher than anticipated. This is a Major fault which first must beviewed before it is cleared upon shutdown of the system.

*** FAULT DISPLAY ***RATIO CONTROL PARAMETERS OUT OF RANGE

The occurrence of the MOTOR CURRENT LIMIT fault, as shown below,indicates that the motor current is greater than 10 amps. Monitoring of themotor current begins 2 seconds after starting the motor. This is a Minorfault.

*** FAULT DISPLAY ***MOTOR AT CURRENT LIMIT

The occurrence of the BATTERY FAILURE IN NVRAM/CLOCK DEVICEfault, as shown below, indicates that the battery is low on theclock/battery−backed RAM device located on the CPU board. This couldresult in the loss of programmed data. In addition, the time−of−day clockcould fail to operate properly, resulting in improper auto event operation.With this Minor fault condition, a new chip should be installed.

*** FAULT DISPLAY ***BATTERY FAILURE IN NVRAM/CLOCK DEVICE

Troubleshooting6-16


The occurrence of the NVRAM ERROR, as shown below, indicates thatincorrect data was detected in the area of memory that stores theprogrammed values. However, the NVRAM device has been tested andfound to be functioning properly. Default values for programmed set pointshave been loaded and will probably need to be adjusted. This is a Majorfault.

*** FAULT DISPLAY ***NVRAM ERROR – DEFAULTS LOADED



Fault messages(contd)The occurrence of the SYSTEM CRC error, as shown below, indicates thatincorrect data was detected in the area of memory that stores theservice−programmable values. However, the NVRAM device has beentested and found to be functioning properly. This problem can only becorrected by obtaining the service password and re−programming thecorrect values for the service−programmable parameters. This is a Majorfault.

*** FAULT DISPLAY ***FATAL ERROR− SYSTEM CRC− CALL SERVICE

The LINE FREQUENCY INTERRUPTS NOT DETECTED Major fault isindicated below. Line frequency interrupts must be connected in order forthe temperature control system to operate. Failure to detect line frequencyinterrupts at the CPU can be caused by an incorrect jumper selection on thetemperature board #0, an improper switch setting on the CPU board, noconnection from the power monitor board to the temperature board, orfailure of the temperature board or power monitor board.

*** FAULT DISPLAY ***LINE FREQUENCY INTERRUPTS NOT DETECTED

The CHANNEL OVERTEMPERATURE fault, as shown below, indicates thatthe actual averaged temperature for the channel is greater than theprogrammed set point plus the overtemperature differential, per theprogrammed temperature range. The overtemperature value for theFoamMix unit is 30F. Overtemperature faults are Minor faults.

*** FAULT DISPLAY ***YYYYYY OVERTEMPERATURE

The CHANNEL ABOVE SHUTDOWN TEMPERATURE fault, as shownbelow, indicates that the actual averaged temperature for the channel isgreater than the programmed shutdown temperature. It must beremembered that the sealant channel shutdown temperature isprogrammed separately.

*** FAULT DISPLAY ***YYYYYY ABOVE SHUTDOWN TEMPERATURE

When the shutdown temperature fault occurs, the overtemperature fault iscleared because the shutdown temperature is always greater than or equalto overtemperature. This is a Major fault.

A LOW OIL LEVEL warning or shutdown will occur when the oil level in thepump reservoir reaches two preset levels. The menus displayed duringthese conditions is as shown below. Two sensors are installed; one toindicate a warning level, and another sensor to indicate a shutdown level.The warning is Minor fault and the shutdown is Major fault.

*** FAULT DISPLAY ***LOW OIL LEVEL WARNING

Troubleshooting6-18


*** FAULT DISPLAY ***LOW OIL LEVEL SHUTDOWN

The CHANNEL OPEN HEATER fault, as shown below, indicates that nocurrent can be detected in response to activating the heater for this channel.The heater test runs at power up and the rate of one channel every 30seconds while the system is in the Startup mode. Therefore, depending onthe total number of channels, several minutes could be required to clear thisfault after it is corrected. It may be faster, when possible, to power−downthe controller to clear this fault. This is a Major fault.

*** FAULT DISPLAY ***YYYYYY OPEN HEATER

The CHANNEL SHORTED SENSOR fault, as shown below, indicates thatthe RTD for the given channel is shorted. This is a Major fault.

