control system cs 20 for bulk melters bm 20 / bm 200 system cs-20 for bm 200.pdf · control system...

Control System CS 20for Bulk Melters BM 20 / BM 200

Manual P/N 458 374 C– English –

NORDSON ENGINEERING GMBH � LÜNEBURG � GERMANY

� 2001 Nordson CorporationAll rights reserved

CS04Issued 12/01

COV_EN_458374C

NoteThis manual applies to the entire Bulk Melters BM 20 / BM 200 with CS 20 series.

Order numberP/N = Order number for Nordson products

NoticeThis is a Nordson Corporation publication which is protected by copyright. Original copyright date 2000.

No part of this document may be photocopied, reproduced, or translated to another language without the priorwritten consent of Nordson Corporation. The information contained in this publication is subject to change without

notice.

TrademarksAccuJet, AquaGuard, Asymtek, Automove, Autotech, Blue Box, CF, CanWorks, Century, Clean Coat, CleanSleeve, CleanSpray, Compumelt, Control Coat,Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, Durafiber, Durasystem, Easy Coat, Easymove Plus, Econo-Coat, EPREG, ETI, Excel 2000, Flex-O-Coat,FlexiCoat, Flexi-Spray, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Helix, Horizon, Hose Mole, Hot Shot, Hot Stitch, Isocoil, Isocore, Iso-Flo, JR, KB30, Little Squirt,Magnastatic, MEG, Meltex, MicroSet, Millenium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson, OmniScan, Opticoat, Package of Values, Pattern View,PluraFoam, Porous Coat, PowderGrid, Powderware, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, PRX, RBX, Rhino, S. design stylized, Saturn, SC5, Select Charge,Select Coat, Select Cure, Slautterback, Smart-Coat, Spray Squirt, Spraymelt, Super Squirt, Sure Coat, System Sentry, Tela-Therm, Trends, Tribomatic, UniScan,UpTime, Veritec, Versa-Coat, Versa-Screen, Versa-Spray, Watermark, When you expect more. are registered trademarks – � – of Nordson Corporation.

ATS, Aerocharge, Auto-Flo, AutoScan, BetterBook, Chameleon, CanNeck, Check Mate, COLORMAX, Control Weave, Controlled Fiberization, CPX, E-Nordson,EasyClean, Eclipse, Equi=Bead, Fillmaster, Gluie, Ink-Dot, Iso-Flex, Kinetix, Maxima, MicroFin, Minimeter, Multifil, OptiMix, PluraMix, Primarc, Prism, Process Sentry,PurTech, Pulse Spray, Seal Sentry, Select Series, Sensomatic, Shaftshield, Spectral, Spectrum, Sure Brand, Swirl Coat, Vista, Walcom, 2 Rings (Design) aretrademarks – � – 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


CS04Issued 12/01

P/N 458374C

Table of Contents

1. Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Intended Use 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unintended Use 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Residual Risks 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Manual References 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. PROFIBUS DP 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plug Connectors 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Speed 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Guidelines 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Definition of Terms 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Host 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stand Alone Mode 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Mode 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Pressure Control (Option) 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Functions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Melt Platen Position Recognition 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drum almost empty 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drum empty 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Interface XS 2 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Control with Two Applications 5. . . . . . . . . . . . . . . . . . . . . . . .

7. Control Panel 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Indication Lamps and Indicator Beacon (Accessory) 7. . . . . . . . . . . . .

9. Overview of Settings 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature Part 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Part 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview

Table of ContentsII


CS04Issued 12/01

P/N 458374C

1. Operation Overview 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Display Overview 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview of Parameters Set by Channel 14. . . . . . . . . . . . . . . . . . . .

3. Basic Settings 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Startup Control with Leading Channel 15. . . . . . . . . . . . . . . . . . . . . .

Temperature Display, Selecting Celsius or Fahrenheit 15. . . . . . . .

Switching Scan Mode On/Off 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting Control or Measuring Mode 16. . . . . . . . . . . . . . . . . . . . . . .

Switching Channel On/Off 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Switching Immediate Temperature Setback On/Off 17. . . . . . . . . . . . .

5. Setting Temperature 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended values 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Setting Parameters 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Parameters by Channel 19. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Example of selecting parameter set 19. . . . . . . . . . . . . . . . . . . . . .

Return Parameter to Factory Setting 19. . . . . . . . . . . . . . . . . . . . . . .

Parameter Overview 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPL = Setback temperature 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

h SPL = Setback period 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lo = Undertemperature value / interlock 20. . . . . . . . . . . . . . . . . .

Hi = Overtemperature-value 20. . . . . . . . . . . . . . . . . . . . . . . . . . . .

OFF = Overtemperature shutdown 20. . . . . . . . . . . . . . . . . . . . . . .

Pid = Predefined control parameters 20. . . . . . . . . . . . . . . . . . . . .

On = Regulation ratio (display) 21. . . . . . . . . . . . . . . . . . . . . . . . . .

SE = Service display 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Automatic Fault Displays 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the TemperaturePart

Table of Contents III


CS04Issued 12/01

P/N 458374C

1. Operation Overview 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Display Overview 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Basic Settings 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Select Manual or Automatic Mode 26. . . . . . . . . . . . . . . . . . . . . . . . . .

4. Test 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Switching ON Motor(s) 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Startup Protection 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Switching OFF Motor(s) 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switching Off One Motor 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switching Off All Motors 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Setting Speed (Manual Mode) 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Setting Speed (Automatic Mode) 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Parameters in Automatic Mode 29. . . . . . . . . . . . . . . . . . . . . .

9. Switching Automatic Temperature Setback On/OFF 30. . . . . . . . . . . . .

10. Setting Parameters 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Returning Parameters to Factory Setting 31. . . . . . . . . . . . . . . . . . . .

Parameter Overview 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ruP = Increase speed 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rLo = Motor speed at 0 % pilot voltage 32. . . . . . . . . . . . . . . . . . .

rhi = Motor speed at pilot voltage Uhi 32. . . . . . . . . . . . . . . . . . . . .

Uhi = Pilot voltage at which the motor rotates constantly at rhi 32. . . . . . . . . . . . . . . .

rLo, rhi and Uhi, graphic illustration 32. . . . . . . . . . . . . . . . . . . . . .

SPL = Temperature setback after motor standstill 33. . . . . . . . . .

rPU = Adapting speed to special gearbox 33. . . . . . . . . . . . . . . . .

Adr = Field bus address of system 33. . . . . . . . . . . . . . . . . . . . . . .

11. Service Displays 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Displays di and do 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Code of DIP Switch S 6 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Display Error 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the Motor Part

Table of ContentsIV


CS04Issued 12/01

P/N 458374C

1. Diagnosis Program 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Activating the Diagnosis Program 44. . . . . . . . . . . . . . . . . . . . . . . . . .

Test phase 0 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Phases 1 to n 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ending the Diagnosis Program 46. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Correcting Temperature Sensors 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Temperature Control Panel Board 47. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LED’s 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIP Switch S 7 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIP Switch S 8 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIP Switch S 8, Switch 6 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plug Connectors 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Temperature Control Module 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ni 120 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LED’s 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plug Connectors 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selector Switch S 1 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIP Switch S 2 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIP Switch S 3 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Potentiometer P 1 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switch S 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Voltage Control of Temperature Control Module 54. . . . . . . . . . . . . . . .

Fuses 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LED’s 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plug Connectors 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Temperature Comparison Measuring Point 55. . . . . . . . . . . . . . . . . . . .

Technical Appendix of theTemperature Part

Table of Contents V


CS04Issued 12/01

P/N 458374C

1. Central Module with Digital Input/Output 57. . . . . . . . . . . . . . . . . . . . . . .

Fuses (Central Module) 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses (Digital Module) 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LEDs (Central Module) 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LEDs (Digital Module) 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Aligning Pilot Voltage 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Aligning pilot voltage input 0 to 10 VDC 59. . . . . . . . . . . . . . . . . . .

Aligning pilot voltage input 0 to 160 VDC 59. . . . . . . . . . . . . . . . .

Switch S 15 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Potentiometer R 18, R 42 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIP Switch S 1 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIP Switch S 6 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIP Switch S 12 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Button S 3 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switch S 2 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selector Switch S 11 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plug Connectors (Voltage Supply) 61. . . . . . . . . . . . . . . . . . . . . . . . . .

Plug Connectors (Pilot Voltage Input) 61. . . . . . . . . . . . . . . . . . . . . . .

Plug Connectors (Inputs/Outputs) 62. . . . . . . . . . . . . . . . . . . . . . . . . .

Plug Connectors 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Function of Input Signals 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Function of Output Signals 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Field Bus Communication Module 67. . . . . . . . . . . . . . . . . . . . . . . . . . . .

LED’s 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROFIBUS Plug Connectors 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Motor Control Panel Board 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LED’s 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIP Switch S 1 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIP Switch S 2 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plug Connectors 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Appendix of theMotor Part

Table of ContentsVI


CS04Issued 12/01

P/N 458374C

4. Analog Module (Option) 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LED’s 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Potentiometer R 48 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIP Switch S 2 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Jumper S 3 to S 10 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plug Connectors 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Motor Module 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LED’s 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIP Switch S 2 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Switch S 3 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Potentiometer R 8 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Potentiometer R 36 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plug Connectors 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Aligning the Motor Module 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Appendix of theMotor Part (contd.)

Control System CS 20 for BM 20 / BM 200 1


CS04Issued 12/01

P/N 458374C

Overview

WARNING: Allow only qualified personnel to perform thefollowing tasks. Observe and follow the safety instructions inthis document and all other related documentation.

The control system may only be used to regulate and control Nordsonbulk melters. The bulk melter is hereafter also referred to as system orunit. The values stated under Specifications in the manual for the bulkmelter (temperatures, speeds, etc.) must be complied with. Nordson willgrant no warranty and assume no liability for damage resulting fromincorrect settings.

Any other use is considered to be unintended. Nordson will not be liablefor personal injury or property damage resulting from unintended use.

Intended use includes compliance with Nordson safety regulations.

The control system may not be used under the following conditions:

� In defective condition

� In a potentially explosive atmosphere

� When changes or modifications have been made by the customer

� By an electrostatically charged person.

Nordson knows of no residual risks.

This manual applies to

� The control system CS 20

� The control system CS 20 with PROFIBUS DP.

1. Safety

2. Intended Use

Unintended Use

Residual Risks

3. Manual References

Control System CS 20 for BM 20 / BM 2002


CS04Issued 12/01

P/N 458374C

When a control system CS 20 without PROFIBUS interface is used, thischapter can be ignored.

For the control system CS 20 with PROFIBUS DP, also refer to separatedocuments Communication Data List and Field Bus Interface PROFIBUSDP.

PROFIBUS DP uses the master-slave access method (Refer to EN50170). Nordson units on the PROFIBUS are always slaves.

Each unit on the PROFIBUS needs a field bus address for communi-cation purposes. Each address may be assigned only once in the fieldbus. The address of the Nordson unit is set on the motor control panelwith the parameter ADR.

Also refer to Technical Appendix of Motor Part, Field Bus CommunicationModule, PROFIBUS Plug Connectors.

The PROFIBUS interface plug connectors are located on the clear coverof the central module.

With the control system CS 20, the cable screen is linked to protectivegrounding / functional grounding with the plug connector X 22.

Two-wire connection according to EIA-RS 485.Line A (usually green) and line B (usually red) must be the same on theentire bus.

To ensure smooth operation, the field bus must end with an active busterminator (terminating resistors) at the beginning and the end of aPROFIBUS segment.

We recommend attaching both sides of the bus cable screen toprotective grounding / functional grounding. When the potential is not thesame at both ends, an equipotential bonding conductor should be laid.

4. PROFIBUS DP

General Information

Plug Connectors

Installation



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P/N 458374C

To minimize electromagnetic compatibility disruptions, the lowest possibleBaud rate should be selected. Recommendation: 1500 kBaud.

For additional information, also refer to PROFIBUS Guideline, SetupGuidelines PROFIBUS DP/FMS, published by the PROFIBUSNutzerorganisation e. V. (user organization).

Host

Customer’s higher-order control unit, also called master.

In conjunction with the option PROFIBUS DP, the modes stand alone andremote are available. For information on changing the mode using themode switch, also refer to separate manual/supplement for the unit andto the wiring diagram.

NOTE: When the mode is changed, activation of the startup protectioncauses all of the drives to stop.

Stand Alone Mode

Stand alone mode is used mainly to visualize data for maintenance andrepair purposes. The unit is operated just like a unit without PROFIBUS:

� Control access only from control panel and from external controlsignals via an interface

� Parameter input only via control panel

� On the host, all parameters can be displayed but not changed. Thehost can always read actual values.

