eclipse series epc-30 pattern control -...

Eclipse Series EPC-30Pattern Control

Customer Product ManualPart 237 514D02

This equipment is regulated by the EuropeanUnion under WEEE Directive 2002/96/EC).

See www.nordson.com for information abouthow to properly dispose of this equipment.

NORDSON CORPORATION • DULUTH, GEORGIA • USAwww.nordson.com

� 2010 Nordson CorporationAll rights reserved

237514D02Issued 2/10

Nordson Corporation welcomes requests for information, comments and inquiries about its products.

Address all correspondence to

Nordson CorporationAttn: Customer Service11475 Lakefield Drive

Duluth, GA 30097

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1999. No part ofthis document may be photocopied, reproduced, or translated to another language without the prior written consent

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

Trademarks

AquaGuard, Blue Box, Control Coat, Equi=Bead, Excel 2000, FloMelt, FoamMelt, FoamMix, Helix, Hot Shot, HotStitch, Meltex, MicroSet, MultiScan, Nordson, the Nordson logo, OmniScan, Porous Coat, Posi-Stop, RBX,

Sure-Bond, UniScan, UpTime, and Versa-Spray are registered trademarks of Nordson Corporation.

BetterBookSM, CF, Controlled Fiberization, Easy-Screen, Fibermelt, Flo-Tracker, PrintGuard, Package of Values,PatternView, and Swirl Coat are trademarks of Nordson Corporation.

Windows is a registered trademark of Microsoft Corporation.

Table of Contents i


237514D02Issued 2/10

Table of Contents

1. Operate Safely 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Safety Symbols 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Qualified Personnel 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Intended Use 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Installation and Electrical Connections 1-4. . . . . . . . . . . . . . . . . . . . . . .

6. Operation 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Less-Obvious Dangers 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Action in the Event of Unit Malfunction 1-5. . . . . . . . . . . . . . . . . . . . .

Danger of Burns 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Maintenance/Repair 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Cleaning 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. Thermoplastic Hot Melt Material 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10. Equipment and Material Disposal 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Product Description 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Integrated Systems 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard System Components 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Control Unit 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Panel 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Trigger 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Supply 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gun 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Encoder 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Options 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I/O Board 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transducer 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Configurations 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Integral Operator Panel 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Operator Panel 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote PC Interface 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1Safety

Section 2System Overview

Table of Contentsii


237514D02Issued 2/10

4. System Capabilities 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup Capabilities 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Autoscaling 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fast Gun Setup 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick Pattern Definition 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Copy and Delete Functions 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . .

Operational Capabilities 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Online Pattern Adjustment 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Online Volume Adjustment 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Run-Permissive Function 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Other Operational Capabilities 2-12. . . . . . . . . . . . . . . . . . . . . . . .

Application Capabilities 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. System Specifications 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Main Parts of Panel 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Display 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windows 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Icons 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Words and Abbreviations 3-6. . . . . . . . . . . . . . . . . . . . . . . . .

4. Indicator Lights 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Keypad 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYSTEM SETTINGS Keys 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAM SETTINGS Keys 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Keys 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Navigation Keys 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Keypad Reference Chart 3-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Equipment Inspection 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. System Design 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting System Components 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . .

Finding the Best Range for Encoder Gearing Ratio 4-3. . . . . . . . . .

Locating System Components 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2System Overview (contd.)

Section 3Operator Panel Overview

Section 4Installation

Table of Contents iii


237514D02Issued 2/10

4. Equipment Mounting 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting the Main Control Unit 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting a Remote Operator Panel 4-12. . . . . . . . . . . . . . . . . . . . . .

Mounting the Encoder 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting a Trigger 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting a Transducer for Run-Up Control 4-15. . . . . . . . . . . . . . . .

Mounting a Power Supply 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Electrical Installation 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Terminal Block Cover 4-16. . . . . . . . . . . . . . . . . . . . . .

Connecting Inputs and Outputs to the Main Control Board 4-17. . .

Connecting Inputs and Outputs to the Optional I/O Board 4-26. . . .

Connecting Inputs to the Optional Remote Operator Panel 4-30. .

Connecting Power to the Power Supply 4-31. . . . . . . . . . . . . . . . . . .

6. Preparation for Setup 4-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Energy Sources from Equipment Attached to the Pat-tern Control 4-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting a Trigger 4-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Determining Trigger Polarity 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking for Correct Encoder Wiring 4-36. . . . . . . . . . . . . . . . . . . . .

Checking for Correct Gun Output Wiring 4-37. . . . . . . . . . . . . . . . . .

Checking for Correct I/O Board Wiring 4-37. . . . . . . . . . . . . . . . . . . .

Replacing the Terminal Block Cover 4-38. . . . . . . . . . . . . . . . . . . . . .

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

2. Basic System Setup 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Understanding Basic System Settings 5-2. . . . . . . . . . . . . . . . . . . . .

Password Feature 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Entering Basic System Settings 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Encoder Setup 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Understanding the Encoder Gearing Ratio 5-9. . . . . . . . . . . . . . . . .

Understanding Encoder-Setup Error Messages 5-10. . . . . . . . . . . .

Clear an Error Message 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Up the Encoder 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use the Product-Length Method 5-11. . . . . . . . . . . . . . . . . . . . . . .

Use the Line-Jog Method 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use the Constant-Line-Speed Method 5-15. . . . . . . . . . . . . . . . . .

To Use the User-Supplied Method 5-16. . . . . . . . . . . . . . . . . . . . .

Section 5System Setup

Table of Contentsiv


237514D02Issued 2/10

4. Gun Setup 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Understanding Gun Settings 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Entering Gun Settings 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measure Gun-to-Trigger Offset (GTO) Distances 5-20. . . . . . . .