*** FAULT DISPLAY ***YYYYYY SHORTED SENSOR

The CHANNEL OPEN SENSOR fault, as shown below, indicates that theRTD for the given channel is open. This is a Major fault.

*** FAULT DISPLAY ***YYYYYY OPEN SENSOR

The SHORTED SSR fault, as shown at the next display, indicates that oneor more SSRs on the given temperature board may be shorted. Theshorted SSR test is run every 30 seconds. Therefore, up to 30 secondsmay be required to clear this fault after it is corrected. This is a Major fault.

*** FAULT DISPLAY ***SHORTED SSR – TEMPERATURE BOARD #_____



Other error messageThe following faults and corresponding error messages can possibly occurand indicate serious Internal fault condition, which prevents furtheroperation of the FoamMix controller. Therefore, the corresponding errormessages will be seen as soon as the fault is detected rather than throughthe previously discussed method of pressing the FAULT key.

The occurrence of either one of the two following displays indicates aserious problem. Neither of these faults should ever occur; however,provisions are made for these diagnostic messages in preparation for theunlikely event that they do occur. There is no recovery from either of thesefaults.

*** FAULT DISPLAY ***ACCESSING BOARD−NOT CONFIGURED

*** FAULT DISPLAY ***_______BOARD ACCESSED AT EVEN ADDRESS

At power up, a test is run by the FoamMix controller to determine whichboards are installed. At that time, if the required boards are not installed,appropriate fault messages are displayed. However, in the event that anerror should subsequently occur in accessing a board which was previouslytagged as installed, one of the following three messages will be displayed.The message displayed could indicate a CPU, bus, connector or peripheralboard problem.

*** FAULT DISPLAY ***FOAMMIX BOARD #____NOT FOUND

*** FAULT DISPLAY ***IO BOARD#_____NOT FOUND

*** FAULT DISPLAY ***TEMP BOARD #_____NOT FOUND

Display of the NON−VOLATILE RAM FAILURE message, as shown below,indicates that the NVRAM/timer chip is defective and needs to be replaced.When it is replaced, all set points (including those protected by the servicepassword) will need to be set. Additionally, the time−of−day clock used forauto timing will need to be set.

*** FAULT DISPLAY ***NON−VOLATILE RAM FAILURE

Display of the RAM FAILURE message, as shown below, indicates that oneor more RAM devices need to be replaced.

*** FAULT DISPLAY ***RAM FAILURE

Troubleshooting6-20


Display of the ROM FAILURE message, as shown below, indicates that thePROM’s contain incorrect data and need to be replaced.

*** FAULT DISPLAY ***ROM FAILURE

Occurrence of the errors shown in the following displays indicates thepresence of an electrical hardware or software problem which preventsfurther operation of the controller.

SYSTEM HALTED – BUS ERRORPC=________ ACC=__________

SYSTEM HALTED – ADDRESS ERRORPC=______ ACC=_________

SYSTEM HALTED – INSTRUCTION ERRORPC=________

SYSTEM HALTED – ZERO DIVIDE ERRORPC=_________

SYSTEM HALTED – DATA REGISTER ERRORPC=_________

SYSTEM HALTED – TRAP ON OVERFLOW ERRORPC=_________

SYSTEM HALTED – PRIVILEGE VIOLATIONPC=_________

SYSTEM HALTED – TRACE ERRORPC=_________

SYSTEM HALTED – LIME EMULATION 0 ERRORPC=_________

SYSTEM HALTED – LIME EMULATION 1 ERRORPC=_________

SYSTEM HALTED – UNINITIALIZED INTRPTPC=_________

SYSTEM HALTED – SPURIOUS INTRPTPC=_________

SYSTEM HALTED – AUTO VECTOR ERRORPC=_________

SYSTEM HALTED – LOW POWER FAILPC=_________



SYSTEM HALTED – SWI TRAPPC=_________

a

b

Troubleshooting question and actionblocks

a) Question b) Action

Troubleshooting6-22


Using the Troubleshooting FlowchartThe following flowcharts are designed to assist you in diagnosing andcorrecting a complete or partial stop in operation. The chart is organized ina simple question-action block format. If your response to a question is yes(Y), continue downward in the chart to the next question or action block. Ifyou response is no (N), continue to the right to the next question or actionblock. All diagnostic paths within the chart end with an action block thatspecifies one of the following three courses of action:

� Refer to information provided elsewhere in this manual

� Replace a component

� Complete a diagnostic procedure (DP.x)

Use of the chart assumes that the FoamMix unit is installed correctly andthat it is set up to support the current manufacturing process.

