Flow-Through-Felt Controller for Gravity Feed Applicators

Flow-Through-Felt Controller for Gravity Feed Applicators Only Applicable to Contract E-001353269 Issued 1/13 For parts and technical support, call the Finishing Customer Support Center at (800) 433-9319. This document is subject to change without notice. Check http://emanuals.nordson.com/finishing for the latest version. NORDSON CORPORATION AMHERST, OHIO USA

Table of Contents Safety... 1 Qualified Personnel... 1 Intended Use... 1 Regulations And Approvals... 1 Personal Safety... 1 High-Pressure Fluids... 2 Fire Safety... 3 Halogenated Hydrocarbon Solvent Hazards... 3 Action In The Event Of A Malfunction... 3 Disposal... 3 Description... 4 Installation... 5 Operator Interface... 6 System Status... 6 View Faults... 7 Alarms... 8 Test Points... 10 System Set-Up... 11 Cleaner Meter Pump... 12 Meter Pump Diagnostic... 12 Clock... 13 Version... 13 Part Id... 14 Fault Set-Up #1... 14 Pump Test Setup... 15 Measure Felt Setup... 15 Fault Setup #2... 16 System Configure... 17 Process Data... 22 Fault Decoder... 22 Manual Controls... 23 Metering Pump Testing Help... 23 Confirm Replace... 24 Preventive Maintenance... 24 Pump Scale... 25 Menu Tree... 26 Operation... 27 Fault Messages... 28 Parts... 29

Safety Read and follow these safety instructions. Task- and equipment-specific warnings, cautions, and instructions are included in equipment documentation where appropriate. Make sure all equipment documentation, including these instructions, is accessible to persons operating or servicing equipment. Qualified Personnel Equipment owners are responsible for making sure that Nordson equipment is installed, operated, and serviced by qualified personnel. Qualified personnel are those employees or contractors who are trained to safely perform their assigned tasks. They are familiar with all relevant safety rules and regulations and are physically capable of performing their assigned tasks. Intended Use Use of Nordson equipment in ways other than those described in the documentation supplied with the equipment may result in injury to persons or damage to property. Some examples of unintended use of equipment include using incompatible materials making unauthorized modifications removing or bypassing safety guards or interlocks using incompatible or damaged parts using unapproved auxiliary equipment operating equipment in excess of maximum ratings Regulations and Approvals Make sure all equipment is rated and approved for the environment in which it is used. Any approvals obtained for Nordson equipment will be voided if instructions for installation, operation, and service are not followed. Personal Safety To prevent injury follow these instructions. Do not operate or service equipment unless you are qualified. Do not operate equipment unless safety guards, doors, or covers are intact and automatic interlocks are operating properly. Do not bypass or disarm any safety devices. Keep clear of moving equipment. Before adjusting or servicing moving equipment, shut off the power supply and wait until the equipment comes to a complete stop. Lock out power and secure the equipment to prevent unexpected movement. Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or servicing pressurized systems or components. Disconnect, lock out, and tag switches before servicing electrical equipment. While operating manual spray guns, make sure you are grounded. Wear electrically conductive gloves or a grounding strap connected to the gun handle or other true earth ground. Do not wear or carry metallic objects such as jewelry or tools. If you receive even a slight electrical shock, shut down all electrical or electrostatic equipment immediately. Do not restart the equipment until the problem has been identified and corrected. (Continued on next page...) E-001353269 1

Obtain and read Material Safety Data Sheets (MSDS) for all materials used. Follow the manufacturer's instructions for safe handling and use of materials, and use recommended personal protection devices. Make sure the spray area is adequately ventilated. To prevent injury, be aware of less-obvious dangers in the workplace that often cannot be completely eliminated, such as hot surfaces, sharp edges, energized electrical circuits, and moving parts that cannot be enclosed or otherwise guarded for practical reasons. High-Pressure Fluids High-pressure fluids, unless they are safely contained, are extremely hazardous. Always relieve fluid pressure before adjusting or servicing high pressure equipment. A jet of high-pressure fluid can cut like a knife and cause serious bodily injury, amputation, or death. Fluids penetrating the skin can also cause toxic poisoning. If you suffer a fluid injection injury, seek medical care immediately. If possible, provide a copy of the MSDS for the injected fluid to the health care provider. The National Spray Equipment Manufacturers Association has created a wallet card that you should carry when you are operating high-pressure spray equipment. These cards are supplied with your equipment. The following is the text of this card: WARNING: Any injury caused by high pressure liquid can be serious. If you are injured or even suspect an injury: Go to an emergency room immediately. Tell the doctor that you suspect an injection injury. Show him this card Tell him what kind of material you were spraying MEDICAL ALERTWOUNDS: NOTE TO PHYSICIAN Injection in the skin is a serious traumatic injury. It is important to treat the injury surgically as soon as possible. Do not delay treatment to research toxicity. Toxicity is a concern with some exotic coatings injected directly into the bloodstream. Consultation with a plastic surgeon or a reconstructive hand surgeon may be advisable. The seriousness of the wound depends on where the injury is on the body, whether the substance hit something on its way in and deflected causing more damage, and many other variables including skin microflora residing in the paint or gun which are blasted into the wound. If the injected paint contains acrylic latex and titanium dioxide that damage the tissue's resistance to infection, bacterial growth will flourish. The treatment that doctors recommend for an injection injury to the hand includes immediate decompression of the closed vascular compartments of the hand to release the underlying tissue distended by the injected paint, judicious wound debridement, and immediate antibiotic treatment. 2 E-001353269