Determine GTO Distances Using the Controller 5-21. . . . . . . . . .

Enter GTO Distances 5-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Enter Known Gun-Compensation Values 5-25. . . . . . . . . . . . . . .

Determine and Enter Gun-Compensation Values 5-26. . . . . . . .

Copy Gun Settings 5-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Record of System Settings 5-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Pattern Definition 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Understanding Pattern Control Terminology 6-2. . . . . . . . . . . . . . . .

Understanding Pattern Settings 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . .

Defining a Pattern Set 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using Quick Keys to Define Pattern Sets 6-8. . . . . . . . . . . . . . . . . . .

Delete a Bead 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Copy a Pattern 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Delete a Pattern 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Setup of Program Options 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Understanding Program Options Settings 6-13. . . . . . . . . . . . . . . . .

Stitched Bead Patterns 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dot Bead Patterns 6-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Modulated Bead Patterns 6-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Random-Length Bead Patterns 6-18. . . . . . . . . . . . . . . . . . . . . . . .

Changing Program Options Settings 6-19. . . . . . . . . . . . . . . . . . . . . .

Creating Custom Bead Patterns 6-19. . . . . . . . . . . . . . . . . . . . . . . . .

Removing Custom Bead Settings from a Pattern 6-22. . . . . . . . . . .

Creating Random-Length Bead Patterns 6-22. . . . . . . . . . . . . . . . . .

Copying Bead-Type Settings 6-23. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Setup of Run-Up Control 6-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Understanding Run-Up-Control Setup 6-25. . . . . . . . . . . . . . . . . . . .

Entering Run-Up-Control Settings 6-27. . . . . . . . . . . . . . . . . . . . . . . .

Copying Run-Up-Control Settings 6-29. . . . . . . . . . . . . . . . . . . . . . . .

Section 5System Setup (contd.)

Section 6Program Setup

Table of Contents v


237514D02Issued 2/10

5. Program Management 6-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Activating a Program 6-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing a Program 6-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Saving a Program 6-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Copying a Program 6-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overwriting a Program 6-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recording Program Settings 6-34. . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Record of Program Settings 6-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Safety in Operation 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Operating Procedures 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the System 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutting Down the System 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Purging the Guns 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Activating a Program 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Running a Program 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping a Program 7-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Making Online Pattern Adjustments 7-12. . . . . . . . . . . . . . . . . . . . . .

Making Online Volume Adjustments 7-14. . . . . . . . . . . . . . . . . . . . . .

Making Online Adjustments to Bead-Type Settings 7-17. . . . . . . . .

4. Monitoring Procedures 7-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Understanding Monitoring Options 7-20. . . . . . . . . . . . . . . . . . . . . . .

Monitoring System Operation 7-22. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resetting the Product Count to Zero 7-24. . . . . . . . . . . . . . . . . . . . . .

Monitoring Bead Volume 7-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Faults and Warnings 7-26. . . . . . . . . . . . . . . . . . . . . . . . . .

Clearing a Fault 7-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clearing a Warning 7-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Program or System Settings 7-30. . . . . . . . . . . . . . . . . . . .

5. Procedures for Remote Operation 7-31. . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping the System Remotely 7-31. . . . . . . . . . . . . . . . . . . . . . . . . .

Disabling the Unit Remotely 7-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switching Between Local and Remote Program Activation 7-32. . .

Recalling a Program 7-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 7Operation

Table of Contentsvi


237514D02Issued 2/10

Stopping a Program Remotely 7-35. . . . . . . . . . . . . . . . . . . . . . . . . . .

Monitoring System Operation Remotely 7-35. . . . . . . . . . . . . . . . . . .

Operating the System from a Personal Computer 7-36. . . . . . . . . .

1. Introduction 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Troubleshooting from Symptoms 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

READY Light Not Turning On 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

All Patterns Missing (All Guns Not Firing) 8-4. . . . . . . . . . . . . . . . . .

Single Pattern Missing (One Gun Not Firing) 8-6. . . . . . . . . . . . . . . .

All Patterns Missing on Some Products 8-8. . . . . . . . . . . . . . . . . . . .

One or More Beads Always Out of Position 8-9. . . . . . . . . . . . . . . . .

One or More Beads Sometimes Out of Position 8-11. . . . . . . . . . . .

One or More Beads Missing on Some Products 8-12. . . . . . . . . . . .

One or More Beads Too Short or Too Long 8-13. . . . . . . . . . . . . . . .

Bead Volume Too Low or Too High 8-14. . . . . . . . . . . . . . . . . . . . . . .

Pools of Adhesive Forming When Line Stops 8-15. . . . . . . . . . . . . .

Settings Not Saved 8-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Troubleshooting from Warning Codes 8-16. . . . . . . . . . . . . . . . . . . . . . .

4. Troubleshooting from Fault Log Codes 8-20. . . . . . . . . . . . . . . . . . . . . .

5. Troubleshooting Checks and Tests 8-21. . . . . . . . . . . . . . . . . . . . . . . . .

Checking Gun Power Draw 8-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Operation of a Single Gun 8-22. . . . . . . . . . . . . . . . . .

Checking Trigger Operation 8-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Gun Compensation 8-26. . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Troubleshooting Aides and Reference Materials 8-28. . . . . . . . . . . . . .

Fuse Information 8-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Voltages 8-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Block Diagram 8-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Input/Output Wiring Diagram 8-32. . . . . . . . . . . . . . . . . . .

1. Introduction 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Recommended Tools 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Service Parts 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 7Operation (contd.)

Section 8Troubleshooting

Section 9Service

Table of Contents vii


237514D02Issued 2/10

4. Other Parts 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a Part in the Pattern Control Unit 9-3. . . . . . . . . . . . . . . .