Troubleshooting Charts

6-23

Part 1052254B

� 2006 N

ordson Corporation Ratio Control Parameters Out of Range

?Replace with a larger capacityvalve.

+

−

Monitor gas flow while FoamMixis operating. Does gas flow peakat maximum valve flow rate?

Verify operation of the gas controlvalve.

+

−

Enter MANUAL mode, adjustGAS FLOW command to 1.0, andwait for adjusted gas pressure tostabilize. Is gas flow indicated?

Replace mixer check valve.

+

−

Reduce MIXER GAS PRESSUREto 7 bar (100 psi). Loosen theoutput fitting on the back pressureregulator. Does gas flow?

Check operation of the gascontrol valve.

+

−

Is the mixer gas pressure greaterthan the sealant pressure?

Increase gas pressure. Refer toSection 4, Operation.

T.1


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Density Reduction Changes

T.2

Go to Ratio Control ParametersOut of Range lists earlier in thissection.

+

−

+

−

Are there differences in foamedbead cell structure (larger/smallerbubbles)?

+

−

Is the software configuration ofthe flow meter and gas flowcontrol valve correct?

Has gun pressure changed fromthe original set point?

Adjust to the original set point.

+

−

Are there leaks in the gas line?

Note: Use leak detection fluid(P/N 900300).

Change software.

Tighten/replace fittings.

Contact Nordson for assistance.

+

−

Are faults found in the RatioControl Parameters?

+

−

Is the Density Ratio Setpointcorrect?

Adjust setpoints as detailed inSection 4, Operation.


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Low Oil Pressure

T.3

+

−

Is there a Low Oil Pressure Faulton the display?

Clear faults.

+

−

Is air leaking from the plumbingand/or fittings?

+

−

Is the oil pump operating airpressure at least 4 bar (55 psig)?

Service the sealant regulator.

+

−

+

−

Go to MANUAL DIAGNOSTICSI/O OUTPUTS menu. Selectchannel 5 (h.p. solenoid). PressINCREASE button. Does oilpressure increase?

Reset oil pump operatingpressure.

Use DECREASE button to closethe solenoid (enter “0”). Selectchannel 1 (l.p. solenoid). UseINCREASE button and enter “1”to close the solenoid. Does oilpressure increase?

+

−

Observe sealant pressure flowingand idle. Does sealant pressureremain steady?

Check I/O board. Refer to DP.1in the following pages.

Service the sealant regulator.

+

−

Is the oil pump cycling?

+

−

Is the air supply pressure at least6 bar (85 psig)?

Reset air supply pressure.

Resume normal operation.


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No Gas Flow Indication

T.4

+

−

+

−

Move “+” DVM lead to pin 8 and“−” lead to pin 1. Use the key padup/down arrows to ramp the flowreference from 0.0 to 1.0 thenback to 0.0. Does DVM voltageramp from 0.0 to 5.0 VDC?

+

−

Move “+” DVM lead to pin 6,recheck voltage. Is the reading15 VDC?

Jumper pin 8 to pin 2. Jumper pin1 to pin 10. Use the key padup/down arrows to ramp the flowcommand to 1.0. Observe theLCD display. DOes flow ramp tofull scale?

Contact Nordson for furtherassistance.

Replace the controller board.

+

−

Is the wiring from the gas flowcontrol valve to the controllerboard intact and correct?

Repair/replace wiring harness.

+

−

Go to MANUAL GAS FLOWmenu. Remove plug P27 fromgas flow control valve. Use aDVM set to 20 VDC to measurevoltage across pins 5 and 9. Isthe reading 15 VDC?

+

−

Is the power supply workingproperly?

Repair/replace power supply.


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Line Frequency Interrupts not Detected (Unheated Units Only)

T.5

+

−

+

−

Is a second board installed?

+

−

Disconnect and lock out powerfrom the unit. Locate and removetemperature control board 0.Locate jumper J1. Is it in position2?

Interchange plug P2 on tempboard 0 with plug P2 on tempboard 1. Connect and apply inputpower. Are frequency interruptsfunctional?