Remote Mode

In remote mode, the host controls the unit:

� Control access only from host

� Parameter input only via host

� On the control panel, all parameters can be displayed but notchanged. Actual values are always shown on the control panel.

The optional pressure control is described in the separate manualPressure Control for Bulk Melters Series BM 20 / BM 200.

Transmission Speed

Guidelines

Definition of Terms

5. Pressure Control(Option)



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P/N 458374C

Also refer to the technical appendix of the motor part Service Displaysand Central Module with Digital Input/Output, Plug Connector X4.

State of Bulk melter Position

Service display POS

Release motor Bulk melter - ready - Bulk melter - error - Yellow lamp onindicator beacon

(accessory)

Platen is up 1 Off Off Normal Off

Normal mode 2 Normal Normal Normal Off

Drum almost empty 3 Normal Normal Normal On (blinking)

Drum empty 4 Off Off On** On

Platen moves up 5 + 6 Off Off Normal Off

Unknown platenposition

225 Normal Normal On* Off

* Refer to Service Display Error, Error number 70** Refer to Service Display Error, Error number 72

NOTE: Normal mode begins as soon as the sealing ring of the meltplaten enters the drum. Also refer to manual Bulk Melters BM 20 / BM 200.

Drum almost empty

The output (Refer to Central Module with Digital Input/Output, PlugConnector X 14) is switched on when Drum almost empty or Drum emptyhas occurred.

Drum empty

The output (Refer to Central Module with Digital Input/Output, PlugConnector X 15) is switched on when Drum empty has occurred.

The standard assignment of interface XS 2 is described in the separatemanual Bulk Melters.

6. Functions

Melt Platen PositionRecognition

Interface XS 2



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P/N 458374C

NOTE: Does not apply to systems with piston pumps.

Also refer to Central Module with Digital Input/Output, Selector SwitchS11 and Plug connector X11.

The set speed can be changed with the parameter ruP (refer to table) onbulk melters where two applications are supplied.

NOTE: To prevent excessive wear, the motor/pump speed should notcontinuously fall below 5 min-1 (rpm) or continuously exceed 80 min-1

(rpm).

Input Speed for motor/pump 1 Output*

Release

Motor forApplication 1

Release

Motor forApplication 2

Release

Application headfor Application 1

Release

Application headfor Application 2

No No 0 min-1 (rpm) No release No release

No Yes Set speed No release Release

Yes No Release No release

Yes Yes Set speed +

Set speed x ruP / 100

Release Release

* The output is active when all requirements have been met (Refer toSwitching ON Motor(s)).

Example

Set speed: 45 min-1 (rpm)ruP (factory setting): 100 %

When both applications are active, the pump speed is calculated asfollows: 45 min-1 + 45 min-1 x 100 % / 100 = 90 min-1 (rpm)

If the calculated speed is higher than 100 min-1 (rpm), error number 71 isdisplayed as long as both applications are active (Refer to ServiceDisplay Error). The pump is running at 100 min-1 (max. speed).

NOTE: The alarm and ready indications are not influenced.

Speed Control with TwoApplications



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P/N 458374C

The control panel is divided into motor and temperature parts. Theelements found in the dotted line box are also referred to as the motorpanel in the following description (up to 2 motor panels per controlsystem are possible – second motor is optional). The motor/pump speedis indicated with the SI-unit min-1 (equivalent to rpm).

1 2 3 4

min–1 barM1 C

F

3130292827

26

25 23 22 21 20 19 18 17 16 15 14 1312 11

109876

543

2

24

R

x10 psi

minn

Motor panel

Motor part Temperature part

002446

5 6 7 8 9 10 11 12

Fig. 1

1 –2 Channel allocation3 Display Temperature channels4 Display Temperature setpoint5 Display Actual temperature6 Illuminated symbol

Degrees Celsius (�C)7 Illuminated symbol

Degrees Fahrenheit (�F)8 Decimal point Heating on9 LED Temperature setback on

10 Key Temperature setback On/Off11 Key Increase values

12 Key Decrease values13 Key Channel up14 Key Channel down15 LED Enter key16 Enter key17 Indication lamp Collective fault (red)18 Indication lamp Switched On (white)19 Indication lamp Ready (green)20 Key Test21 Key Manual/Automatic mode22 Key Increase motor/pump speed

23 Key Decrease motor/pump speed24 LED Motor(s) On25 Key Motor(s) On/Off26 Illuminated symbol Manual mode27 Key Motor pre-selection28 LED Motor pre-selected29 Illuminated symbol Motor On30 Display Motor/Pump speed31 Display Pressure (Option)

7. Control Panel



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P/N 458374C

The indication lamps and the indicator beacon available as an accessoryshow the operating modes Collective fault, Switched on and Ready. Inaddition, there is a yellow light on the indicator beacon that indicates thestates Drum almost empty and Drum empty.

Red

Green

White

17

18

19

DGCO217L067A0299

Fig. 2 (Also refer to Fig. 1 for position numbers)

Indication lamp Message(s) Notes

Red (17) Overtemperature message from control system Display 5: Hi blinking

Collective fault Overtemperature shutdown by control system, e.g. channel 2 Displays 3, 4 and 5: 2 ––– ––– blinking

Undertemperature during operation Display 5: Lo blinking

Ambient temperature too high Displays 3, 4 and 5: AM bIE nT blinking

Temperature sensor short circuit Display 5: – S – blinking

Temperature sensor interruption Display 5: – E – blinking

Memory error Displays 4 and 5: Error blinking

Other error messages Display 30: Err indicated

(Refer to service display Error) Display 31: Error number indicated

8. Indication Lamps andIndicator Beacon(Accessory)



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P/N 458374C

Indication lamp Message(s) Notes

White (18)

Turned on

After switching on the unit and during the initial heatingphase, only the white indication lamp is lit

If, after the initial heating phase (1 hour and longer), thegreen indication lamp is not lit: Refer to manual Bulk Melters,section Troubleshooting.

Green (19)

Ready foroperation

The green indication lamp does not light until all channelshave reached their temperature setpoints and when thefollowing conditions have been met:ope a oRelease Unit must be bridged or activated Refer to manual Bulk Melters, section Installation, XS 2

Interface

Temperature setback may not be switched on Refer to section Temperature Setback in this manual and tosection Installation, Interface XS 2 in the manual BulkMelters.

The melt platen has reached the upper switch. –

Drum is not empty –

Indicator beacon(accessory)

Message(s) Notes

Yellow (blinking) Indication Drum almost empty The customer can utilize the signals Drum almost empty andDrum empty via the interface XS 2Yellow (remains

lit)Indication Drum empty Drum empty via the interface XS 2.



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P/N 458374C

The possible settings and parameters described here are not availablefor every bulk melter (Refer to column Notes).

NOTE: The indexes in the column Notes indicate the correspondingposition in the separate communication data list. These references canbe ignored when a control system CS 20 without PROFIBUS is used.

NOTE: – – – means that the function is switched off. Do this by settingthe value to > 9.99.

Parameter Function / possible setting Setting range Factorysetting

Notes

Temperature setpoint for each channel Refer to manual Bulk Melters, Section Specifications

Dependent onsystem

Index 154

SPL Temperature setback (setback value) 5 to 100 �C (9 to 180 �F) 50 �C Index 166

h SPL Temperature setback (setback period) 0.05 to 9.99 hours – – – (off) –

Lo Undertemperature value 5 to 30 �C (9 to 54 �F) 10 �C Index 163

Hi Overtemperature value 5 to 30 �C (9 to 54 �F) 10 �C Index 164

OFF Overtemperature shutdown 70 to 260 �C (158 to 500 �F);

70 to 280 �C (158 to 536 �F)with high temperature units

– Only display

Pid Predefined control parameters SLO, nor, FA1, FA2 nor SLO: Slow controlled system

nor: Normal controlledsystem

FA1: Fast controlled system


SE Service display (sensor type) Pt, FEC, ni – Only display

�C Select temperature display in �C or �F �C / �F �C –

CLr Return parameters to factory setting no / yes no –

9. Overview of Settings

Temperature Part



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P/N 458374C

The parameters marked with an asterisk (*) are not available for systemmodels with piston pumps.

NOTE: OFF means that the function is switched off. Do this by settingvalue to 0 (zero).

Parameter Function / possible setting Setting range Factory setting Notes

rSP* Speed setpoint for each motor panel(manual mode)

1.0 to 100 min-1 (rpm) 5.0 min-1 (rpm) Index 75

rLo* Speed at 0% pilot voltage 1.0 to 100 min-1 (rpm) 1.0 min-1 (rpm) Index 80

Special function may be activated

rhi* Speed at pilot voltage Uhi 1.0 to 100 min-1 80 min-1 (rpm) Index 79

ruP* Speed increase in one pump, twoguns/applications

OFF or 1.0 to 250 % 100 % –

Uhi* Pilot voltage in % at which the motorrotates at speed rhi. If the pilot voltageexceeds Uhi, the speed remainsconstant at rhi.

0 to 100 % pilot voltage 100 % Index 78


SPL Period after motor standstill at whichthe temperature setback isautomatically switched on

15 to 240 minutes OFF –

rPU* Adapting speed to special gearbox 1.0 to 250 min-1 (rpm) 100 min-1 (rpm) Index 83


CLr Return values to factory setting no / yes no –

Adr Filed bus address of system 2 to 126 10 Index 9

Only with option PROFIBUS DP

NOTE: When the optional pressure control is used, other settings andparameters are possible. These are described in the manual PressureControl for Bulk Melters of the Series BM 20 / BM 200.

Motor Part



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P/N 458374C

Operating the Temperature Part


NOTE: Operation by electrostatically-charged persons can lead toimproper functioning of the control system.



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P/N 458374C

Switching on/off immediate temperature setbackSwitching ON: Press key 10; SPL blinks in display 4 and the LEDin the key lights.Switching OFF: Press key 10 or wait until the setback period hasexpired (if the setback period is longer than 9.99 hours, thetemperature setback is not automatically ended).

Note: The temperature setback can also be switched on via theXS 2 interface. When the temperature setback is switched on, SPLblinks in displays 4 and 30 (Fig. 1). A setback period is ineffectivein this case.Note: The Automatic Temperature Setback After Motor Standstillis ended by pressing key 25 (Fig. 1) on the motor part. Press key25 for approx. 2 seconds.

Setting temperature setpoint and parametersHold down key 16 and increase value with key 11 or decrease withkey 12. Pressing once changes the value by 1, holding the keychanges the value faster.The LED in key 16 is lit when adjustable parameters are shown indisplays 3, 4 and 5. The following parameters can be adjusted:

Switching channels / selecting parametersPress key 13 or 14 until the desired channel appears indisplay 3.

When the highest channel that is switched on is exceeded,the following displays/parameters can be called up:

C

F

3 4 5

101112131416

DisplaysRefer to Overview of Displays and DiagnosisProgram in technical appendix.

Decimal pointLit when the displayedchannel is heating.

�C / �F status display

Temperature setpointSPL Temperature setback valueh SPL Temperature setback periodLo Undertemperature valueHi Overtemperature value�C � �F Temperature unitCLr Return parameter to factory setting

SPL Temperature setback valueh SPL Temperature setback periodLo Undertemperature valueHi Overtemperature valueOFF Overtemperature shutdownSE Service display (sensor type)�C � �F Temperature unitCLr Return parameter to factory setting

If no other key is pressed within 120 sec., these displaysreturn to the reference channel or the channel with thelowest number.

DGCO231L218A0399

Fig. 3

1. Operation Overview



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P/N 458374C

NOTE: Some parameters can be set individually for each channel. Referto Setting Parameters by Channel.

Normal display

Lo / untertemperature (during initial heating phase)

SPL / temperature setback

OFF / overtemperature shutdown

Lo / undertemperature value

Hi / overtemperature value

SE / service display (sensor type)

�

�

Heaters and motors are switched off

Channel Temperature setpoint Undertemperature

Operating mode displays

Temperature setback on

Unit release not switched

Appears when the channel is heated up.

Initial display when unit is switched on.

Whe

n th

e hi

ghes

t act

ive

chan

nel i

s ex

ceed

ed, t

hese

dis

play

s ca

n be

cal

led

up in

this

ord

er.

Appear automatically.

Channel Temperature setpoint Actual temperature

Also refer to Switching immediate temperature setback on/off.

The type of temperature sensor usedcan be determined via the service display.

The overtemperature shutdown value is set automatically 30 �C(54 �F) higher than the highest temperature setpoint value.

Val

ues

can

be a

djus

ted

in th

ese

disp

lays

Startup control with reference channel is active.

Return parameters to factory setting

Temperature unit (�C / �F)

Fe-CuNi

Setback value

Setback period

9.99 hours exceeded

002447

Fig. 4

2. Display Overview



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P/N 458374C

Undertemperature during operation

Automatic fault displays

Overtemperature shutdown

Ambient temperature too high

Temperature sensor interruption

Temperature sensor short circuit

Overtemperature

Memory error

Diagnosis displaysNot shown here. Refer to Technical Appendix forTemperature Part, Diagnosis Program.