Main Control Unit Parts List (Unit with Integral Operator Panel) 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Control Unit Parts List (Unit with Remote Operator Panel) 9-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Control Board Assembly Parts List 9-10. . . . . . . . . . . . . . . . . .

Operator Panel Assembly Parts List 9-12. . . . . . . . . . . . . . . . . . . . . .

Remote Operator Panel Parts List 9-13. . . . . . . . . . . . . . . . . . . . . . . .

External Components Parts List 9-14. . . . . . . . . . . . . . . . . . . . . . . . .

5. Recommended Spare Parts 9-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Related Information 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AppendixTemplate for RemoteOperator Panel

Table of Contentsviii


237514D02Issued 2/10


Issued 11/94 A1EN−02−[XX−SAFE]−4

Section 1

Safety

Safety1-0


Issued 11/94A1EN−02−[XX−SAFE]−4

Safety 1-1



Section 1Safety

Safety instructions contained in this section and throughout thisdocument apply to tasks that may be performed with or on the unit.Warnings related to specific safety concerns are included within the textas appropriate. It is very important that these safety instructions arealways followed. Failure to do so could result in personal injury and/ordamage to the unit or other equipment.

With this in mind, here are some basic safety recommendations:

� Read and become familiar with this Safety section prior to installing,operating, maintaining, or repairing the unit.

� Read and follow the warnings which appear within the text and arerelated to specific tasks.

� Store this document within easy reach of personnel operating ormaintaining the unit.

� Wear personal protective equipment and clothing such as safetygoggles and gloves.

� Familiarize yourself with and follow all safety instructions prescribedby your company, general accident-prevention regulations, andgovernment safety regulations.

1. Operate Safely

Safety1-2



The following symbols are used to warn against dangers or possiblesources of danger. Become familiar with them! Failure to heed awarning could lead to personal injury and/or damage to the unit or otherequipment.

WARNING: Failure to observe may result in personal injury,death, or equipment damage.

WARNING: Risk of electrical shock. Failure to observe mayresult in personal injury, death, or equipment damage.

WARNING: Disconnect equipment from the line voltage.

WARNING: Hot! Risk of burns. Wear heat-protective clothing,safety goggles, and/or heat-protective gloves depending on thesymbols shown.

WARNING: Risk of explosion or fire. Fire, open flames, andsmoking prohibited.

WARNING: System or material pressurized. Relieve pressure.Failure to observe may result in serious burns.

CAUTION: Failure to observe may result in equipmentdamage.

CAUTION: Hot surface. Failure to observe may result inburns.

2. Safety Symbols

Safety 1-3



“Qualified personnel” is defined here as individuals who thoroughlyunderstand the equipment and its safe operation, maintenance, andrepair. Qualified personnel are physically capable of performing therequired tasks, familiar with all relevant safety rules and regulations, andhave been trained to safely install, operate, maintain, and/or repair theequipment. It is the responsibility of the company operating theequipment to see that its personnel meet these requirements.

The unit is designed and intended to be used only for the purposedescribed in the Description section. Uses not in accordance with thatsection or as described in this document are considered unintended usesand not in accordance with governing regulations.

WARNING: Use of this equipment in ways other thandescribed in this document may result in personal injury, death,or equipment damage.

The following actions of the owner or operator of the unit are some, butnot all, examples of unintended use which would permit Nordson to claimit is not responsible for personal injury or property damage arising fromsuch unintended use:

� Unapproved modifications or changes to the unit

� Failure to comply with the safety instructions

� Failure to comply with instructions concerning installation, use,operation, maintenance, or repair, or when these tasks are carried outby unqualified personnel

� Use of inappropriate or incompatible foreign materials or auxiliaryequipment

� Failure to observe workplace safety rules or regulations issued bygovernment authorities or safety councils

3. Qualified Personnel

4. Intended Use

Safety1-4



WARNING: Failure to follow the safety procedures can result ininjury or death.

� All electrical, pneumatic, gas, and hydraulic connections andinstallations of hot melt equipment may only be carried out byqualified personnel. Be sure to observe installation instructions forcomponents and accessories.

� Equipment must be properly grounded and fused according to itsrated current consumption (see ID plate).

� Cables which run outside the unit must regularly be checked for wearor damage.

� Power supply wire gauge and insulation must be sufficient to handlerated current consumption.

� Cables must never be squeezed or pinched. Do not locate cables orhoses in high traffic areas.

The unit should be operated by qualified personnel in accordance withthe instructions presented in this document.

WARNING: Failure to follow the safety procedures can result ininjury or death.

� Never allow the unit to be operated by personnel under the influenceof substances which reduce their reaction times, or who are not ableto operate the equipment for physical reasons.

� Prior to each start-up of the unit, check protection and warningdevices and make sure they are fully functional. Do not operate theunit if these devices are not functioning properly.

� When the removal of safety equipment is required for installation,maintenance, or repair of the unit, it must be re-connectedimmediately upon completion of the work.

� Prior to start-up of the unit, check to make sure all safety guards andsafety equipment are in place and functioning properly.

5. Installation and ElectricalConnections

6. Operation

Safety 1-5



� In a humid environment, only equipment featuring a correspondingclass of protection may be operated.

� Do not operate the unit in an explosive environment.

� Keep parts of the body or clothing away from rotating parts. Do notwear loose articles of clothing when operating or servicing units withrotating parts. Take off wrist watches, rings, necklaces, or similarpieces of jewelry and pin up or cover long hair before performing anywork on or with the unit.

� To carry out measurements on work pieces, switch off the unit andwait until it comes to a standstill.

� Never point hand guns or applicator nozzles at yourself or otherpersons.

WARNING: An operator or service technician working with theunit should be aware of less-obvious dangers that often cannotbe completely minimized at production sites:

� Exposed surfaces of the unit which cannot be practicallysafeguarded. They may be hot and take time to cool after the unithas been operating.