Fire Safety To avoid a fire or explosion, follow these instructions. Ground all conductive equipment. Use only grounded air and fluid hoses. Check equipment and workpiece grounding devices regularly. Resistance to ground must not exceed one megohm. Shut down all equipment immediately if you notice static sparking or arcing. Do not restart the equipment until the cause has been identified and corrected. Do not smoke, weld, grind, or use open flames where flammable materials are being used or stored. Do not heat materials to temperatures above those recommended by the manufacturer. Make sure heat monitoring and limiting devices are working properly. Provide adequate ventilation to prevent dangerous concentrations of volatile particles or vapors. Refer to local codes or your material MSDS for guidance. Do not disconnect live electrical circuits when working with flammable materials. Shut off power at a disconnect switch first to prevent sparking. Know where emergency stop buttons, shutoff valves, and fire extinguishers are located. If a fire starts in a spray booth, immediately shut off the spray system and exhaust fans. Shut off electrostatic power and ground the charging system before adjusting, cleaning, or repairing electrostatic equipment. Clean, maintain, test, and repair equipment according to the instructions in your equipment documentation. Use only replacement parts that are designed for use with original equipment. Contact your Nordson representative for parts information and advice. Halogenated Hydrocarbon Solvent Hazards Do not use halogenated hydrocarbon solvents in a pressurized system that contains aluminum components. Under pressure, these solvents can react with aluminum and explode, causing injury, death, or property damage. Halogenated hydrocarbon solvents contain one or more of the following elements: Element Symbol Prefix Fluorine F Fluoro- Chlorine Cl Chloro- Bromine Br Bromo- Iodine I Iodo- Check your material MSDS or contact your material supplier for more information. If you must use halogenated hydrocarbon solvents, contact your Nordson representative for information about compatible Nordson components. Action in the Event of a Malfunction If a system or any equipment in a system malfunctions, shut off the system immediately and perform the following steps: Disconnect and lock out system electrical power. Close hydraulic and pneumatic shutoff valves and relieve pressures. Identify the reason for the malfunction and correct it before restarting the system. If necessary, contact your Nordson service technician for assistance. Disposal Dispose of equipment and materials used in operation and servicing according to local codes. E-001353269 3

Description A typical controller consists of the components listed in Table 1. A 7 8 A ROBOT INTERFACE DIGITAL 1 QUALITY AB Allen-Bradley Panelview Plus 700 6 O FF ON VALVE PACK 2 PB153B PB153A 3 ETHERNET 5 ROBOT INTERFACE ANALOG APPLICATOR TOOL J-BLOCK 4 Figure 1 Typical Controller Item Description Table 1 Controller Components 1 Control Panel Touch Screen: Operator interface for the system; Refer to the Operator Interface section for more information. 2 POWER ON Switch: Enables power to the controller 3 POWER OFF Switch: Disables power to the controller 4 Foldable Shelf: Provides an area for a laptop computer 5 For Programmers Only: PLC programming port 6 Main Power Switch: Enables and disables main power supply to the controller 7 Alarm Tower: Alerts operator that a fault condition exists 8 Connector Panel: Connections for robot interface, applicator, and valve pack 4 E-001353269

Installation Installation is dependent upon the application requirements. Review the following guidelines: Unpack the controller and inspect it for dents, scratches, corrosion, or other physical damage. If there is any visible damage, call a local Nordson Corporation representative immediately. Install the controller as close to the robot controller as possible. Electrical, fluid, and air connections are dependent upon application requirements. Use the System Layout and Interconnect drawings provided with the system documentation for all connections. See the system documentation that shipped with the controller for schematics and wiring diagrams specific to this system. Install all electrical connections to local code. Install a locking disconnect switch or breaker in the service line ahead of any electrical equipment. Hard-wire the controller to a dedicated power supply to provide safe operation and reduce interference from electrical noise. Make sure that there is enough slack in all hose and cable routings to allow for proper system operation. E-001353269 5