002448

Fig. 5

Also refer to Setting Parameters, Setting Parameters by Channel andDIP switch S 8 on the temperature control panel board.

Normal display

Service display (sensor type)

PID parameter set

Regulation ratio (only display)

Display by channel

002449

Fig. 6

Overview of Parameters Set byChannel

MXCO010S025A0295

C

F

3 4 5

101112131416

15 9

8



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P/N 458374C

The startup control with leading channel is only active if a leadingchannel has been selected. It prevents hot melt material from charring inhoses / application heads and the build-up of material expansionpressure during the initial heating phase. It also helps to save energy.

Factory setting: The factory setting depends on the systemmodel. The channel with the longest initialheating phase should be chosen as leadingchannel.

Setting range: Refer to Technical Appendix of theTemperature Part, Temperature ControlPanel Board, DIP-Switch S 8.

Depending on the display selected, either C (Celsius) or F (Fahrenheit) ofstatus display 8 is lit. When display is in Fahrenheit, the control systemcontinues to use Celsius internally. This may result in up to one degreeFahrenheit being skipped.

Changing: Use key 13 to select display temperature unit. Press key 16until –P– blinks in display 5. Change to the other temperature unit usingkey 11 or key 12. Status display 8 changes accordingly.

Factory setting: Degrees Celsius (�C)

Fig. 7 Details from Fig. 1

In Scan Mode, all activated channels are displayed consecutively at3 second intervals.

Switching ON: Press keys 13 and 14 simultaneously.

Switching OFF: Press key 13 or 14.

Factory setting: Scan Mode switched off

3. Basic Settings

Startup Control with LeadingChannel

��

Switching Scan Mode On/Off

MXCO010S025A0295

C

F

3 4 5

101112131416

15 9

8



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P/N 458374C

Control mode is the normal function of a channel. The actual temperatureis adapted to the setpoint temperature and kept stable.

In measuring mode, temperature control and monitoring for faults do nottake place. Display 4 is switched off. The measured temperature appearsin display 5. The leading channel cannot be switched into measuringmode.

Factory setting: Control mode

Selecting measuring mode: Set temperature setpoint of the channel tobe measured to 40 �C (104 �F). Press and hold key 16 and press key 12twice.

Switching back to control mode: Press and hold key 16 and press key11 twice.


Unused channels are switched off. Switched-off channels are no longerdisplayed. The leading channel can not be switched off. Switching onunconnected channels causes error message 34.

Switching off: Set temperature setpoint to 40 �C (104 �F). Press andhold key 16 and press key 12 once.

Switching ON:

1. Use key 13 or 14 to select the last switched-on channel.

2. Press and hold key 16 and use key 13 or 14 to select the switched-offchannel.

3. Press and hold key 16 and use key 11 to set the temperature setpointto 40 �C (104 �F) or higher.

Display examples

Channel Temperature setpoint Actual temperature Status� Channel switched on and� Channel in control mode and� Channel activated

� Channel switched on and� Channel in measuring mode and� Channel activated

� Channel switched on and� Channel not activatedor Unit release not switched

� Channel switched off and� Channel not activatedThis means that the channels that areswitched off are not displayed in themenu

Selecting Control or MeasuringMode

Switching Channel On/Off



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P/N 458374C

The temperature setback serves to protect the hot melt material and tosave energy during breaks in production. The setback temperature andsetback period can be set (refer to Parameter Overview, Parameters SPLand h SPL).

The temperature setback is switched on and off by the operator. (Refer toSwitching On/Off Automatic Temperature Setback in the motor part)

Switching ON: Press key 10; SPL blinks in display 4 and the LED in thekey lights.

Switching OFF: Press key 10 or wait until the setback period hasexpired (if the setback period is longer than 9.99 hours, the temperaturesetback is not automatically ended).

NOTE: The temperature setback can also be switched on via the XS 2interface. When the temperature setback is switched on, SPL blinks indisplays 4 and 30 (Fig. 1). A setback period is ineffective in this case.

4. Switching ImmediateTemperature SetbackOn/Off

MXCO010S025A0295

C

F

3 4 5

101112131416

15 9

8



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P/N 458374C

WARNING: When setting the temperature, the temperatureprescribed by the material manufacturer is decisive. Themaximum operating temperatures of the system and of heatedsystem components may not be exceeded.

Nordson will grant no warranty and assume no liability for damageresulting from incorrect temperature settings.

NOTE: When processing polyurethane hot melt adhesives (PUR),ensure that the processing temperature is not set higher than thethermostat used permits; otherwise overtemperature shutdown will occur.If necessary, adapt the overtemperature thermostat of the melt platen tothe maximum processing temperature of the adhesive (It must bereplaced). For information on thermostats, refer to manual Bulk Melters,section Specifications.

1. Selecting channel: Press key 13 or 14.

2. Press and hold key 16 (in display 4, –P– blinks) and use key 11 toincrease value or key 12 to decrease value.

Pressing once changes the value by 1, holding the key changes thevalue faster.


Factory setting: Dependent on system

Setting range: For maximum operating temperature, refer tomanual Bulk Melters, section Specifications.

Recommended values

The values stated in the tables are general values determined byexperience; deviation may prove necessary.

Heating zone / temperature / time Setting

Melt platen 10 �C below prescribed processing temperature

Undertemperature value 10 �C below set processing temperature

Overtemperature value 10 to 30 �C above set processing temperature

Temperature setback value (Standby) As needed

Setback period As needed

Application head (accessory) Prescribed processing temperature(s)

Heated hose (accessory) Prescribed processing temperature

5. Setting Temperature

Setbackvalue



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P/N 458374C

1. Press key 13 or 14 until the desired parameters appear in displays 3and/or 4.

2. Press and hold key 16 (in display 5, –P– blinks) and use key 11 toincrease value or key 12 to decrease value.Pressing once changes the value by 1, holding the key changes thevalue faster.

NOTE: With the parameters SPL, Hi and Lo, all of which can be setindividually for each channel, three lines appear in the display when atleast one channel has a setting that differs from the others. A setting thatapplies to all channels is usually sufficient.

Refer to DIP switch S 8 on the temperature control panel board.

Example of selecting parameter set

1. Press and hold keys 11 and 12, then press key 16 until the displayblinks.

2. Press key 13 or 14 until the desired channel is displayed.

NOTE: Channels that are switched off are automatically skipped.

3. Press key 11 or 12 until Pid is displayed.

4. Select parameter set (Refer to previous section, Setting Parameters)

5. Press and hold keys 11 and 12, then press key 16 at the same time toleave the menu.

NOTE: If no keys are pressed for approx. 2 minutes, the programautomatically returns to the normal display.

1. Press key 13 or 14 until parameter CLr appears in display 4.

2. Press and hold key 16 (in display 5, –P– blinks) and set displayedvalue from no to yes , using key 11 or 12.

3. Release all keys. The temperature parameters (with the exception oftemperature setpoint values) will be reset to factory settings.

NOTE: The value will be no again after resetting.

6. Setting Parameters

Setting Parameters by Channel

Return Parameter to FactorySetting



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P/N 458374C

SPL = Setback temperature

h SPL = Setback period

The temperature setback serves to protect the hot melt material and to save energy during breaks in production. After the setback period hasexpired, the heating is automatically switched back on, but not automatically if the setback period has been set to higher than 9.99 hours. After9.99 hours, three dashes appear in display 5 (Fig. 1).

SPL Factory setting: 50 �C Note: The temperature setback period affects all channels. Thesetback temperature can also be entered by channel (Also refer to

Setting range: � �C to 100 �C (9 to180 �F)setback tem erature can also be entered by channel (Also refer toDisplay Overview, Setting Parameters by Channel).

h SPL Factory setting: – – – (off) The temperature can not be lowered below the lowest temperaturesetpoint The setting range for the parameter SPL is then

Setting range: 0.05 to 9.99 hoursset oint. The setting range for the arameter SPL is thenautomatically limited.

Lo = Undertemperature value / interlock

The undertemperature locking device prevents the unit or system from being started up when the application material is too cold until thetemperature setpoint minus undertemperature value has been exceeded. On every initial heating, however, the locking device is not releaseduntil the actual temperature is 3 �C (5.4 �F) below the temperature setpoint .

The undertemperature locking device blocks the motors, and possibly other components of the application system. Refer to the Wiring Diagramfor an indication of which components are blocked.

Lo Factory setting: 10 �C Note: The undertemperature value can also be entered by channel(Also refer to Display Overview Setting Parameters by Channel)Setting range: 5 �C to 30 �C (9 to 54 �F) (Also refer to Display Overview, Setting Parameters by Channel).

Hi = Overtemperature value

When the temperature setpoint plus overtemperature value has been reached, the relay output Collective fault is switched and the red indicationlamp Collective fault lights. The unit remains ready for operation.

Hi Factory setting: 10 �C Note: The overtemperature value can also be entered by channel(Also refer to Display Overview Setting Parameters by Channel)Setting range: 5 �C to 30 �C (9 to 54 �F) (Also refer to Display Overview, Setting Parameters by Channel).

OFF = Overtemperature shutdown

When the overtemperature shutdown reacts (refer to Automatic faultdisplays), there is a unit fault. Switch off the unit and have the faulteliminated by qualified personnel.

Pid = Predefined control parameters

WARNING: The PID controller may be adjusted only bypersonnel trained especially in control technology.

The control parameters (parameter sets SLO, nor, FA1, FA2) can only be set by channel. Refer to DIP switch S 8 on the temperature controlpanel board.

Pid Factory setting: nor SLO: Slow controlled system

nor: Normal controlled system

Setting range: SLO, nor, FA1, FA2 FA1: Fast controlled system


Parameter Overview



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P/N 458374C

On = Regulation ratio (display)

The regulation ratio determines the percentage of an interval duringwhich the heater output is switched on.

Range of values: 0 to 100 %

100 % means that the heater output is always on.

SE = Service display

The user can find out the type of temperature sensor used fortemperature module 1 via the service display SE; for each channel underSetting by Channel:

� FEC = Fe-CuNi

� Pt = Pt 100

� ni = Ni 120.

NOTE: With bulk melters only temperature sensors Ni 120 are used.

If multiple faults are present, the channel with the lowest channel numberand the fault with the highest priority are displayed.

The number of a faulty channel appears in the left display; the faultindication is shown in the middle and right displays.

Overtemperature shutdown

NOTE: The shutdown depends on the setting of the DIP switch S 8.8 onthe temperature control panel board (Refer to Technical Appendix forTemperature Part).

Activation When the overtemperature shutdown value isreached

or

Shutdown temperature was exceeded for morethan 120 seconds / temperature increased

Deactivation Switch on/off unit

7. Automatic Fault Displays



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P/N 458374C

Ambient temperature too high

Activation Electrical cabinet internal temperature is higherthan 60 �C (140 �F) for more than 120 seconds


Temperature sensor interruption

Activation Interruption for more than 5 seconds

Deactivation Eliminate fault

Temperature sensor short-circuit (not for Fe-CuNi sensors)

Activation Short-circuit for more than 5 seconds

Deactivation Eliminate fault

Undertemperature during operation

Activation Actual temperature goes below temperaturesetpoint minus undertemperature value for morethan 10 seconds

Automatic deac-tivation

Actual temperature exceeds temperaturesetpoint minus 3 �C (5.4 �F) for more than5 seconds

Overtemperature

Activation Actual temperature exceeds temperaturesetpoint plus overtemperature value for morethan 10 seconds

Automatic deac-tivation

Actual temperature goes below temperaturesetpoint plus 3 �C (5.4 �F) for more than5 seconds

Memory error

Activation The memory of the displayed temperaturechannel is probably defective. Replacecorresponding module if this occurs again.




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P/N 458374C

Operating the Motor Part


NOTE: Operation by electrostatically-charged persons can lead toimproper functioning of the control system.

NOTE: Alteration of values and parameters can be blocked (seeTechnical Appendix of the Motor Part, Central Module, DIP Switch S 6).

NOTE: To prevent excessive wear, the motor/pump speed should notcontinuously fall below 5 min-1 (rpm) or continuously exceed 80 min -1

(rpm).

NOTE: Not all parameters are available in the motor part for systemmodels with air motor / piston pump (Refer to Overview, Overview ofSettings, Motor Part).



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P/N 458374C

DisplaysRefer to Display Overview and Service Display.

Select manual or automatic modePress key 27 for approx. 2 seconds (until in display 30,–P– blinks). Then use key 21 to select manual orautomatic mode. In manual mode, symbol 26 lights.

Setting speed (manual mode)Press key 27 for approx. 2 seconds (until indisplay 30, –P– blinks). Then increase value withkey 22 or decrease with key 23.