� The possibility that electrical potentials may remain in the unit afterthe unit was de-energized

� Hot melt material and vapors

� Hydraulically or pneumatically operated parts of the unit

� Parts winding something up or down which are not covered

If the unit malfunctions, switch it off immediately.

� Turn the circuit breaker or main power switch OFF.

� Have the unit repaired by qualified personnel only.

6. Operation (contd.)

Less-Obvious Dangers

Action in the Event of UnitMalfunction

Safety1-6



Contact with hot melt materials or hot areas of the unit may produce asevere skin burn.

WARNING: Hot! Risk of burns. Wear heat-protective clothing,safety goggles, and/or heat-protective gloves depending on thesymbols shown.

� Be extremely careful when using hot melt material. Even solidifiedmaterial may still be very hot.

� Always wear protective clothing which safely covers all exposed partsof the body.

In case of burns:

� Immediately cool affected skin areas using cold, clean water.

� Do not forcefully remove hot melt material from the skin.

� Immediately seek medical attention.

Allow only qualified personnel to perform the procedures described in thisdocument. When performing such tasks, wear protective clothing, andequipment.

WARNING: Even when the circuit breaker or main powerswitch is OFF, the unit is still electrically energized. Completethe following steps prior to maintenance or repair:

� Disconnect, lock out, and tag external power supply.

� To ensure the external power supply is disconnected, attempt tooperate the unit. If the unit does not energize, proceed withmaintenance or repair work.

� If the unit energizes, repeat the disconnect, lock out, and tagprocedure. Re-test the unit.

Danger of Burns

7. Maintenance/Repair

Safety 1-7



� Follow the specific instructions provided in this manual to relieve thesystem pressure in the entire unit.

� Secure pneumatically- or hydraulically-operated equipment againstuncontrolled movement.

� Only use parts which do not compromise the safety of the unit. Onlyuse genuine Nordson parts.

� Always use tools with insulated handles when removing or installingcomponents.

NOTE: Always refer to the material manufacturer’s Material Safety DataSheet (MSDS) or material information sheet before working with any ma-terial.

WARNING: Never clean any aluminum part or flush anysystem using halogenated hydrocarbon fluids. Examples ofcommon halogenated hydrocarbons are: dichloromethylene,1,1,1-trichloroethylene, and perchloroethylene. Halogenatedhydrocarbons may react violently with aluminum parts.

WARNING: Fire, open flame, and smoking are prohibited whencleaning fluids are used. Observe all explosion preventionregulations. Cleaning fluids may only be heated usingtemperature-controlled and explosion-protected heaters.

� Never use an open flame to clean the unit or components of the unit.

� Use only cleaning fluids designed or intended to be used with the hotmelt material being used in the unit. Never use paint fluids under anycircumstances.

� Note the flash point of the cleaning fluid used. Only use a controlledheating method to heat fluids.

� Ensure sufficient room ventilation to draw off generated vapors.Avoid prolonged breathing of vapors.

7. Maintenance/Repair (contd.)

8. Cleaning

Safety1-8



NOTE: Always refer to the material manufacturer’s Material Safety DataSheet (MSDS) or material information sheet before working with any hotmelt material.

� Ensure the work area is adequately ventilated.

� Do not exceed recommended processing temperatures. Doing socreates a danger to personnel due to decomposition of the material.

Dispose of equipment and materials used in operation and cleaningaccording to local regulations.

9. Thermoplastic Hot MeltMaterial

10.Equipment and MaterialDisposal


237514D02Issued 2/10

Section 2

System Overview

System Overview2-0


237514D02Issued 2/10

System Overview 2-1


237514D02Issued 2/10

Section 2System Overview

This section describes the Eclipse Series EPC-30 pattern control systemand its capabilities. The section is divided into four major parts:

� Product Description� Integrated Systems� System Capabilities� System Specifications

Refer to the glossary at the end of this manual for definitions of technicalterms referenced in this manual.

With its ability to continuously track line position to within one millimeter(or 0.1 inch), the EPC-30 can generate precise adhesive patterns atproduction speeds that reach 300 m/min (983 ft/min). It can receive inputfrom either one or two triggers, control four independent outputs, produceup to 24 beads per output, store as many as 50 programs, and createsolid, stitched, and other types of bead patterns.

5742007A

Fig. 2-1 The Eclipse Series EPC-30 Pattern Control

1. Introduction

2. Product Description

System Overview2-2


237514D02Issued 2/10

Create an integrated pattern control system for a specific application byselecting from the different components, options, and accessories thatmake up the Eclipse control. Refer to

� Standard System Components� System Options� System Configurations

5742005A

3

4

2

5

1

3

Fig. 2-2 Standard Components of the Eclipse Pattern Control System

1. Main control unit with integraloperator panel

2. Encoder (shown with a frictionwheel)

3. Trigger (photosensor) with reflector4. Gun and gun actuator

5. Power supply

3. Integrated Systems

System Overview 2-3


237514D02Issued 2/10

Standard components include:

� main control unit with an integral operator panel� one or two triggers� one or two external power supplies� guns and gun actuators for up to four outputs� encoder.

Main Control Unit

The main control unit consists of a main control board, a DC-converterboard, and a surrounding enclosure and base plate. When ordered, themain control unit also includes the panel and attached display board.When the optional remote operator panel is ordered, the main control unitcomes with an indicator panel instead of the operator panel. Bothversions of the main control unit mount on a standard DIN rail.

Operator Panel

The operator panel is used to set up, operate, and monitor the patterncontrol system. It is divided into the six basic areas shown in Figure 2-3.For more information about the operator panel, refer to Operator PanelOverview.