+

−

Disconnect and lock out inputpower. Use an ohmmeter tomeasure continuity of wiringharness connecting the tempboard with the power monitorboard. Harness OK?

Replace the power monitor boardand the temperature controlboard.

Correctly install jumper J1.

Swap temp board 0 with tempboard 1 or replace temp board 0.

Repair/replace wiring. Replace power monitor board.

+

−

Is plug P2 on the power monitorboard properly installed inconnector 2?

Correctly install plug P2.


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Open Heater

Use the following printed instruconjunction with this chart to dheater problems.

T.6

+

−

+

−

Is heater resistance normal?

+

−

Identify the system channelnumber, temperature board,board channel, power module anddiagnostic lights. Toggle thesafety relay and observe thelights. Do the lights come on?

Is there continuity in the heaterwiring?


+

−

Is current detected?

+

−

Toggle the heater signal andsafety relay. Check LED andneon status lights. If neither lightis on, go to the steps below. Isthe LED on but the neon off?


+

−

Are the fuses good?

+

−

Is the safety relay working? Replace the safety relay.

Replace the power module.

Replace the fuses.

Replace the temperature board. Replace the ribbon cable.

+

−Check the ribbon cable condition.Is it okay?

If the LED and neon statuslights are not on:


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Open Heater TroubleshootingUse the text to assist in working through the accompanying troubleshootingtree:

1. Determine which channel number or numbers match the heater zoneidentified in the fault message. The Temperature Channel Identificationchart near the beginning of this section gives this information.

2. Locate the temperature board and power module for the faulty channel(see the Temperature Channel Identification chart). The temperatureboards are identified by the number on the selector dial visible on theboard edge.The following talble shows the power module/channelconfiguration. Refer to the electrical drawings provided with the unitwhen using this table.

Power Module Channels Internal/External

1 1−4 Internal

2 5−8 Internal

3 9−12 External

4 13−16 External

5 17−20 External

3. Locate the diagnostic lights associated with the heater channel inquestion. Each power module has a red LED and a white neon light foreach of its four channels. The red LED is illuminated by the 5 VDCsignal from the temperature board; the white neon light is illuminated bythe 240 VAC output. The neon circuit is in parallel with the heater. Thelights are in pairs in ascending order from top to bottom.

Example: Fault message: REGLTR OPEN HEATER

Referencing the Temperature Channel Identification table near thebeginning of this section:

� REGLTR is channel number 2.

� Dividing the channels into groups of 4, we determine that channel 2 isthe second channel in the first group.

� The diagnostic lights for channel 2 are the second pair down, on the toppower module.

� Channel 2 is part of “Board group 0” (the heater signals for this channelare processed by temperature board 0).

� Temp boards are all adjacent to each other in the card rack. Tempboard 0 is identified by the number on its selector dial (the boardselector dials are numbered 0, 1 and 2).

Troubleshooting6-36


Open Heater Troubleshooting(contd)1. Press the MANUAL key to enter the manual mode, then enter your

password. Move the cursor to DIAG, then press ENTER. Move thecursor to TEMP, then press ENTER. Use the INCREASE andDECREASE keys to select the right temperature control board, thenpress ENTER. Move the cursor to AUX−OUT, then press ENTER.Move the cursor to the “0” at the far right (this is the safety relay “bit”).The safety relay interrupts 240 VAC to the power module in case of anovertemp condition. Use the INCREASE key to change the “0” to “1”,then press ENTER. This enables 240 VAC to the power modulesassociated with the temperature board you selected.

2. Check the diagnostic lights for the tested heater channel. A normalindication now is both lights off.

� If the white neon light is on, either an open heater or open wiringbetween the power module and the heater exists. Use a digitalvolt/ohmmeter to check the heater channel resistance with theheaters at room temperature (see the Temperature ChannelIdentification chart for channel resistance values). To check theresistance, open the lid to the hydraulic enclosureremove the upperside panel, locate the terminal blocks and probe at the terminalblocks with the volt/ohmmeter.

� If the white neon light is off, go to step 8 of the troubleshooting tree.

NOTE: The white neon lights of other channels may be on at this time.These channels are not being used and, therefore, do not have heaters toload down the solid state switching circuit. Therefore, a small amount ofpower leaks through to partially illuminate the neon. This means that thesafety relay is working.