Operator Interface See Figure 2. The SYSTEM STATUS screen is the default screen that appears at controller power-up. The following paragraphs describe the operator interface functions. Note: Use the menu tree located at the end of this section as a quick reference guide. System Status This screen shows the layout of major system components including the applicator and the controller. Each component image flashes red when a fault condition occurs involving that component. When an image or is flashing, touching the flashing image or VIEW FAULTS takes the user to the VIEW FAULTS screen where detailed information on the fault and recovery instructions appears. Figure 2 Typical System Status Screen Table 2 Screen Functions Item Description Function 1 MENU BUTTONS Access to various screens and setup menus. 2 DISPENSER STATUS Green when Ready, Red if Not Ready. 3 FAULT INDICATOR FIELD Displays latest current fault message. 4 CURRENT PART VOLUME Visually indicates the percent of the job that is completed and the actual dispense volume at the end of the part cycle. 5 SYSTEM STATUS SCREEN Appears as the default screen; displays the system configuration. 6 PUMP SCALE Access to the Pump Scale screen 7 PART I.D. Displays the current part I.D. 6 E-001353269

View Faults The VIEW FAULTS screen displays the description of the current fault(s) and the corrective action required. Touch FAULT LOG to view the history of faults by time and date (most recent at top). Touch RESET FAULTS to clear the current faults. Note that this only applies to non-self-clearing faults. VIEW FAULTS Screen E-001353269 7

Alarms The following screens display alarm data. Touch Ack Alarm (1) to acknowledge the selected alarm. Ack All (2) to acknowledge all alarms. Sort Alarms (3) to sort alarms either by alarm time or alphabetical order. Status Mode (4) to toggle between All Alarms, Past Alarm, and Active Alarms Alarms can be silenced. Alarm history and status can be printed. 1 2 Alarm Time Screen 8 E-001353269

1 2 Alarm History Screen 3 4 Alarm Status Screen E-001353269 9

Test Points The TEST POINTS screen verifies the state of IO signals to/from the robot and peripheral devices. The screen display depends on the system configuration. Note: The refresh rate of the display can affect the ability of the indicators to light in response to fast-acting signals. TEST POINTS Screen 10 E-001353269

System Set-Up Use the SYSTEM SET-UP screen to configure the system parameters. This screen password protected. These parameters can be accessed from the System Set-Up screen: Cleaner Meter Pump Meter Pump Diagnostics Felt Feeder Timers Clock Version Part ID Setup Fault Setup #1 Pump Test Setup Measure Fault Setup Fault Setup #2 System Configure The following paragraphs provide a description of each screen. System Set-Up Screen E-001353269 11

Cleaner Meter Pump Use this screen to enter the counts per cc that is stamped on the bottom of the metering pumps. Meter Pump Diagnostic Cleaner Metering Pump Use this screen to test the metering pumps. Follow the directions on the screen. Meter Pump Diagnostic Screen 12 E-001353269

Clock The PanelView time automatically updates with the PLC once every hour. Touch the desired field to manually update the desired fields. Clock Screen Version This screen displays the current version of the system software. Version Screen E-001353269 13

Part ID Use this screen to enter the setpoint of the Cleaner Volume. Fault Set-Up #1 Part ID Set-Up Use this screen to setup the fault conditions for the felt and the slide Fault Set-Up #1 Screen 14 E-001353269

Pump Test Setup Use this screen to enter data for Cleaner Dispense on time, Cleaner Volume, and Cleaner Specific Gravity. Measure Felt Setup Pump Test Setup Screen Use this screen to enter data for the felt spool and set signal parameters. Measure Felt Setup Screen E-001353269 15

Fault Setup #2 Use this screen to set the Cleaner Volume alarms. Fault Setup #2 Screen 16 E-001353269

System Configure The System Configure screen is accessed from the System Set-Up screen. This screen is password protected. These parameters can be accessed from the System Configure screen: Devices Enabled Fault Tester Dispense Pumps R & M Data P.M. Setup Force Solenoids Robot Simulator Transducer Offsets The following paragraphs provide a description of each parameter. System Configure Screen E-001353269 17

Devices Enabled Use this screen to enable or disable the pump and desired dispense tool mounting configuration. Devices Enabled Fault Tester When a fault number is entered, touching Enable causes the fault message to appear. Disable disables or clears the fault. Fault Tester Screen 18 E-001353269