5742008A

CLIPSEE SPATTERN CONTROL SYSTEM

ERIES

1

2 345

6

2

Fig. 2-3 Main Parts of the Operator Panel

1. Liquid crystal display (LCD)2. Operating keys

3. Navigation keys4. PROGRAM SETTINGS keys

5. SYSTEM SETTINGS keys6. Indicator lights

Standard System Components

System Overview2-4


237514D02Issued 2/10

Trigger

A trigger, or photosensor, detects products as they move along theproduction line and also provides input to the pattern control. Forcomplex patterns or dual gluing applications, the EPC-30 can beequipped with two triggers. Nordson offers three different types oftriggers: a retroreflective photosensor, a retroreflective photosensor witha polarized lens, and a diffuse-reflective photosensor. The type of triggerto be used depends upon the reflectivity of the product being sensed andupon lighting conditions in the sensing area.

Power Supply

The Eclipse system requires an external power supply to convert AC toDC power. Nordson offers two different power supplies: a 2.5-amppower supply in an IP54 sealed enclosure and a 2.5-amp power supply inan unsealed enclosure. Both are autoranging units that can acceptpower from 90 to 135 VAC or from 175 to 264 VAC and convert it to aregulated 24 VDC.

The power supply must be sized to handle the total load of all guns plusthe load of the pattern control. For information on selecting a powersupply for the pattern control system, refer to System Design in theInstallation section.

Gun

The EPC-30 controller must include one or more adhesive-dispensingguns, up to four guns total. Use either pneumatic solenoid valves orelectric gun drivers with the EPC-30, depending upon systemrequirements.

Encoder

The EPC-30 pattern control requires an encoder for tracking line position.Two encoders are offered with the EPC-30 system, one with metricdimensions and one with U.S. Standard dimensions. Both encodersproduce 500 pulses per revolution (ppr) and have the ability to trackbackward as well as forward line movement.

System Overview 2-5


237514D02Issued 2/10

Expand the capabilities of the EPC-30 with optional equipment. Optionsinclude:

� an input/output (I/O) board� one or two transducers

5742009A

Fig. 2-4 EPC-30 Pattern Control with Optional I/O Board

I/O Board

An optional I/O board can be added to the EPC-30 for control of beadvolume based on input from an encoder, or to recall programs from aremote location. The I/O board can activate up to 15 different programsand control the output from one or two hot melt pumps. The patterncontrol’s two 4−20 mA outputs can be connected to two transducers tocontrol air supplied to two piston pumps. Or, the two 0−10 VDC outputscan be connected to two DC drives to control the output of two gearpumps. The I/O board is shown in Figure 2-4. The I/O board alsoprovides inputs for parent machine integration and output contacts forfaults and warnings.

Transducer

Two current-to-pressure (I/P) transducers are available for use inrun-up-control applications. One has an IP66 rating for waterwashconditions and the other has an IP54 rating.

System Options

System Overview2-6


237514D02Issued 2/10

The Eclipse pattern control is available in three different configurations tomeet different operating and production requirements.

Integral Operator Panel

The standard configuration combines the main controller and theoperator panel in the same housing. All control boards and the operatorinterface reside in a single enclosure.

Remote Operator Panel

EPC-30 pattern controls can be ordered with a separate operator panelthat is connected by a cable to the main control unit. The operator panelcan be mounted to the operator panel right at the production line close tothe application.

5742010A

1

23

Fig. 2-5 EPC-30 System with Remote Operator Panel

1. Main control panel with indicatorpanel

2. Customer enclosure with remoteoperator panel

3. Connecting cable

System Configurations

System Overview 2-7


237514D02Issued 2/10

Remote PC Interface

Each EPC-30 pattern control comes with a copy of PatternView�, aWindows®-based software program. PatternView can define patternsets, upload or download programs, operate the pattern control system,monitor real-time variables, manage project files, and generate reports.

PatternView makes it easy to enter system and program settings evenfrom remote locations. To transfer program files to the pattern control,simply link it to a remote computer by means of a Nordson-suppliedcable.

For more information about PatternView, contact a Nordsonrepresentative.

5742096A

3

1

2

Fig. 2-6 Using PatternView with the EPC-30 System

1. Pattern control 2. Connecting cable 3. Notebook computer withPatternView installed

System Overview2-8


237514D02Issued 2/10

The EPC-30 system incorporates some advanced features and newtechnology that facilitate the setup and operation of the system andprovide the ability to do special patterns or applications. This part ofSection 2 includes:

� Setup Capabilities� Operational Capabilities� Application Capabilities

Eclipse pattern control systems provide several new features that reducethe amount of time required to enter system and pattern settings:

� Autoscaling� Fast Gun Setup� Quick Pattern Definition� Copy and Delete Functions

The following paragraphs describe each of these features. For moreinformation, refer to System Setup and Program Setup.

Autoscaling

The EPC-30 provides several quick ways to set up the encoder,eliminating the need for lengthy calculations. Using the control’sautoscaling feature, any size encoder wheel or gear can be installed, andthe pattern control will determine the correct encoder gearing ratio. Forautoscaling, simply run product past the sensor and enter the length ofthe product. This gives the EPC-30 all the information it needs tocalculate the encoder gearing ratio. Another way to autoscale is to jogthe line, measure the distance it travels, and enter this distance into thecontrol. If line speed is known, select the line-speed method of setup andenter the speed. Select the method of autoscaling that is mostconvenient.

4. System Capabilities

Setup Capabilities

System Overview 2-9


237514D02Issued 2/10

Fast Gun Setup

Gun compensation is easy to determine with the EPC-30. To enter guncompensation values, enter the time required to allow for the electricaland mechanical delays in the opening and closing of each gun into thecontrol system. If gun compensation is already known, enter the gun-onand gun-off times in milliseconds. If gun compensation is not known,enter the distance by first producing a test pattern and then by measuringthe length needed to advance or move back the start and end points of abead.