3. Exit the AUX−OUT screen while leaving the safety relay activated.Reference the Temperature Channel Identification chart once more anddetermine the temperature board channel of the zone you are testing.Each zone has a system channel number and a channel on itscontrolling temperature board. Once you have determined the “BoardChannel,” move the cursor to the HEATER selection and press ENTER.

CAUTION: In this operation, the heater will be on at full power withoutcontrol or any safety features operational. Perform this test quickly, thenimmediately turn off the heater. Equipment damage, personal injury ordeath can result if you do not follow and observe this warning.

The rows of zeros on the screen represent the channels controlled by thetemperature board you are manipulating. Determine the “bit” thatcorresponds to the channel you wish to test by counting from right to leftstarting at the “0” at the far right. Move the cursor to the “bit”, then pressENTER. Normally, the heater you toggled will heat up and both thediagnostic lights for that channel will be turned on. If so, move the cursor tothe CURRENT selection, press ENTER and confirm proper operation withan indication of CURRENT IS DETECTED. If both lights are not on, refer tothe appropriate paragraph below.



� Red LED off – The 5 VDC signal from the temperature board is notreaching the power module. Check the ribbon cable connections; if noproblem is found, replace the temperature board. Be sure to set theselector dial on the new temperature board to the correct number on thenew board.

� Red LED on, white neon off – The 5 VDC is reaching the power module,but the 240 VAC power is not being switched. First, disconnect powerfrom the unit, then check the power module fuses with an ohmmeter.The top two fuses both 240 VAC legs for the top two channels. Thebottom two fuses serve the bottom two channels. Be sure to check bothfuses serving the channel you are troubleshooting. If the fuses testgood, the fault is with the solid state circuitry of either the power moduleor the safety relay.

A bad safety relay is indicated by open heater faults for all zones assignedto a particular temperature board. If so, replace the safety relay.

If there are only one or two channels being used on the temperature boardassociated with the zone being tested, proper operation of the safety relaycan be confirmed if the white neon lights for the empty channels are onwhen the safety relay has been toggled (step3).

If the safety relay operates properly, replace the power module.

DP.1 − Check FoamMix Printed Circuit Board 1. Do the following:

� Remove the connector from the gas valve

� Insert voltmeter probes into sockets 1 and 8 to read 0−5 VDCcommand voltage

� Set commands in MANUAL and read voltages:

Command Voltage (DC)

0.0 0.0

0.5 2.5

1.0 5.0

If readings are within specifications, proceed to step 2. If not, check wirecontinuity. If wire continuity is good, replace the printed circuit board. If not,replace the wiring harness.

Troubleshooting6-38


2. Check input to the FoamMix printed circuit board:

� Reconnect the harness to the gas control valve

� Insert voltmeter probes into sockets 5 and 4 of the connector 3 onthe FoamMix card

� Enter MANUAL mode

� Set valve commands in MANUAL mode and read voltages

Command Voltage (DC)

0.0 0.0

0.5 2.5

1.0 5.0

If readings are within specifications, contact Nordson for further assistance.If not, check wire continuity. If wire continuity is good, replace the gascontrol valve. If not, replace the wiring harness.

DP.2 − Check the I/O Board 1. Use the keybad to enter the MANUAL DIAGNOSTICS I/O OUTPUTS

menu.

2. Use the following table to determine channel numbers and connector pinnumbers to check.

Output LED Conn / Pins

Pump Interlock d9 3 / 1 − 2

High Pressure Oil d11 3 / 5 − 6

System Ready d13 4 / 3 − 4

Fault d14 4 / 5 − 6

Low Pressure Oil d15 4 / 7 − 8

Motor Relay d16 4 / 9 − 10

3. Toggle the output.

4. Measure the voltage across the appropriate pins with a digital voltmeter.If voltage is present, the I/O board is okay. If not, check the wiringharness for continuity. If there is continuity, replace the I/O board. If not,replace the wiring harness.

## TABSHEET ## Parts

Parts 7-1


Section 7Parts

Using the Illustrated Parts Tables To order parts, call the Nordson Customer Service Center or your localNordson representative. Use the following tables and the and theaccompanying drawings to describe and locate parts correctly.

The number in the Item column corresponds to the circled item number in theparts list illustration. A dash in this column indicates that the item is anassembly.