Dispense Pumps Use this screen to set the PLC registers for the cleaner purge voltage, low outlet pressure, and high outlet pressure. R & M Data Dispense Pumps Screen This screen displays reliability and maintainability data. R & M Data Screen E-001353269 19

P.M. Setup Use this screen to set the preventive maintenance schedule for the cleaner pump. Force Solenoids P.M. Setup Screen Use this screen to manually activate the dispense system solenoids. Force Solenoid Screen 20 E-001353269

Robot Simulator Use this screen to dispense part cycles without the use of the robot. Transducer Offsets Robot Simulator Use this screen to set up a new transducer. Follow the directions on the screen. Transducer Offsets E-001353269 21

Process Data Access this screen to view production data. Process Data Screen Fault Decoder Use this screen to display text descriptions of the fault codes that appear on the PROCESS DATA screen. Follow the directions on the screen. Fault Decoder Screen 22 E-001353269

Manual Controls Use this screen to manually operate the applicator. Metering Pump Testing Help Manual Controls Screen Use this screen to test the metering pump. Follow the directions on the screen. Metering Pump Test Screen E-001353269 23

Confirm Replace Use this screen to reset felt tracking. Follow the directions on the screen. Confirm Felt Replace Screen Preventive Maintenance Use this screen to view preventive maintenance data. Preventive Maintenance Screen 24 E-001353269

Pump Scale Use this screen to scale the analog input from the robot controller. It is set as a percentage (1-100%). Pump Scale Screen E-001353269 25

Menu Tree Use the following menu tree as a guide for accessing controller screens. Main Menu View Faults Alarm History Alarm Status Test Points System Setup Cleaner Meter Pump Meter Pump Diagnostics Felt Feeder Timers Clock Version Part ID Setup Fault Setup #1 Pump Test Setup Measure Felt Setup Fault Setup #2 System Configure Device Enabled Fault Tester Dispense Pumps R & M Data P.M. Setup Force Solenoids Robot Simulator Transducer Offsets Process data Fault Decoder Manual Controls Metering Pump Testing Help Confirm Replace Preventive Maintenance Pump Scale Notes 26 E-001353269

Operation Controller operation is application specific. The following paragraphs only provide typical operating procedures for a controller. Refer to your System Parameter Sheet for specific operating settings. WARNING Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Read and understand these procedures before operating the controller. Before operating the controller, make sure that the robot is taught the proper tool path. Refer to the robot controller manual for procedures. 1. Turn the main disconnect switch on the controller to ON. 2. Press the SEALER POWER ON button. 3. Make sure that the system parameters are set according to your System Parameter Sheet. 4. Make sure that the system is in Auto Mode on the System Setup screen. Entering Data Some parameters require the use of the screen keypad to enter data. Touch the desired field (1) and the keypad (2) appears. 1 2 Diagnostic Pop-Up Screen Entering Data When entering data, this screen alerts the operator to important diagnostic messages. For example: Requested screen is already open. Numeric input out of range for this object. Current user does not have access to the Transducer Offsets screen. Diagnostic Pop-Up Screen E-001353269 27

Fault Messages If a fault is detected during operation, the alarm tower red light turns on and the type of fault appears on the controller screen. Images on the SYSTEM STATUS screen flash red when a fault condition occurs within that component. Touch the flashing image or VIEW FAULTS to access the VIEW FAULTS screen. A description of the current fault appears along with the corrective action. VIEW FAULTS Screen Note that some faults are self-resetting, meaning that the fault condition must be corrected before the fault will automatically clear. Pressing Fault Reset does not reset self-resetting faults. The following table lists the fault numbers and messages: Fault Message Fault Message 1 No DC Power Fault 25 Felt Spool Low 2 Master Control Relay is Off 28 Part Strobe is Missing 3 No Air to Primer Stand 29 Robot Missing Advance Felt 4 Major Low Cleaner Volume Fault 30 Dispense On Signal is Missing 5 Major High Cleaner Volume Fault 35 Slide Fully Extended 6 Minor Low Cleaner Volume Fault 36 Slide Fully Retracted 7 Minor High Cleaner Volume Fault 39 Not In Manual Mode Fault 15 Not Over Purge Bucket 40 Cleaner Outlet Pressure High 16 In Manual Mode 41 Cleaner Outlet Pressure High 19 Battery is Low 44 Robot In No Flow Mode 24 Felt Spool Empty 47 Tool Parked By Robot 28 E-001353269