Pressing once changes the value by 1, holdingthe key changes the value faster.

Switch on motorFirst press key 27 on the appropriate motor panel (motor is pre-selected, LED in key 27 is lit). Then press key 25 (motor isswitched on, LED in key 25 and illuminated symbol 29 are lit).

TestPress and hold key 27 until –P– blinks indisplay 30. Then press 20 for the duration ofthe testWARNING: Risk of burns. Hot melt materialcan flow out of the application head.

In test mode, the motor runs (in manualmode at the set speed, in automatic mode atspeed rhi ). Other components may also betriggered. Refer to the wiring diagram to seewhich components are controlled.

min–1 barpsi

3027 31

26

23 22 21 20

29

25

Switch off one motorPress only key 27 on the corresponding motor panel.

Switch off all motorsPress only key 25.

Set values and parametersRefer to Display Overview and the detailed description.

Test displays and indicator beacon(option)Press key 20.

1. Press and hold keys 22 and 23 and press key 27 for approx. 2 seconds. Displays 30 and 31 blink.

2. Press key 22 or 23 until the desired parameter appears in display 30.3. Press and hold key 27 (in display 31, –P– blinks) and use key 22 to

increase value or key 23 to decrease value.Complete: Press and hold keys 22 and 23 and press key 27 for approx. 2 seconds.

Switch off automatic temperature setbackPress only key 25 for approx. 2 seconds.

Setting speed (automatic mode)In automatic mode the motor/pump speed isregulated synchronously to the speed of theparent machine. Adjustment directly affectsthe parameter rhi (Refer to Display Overviewand Parameter Overview).

DGCO232L214A0399

Fig. 10

1. Operation Overview



CS04Issued 12/01

P/N 458374C

Normal display

Speed min-1 (rpm) Pressure (option)

Temperature setback active

Parameters and values

NOTE: When the pressure display showspsi, multiply the value by 10.

Service displaysRefer to Service Display.

Period after motor standstill atwhich the temperature setbackis automatically switched on.

Options and special functions are dis-played only when they are available in thesystem. Also refer to Parameter Overview.

Operating mode displaysAppear automatically.Works only in automatic mode, additional

function that can be activated

Motor speed at 0 % pilot voltage

Motor speed at pilot voltageUhiFunctions only in automatic mode

Pilot voltage in % at which themotor rotates at speed rhi.Works only in automatic mode, additionalfunction that can be activated

Return values to factory setting

Automatic Fault Displays

Also refer to Parameter Overview.

Speed adapted to special gearbox (additional function that canbe activated)

Unit release not switched

Error displayThe error number appears in the rightdisplay. Refer to service display Errorfor details on the error numbers.

�

Con

tinua

tion

of p

aram

eter

s an

d va

lues

�

Normal display Piston pump

Pump OFF

Pump ON

Field bus address of system(only for PROFIBUS-DP)

Speed increase with twoapplications

Speed setpoint (manual mode)

*

*

*

*

*

* Not on systems with piston pump

002450

*

Fig. 11

2. Display Overview

min–1 barpsiM127

29

26

30 31

25

24

23 22 21 20

28

MXCO009S0270295



CS04Issued 12/01

P/N 458374C

Manual mode: The setpoint is equal to the set value and remains stable.

Automatic mode: The speed is controlled by pilot voltage. Theparameters rLo, rHi and Uhi can be set.

NOTE: Automatic mode is only possible if pilot voltage is available.

NOTE: The parameters rLo, rHi and Uhi have no effect on systems witha piston pump.

1. Press key 27 for approx. 2 seconds (until 30, –P– blinks in display).

2. Press key 21 until the desired operating mode appears. In manualmode, symbol 26 lights

Special function: Manual mode supersedes automatic mode; thismeans:

If manual mode was activated on the control panel, the digital modulecan not be used to switch to automatic mode.If the digital module was used to switch to manual mode, automatic modecan not be activated on the control panel.

WARNING: Risk of burns. Hot melt material can flow out of theapplication head (accessory).

In test mode, the motor runs (in manual mode at the set speed, inautomatic mode at speed rhi ). Other components of the applicationsystem may also be controlled. Refer to the wiring diagram to see whichcomponents are controlled.

1. Press and hold key 27 until –P– blinks in display 30. Then press 20for the duration of the test


3. Basic Settings

Select Manual or AutomaticMode

4. Test



CS04Issued 12/01

P/N 458374C

NOTE: Motors can not be switched on until the green indication lampReady (19, Fig. 1 and 2) is lit.

NOTE: In automatic mode, the operating characteristic of the motor isdetermined by parameters rLo, rhi and Uhi.

NOTE: The motor can also be switched on/off externally through aninterface.

1. Pre-select the motor(s): Press key 27 (pre-selected motor is indicatedby LED 28).

2. Switch on motor(s): Press key 25 (switched-on motors are indicatedby LED 24 and illuminated symbol 29).

The motor startup protection prevents the motors from starting up afterthe initial heating phase or after a system error. When the startupprotection is activated, LED 24 in key 25 blinks.

To switch the motors back on: Press key 25 or, with external control viainterface, activate the input Release all motors once.

5. Switching ON Motor(s)

Motor Startup Protection

min–1 barpsiM127

29

26

30 31

25

24

23 22 21 20

28

MXCO009S0270295



CS04Issued 12/01

P/N 458374C

Press key 27 of the corresponding motor panel. The LED Motorpreselected turns off.

Press key 25. The LED Motor(s) on turns off.


(rpm).

NOTE: The speed setpoint can be adjusted in steps of 0.1. The actualspeed display is shown in steps of 1.0.

Changing speed directly:

1. Press key 27 for approx. 2 seconds (until in display 30, –P– blinks).

2. Increase value with key 22 or decrease with key 23.

The speed setpoint can also be changed in the menu (parameter rSP);proceed as described under Setting parameters.


Factory setting: 5.0 min-1

Setting range : 1.0 to 100 ��

6. Switching OFF Motor(s)

Switching Off One Motor

Switching Off All Motors

7. Setting Speed (ManualMode)

min–1 barpsiM127

29

26

30 31

25

24

23 22 21 20

28

MXCO009S0270295



CS04Issued 12/01

P/N 458374C


(rpm).

Changing speed directly ( rhi):

1. Press key 27 for approx. 2 seconds (until –P– blinks in display 30and rhi blinks in display 31).

2. Increase value with key 22 or decrease with key 23.

rhi increases (decreases) as soon as the motor speed is increased(decreased). The motor speed can be increased until rhi=100 ��

��

(rpm).

Fig. 14 Details from Fig. 1rhi can also be changed in the menu; then proceed as described underSetting Parameters.

Factory setting (rhi) : 80 min-1

Setting range (rhi) : 1.0 to 100 ��

Via interface XS 5 without Profibus (option)

The parameters rLo, rhi and Uhi function in automatic mode (Refer toParameter Overview).

1. Select automatic mode (Refer to Selecting Manual or AutomaticMode).

2. Set parameters:rhi Refer to Setting Speed (Automatic Mode) - direct change orrefer to Setting ParametersrLo Refer to Setting ParametersUhi Refer to Setting Parameters

3. Determine pilot voltage via interface XS 5.

Via interface XS 5 with Profibus (option)

1. Select automatic mode (index 72, bit 1=1)

2. Select pilot voltage via interface XS (analog signal)(index 60, bit 10=1)

3. Set parameters:Set Limit maximum pump speed (index 79)Set Limit minimum pump speed (index 80)Set Limit pilot voltage/machine speed (Index 78)

4. Determine pilot voltage via interface XS 5.

8. Setting Speed (Automati cMode)

Speed Parameters in AutomaticMode



CS04Issued 12/01

P/N 458374C

Via PROFIBUS (option)

1. Select automatic mode (index 72, bit 1=1)

2. Select machine speed via field bus (digital signal)(index 60, bit 10=0)

3. Set parameters:Set Limit maximum pump speed (index 79)Set Limit minimum pump speed (index 80)Set Limit pilot voltage/machine speed (Index 78)

4. Determine Pilot voltage/machine speed (automatic mode) (Index 82).

The purpose of the temperature setback is to protect the material and tosave energy during breaks (Refer to Parameter Overview, parameterSPL).

SPL is the motor standstill time after which the temperature setback isautomatically switched back on. (Refer to Immediate TemperatureSetback in the temperature part.)

Switching ON: SPL must be set to a value equal to or greater than 15 minutes (factory setting is OFF).

Switching OFF: The Automatic temperature setback after motorstandstill is ended by pressing key 25 (Fig. 1). Press key 25 for approx. 2 seconds.

Speed Parameters inAutomatic Mode (contd.)

9. Switching AutomaticTemperature SetbackOn/OFF



CS04Issued 12/01

P/N 458374C


2. Press key 22 or 23 until the desired parameter appears in display 30.

3. Press and hold key 27 (in display 31, –P– blinks) and use key 22 toincrease value or key 23 to decrease value.Pressing once changes the value by 1, holding the key changes thevalue faster.

4. End Setting parameters: Press and hold keys 22 and 23 and presskey 27 for approx. 2 seconds.


2. Press key 22 or 23 until display 30 shows CLr and display 31 showsno .

3. Press and hold key 27 (in display 31, –P– and no blink).

4. Press key 22 or 23 until display 31 shows YES.

5. Release key 27 (after approx. 2 seconds display 31 shows no ). Allsettings have now been returned to factory settings.

6. End Returning parameters to factory settings: Press and hold keys 22and 23 and press key 27 for approx. 2 seconds.

Also refer to Setting Parameters.

ruP = Increase speed

Speed increase with two applications

ruP Factory setting: 100 % Note: The parameter appears after the parameter rhi.

Setting range: OFF, 1.0 to 250 %

Setting increments: 0.1-steps

Above 100 %: 1.0-steps

10. Setting Parameters

Returning Parameters toFactory Setting

Parameter Overview



CS04Issued 12/01

P/N 458374C

Also refer to Setting Parameters.

rLo = Motor speed at 0 % pilot voltage

See rLo, rhi and Uhi, graphic illustration

rLo Factory setting: 1.0 min-1 (rpm) Note: Functions only in automatic mode

Setting range: 1.0 to 100 min-1 (rpm) Note: Special function may be activated; DIP switch S 6 on thecentral module

Setting increments: 0.1-stepscentral module

rhi = Motor speed at pilot voltage Uhi

See rLo, rhi and Uhi, graphic illustration

rhi Factory setting: 80 min-1 (rpm) Note: Functions only in automatic mode

Setting range: 1.0 to 100 min-1 (rpm)


Uhi = Pilot voltage at which the motor rotates constantly at rhi

Pilot voltage at which the motor rotates at speed rhi. If the pilot voltage exceeds Uhi, the speed remains constant at rhi. See rLo, rhi and Uhi,graphic illustration

Uhi Factory setting: 100 % pilot voltage Note: Functions only in automatic mode

Setting range: 0 to 100 % pilot voltage Note: Special function may be activated. DIP switch S 6 on thecentral module

Setting increments: 0.1-stepscentral module

rLo, rhi and Uhi, graphic illustration

20 40 60 80 100

Pilot voltage in %

0

20

40

60

80

100

0

rLo = 1 min -1 / rhi = 75 min -1 / Uhi = 100 %

20 40 60 80 100

Pilot voltage in %

0

20

40

60

80

100

0

Mot

or s

peed

in m

in-1


20 40 60 80 100

Pilot voltage in %

0

20

40

60

80

100

0


20 40 60 80 100

Pilot voltage in %

0

20

40

60

80

100

0


Mot

or s

peed

in m

in-1

Mot

or s

peed

in m

in-1

Mot

or s

peed

in m

in-1

See also Central Module, DIP-Switch S 6, Switch 4 002451

Fig. 15 Motor speed to pilot voltage – Examples –

Parameter Overview (contd.)



CS04Issued 12/01

P/N 458374C

SPL = Temperature setback after motor standstill

SPL is the time after which the automatic temperature setback after motor standstill begins. The temperature is then decreased to the value ofparameter SPL (setback temperature) set in the temperature part.

SPL Factory setting: OFF Note: The function Temperature setback is only switched on if the value ofSPL is within the setting rangeSetting range: 15 to 240 minutes SPL is within the setting range.

N t E d t t tb k P k 25 f 2 dSetting increments: Steps of 1 Note: End temperature setback: Press key 25 for approx. 2 seconds.

rPU = Adapting speed to special gearbox

The parameter rPU serves to adjust the speed display to the max. gearbox output speed of a special gearbox (all other parameters remainunchanged). For example, if the max. gearbox output speed is 60 min-1, the parameter is set so that the speed display shows also 60 min-1.

rPU Factory setting: 100 min-1 (rpm) Note: Special function may be activated. Refer to Technical Appendix of theMotor Part Motor Panel Board DIP Switch S 2Setting range: 1.0 to 250 min-1 (rpm) Motor Part, Motor Panel Board, DIP Switch S 2


Adr = Field bus address of system

NOTE: Only with option PROFIBUS DP

Adr Factory setting: 10 Note: Every unit on the PROFIBUS needs a field bus address forcommunication Each address may be assigned only once in the field busSetting range: 2 to 126 communication. Each address may be assigned only once in the field bus.