The EPC-30 automatically calculates the correct gun-on and gun-offtimes from the distances entered, eliminating the need for a longtrial-and-error process.

Quick Pattern Definition

The EPC-30 pattern control defines patterns quickly. Measure the lengthof each bead and the distance from the leading edge of the product to thestart of the bead. Then, select the beads by gun number and beadnumber and enter the measurements in either millimeters or inches todefine patterns.

Figure 2-7 shows a typical bead (bead 2 from gun 1) and themeasurements required to define it:

� The bead offset (120 mm)� The bead length (30 mm)

As shown in Figure 2-7, enter these same bead measurements into thepattern control.

5742100A

120 mm

30 mm

Fig. 2-7 Entering the Bead Measurements for Bead Number 2

System Overview2-10


237514D02Issued 2/10

Copy and Delete Functions

The EPC-30 pattern control provides copy and delete functions to speedup the entry of patterns and other settings. Pressing the shift keyenables the top three navigation keys to perform various copy, paste, anddelete operations. This will

� copy the settings of one gun to another gun� copy a pattern from one gun to another gun� copy stitch settings from one gun to another gun� copy run-up settings (if the system is equipped for run-up control)� delete a bead� delete a pattern

The delete function is also used to remove latched warning messages,and to quickly change any setting to its minimum possible value.

5742011A

1

2 3 4

Fig. 2-8 Keys Used for Copy and Delete Functions

1. SHIFT key2. DELETE key

3. COPY key4. PASTE key

System Overview 2-11


237514D02Issued 2/10

The EPC-30 makes it easy to operate the pattern control system andkeep it running smoothly. It provides operators access to real-time dataabout system variables in order to make on-the-spot adjustments topatterns or bead volume when adjustments are needed. The differentoperational capabilities of the system are described in the followingparagraphs.

Online Pattern Adjustment

Online pattern adjustment permits fine-tuning of patterns as they aregenerated on the production line. For example, to increase the length ofa particular bead by two millimeters, select the appropriate gun numberand bead number, move to the bead-length window of the display, andpress the up key twice to add two millimeters. The change will take placewithin seconds on the production line. In addition, the program numberwill change to dashes to show that the active program has beenchanged. At any time, either return to the original program or overwritethe original program with the revised settings. Or, save both the originaland the revised program.

Online Volume Adjustment

Systems equipped with the optional I/O board can also adjust beadvolume online. To increase or decrease the amount of adhesive in apattern, select the transducer and use the up or down key to achieve thedesired result.

Run-Permissive Function

The run-permissive function of the EPC-30 provides a convenient way toreliably remove power from the control’s output circuits and to disable itsinput circuits. An open circuit on the run-permissive terminals(X7−14 and X7−15) removes power from the gun outputs and disablesthe trigger inputs. It also removes power from the optional run-up outputsand disables all of the I/O board inputs. In summary, an open circuitacross X7−14 and X7−15 causes all pattern control inputs and outputs togo to their de-energized state except for the encoder inputs and the twooutput contacts on the I/O board. To enable all inputs to the patterncontrol or to apply power sourced from the pattern control to its outputs,this circuit must be closed.

Operational Capabilities

System Overview2-12


237514D02Issued 2/10

Other Operational Capabilities

In addition to its pattern adjustment features, the EPC-30 has othercapabilities that facilitate operation. The following table explains the mostsignificant of these capabilities.

Table 2-1 Operational Capabilities of EPC-30 System

Purpose ofFeature/Capability

Feature/Capability Description of Feature/Capability

Facilitate startup orshutdown

Auto-start option Permits set up of the pattern control into run modeautomatically when turned on, eliminating the need for anoperator to press the RUN key

READY light Shows when the system is ready for operation. On unitswith the optional I/O board, this light can be used to showthat the hot melt system is ready.

PURGE key Purges air or char from the hot melt system while standingat the operator panel

Provide real-time dataabout system operation

Display of line speed Shows the current line speed on the display

Display of product count Shows the current product count on the display and resetsthe count to zero as needed

Display ofbead-volume-controloutput

On units with the optional run-up-control feature, shows thecurrent percentage output to one or two transducers ormotor drives

Assist in solving systemproblems

Jam-detect feature Receives a warning when a user-selected maximumdistance for product spacing is exceeded

Low-line-speed alarm Sets a low line speed at which the system will give awarning

Display of diagnosticcodes

Provides a warning or fault code number that indicates thecause of each warning and fault

The EPC-30 has the flexibility to handle a variety of applications andmeet different production requirements that can

� generate custom patterns� reduce adhesive usage� run the production line faster� reduce equipment costs by operating with fewer system components

The following table summarizes these capabilities. For detailedinformation, refer to the appropriate instructions in System Setup andProgram Setup.

Application Capabilities



237514D02Issued 2/10

Table 2-2 Application Capabilities of EPC-30 System

Capability/Feature

Purpose or Application EquipmentRequirements

Position-basedoperation

Helps to meet demanding high-performance requirements. Using aquadrature-type encoder to track line position, the EPC-30 can producecomplex patterns with high resolution at line speeds of up to 300 m/min(983 ft/min).

None

Random-lengthbead patterns

Generates continuous single-bead patterns on products of differing lengthwithout changing the program. Allows mixing of various short and longproducts on the production line where the EPC-30 automatically adjusts thelength of the pattern to fit each product. Permits margin setting at each endof the product where adhesive will not be applied.

None

Run-up control Produces a uniform bead volume even as line speed changes. Using inputfrom the encoder, the EPC-30 controls the output of one or two transducersor motor drives. A transducer controls the output of a piston pump while aDC-motor drive controls output of a gear pump.