PB153B AB Allen-Bradley PB153A ETHERNET ON TB1 TB2 MCR153 PWS136 N L + - dc ok 0 1 2 3 13 12 11 10 15 14 0 1 2 3 13 12 11 10 98 15 14 6 7 P 5 4 3 2 1 CB134 CB155 PE FU103 DISC101 400 VOLTS CAUTION For continued protection against risk of fire, replace only with same type and rating of fuse. Flow-Through-Felt Controller for Gravity Feed Applicators Parts Item Part Description Quantity 1 1060820 7-in. PanelView Plus, ENET, RS232 1 2 1052393 Power supply, 24 Vdc, 10A output 1 3 1052390 Barrier, safety, dual channel, DC, Z787 2 4 1062331 Barrier, safety, electric, out, dual channel, DC 1 5 1052392 Barrier, safety, relay, out, dual channel, DC 2 6 1064317 16 PT input card 1 3 5 4 1 A Z787 Z787 Z787 SA434 Z787 KFD2-ST2-Ex2 SA441 SA501 KFD2-SR2-Ex2.W SA511 SA522 KFD2-SR2-Ex2.W 45 6 7 45 6 7 98 0 1 2345 I:1.0/0 I:1.0/0 I:1.0/1 I:1.0/1 I:1.0/2 I:1.0/2 I:1.0/3 I:1.0/3 I:1.0/4 I:1.0/4 I:1.0/5 I:1.0/5 I:1.0/6 I:1.0/6 I:1.0/7 I:1.0/7 I:1.0/8 I:1.0/8 I:1.0/9 I:1.0/9 I:1.0/10 I:1.0/10 I:1.0/11 I:1.0/11 I:1.0/12 I:1.0/12 I:1.0/13 I:1.0/13 I:1.0/14 I:1.0/14 I:1.0/15 I:1.0/15 - - O:2.0/0 O:2.0/0 O:2.0/1 O:2.0/1 O:2.0/2 O:2.0/2 O:2.0/3 O:2.0/3 O:2.0/4 O:2.0/4 O:2.0/5 O:2.0/5 O:2.0/6 O:2.0/6 O:2.0/7 O:2.0/7 O:2.0/8 O:2.0/8 O:2.0/9 O:2.0/9 O:2.0/10 O:2.0/10 O:2.0/11 O:2.0/11 O:2.0/12 O:2.0/12 O:2.0/13 O:2.0/13 O:2.0/14 O:2.0/14 O:2.0/15 O:2.0/15 - - I:3.0/0+ I:3.0/0+ 1402 1402 I:3.0/1+ I:3.0/1+ 1402 1402 O:3.0/2 O:3.0/2 O:3.0/3 O:3.0/3 1402 1402 1402 1402 - - - - 1051 1051 1051 1051 1051 1051 1070 1070 1070 1070 1070 1070 1182 1182 1183 1183 1550 1550 1390 1390 1400 1400 1400 1400 1400 1400 1400 1400 1400 1400 1402 1402 1402 1402 1402 1402 1402 1402 1402 1402 - - I:0.0/0 I:0.0/0 I:0.0/1 I:0.0/1 I:0.0/2 I:0.0/2 I:0.0/3 I:0.0/3 I:0.0/4 I:0.0/4 I:0.0/5 I:0.0/5 I:0.0/6 I:0.0/6 I:0.0/7 I:0.0/7 I:0.0/8 I:0.0/8 I:0.0/9 I:0.0/9 I:0.4+ I:0.4+ I:0.5+ I:0.5+ O:0.0/0 O:0.0/0 O:0.0/1 O:0.0/1 O:0.0/2 O:0.0/2 O:0.0/3 O:0.0/3 O:0.0/4 O:0.0/4 O:0.0/5 O:0.0/5 1400 1400 - - - - - - - - ON - KFD2-ST2-Ex2 KFD2-SR2-Ex2.W KFD2-SR2-Ex2.W 2 QUALITY Panelview Plus 700 O FF A 6 Controller Parts E-001353269 29

Contact Us Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General information about Nordson can be found on the Internet using the following address: www.nordson.com Address all correspondence to: Nordson Corporation 300 Nordson Drive Amherst, OH 44001 Attn: Customer Service Mail Station 48 Notice This is a Nordson Corporation publication, which is protected by copyright. Original copyright date: 2013 Copying or downloading this information for the purpose of properly operating and maintaining Nordson products is allowed provided that the information is copied in full with no changes unless prior agreement is obtained from Nordson Corporation. neither the copy nor the original is resold or distributed with the intention of earning a profit. Trademarks Nordson, the Nordson logo are registered trademarks of Nordson Corporation. All other trademarks are the property of their respective owners. 30 E-001353269