Setting increments: Steps of 1

min–1 barpsiM127

29

26

30 31

25

24

23 22 21 20

28

MXCO009S0270295



CS04Issued 12/01

P/N 458374C

General service displays appear only in the display for motor 1;motor-related displays appear in the display for the motor in question.The service displays can be activated as follows:

1. DIP switch S 6 on the central module must be at or switched to thefactory setting (switches 1 and 2 in position OFF).


3. Press key 22 or 23 until the desired service display appears in display31.


4. End Service Display: Press and hold keys 22 and 23 and press key27 for approx. 2 seconds.

Display / meaning Value range

Total operating hours 0 to 99999

Hours.minutes since last switching on 0 to 999.59

Hours the corresponding motor was released 0 to 99999

Inputs of digital module 1 hexadecimally coded(refer to Service display di and do and DigitalModule)Other digital modules possible (display then di 2,di 3 etc., according to selector switch position /module number)

00 to FF

Outputs of digital module 1 hexadecimally coded(refer to Service display di and do and DigitalModule)

Other digital modules possible (display then di 2,di 3 etc., according to selector switch position /module number)

00 to FF

Pilot voltage input 0 to 10 VDC or 0 to 160 VDC(display in percent)

0 to 100

Field bus type Profibus DP available –

11. Service Displays



CS04Issued 12/01

P/N 458374C

Display / meaning Value range

Memory of the last 10 unit faults (refer to TableService Display Error)

001 to 255

Software version 0.00 to 999

Setting of DIP switch S 6 on the central module(refer to Code of DIP Switch S 6)

00 to FF

POS

1

2

3

4

5+6

255

Current state of systemPlaten is up

Normal mode

Drum almost empty

Drum empty

Platen moves up

Unknown platen position

1 to 6 and 255



CS04Issued 12/01

P/N 458374C

Display di shows the levels of the inputs, and display do shows theswitching state of the outputs of the digital module hexadecimally coded(Also refer to Service Displays).

NOTE: The ”b” can be mistaken for a ”6”.

The digital module has 8 inputs and 8 outputs. This means that there are256 possible combinations of inputs/outputs. The following binary tablecan be used to assist in translation of the signals (an example has beenshaded).

� �

Code Inputs/outputs 5 to 8 Code Inputs/outputs 1 to 4

8 7 6 5 4 3 2 1

0 OFF OFF OFF OFF 0 OFF OFF OFF OFF

1 OFF OFF OFF ON 1 OFF OFF OFF ON

2 OFF OFF ON OFF 2 OFF OFF ON OFF

3 OFF OFF ON ON 3 OFF OFF ON ON

4 OFF ON OFF OFF 4 OFF ON OFF OFF

5 OFF ON OFF ON 5 OFF ON OFF ON

6 OFF ON ON OFF 6 OFF ON ON OFF

7 OFF ON ON ON 7 OFF ON ON ON

8 ON OFF OFF OFF 8 ON OFF OFF OFF

9 ON OFF OFF ON 9 ON OFF OFF ON

A ON OFF ON OFF A ON OFF ON OFF

b ON OFF ON ON b ON OFF ON ON

C ON ON OFF OFF C ON ON OFF OFF

d ON ON OFF ON d ON ON OFF ON

E ON ON ON OFF E ON ON ON OFF

F ON ON ON ON F ON ON ON ON

OFF = input/output open; ON = input/output closed

The codification for 00 to FF can be found in the above chart.

� �

Example Example

Code Switch positions 5 to 8 Code Switch positions 1 to 4

8 7 6 5 4 3 2 1

6 OFF ON ON OFF b ON OFF ON ON

OFF = switch open

ON = switch closed

OFF = switch open

ON = switch closed

Service Displays di and do

Code of DIP Switch S 6

min–1 barpsiM1

30 31



CS04Issued 12/01

P/N 458374C

The error displays can be shown in the service display of the motor part(Refer to Service Displays). Errors which do not appear in display 30(e.g. r_d) are displayed as error numbers in display 31 of motor panel1.

NOTE: When faults are caused by situations not described here,Nordson’s customer service can help.

Error Cause / Troubleshooting

Err

or n

umbe

r

0 The software has not recognized an error. Thesystem is ready for operation.

If an error still occurs, check the following:

- LED’s on the boards/modules

- Voltage supply of the boards/modules

- DIP switch positions on the boards/modules

- Inputs/outputs of the boards/modules

- Wiring between motor and temperature parts

- External components

1 Motor overtemperature Check the following:

- Motor defective, pump defective or too sluggish

- Check wiring and output voltage of frequency converter

12 Overtemperature of one or more temperaturechannels

Defective channels are displayed in the temperature controller display.

Check the following:

- Overtemperature value setting (Parameter Hi )

- Wiring of the heating zones

- Wiring of the temperature sensors (Sensor connected to correct channel?)

- Is the correct temperature sensor type being used (also for external components)?

- Is the temperature control system functioning properly?

14 Overtemperature shutdown of one or moretemperature channels

Main contactor has dropped. The load circuit isde-energized



- Solid-State-Relay (short-circuit)

- Wiring of the heating zones




Service Display Error



CS04Issued 12/01

P/N 458374C


Err

or n

umbe

r

16 No error, the system is in initial heating phaseOR the Temperature setback function has beenactivated

Initial heating phase does not end:



- Temperature setback active? (Refer to Switching immediate temperature setbackON/OFF in the temperature part and Switching automatic temperature setbackON/OFF in the motor part.)

- Are the temperature setpoints set too high?

- Is the temperature controller functioning properly?

- Is the right decimal point in display 5 (Fig. 4) lit?

- Has the correct leading channel been selected?

- Are the solid-state-relays controlled?

- Are the solid-state-relays switching line voltage through?

- Is line voltage too low?

- Is the heating defective?

- Wiring of the heating zones (Channel connected to correct heating zone?)




20 Undertemperature of one or more channels Defective channels are displayed in the temperature controller display.














Service Display Error (contd.)



CS04Issued 12/01

P/N 458374C

Error Cause / TroubleshootingE

rror

num

ber

28 One or more channels have undertemperatureAND one or more channels haveovertemperature.















32 Temperature comparison measuring pointdefective

Replace measuring point

33 Ambient temperature too high Lower ambient temperature of comparison measuring point

34 Temperature sensor error Temperature sensor short circuit, breakage or heated hose / application head notconnected

35 Memory error of temperature control module Clear error message by switching unit on/off. Then check all temperature parameters.

Replace defective temperature control module. Refer to Automatic fault displays,Memory error

65 No motor module release (motor does notrotate)

Possible causes:

- Frequency converter fault (Refer to separate manual Frequency Converter, Series8200 Vector).

- Module defective



CS04Issued 12/01

P/N 458374C


Err

or n

umbe

r

70 Warning: Undefined state of drum melter

Collective fault; has no effect on Ready andmain contactor

Check switch on hydraulic cylinder; platen recognition faulty

Switch drum melter off then on again; the error is not reset automatically.

71 Pump speed can not be achieved

No effect on Collective fault, Ready and maincontactor

Corrective action:

Set speed lower

Install larger pump

Do not activate applications at the same time

The error is reset when the cause is not longer present.

72 Error: Drum empty

Not Ready, but no effect on main contactor

Corrective action:

Replace drum

75 Heating zone(s) not ready

Collective fault and not Ready, but no effect onmain contactor

When large quantity of material is used: Re-position switch Drum almost empty(recognition of melt platen position)

Check heating zone hardware

79 Configuration error

Collective fault, and not Ready, main contactorhas dropped

Check DIP switch on temperature panel board

Check DIP switch on temperature control module




CS04Issued 12/01

P/N 458374C

Error Cause / TroubleshootingE

rror

num

ber

200 Short operating voltage failure(< 1 second)

Corrective action: check operating voltage / network power supply

Reset error message:

Switch off the unit for at least 10 seconds.

201 Error: Failure of field bus communication

All drives stop in Remote mode because startupprotection is activated. Refer to communicationdata list for information on remote mode.

Possible causes:

- Defect in bus cable

- Bus terminating resistor missing or defective

- Failure of host/master

217 Failure of field bus communication module Failure of a module: In most cases, the module is defective. But the following faults arealso possible:

218 Reset of field bus communication modulealso ossible:

- Contact fault in voltage supply

225 Failure of temperature bar graph - Fuse(s) on the module defective

Incorrect or fluctuating operating voltage226 Reset of temperature bar graph - Incorrect or fluctuating operating voltage

- A selector switch on a module was moved while the unit was operating.227 Failure of temperature control panel

A selector switch on a module was moved while the unit was o erating.

All d l f il ithi f d P ibl228 Reset of temperature control panel All modules fail within a few seconds. Possible cause:

There may be a problem with the CAN bus system. The yellow LED’s on the modules229 Failure of temperature control module

There may be a roblem with the CAN bus system. The yellow LED s on the moduleswill then be lit. In such cases it is recommended to replace all modules and boards(including the control panel board) as well as all CAN bus cables as the

230 Reset of temperature control module(including the control anel board) as well as all CAN bus cables as thecommunication in the CAN bus system is most likely disrupted.

231 Reset of central moduleReset of a module: A reset usually occurs as a result of external disturbances.

232 Failure of control panel boardy

Possible causes:

233 Reset of control panel board - External, inductive loads (e.g. solenoid valves) without recovery diodes or varistors

- Level of interference to the power cables (e g plug connector XS 2) too high234 Failure of analog module

- Level of interference to the ower cables (e.g. lug connector XS 2) too high

- The unit was operated by an electrostatically charged person235 Reset of analog module

y y g

- Incorrect or fluctuating operating voltage

236 Failure of motor module - Short interruption in operating voltage supply.

Corrective action: Use shielded power cables change cable path switch inductive237 Reset of motor module

Corrective action: Use shielded ower cables, change cable ath, switch inductiveloads with recovery diodes or varistors.

238 Failure of digital moduleResetting error messages Failure and Reset:

239 Reset of digital moduleg g

Switch off the unit for at least 10 seconds.



CS04Issued 12/01

P/N 458374C


Err

or n

umbe

r

248 Spare –

249 Spare –

250 Motor module with incorrect software version onthe bus system

Check the software version of the module (can be found on the module).

Valid version numbers: R 3.01 to R 3.99

251 Control panel board with incorrect softwareversion on the bus system

Check the software version of the board (can be found on the board).


252 Analog module with incorrect software versionon the bus system

Check the software version of the module (can be found on the module).


253 Digital module with incorrect software version onthe bus system

Switch unit off/on. Error still present? If yes, check the software version of the module(can be found on the module).


254 When the unit was switched off, all parametersettings may not have been saved

Hardware fault on the central module

Delete fault indication by switching the unit off then on again, then check all parametersettings.

Replace central module if the fault occurs repeatedly

255 Main contactor does not switch properly, orovertemperature thermostat on the tank hasbeen triggered


- Wiring of the main contactor

- Acknowledgement contact and wiring of the contact on the central module

- Main contactor




CS04Issued 12/01

P/N 458374C

Technical Appendix of the Temperature Part

The �� is meant for personnel who are trained andequipped for tasks which go beyond the normal operation of the unit.


WARNING: Observe all safety instructions concerning handlingof energized components (active parts). Failure to observe mayresult in an electric shock.

The diagnosis program serves to indicate defects in temperaturesensors, heaters and Solid-State-Relays. When an error is detected, thediagnosis program does not continue; the error must first be eliminated.The error codes are shown in the digital displays of the temperature part.

Canceling diagnosis program:

1. Confirm error with key 13 or 14.

2. Press key 13 or 14 to end.

1. Diagnosis Program

MXCO019S024A0295

C

F

3 4 5

101112131416

7

6

15 9



CS04Issued 12/01

P/N 458374C

NOTE: The unit, application heads and heated hoses (and air heaters, ifpresent) must be cold; the diagnosis program expects an increase intemperature of 10 �C (18 �F) in every channel within 10 minutes.

NOTE: Unused channels must be switched off (set the temperaturesetpoint to less than 40 �C (104 �F).

Activate:

1. Switch off the unit.

2. Press keys 13 and 14 simultaneously and switch the unit back on.


All segments of the digital displays now light up for approx. 2 seconds. A decimal point running through all displays indicates that the diagnosisprogram is active. Test phase 0 begins.

Tests the Solid-State-Relays and the temperature sensors.