The number in the Part column is the Nordson part number you canuse to order the part. A series of dashes indicates that the part isnot saleable. In this case, you must order either the assembly inwhich the part is used or a service kit that includes the part.

The Description column describes the part and sometimesincludes dimensions or specifications.

The Note column contains letters that refer to notes at thebottom of the parts list. These notes provide importantinformation about the part.

The Quantity column tells you how many of the part isused to manufacture the assembly shown in the partslist illustration. A dash or AR in this column indicatesthat the amount of the item required in the assembly isnot quantifiable.

Item Part Description Quantity Note— 0000000 Assembly A —1 000000 � Part of assembly A 2 A2 - - - - - - � � Part of item 1 13 0000000 � � � Part of item 2 AR

NS 000000 � � � � Part of item 3 2NOTE A: Important information about item 1

AR: As Required

NS: Not Shown

Parts7-2


Heated System ControllerDrawing number 1045177 should be used as reference with this parts list.

Continued....

Parts 7-3


Continued....

Parts7-4


Heated System Controller(contd)

Parts 7-5


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Parts7-6


Unheated System ControllerDrawing number 1045163 should be used as reference with this parts list.

Continued....

Parts 7-7


Continued....

Parts7-8


Unheated System Controller(contd)

Parts 7-9



Parts7-10


Standard Oil System Drawing number 1045174 should be used as reference with this parts list.

Continued....

Parts 7-11


Parts7-12


High Pressure Oil System Drawing number 1045174 should be used as reference with this parts list.

Continued....

Parts 7-13


Parts7-14


Standard Pressure Gas Supply System Drawing number 1045172 should be used as reference with this parts list.

Continued....

Parts 7-15


Continued....

Parts7-16


Standard Pressure Gas Supply System (contd)

Parts 7-17



Parts7-18


High Pressure Gas Supply System Drawing number 1045172 should be used as reference with this parts list.

Continued....

Parts 7-19


Continued....

Parts7-20


High Pressure Gas Supply System (contd)

Parts 7-21



Parts7-22


Unheated Sealant System Drawing number 1045167 should be used as reference with this parts list.

Continued....

Parts 7-23


Parts7-24


Heated Sealant System Drawing number 1045167 should be used as reference with this parts list.

Continued....

Parts 7-25


Parts7-26


Heated HP Sealant System Drawing number 1045167 should be used as reference with this parts list.

Continued....

Parts 7-27


Parts7-28


Polyamide Sealant System Drawing number 1045167 should be used as reference with this parts list.

Continued...

Parts 7-29


Parts7-30


Service Kits

Clock

Part Description Quantity114342 Kit, I.C., Clock, T.O.D. —310895 � Memory, RAM, w/battery back-up 1

Oil Filter

Part Description Quantity163520 Repl, oil filter —

Oil Pump

Part Description Quantity163523 Service kit, oil pump —

Impeller, Hi Flow

Part Description Quantity163521 Service kit, impeller, hi-flow —163525 Service kit, o-ring —

Impeller, Low Flow

Part Description Quantity163524 Service kit, impeller, low-flow —163522 Service kit, o-ring —

Parts 7-31


Sealant Regulator

Part Description Quantity165883 Service kit, sealant regulator seal —165859 � Seal, piston 1165860 � Seal, poppet 1941290 � O-ring, Viton, blk, 1.562 x 1.750 1941281 � O-ring, Viton, 1.4871 ID x .103 W 1

------ � O-lube, hi−temp, 1/2 oz 1

Part Description Quantity165884 Service kit, sealant regulator seal/poppet —165859 � Seal, piston 1165860 � Seal, poppet 1941290 � O-ring, Viton, blk, 1.562 x 1.750 1941281 � O-ring, Viton, 1.4871 ID x .103 W 1156543 � Poppet 1156545 � Seat 1

------ � O-lube, hi−temp, 1/2 oz 1

Mixer Seals

Part Description Quantity1063501 Repl, mixer seal —1046303 � Oil Seal 11046285 � Flex Seal 1

------ � O-lube, hi−temp, 1/2 oz 1

Parts7-32


RTD Replacement

Part Description Quantity1063502 Repl, RTD, Flowmeter, mixer, endcap —132566 � Sensor, RTD 41023441 � Compound, thermal, silicon base, 1 g 1

Part Description Quantity1063503 Repl, RTD, regulator, union, oil, endcap —1046953 � Sensor, RTD 41023441 � Compound, thermal, silicon base, 1 g 1