I/O board andone or twotransducers ormotor drives

Stitched beadpatterns

Allows entry of a single setting for desired glue savings. Based upon thepercentage of glue savings entered, the control automatically determinesthe best stitch pattern that will provide the savings. Use the default intervalof 25 mm (1.0 in.), or set the control to produce some other interval. Turnthe stitch function on or off for any of the four guns as needed.

None

Modulated beadpatterns

Provides a nearly constant bead volume without using run-up equipment.When the production line slows down to a user-selected speed, the controlbegins dividing the beads into smaller, spaced sub-beads to prevent beadvolume from increasing. Turn the modulated bead feature on or off forindividual programs and for individual guns. When the highly precisevolume control that an I/O board and transducer provide is not arequirement, use the modulated bead mode to reduce the cost of thesystem. This feature can be used in systems with run-up control.

None

Dot beadpatterns

Produces patterns of constant-weight (constant-volume) adhesive dots thatare spaced apart by a user-determined distance. Control the dot weight byspecifying a gun-on time. Control the distance between dots by specifyingthe dot-interval distance. A constant dot weight and interval can beproduced over the entire range of line speed without using external run-upequipment.

None

Palletizing Provides programming for pallet stabilization. Enter the number ofconsecutive boxes to glue and the number of consecutive boxes to skip.Based upon this information, the EPC-30 will apply the stabilizing pattern toall but the top level of boxes on the pallet. Use one trigger for palletizingand the other one for case sealing, thereby taking care of two tasks with thesame pattern control.

None

Multiple patternprocessing

Permits installation of the sensor farther from the guns, spacing productscloser together, and faster line speed. Most pattern controls can track theposition of only one product at a time, so they must complete each patternbefore the next product is sensed. This requires installing the trigger asclose as possible to the guns or run at a slower speed. The EPC-30, on theother hand, is able to simultaneously track up to four products past thetrigger or, if a second trigger is installed, past both triggers.

None

System Overview2-14


237514D02Issued 2/10

The following table provides specifications for the pattern control systemas a whole and for individual components of the system.

Table 2-3 System Specifications

Description Specification Notes

Pattern control system

Maximum line speed 300 m/min (984 ft/min)

Pattern accuracy at maximum linespeed

±1 mm (0.1 in.) A

Minimum bead length 1 mm (0.1 in.) at low line speeds A

Minimum distance between beads 1 mm (0.1 in.) at low line speeds A

Maximum bead length 8.2 m (26.9 ft) @ 1 pulse/mm(25.4 pulses/in.)

Maximum beads per output 24

Program memory 50 programs

Minimum gun-to-trigger distance 2 mm (0.1 in.) B

Independent outputs for gun control 4

Independent trigger inputs 2

Enclosure ratings (except trigger orencoder)

IP54 (dust-protected, splash-resistant) C

Approvals UL, CE

Main control unit

Input voltage requirement 24 VDC (±25%)

Input current requirement 0.5 A plus gun output loads

Voltage/amperage per output 24 VDC/1.10 A D

Gun compensation range 0−200 ms

NOTE A: Based upon an encoder gearing ratio of 1 pulse/mm or greater and gun compensation of 30 ms or lessat constant line speed

B: Distance increase may be needed to allow for gun compensation or to produce random-length beadpatterns. For random-length bead patterns, the minimum gun-to-trigger distance is 10 mm (0.4 in.). Toknow the effect of gun compensation on the minimum gun-to-trigger distance, refer to the triggerlocation guidelines in Locating System Components in Installation.

C: Based upon the use of water-tight conduit fittings

D: The total current rating of all gun actuators (pneumatic solenoid valves or electric gun drivers) must notexceed the rating of the system power supply.

Continued on next page

5. System Specifications



237514D02Issued 2/10


Trigger

Required supply voltage/current 18−30 VDC/150 mA maximum

Output load current 20 mA

Type Retroreflective or diffuse-reflective

Output type NPN transistor

Enclosure rating IP54

Cable length 9.14 m (30 ft)

Encoder

Encoder type Quadrature

Resolution 500 pulses/revolution

Maximum frequency Up to 100 kHz

Output Differential line driver

Mounting Metric or U.S. Standard

Enclosure rating IP66

Cable length 9.14 m (30 ft)

Cable rating IP54 or IP66

EPS20 power supply E

Input voltage 100−240 VAC (universal input)

Input frequency 47−63 Hz

Maximum input current 1.2 A

Output voltage 24 VDC

Maximum output current 2.5 A

Operating temperature range 0 �C−60 �C (32 �F−140 �F)

NOTE E: Nordson offers two power supplies for use with the EPC-30: the PS40 and the EPS20 power supplies.The PS40 power supply has an IP54-rated enclosure (one that is dust and splash resistant) while theEPS20 power supply has an IP20-rated enclosure (one that prevents fingers from coming into contactwith the circuitry inside).


System Overview2-16


237514D02Issued 2/10

Table 2-3 System Specifications (contd.)


PS-40 power supply E

Input voltage 90−132/180−264 VAC (selectablerange)

Input frequency 47−63 Hz

Maximum input current 2.0 A

Output voltage 24 VDC

Maximum output current 2.5 A

Operating temperature range 0 �C−50 �C (32 �F−122 �F)

PC-interface software

Operating system(minimum requirement)

Windows 95

Cable length 3.6 m (12 ft) or 9.1 m (30 ft)

PC connector Standard serial 9-pin D connector

Optional I/O board

Independent pressure-control outputs 2

Output current/voltage of control outputs 4−20 mA/0−10 VDC

Program recall Up to 15 programs

Inputs (unit enable and unit disable) 2

Outputs (low line speed andfault/warning)

2

Optional transducer

Input current 4−20 mA

Output air pressure 13.8−620 kPa (2−90 psi) F

Supply air pressure At least 35 kPa (5 psi) abovemaximum output pressure

Optional remote operator panel

Cable length 3.6 m (12 ft) or 9.1 m (30 ft)

NOTE E: Nordson offers two power supplies for use with the EPC-30: the PS40 and the EPS20 power supplies.The PS40 power supply has an IP54-rated enclosure (one that is dust and splash resistant) while theEPS20 power supply has an IP20-rated enclosure (one that prevents fingers from coming into contactwith the circuitry inside).