Testing the Solid-State-Relays : A Solid-State-Relay which is notcontrolled is checked to find out whether the temperature still increases.If in one channel the temperature increases by 10 �C (18 �F) within 10 minutes, the illustrated error code appears.

Display 3: Test phase 0

Display 4: Error code P (heating zone heats although not controlled).

Display 5: Number of the channel / heating zoneFig. 18

Testing the temperature sensors: Temperature sensors are tested forinterruptions and short-circuits (no short-circuit for Fe-CuNi-sensor).


Display 4: Error code E (interruption)



Display 4: Error code S (short-circuit)


When execution of test phase 0 is error-free, the diagnosis programautomatically goes to test phases 1 to n.

Activating the DiagnosisProgram

Test phase 0



CS04Issued 12/01

P/N 458374C

Checks whether heating zones 1 to n (n= number of highest channel thatis switched on) are being heated. The heaters are controlled for 10minutes. The temperature must increase by 10 �C (18 ��

��

If the temperature increases within 10 minutes, the program switchesautomatically to the next channel.

Display during the test phase:

Display 3: Test phase 1 (Channel / Heating zone 1 is tested)

Display 4: Channel / Heating zone 1 has been tested for 40 seconds.

Display 5: Actual temperature is 30 �C (86 �F).Fig. 21

Error: Heating zone does not heat


Display 4: Error code E (Heating zone does not heat)


Possible faults: Fuse(s) defective

Solid-State-Relay defective

Temperature sensor defective

Damaged cable

Polarity of Fe-CuNi-sensor interchanged

Heating defective

Error: Wrong heating zone heats


Display 4: Error code H (wrong heating zone heats)

Display 5: Number of the heating zone which is heated (wrong heatingzone)

Fig. 23

Possible faults: Temperature sensors interchanged

Heating connections interchanged

Test Phases 1 to n

MXCO010S025A0295

C

F

3 4 5

101112131416

15 9

8



CS04Issued 12/01

P/N 458374C

1. Wait until End is displayed (is only displayed when the diagnosisprogram has ended without any error messages).

Fig. 242. Press key 13 or 14 to end.

The offset is used to correct

� Known temperature sensor measurement faults

� Known and constant temperature deviations

� Known measurement faults that result e.g. from temperature sensorcable that is too long.

Example

Actual temperature: 180 �C

Actual temperature transmitted (displayed): 175 �C

An actual temperature value of 180 �C (356 �F) is transmitted(displayed) with a temperature channel offset of 5 �C (9 �F).

1. Press and hold key 16 and press key 13 until the correction forchannel 1 is displayed (the correction begins after the display �� ).

2. Use key 11 to increase the offset value or key 12 to decrease theoffset value (middle display).

NOTE: The offset can also be entered by channel (Also refer to � �� ).


Factory setting �� C (�� F)

Setting range - 9.5 �C to + 9,5 �C in 0.1 �C steps

-17 �F to + 17 �F

Ending the Diagnosis Program

2. Correcting TemperatureSensors



CS04Issued 12/01

P/N 458374C

ON

1 2 3 4 5 6 7 8

S7

DIP ON

1 2 3 4 5 6 7 8

S8

DIP X1

X2

F1

D3

DGCO225L088A0399

D8D9

D10

Fig. 26 Plug side (only parts described are shown)

Fuse Value Order Number

F 1 Operating voltage of control panel board electronics 1 AT P/N 285 957

Number Color State Meaning

D 3 Green Lit Fuse F 1 Operating voltage of electronics is correct.

D 8 Red Lit A software reset has occurred. It can be caused by a brief loss of voltage supply or e.g. by strong,external interfering impulses or glitches (EMC). See also reset of various modules (error number217 to 239, Service Display Error)

Blinking Problems with CAN bus hardware. Check and, if necessary replace CAN bus and modules/boards.

D 9 Yellow Lit A CAN bus command could not be sent. Check or replace: CAN bus cable, central module andcontrol panel board.

D 10 Green Flickering Valid data are being transmitted or received via CAN bus.

3. Temperature ControlPanel Board

Fuses

LED’s



CS04Issued 12/01

P/N 458374C

Switch Function

1 2 3 4 5 6 7 8

ON OFF OFF ON ON ON ON OFF Channel number of temperature control panel board (other channel numbers notpermitted)

WARNING: The DIP switches S 8.1 and S 8.2 must be set toOFF (no leading channel) in changeover systems.

Switch Function

1 2 3 4 5 6 7 8

OFF OFF No leading channel

ON OFF Channel 1 is leading channel (refer to table DIP switch S 8, switch 6)

OFF ON Channel 2 is leading channel (refer to table DIP switch S 8, switch 6)

ON ON Channel 3 is leading channel (refer to table DIP switch S 8, switch 6)

OFF Setting by channel deactivated (only SE and offset displayed)-Factory setting-

ON Setting by channel activated

OFF Predefined control parameter (parameter sets) accessible, if Setting by Channel isactivated with DIP switch S 8, switch 3. - Factory setting -

ON Predefined control parameter (parameter sets) blocked

OFF -Factory setting- Note: Do not adjust!

OFF Refer to table DIP switch S 8, switch 6

ON Refer to table DIP switch S 8, switch 6

X No function

OFF Immediate shutdown when overtemperature shutdown value OFF is reached.

NOTE: If the highest temperature setpoint is reduced by 30 �C (54 �F) or more,shutdown may occur.

ON Shutdown when the shutdown temperature has been exceeded for more than 120 seconds and the temperature continues to rise.-Factory setting-

3. Temperature ControlPanel Board (contd.)

DIP Switch S 7

DIP Switch S 8



CS04Issued 12/01

P/N 458374C

The leading channel is determined by switches 1 and 2 of the DIP switchS 8 (Refer to DIP Switch S 8). The initial heating behavior of the channelsis determined by switch 6 of the DIP switch S 8.

Leading channel Switch 6 Initial heating behavior

No leading channel OFF / ON All channels heat independently of one another (no start up control)

Channel 1 OFF The leading channel heats up first. The other channels do not begin to heat until the leadingchannel has reached a temperature of 50 �C (90 ��

��

�� C (18 ��

��

ON All channels heat up simultaneously with the leading channel, but they can not exceed theactual temperature of the leading channel until the leading channel has reached a temperatureof 10 �C (18 ��

Channel 2 OFF Channel 1 heats simultaneously with the leading channel, but it can not heat to a highertemperature than that of the leading channel. The other channels do not begin to heat until theleading channel has reached a temperature of 50 �C (90 ��

��

�� C (18 ��


Channel 3 OFF Channels 1 and 2 heat at the same time as the leading channel. However, channels 1 and 2can not heat higher than the leading channel. The other channels do not begin to heat until theleading channel has reached a temperature of 50 �C (90 ��

��

�� C (18 ��


X1, X2 CAN bus (Refer to central module)

DIP Switch S 8, Switch 6

Plug Connectors



CS04Issued 12/01

P/N 458374C

One unit may have several temperature control modules. Refer to�� .

For temperature sensor Ni 120.

123

X1 S3 S1 S2

D23

D24

D25

X3 X4 X5

P1

0 - F

4

C

1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 12

D10 D11 D12 D13 D14 D15

1 2 3 4

Board Voltage controlof temperature controlmodule 123456

X2

S

DGCO227L134A0399

Fig. 27

4. Temperature ControlModule

Ni 120



CS04Issued 12/01

P/N 458374C


D 10 Green Lit Heater output of the first channel (plug connector X4) of this temperature control module is switchedon. Depending on how switch S 1 is set on the control module, the first channel of this temperaturecontrol module is 1, 7, 13, 19, 25, 31, 37 or 43.

D 11 Green Lit Heater output of the second channel (plug connector X4) of this temperature control module isswitched on. Depending on how switch S 1 is set on the control module, the second channel of thistemperature control module is 2, 8, 14, 20, 26, 32, 38 or 44.

D 12 Green Lit Heater output of the third channel (plug connector X4) of this temperature control module isswitched on. Depending on how switch S 1 is set on the control module, the third channel of thistemperature control module is 3, 9, 15, 21, 27, 33, 39 or 45.

D 13 Green Lit Heater output of the fourth channel (plug connector X4) of this temperature control module isswitched on. Depending on how switch S 1 is set on the control module, the fourth channel of thistemperature control module is 4, 10, 16, 22, 28, 34, 40 or 46.

D 14 Green Lit Heater output of the fifth channel (plug connector X4) of this temperature control module is switchedon. Depending on how switch S 1 is set on the control module, the fifth channel of this temperaturecontrol module is 5, 11, 17, 23, 29, 35, 41 or 47.

D 15 Green Lit Heater output of the sixth channel (plug connector X4) of this temperature control module isswitched on. Depending on how switch S 1 is set on the control module, the sixth channel of thistemperature control module is 6, 12, 18, 24, 30, 36, 42 or 48.

D 23 Red Lit A software reset has occurred. It can be caused by a brief loss of voltage supply or e.g. by strong,external interfering impulses or glitches (EMC). See also reset of various modules (error number217 to 239, Service Display Error)


D 24 Yellow Lit A CAN bus command could not be sent. Check or replace: CAN bus cable and temperature controlmodule.

D 25 Green Flickering Valid data is being transmitted or received via CAN bus.

LED’s



CS04Issued 12/01

P/N 458374C

X 1 Connection temperature comparison measuring point

Pin Function Level Notes

1 Voltage supply for temperature comparison measuring point +6 VDC –

2 Signal approx. 1 VDC at 20 �C –

3 Reference potential 0 VDC –

X 2 No function

X 3 Voltage supply

Pin Level Function

1 +24 VDC Pins 1/2 and 3/4 can be bridged. External components that are connected to the temperature control module arethen supplied via the Bus cable with 24 V for external components (Refer to X 1 of central module)2 +24 VDCthen supplied via the Bus cable with 24 VDC for external components (Refer to X 1 of central module).

Oth i Pi 2 d Pi 4 b t d t t l 24 V lt l Th t l t f3 Reference poten-tial

Otherwise, Pin 2 and Pin 4 can be connected to an external 24 VDC voltage supply. The external components ofthe temperature control module can thereby be electrically separated from the rest of the control system.

Pi 2 (24 V t t l t ) i f t t d ith 1 A f4 Reference poten-tial

Pin 2 (24 VDC to external components) is fuse-protected with a 1 A fuse.

X 4 Heater outputs 1 to 6

Pin Function Level Pin Function Level

1 Voltage supply +24 VDC 5 Heater channel 4 + Output open collector

2 Heater channel 1 + Output open collector 6 Heater channel 5 + Output open collector

3 Heater channel 2 + Output open collector 7 Heater channel 6 + Output open collector

4 Heater channel 3 + Output open collector

X 5 Temperature sensors 1 to 6

Pin Function Pin

1 Temperature sensor channel 1 + 7 Temperature sensor channel 4 +

2 Temperature sensor channel 1 – 8 Temperature sensor channel 4 –





CAN bus (Refer to central module)

Plug Connectors



CS04Issued 12/01

P/N 458374C

Position Temperature channel Position Temperature channel

1 (= Temperature control module 1) 1 to 6 6 (= Temperature control module 6) 31 to 36



4 (= Temperature control module 4) 19 to 24 9 to F No function

5 (= Temperature control module 5) 25 to 30

Switch Function

1 2 3 4 5 6

OFF OFF OFF ON ON ON Channel number of temperature control module (No other channel numbers permitted).

Switch Function

1 2 3 4 5 6 7 8

ON The temperature control module has its own comparison measuring point. It must beconnected to the plug connector X1. *)

OFF The comparison measuring point must be connected to a different temperaturecontrol module.

OFF OFF - Factory setting -NOTE: Do not adjust!

– – – – – Switches 4 to 8 have no function.

*) NOTE: The comparison measuring point is connected either to the first temperature control module (selectorswitch S 1 in position 1) or all modules get a comparison measuring point (Refer to wiring diagram).

NOTE: The potentiometer may not be adjusted.

P1 Factory set

S Switches S must be closed.

Selector Switch S 1

DIP Switch S 2

DIP Switch S 3

Potentiometer P 1

Switch S



CS04Issued 12/01

P/N 458374C

D3 F2 F1 D6X1

DGCO228L096A0399

Fig. 28 Board Voltage control


F 1 Operating voltage of Voltage control board of temperature control module 1 AT P/N 285 957

F 2 Operating voltage for external components


D 3 Green Lit Fuse F 2 Operating voltage of external components is correct

D 6 Green Lit Fuse F 1 Operating voltage of voltage control board is correct

X 1 CAN bus (Refer to central module)

5. Voltage Control ofTemperature ControlModule

Fuses

LED’s

Plug Connectors



CS04Issued 12/01

P/N 458374C

3

1

1

3

22

XXPN064L096A1198

Fig. 29

The temperature comparison measuring point is attached to a top hat railin the electrical cabinet and is connected to the plug connector X1 of thetemperature control module.