Heater Replacement

Part Description Quantity1063504 Repl, heater, regulator —172531 � Heater, .38 x 2.25, 250W, 240V, 10LD 21023441 � Compound, thermal, silicon base, 1 g 2

Part Description Quantity1063505 Repl, heater, flowmeter/endcap —938079 � Heater, .38 x 2, 150W, 240V 41023441 � Compound, thermal, silicon base, 1 g 2

Part Description Quantity1063506 Repl, heater, mixer body —155293 � Heater 41023441 � Compound, thermal, silicon base, 1 g 2

Part Description Quantity1063507 Repl, heater, union —132606 � Heater, band, 240V, 150W, 1.75 ID 4

Parts 7-33


Recommended Spare Parts

Controller Part Number Description Quantity Note

102812 Temperature control board 1 A

109302 Power monitor board 1

233612 Power supply +5 +24 +15 −15 1

939842 Fuse, 35A, Class J 3

125497 Power module board, 4 channel 1

939683 Power module board fuse 4

1046357 AC Drive 2 HP 208/240 3 1

NOTE A: Heated Units Only

Mixer Assembly Part Number Description Quantity Note

X116209 Face seal, inner, RBX 1

1046285 Seal, Flexiseal 2

1046303 Seal, Oil 2

942371 O-ring, mixer and bearing end cap 2

952371 Backup ring, mixer and bearing end cap 2

115897 Tapered bearing 1

973221 Oil plug 1

945039 O-ring, #12 SAE 2

1046953 RTD, 3 in., sealant temp. 2

971311 Adapter, RTD 2

942281 O-ring, mixer end cap 2

954034 Backup ring mixer end cap 2

135800 Transducer washer seal 1

941161 O-ring, VCO fitting 1

973308 Adapter, Dynisco transducer to 1/2G 1

138161 Transducer, with transmitter, hi temp 1

152293 Mixer housing heater, 350W 4 A

132566 RTD, mixer end cap, mixer body 3 A

938079 Heaters, mixer end cap 4 A

940101 O-ring, autoflo dump valve 2


Parts7-34


Union Part Number Description Quantity Note

132606 Band heater, 150W 1 A

132566 RTD 1 A


Flowmeter Part Number Description Quantity Note

945039 O-ring, #12 SAE 2

941161 O-ring, VCO fitting 1

163524 Service kit, impeller, low flow 1

163522 O-ring, flowmeter, low flow 1

163521 Service kit, impeller, high flow 1

163525 O-ring, flowmeter, high flow 1

1054937 Encoder, uncooled 1

1052247 Encoder, cooled 1 A

132566 RTD, flowmeter 1 A

938079 Heater, 150W, flowmeter 4 A

146491 Flowmeter, low flow, complete 1

146940 Flowmeter, high flow, complete 1


Sealant Regulator Part Number Description Quantity Note

165884 Service kit, sealant regulator 1

945039 O-ring, #12 SAE 2

172531 Heater, 250W, 30 in. leads 2 A

1046953 RTD, 3 in., sealant regulator temp 1 A

156549 Sealant regulator 1


Parts 7-35


Gas Control Assembly Part Number Description Quantity Note

116181 Back pressure regulator 1

129964 Diaphragm, back pressure regulator 1

940101 O-ring, −010, back pressure regulator 2

945026 O-ring, #4 SAE port 4

1046631 Gas valve, 250 SCCM, 1500 psi 1 A





1045161 Gas check valve 1

NOTE A: Refer to the specifications of the FoamMix III unit for the correct gas valve to be ordered.

Gas/Air Supply Part Number Description Quantity

141792 Service kit, cartridge dryer 1

141793 Service kit, gas filter 1

Oil System Part Number Description Quantity

163520 Service kit, oil filter 1

1046197 Oil, heat transfer fluid, 5 gal. 1

Parts7-36


Miscellaneous Part Number Description Quantity Note

900493 High temp o-ring lube 1

900300 Leak detector fluid 1

945026 O-ring, #4 SAE 5

945032 O-ring, #6 SAE 5

945039 O-ring, #12 SAE 1

945027 O-ring, #5 SAE 1

945034 O-ring, #8 SAE 1

275386 Heating thermal compound 1 A


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Parts Drawings

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