The connections are labeled with numbers: cable terminal 1 oftemperature comparison measuring point to cable clamp 1 of plugconnector, etc.

6. Temperature ComparisonMeasuring Point



CS04Issued 12/01

P/N 458374C

Technical Appendix of the Motor Part

The Technical Appendix is meant for personnel who are trained andequipped for tasks which go beyond the normal operation of the unit.


WARNING: Observe all safety instructions concerning handlingof energized components (active parts). Failure to observe mayresult in an electric shock.



CS04Issued 12/01

P/N 458374C

The central module with digital input/output is a combination of centralmodule, digital module and possibly field bus communication module.The field bus communication module is present only in control systemswith PROFIBUS DP (option).

The analog input on the central module must be aligned (Refer toAligning Pilot Voltage).

V67

X5X3X8

5

9

1

6

5

9

1

6

1234

1 2 3 4 5 6 7 8 1 2 3 4 5 62 3 41

12

X1 X7 X4 X6

S1 S6 X13 X11S12S114

C

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

X14 X15

R18

F1

F2

F3 F4

X9

V49V50V51

1

15

2

16

+

S2S3

R42 S15

V69 V68 V66 V65 V64 V63 V62V70

F13

V76 V77 V78V75V72 V73 V74V71V53V54

V55

V41

V42

Digital module

Central Module

V56

ULERRRUNRDY

Field Bus CommunicationModule

002879

V48

V45

V43

V44

V47



F 1 Operating voltage of central module electronics 1 AT P/N 285 957

F 2 Operating voltage of external components

F 3 Incoming supply voltage for electronics 6.3 AT P/N 289 630

F 4 Incoming supply voltage for external components


F 13 Incoming supply voltage for digital inputs of external components 1 AT P/N 285 957

1. Central Module withDigital Input/Output

Fuses (Central Module)

Fuses (Digital Module)



CS04Issued 12/01

P/N 458374C


V 41 Green Lit Fuse F 1 Operating voltage of electronics is correct

V 42 Green Lit Fuse F 2 Operating voltage of external components is correct

V 43 Green Lit Input X 4 / Pin 4 is active



V 47 Green Lit Relay for output X 4 / Pin 6, X 4 / Pin 7, X 4 / Pin 8 has picked up


V 49 Green Flickering Valid data are being transmitted or received via CAN bus.

V 50 Yellow Lit A CAN bus command could not be sent. Check or replace: CAN bus cable and central module.

V 51 Red Lit A software reset has occurred. It can be caused by a brief loss of voltage supply or e.g. by strong,external interfering impulses or glitches (EMC). See also reset of various modules (error number217 to 239, Service Display Error)




V 55 Green Lit Fuse F 3 Supply voltage for electronics is correct

V 56 Green Lit Fuse F 4 Supply voltage for external components is correct


V 62 Green Lit Input 1 (X 11 / Pin 2) is active








V 70 Green Lit Fuse F 13 Supply voltage for digital inputs of external components is correct

V 71 Green Lit Output 1 (X 14 / Pin 1 and 2) is active








LEDs (Central Module)

LEDs (Digital Module)



CS04Issued 12/01

P/N 458374C

Before aligning the pilot voltage input, it must be determined whether pilotvoltage is 0 to 10 VDC or 0 to 160 VDC.

Aligning pilot voltage input 0 to 10 V DC

1. Ensure that switch S 15 is set to ON (factory setting).

2. Operate parent machine at max. speed.

3. Display Uin for Motor 1 (see Service Displays).

4. Set Uin with potentiometer R 18 to 100 (100% pilot voltage).

Aligning pilot voltage input 0 to 160 V DC

1. Set switch S 15 to OFF.

2. Operate parent machine at max. speed.

3. Display Uin for Motor 1 (see Service Displays).

4. Set Uin with potentiometer R 42 to 100 (100% pilot voltage).

Aligning Pilot Voltage



CS04Issued 12/01

P/N 458374C

OFF Input voltage 0 to 160 VDC pilot voltage

ON Input voltage 0 to 10 VDC pilot voltage (factory setting)

R 18 Align pilot voltage input 0 to 10 VDC (Refer to Aligning Pilot Voltage)

R 42 Align pilot voltage input 0 to 160 VDC (Refer to Aligning Pilot Voltage)

Switch Function

1 2 3 4

ON ON OFF ON Channel and module number of the central module (other switch positions not permitted)

Switch Function

1 2 3 4 5 6 7 8

OFF OFF – – – Factory setting, values and parameters are displayed and can be altered. Servicedisplay can also be activated.

ON OFF – – – Values and parameters are displayed and can be altered. Service display cannot beactivated.

OFF ON – – – Values and parameters can only be displayed; they cannot be altered.

ON ON – – – Only the software version number and the DIP switch positions on the centralmodule can be displayed.

OFF – – – No function

ON – – – No function

OFF – – – Automatic mode: If the speed setpoint is below 1.0 min-1 or below rLo, the motorruns at 1 min-1 or at speed rLo.

Manual mode: No function

ON – – – Automatic mode: If the speed setpoint is below 1.0 min-1 or below rLo, the motordoes not run.

Manual mode: No function

(Factory setting)

OFF – – – Parameters rLo and Uhi are activated

ON – – – Parameters rLo and Uhi are factory set and cannot be changed (rLo = 1.0 min-1, Uhi = 100 % pilot voltage)

Switch Function

1 2 3 4 5 6

OFF ON OFF ON ON ON Channel number of the digital module (other channel numbers not permitted)

Switch S 15

Potentiometer R 18, R 42

DIP Switch S 1

DIP Switch S 6

DIP Switch S 12



CS04Issued 12/01

P/N 458374C

Pressing the button activates a software reset.

The switch position first takes effect following a software reset.

Switch position outward (factory setting) Normal operation

Switch position inward Switch position permitted only for Nordson personnel

Series BM Notes

Position Function Description of functions/special functionsrefer to Plug connectors1 Single mode refer to Plug connectors.

The remaining switch positions have no function

X 1 Voltage supply (central module)


1 Input for operating voltage ofelectronics

+24 VDC Both voltages are electrically isolated from one another and are led through theCAN bus cable. Pin 1 / 3 are fuse protected internally with 6.3 A (F3 and F4) andprotected against reversing of polarity behind the fuses with a protective diode.

2 Reference potential for Pin 1 0 VDCrotected against reversing of olarity behind the fuses with a rotective diode.

The operating voltage for the electronics may only be used for the boards/modules3 Input for operating voltage of

external components+24 VDC

g gof the control system.

The inputs/outputs of all boards/modules of the control system are operated withthe operating voltage of external components All external components have the

4 Reference potential for Pin 3 0 VDCthe operating voltage of external components. All external components have thesame reference potential (Pin 4).

X 13 Voltage supply (digital module)

Pin Level Function

1 +24 VDC Pins 1/2 and 3/4 can be bridged. External components connected to the central module with digital input/output arethen supplied internally with 24 V for external components (Refer to X 1)2 +24 VDCthen supplied internally with 24 VDC for external components (Refer to X 1).

Oth i t l 24 V lt l b t d t Pi 2 d Pi 4 Th t l t f3 Referencepotential

Otherwise, an external 24 VDC voltage supply can be connected to Pin 2 and Pin 4. The external components ofthe central module with digital input/output can thereby be electrically separated from the rest of the controlsystem

4 Referencepotential

system.

Pin 2 (24 VDC to external components) is fuse-protected with a 1 A fuse (F 13).

X 3 Pilot voltage input


1 Pilot voltage input 0 to 10 VDC or0 to 160 VDC

Also refer to Aligning pilot voltage

Potential-free in relation to 24 VDC supply.2 Reference potential for pilot

voltage input0 VDC

Potential free in relation to 24 VDC su ly.

Button S 3

Switch S 2

Selector Switch S 11

Plug Connectors (Voltage Supply)

Plug Connectors (Pilot Voltage Input)



CS04Issued 12/01

P/N 458374C

The inputs must be connected to 24 VDC switching voltage in order toactivate each function.

The outputs switch when the function is active or the operating mode hasbeen reached.

X 4 Inputs

Pin Desig. Function Level Notes

1 - Must be switched to theoptocoupler inputs toactivate them

+24 VDC Reference potential is the reference voltage of the external components ofthe control system

2 E1 Input for mode switch Input optocoupler With the mode switch on the Nordson unit, one of the two modes can beselected: Stand alone mode or Remote mode.

Note: Only with the option PROFIBUS. Also refer to separate manualCommunication Data List.

3 E2 Input Upper edge of drum Input optocoupler Switch Upper edge of drum reached

4 E3 Input Drum almost empty Input optocoupler Switch Drum almost empty reached

5 E4 Input Drum empty Input optocoupler Switch Drum empty reached

6 A1 – Relay changeover contact

–

7 – Relay breakcontact

–

8 – Relay makecontact

–

X 5 Interface to main contactor


1 A2 Relay picks up when maincontactor should pick up

Relay makecontact

Capacity: 250 VAC / 2 A

2 contactor should pick up contact

3 E5 Input must be active whenmain contactor has pickedup

Input optocoupler Serves to monitor the main contactor and the function Overtemperatureshutdown by the thermostat.

4 - Must be switched to theoptocoupler to activate it

+24 VDC

X 6 Outputs indicator beacon (indicator beacon is an accessory)


1 A3 Indication Ready

Relay picks up when the

Relay changeover contact


2Relay icks u when thesystem is ready for opera-tion (green indication lampi lit)

Relay breakcontact

3 is lit) Relay makecontact

4 A4 Indication Collective fault

Relay picks up when the

Relay changeover contact


5Relay icks u when thesystem has recognized anerror (red indication lamp islit)

Relay breakcontact

6 lit) Relay makecontact

Plug Connectors (Inputs/Outputs)



CS04Issued 12/01

P/N 458374C

X 11 Inputs

Pin Desig. Level Selector Switch S 11Position 1

1 - +24 VDC Switching voltage

2 E7 Optocoupler Release Unit

3 E8 Optocoupler Release Motors

4 E9 Optocoupler Temperature setback

5 E10 Optocoupler Release Motor application 1

6 E11 Optocoupler Heating zone 1 – 6 off (Refer to manual for control unit Changeover)

7 - + 24 VDC Switching voltage

8 E12 Optocoupler Release Motor application 2

9 E13 Optocoupler Heating zone 1 – 6 on (Refer to manual for control unit Changeover)

10 E14 Optocoupler -

X 14 Outputs

Pin Desig. Switching state Selector Switch S 11Position 1

1 / 2 A5 Relay output 1 Unit ready for operation

3 / 4 A6 Relay output 2 Collective fault

5 / 6 A7 Relay output 3 Drum almost empty

7 / 8 A8 Relay output 4 Yellow indicator beacon

X 15 Outputs

Pin Desig. Switching state Selector Switch S 11Position 1

1 / 2 A9 Relay output 5 Release application head application 1 and, when appropriate, release piston pump

3 / 4 A10 Relay output 6 Release application head application 2 and, when appropriate, release piston pump

5 / 6 A11 Relay output 7 Heating zone 7 – n ready (Refer to manual for control unit Changeover)

7 / 8 A12 Relay output 8 Drum empty



CS04Issued 12/01

P/N 458374C

X 7 RS 232-Interface (use only permitted by Nordsonpersonnel)

Corresponds to PC-Interface

Pin Function Notes 9-pin 25-pin

1 – – – –

2 TXD Transmittal data Pin 2 (RXD) Pin 3 (RXD)

3 RXD Received data Pin 3 (TXD) Pin 2 (TXD)

4 DTR Always active Not needed Not needed

5 Reference potential – Pin 5 (Ground) Pin 5 (Ground)

6 – – – –

7 – – – –

8 RTS Always active Not needed Not needed

9 – – _ –

X 8 Not in use

X 9 Internal plug

CAN bus


1 Data CAN High The CAN bus is electrically connected to the processor potential

9 Data reference potential CAN 0 VDC (see central module, X 1 / Pin 2)

2 Data CAN Low

10 – +24 VDCelectronics

Voltage supply of processors on the boards and modules.

3 electronics The input of the central module (X1 / Pin 1, +24 VDC) is connected to these pinsth h 6 3 A f11 through a 6.3 A fuse.

4 – 0 VDC electronics Voltage supply of processors on the boards and modules.

12 The input of the central module (X1 / Pin 2, Ground) is connected with these pins.

5

13 – +24 VDC externalcomponents

Voltage supply of external components and the inputs/outputs of theboards/modules

6com onents boards/modules.

The input of the central module (X1 / Pin 3, +24 VDC) is connected to these pins14

The in ut of the central module (X1 / Pin 3, +24 VDC) is connected to these insthrough a 6.3 A fuse.

7 – 0 VDC externalcomponents

Voltage supply of external components and the inputs/outputs of theboards/modules15 components boards/modules.

Th i t f th t l d l (X1 / Pi 4 G d) i t d ith th i8 The input of the central module (X1 / Pin 4, Ground) is connected with these pins.

Plug Connectors



CS04Issued 12/01

P/N 458374C

Release Unit

Level Function Notes

0 VDC Main contactor is not switched on; heaters and motors areswitched off. In display 30 (Fig. 1), OFF appears.

The electronics are supplied with voltage. The load current circuitfor heaters and motors is switched off.

24 VDC After approx. 2 seconds the relay for X5, Pin 1 / 2 on the centralmodule closes and the main contactor (load current circuit forheaters and motors) is switched on.

–

Release Motors


0 VDC All motors are blocked even when the unit/system is ready foroperation.

The input must be switched from 0 VDC to 24 VDC in order todeactivate the motor startup protection.

24 VDC All pre-selected motors are released when the unit/system isready for operation.

See also Operating the motor part, motor startup protection.

Temperature setback


0 VDC No temperature setback Also refer to Switching temperature setback on/off.

24 VDC After approx. 2 seconds, the temperature setback is switched on.All channels are set back by the set value. The motors arestopped and the motor startup protection is activated. In display 4and 30 (Fig. 1), SPL appears.

See also Operating the temperature part, parameter overview.

Release motor application 1 or application 2


0 VDC No release Also refer to Speed Control with Two Applications

24 VDC Release

Function of Input Signals



CS04Issued 12/01

P/N 458374C

Unit ready for operation

Switching state Function Notes

Open Unit not ready for operation –

Closed Unit ready for operation

Collective fault


Open No fault If the output Ready for operation is also active, the unit is readyfor operation in certain cases (e g when overtemperature oc-

Closed Fault (Unit is not ready for operation)for o eration in certain cases (e.g. when overtem erature oc-curs).

Drum almost empty


Open No Drum almost empty signal The output is activated when the drum melter state Drum almostempty (POS 3) or Drum empty (POS 4) is reachedClosed Drum almost empty signal empty (POS:3) or Drum empty (POS:4) is reached.

Drum empty


Open No Drum empty signal The output is activated when the drum melter state Drum empty(POS:4) is reachedClosed Drum empty signal (POS:4) is reached.

Release application head application 1 or application 2 (Systems with piston pump: plus release piston pump)


Open No release The relay picks up as soon as the motor rotates. This signalserves to release the application heads and is normally required

Closed Releaseserves to release the a lication heads and is normally requiredin the electrical cabinet.

Function of Output Signals



CS04Issued 12/01

P/N 458374C

The communication module is available only on control systems withPROFIBUS (option).


UL Green Lit Operating voltage of communication module is correct

ERR Red Lit Error on field bus interface

RUN Green Lit

Blinking regu-larly

Blinking irreg-ularly

Not lit

Communication operating

Ready for communication

Communication module parameterization error

No communication possible

RDY Orange Lit

Not lit or blink-ing

Communication module functions properly

Hardware or firmware of communication module is defective

The PROFIBUS interface plug connectors are located on the clear coverof the central module.

X 20 /X21

PROFIBUS interface


1 Shield Protective grounding PE Bus cable shield

2 - Not connected -

3 RxD/TxD-P RS-485 Receipt/transmission line of data-P,B-line

4 - Not connected -

5 DGND Ground to VP Data transmission potential

6 VP +5 VDC Supply voltage to terminating resistors P

7 - Not connected -

8 RxD/TxD-N RS-485 Receipt/transmission line of data-N,A-line

9 - Not connected -

X 22 PROFIBUS shield


1 Shield Protective grounding PE / functionalgrounding

Bus cable shield

2 Shield Protective grounding PE / functionalgrounding

Bus cable shield

2. Field BusCommunication Module

LED’s

PROFIBUS Plug Connectors



CS04Issued 12/01

P/N 458374C

25 26

S1 S21 2

ON

1 2 3 4 5 6 7 8

ON

1 2 3 4 5 6 7 8

X2

X1

F1

X5

V27

V3

V4

V5

002202



F 1 Operating voltage of control panel board electronics 1 AT P/N 285 957



V 4 Yellow Lit A CAN bus command could not be sent. Check or replace: CAN bus cable, central module andcontrol panel board.



V 27 Green Lit Fuse F 1 is OK

3. Motor Control PanelBoard

Fuses

LED’s



CS04Issued 12/01

P/N 458374C

Switch Function

1 2 3 4 5 6 7 8

ON OFF ON ON ON ON ON ON Channel number of motor control panel board (other channel numbers not permitted)

The DIP switch S 2.3 on the motor control panel board can be used toselect pressure display resolution of either 1 or 0.1 bar. If the measuringrange of the pressure sensor is always greater than 100 bar, the pressureis always shown as a whole number. If the pressure display is set to psi,switch 2.3 has no function.

Switch Function

1 2 3 4 5 6 7 8

OFF – – – – – – – Parameter rPU not activated (factory setting)

ON – – – – – – – Parameter rPU activated (refer to Parameter overview)

– OFF – – – – – – Motor present

– ON – – – – – – Piston pump present

– – ON – – – – – Resolution of all pressure displays is 0.1 bar

– – OFF – – – – – Resolution of all pressure displays is 1.0 bar (factory setting)

X 5 Internal plug

CAN bus (Refer to central module)

DIP Switch S 1

DIP Switch S 2

Plug Connectors



CS04Issued 12/01

P/N 458374C

The analog module is present only when the drum melter is equippedwith the option pressure control.

MXCO025L089A0595

X2 X3

X4 X5 X6

S6

S5 S7

S8

S9

S10

S3

S4

F3

F1

F2

R48

S1 S2

V2

V3

4

C

1234

1 2 3 4 5 61 2 3 4 5 6 1 2 3 4 5 6

1 2

15 16

X1

V9

V28 V27 V26



F 1 Operating voltage of analog module electronics 1 AT P/N 285 957

F 2 Voltage supply of analog module inputs

F 3 Voltage supply of analog module inputs






V 27 Yellow Lit A CAN bus command could not be sent. Check or replace: CAN bus cable, central module andanalog module.



4. Analog Module (Option)

Fuses

LED’s



CS04Issued 12/01

P/N 458374C

NOTE: The potentiometer has been factory-set. Do not adjust!

It was aligned to 80 % of the measuring range. For example:

� Measuring range 100 bar (1450 psi): Input voltage 80 % = 8 VDC = 80 bar (1160 psi)

� Measuring range 400 bar (5800 psi): Input voltage 80 % = 8 VDC = 320 bar (4640 psi).

Switch Function

1 2 3 4 5 6

ON ON OFF ON ON ON Channel number of the analog module (other channel number not permitted)

Position Function

1 Measuring range 10 bar (145 psi) (special function) 10 VDC at input = 10 bar in the display

2 Measuring range 35 bar (507,5 psi) (special function) 10 VDC at input = 35 bar in the display

3 Measuring range 100 bar (1450 psi) (factory setting) 10 VDC at input = 100 bar in the display

4 Measuring range 400 bar (5800 psi) (special function) 10 VDC at input = 400 bar in the display

5 Measuring range variable 1 to 680 bar (14.5 to 9860 psi) (special function) 10 VDC at input = 1 to 680 bar in the display

6 No function

7 No function

8 No function

9 No function

A to F No function

Jumper position A: Input 0 to 20 mA (special function)

Jumper position B: Input 0 to 10 V DC (factory setting)

Notes

Jumper S3 Input 1 See plug connector X3

Jumper S4 Input 2


Jumper S6 Input 4


Jumper S8 Input 6


Jumper S10 Input 8

Potentiometer R 48

DIP Switch S 2

Selector Switch S 1

Jumper S 3 to S 10



CS04Issued 12/01

P/N 458374C

CAN Bus (Refer to Central Module with Digital Input/Output)

X 1 Internal plug

X 2 Voltage supply

Pin Level Function

1 + 24 VDC Pins 1/2 and 3/4 can be bridged. External components connected to the analog module are then supplied via thebus cable with 24 V for external components (see X 1 of the central module)2 + 24 VDCbus cable with 24 VDC for external components (see X 1 of the central module).

Oth i t l 24 V lt l b t d t Pi 2 d Pi 4 Th t l t f3 Referencepotential

Otherwise, an external 24 VDC voltage supply can be connected to Pin 2 and Pin 4. The external components ofthe analog module can thereby be electrically separated from the rest of the control system.

Pi 2 (24 V t t l t ) i f t t d ith 1 A f4 Referencepotential

Pin 2 (24 VDC to external components) is fuse-protected with a 1 A fuse.

X 3 Analog inputs 1 and 2

Input Pin Function Level Notes

4 Analog input 1 0 to 10 VDC Pressure sensor for motor 1. The inputvoltage is converted to bar or psi and

1 5 Reference potential 0 VDC

voltage is converted to bar or si anddisplayed in the pressure display of themotor.

6 Supply voltage for external components + 24 VDC

motor.

2 Not in use - -

X 4 Not in use

X 5 Not in use

X 6 Not in use

Plug Connectors



CS04Issued 12/01

P/N 458374C

The motor module is used to trigger a frequency converter or a motorcontroller.

NOTE: When the system contains a piston pump, the motor module isomitted.

X3X1

F2

F1

X5 X4 S2

X2

R36

V27

V28

V29

V30

V31

S3

R8

S1

1 2 3 1 2 1 2 3 4

ON

123456

1 2

15 16

V26

V14 V9

V19

V24

4

C

MXCO027L075A0595

Fig. 33


F 1 Operating voltage for motor module electronics 1 AT P/N 285 957

F 2 Operating voltage for external components


V 9 Green Lit Input Motor overtemperature (X 2 / Pin 2) is active (active = no overtemperature)

V 14 Green Lit Input of initiator Actual speed display (X 1 / Pin 3) is active

V 19 Green Lit Input Release Motor (X 3 / Pin 2) is active (active = released)

V 24 – – –

V 26 Green Lit Output Release Motor (X 4 / Pin 3 and Pin 4) has switched



V 29 Yellow Lit A CAN bus command could not be sent. Check or replace: CAN bus cable, central module andmotor module.




5. Motor Module

Fuses

LED’s



CS04Issued 12/01

P/N 458374C

Switch Function

1 2 3 4 5 6

OFF OFF ON ON ON ON Channel number of the motor module (other channel numbers not permitted)

Drum melter without actual speed compiling Notes

Position Motor Do not set a higher number.

1 1 The remaining positions have no function

Open Analog output 0 to 20 mA (special function)

Closed Analog output 0 to 10 VDC (factory setting)

Used to align the motor speed (see Aligning the Motor Module).

No function.

X 2 Motor overtemperature


1 Switching voltage for motor overtemperature +24 VDC for externalcomponents

–

2 Input for motor overtemperature Optocoupler If the input is not connected to the + 24 VDC forexternal components, no motor overtemperaturewill be recognized.

X 3 Module release


1 Switching voltage for release input +24 VDC for externalcomponents

If the input is not connected to the + 24 VDC forexternal components, the fault frequencyconverter is recognized (Refer to separatemanual Frequency Converter of Series 8200

2 Input fault frequency converter Optocouplermanual Frequency Converter of Series 8200vector).

3 No function Relay output –

4

DIP Switch S 2

Selector Switch S 1

Switch S 3

Potentiometer R 8

Potentiometer R 36

Plug Connectors



CS04Issued 12/01

P/N 458374C

X 4 Converter control


1 Motor speed setpoint 0 VDC The analog output is potential-free.

0 V = 0 min-1 / 10 VDC = 100 min-1

2 0 to 10 V orDC

(S 3 closed)

0 to 20 mA 0 mA = 0 min-1 / 20 mA = 100 min-1

(S 3 open)

3 Release motor Relay output The relay switches when the motor is to rotate.Release is only activated if the system has not

4Release is only activated if the system has notrecognized any faults.

X 5 Analog input


1 Not in use 0 to 10 V

2 0 VDC

CAN Bus (Refer to Central Module with Digital Input/Output)



CS04Issued 12/01

P/N 458374C

The motor speed is aligned on the motor module.

NOTE: Alignment was carried out at the factory. Setting or alignment isonly necessary after replacement of modules/boards or if alignmentelements have been mistakenly adjusted.

NOTE: If the speed at which the motor is normally operated duringproduction (production speed) is known, the speed should not be alignedat 80 min-1 but at the production speed.

1. Set operating mode of the motor to manual mode (illuminated symbolmanual mode must be lit).

2. Note the set motor speed (manual mode).

3. Set motor speed to 80 min-1 or the production speed.

4. Switch on the motor.

5. Set the motor speed to 80 min-1 or to the production speed with thepotentiometer R8.

6. Set the motor speed back to the original value (step 2).

Aligning the Motor Module

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