F: A transducer with an extended range (21−1000 kPa or 3−145 psi) and an IP66 rating (waterwash) isalso available. Refer to External Components Parts List in the Service section.


237514D02Issued 2/10

Section 3

Operator Panel Overview

Operator Panel Overview3-0


237514D02Issued 2/10

Operator Panel Overview 3-1


237514D02Issued 2/10

Section 3Operator Panel Overview

This section explains how to use the operator panel and describes thedifferent functions of the keys, indicators, and display. The section isdivided into the following parts:

� Main Parts of Panel� Display� Indicator Lights� Keypad

For information on daily operation of the pattern control system, refer tothe Operation section.

The operator panel has three major parts: the display, the keypad, and agroup of three indicator lights. Each part is identified in Figure 3-1.

5742012A


ERIES

1

3

2

Fig. 3-1 Main Parts of the Operator Panel

1. Display 2. Indicator lights 3. Keypad

1. Introduction

2. Main Parts of Panel



237514D02Issued 2/10

The display is divided into six windows that provide the information for setup, operation, and monitoring of the pattern control system. Variouswords, abbreviations and icons are shown in the windows for clarity.

The windows of the display are designed to provide needed information.When the pattern-definition screen is on display, for example, theleft-most window shows the number of the active program. Figure 3-2shows how this information is presented on the display.

5742013A1 2 3 4 5 6

Fig. 3-2 Information Contained on Pattern-Definition Screen (typical valuesshown)

1. Program number2. Gun number3. Trigger number

4. Bead number5. Bead offset6. Bead length

The windows of the display also have other functions. The followingfigure and table identify each window and summarize their primaryfunctions.

NOTE: Flashing information in any window indicates that the window iscurrently selected and that the value or option that is flashing can bechanged unless the password is enabled. If the password is enabled,password-protected settings can be viewed but not changed.

3. Display

Windows



237514D02Issued 2/10

5742014A


ERIES

1 2 3 4 5 6

Fig. 3-3 The Six Windows of the Display

Table 3-1 Main Functions of Display Windows

WindowNumber inFigure 3-3

Main Functions of Window

1 � Shows the program number of the active program (when program-related information is onthe display)

� Shows that the active program has been modified by displaying two dashes (- -)

2 � Shows the number of the gun (1, 2, 3, or 4)� Shows the number of the run-up-control device (1 or 2) on units with run-up control

3 � Shows the trigger number (1 or 2)

4 � Shows the bead number (based on its position in the pattern) when the display containspattern-related information

� Shows the item number when an item from a numbered list is displayed in Window No. 5

5 � Shows words, or abbreviations of words, that describe the setting, data, or monitoring optionbeing displayed

� Shows the bead-offset distance when the display contains pattern-related information� Shows the leading-edge margin for setting up random-length patterns� Indicates faults and warnings with the words FAULT and WARN

6 � Shows the bead length when the display contains pattern-related information� Shows the current value of the setting or parameter displayed in Window No. 5� Shows the trailing-edge margin for setting up random-length patterns� Shows the fault or warning code number when a fault or warning is displayed



237514D02Issued 2/10

Icons are used on the display to help identify key information and to showthe status of important system settings. The following figure and tableshow each icon that can appear on the display and explain how it isused.

5742015A

1 2 3 4 5 6 7 8 9 10 11

1213 14 15 16

Fig. 3-4 Icons Used on the Display

Table 3-2 Explanation of Icons Used on the Display

Icon NumberinFigure 3-4

Name of Icon Type of Information Displayed in Window When Icon Appears

1 Program icon The program number

2 Run-up icon The number of the device (transducer or motor drive) used for run-upcontrol

3 Gun icon The gun number

4 Trigger icon The trigger number

5 Bead icon The bead number

6 Bead-offset icon The distance from the leading edge to the start of the bead. This icon isalso the leading-edge-margin icon when setting the length of margins forgenerating random-length beads.

7 Parameter/settingicon

A parameter or option that can be set or changed

8 Monitor icon(eye symbol used)

A monitoring option or one of the two read-only values (TRAVL orLPSPd) that can be displayed when depressing the GUN key.


Display Icons



237514D02Issued 2/10

Icon Numberin Figure 3-4

Name of Icon Type of Information Displayed in Window When Icon Appears

9 Bead-length icon The bead length of the currently selected bead

10 Value icon The current value or setting of a parameter or option

11 Trailing-edge-marginicon

The length of the trailing-edge margin when setting the margins forrandom-length beads

12 Sub-bead icon The gun number when the pattern generated by the gun is set togenerate a stitched, dot, or modulated bead

13 Encoder icon The encoder icon appears when a gun is set to produce a solid, stitched,dot or modulated bead.

14 Random-length icon The random-length icon appears when a gun is set to producerandom-length beads.

15 Palletizing icon The palletizing icon appears when one or both triggers in the activeprogram are set for palletizing.

16 Password icon The password icon appears when the password is currently enabledeither for the SYSTEM SETTINGS keys or for both the SYSTEMSETTINGS and the PROGRAM SETTINGS keys. Users without thepassword can view but not change the settings accessed bypassword-protected keys.



237514D02Issued 2/10

The following table provides an alphabetical list of all words andabbreviations that are used on the display. Refer to it as needed.

Table 3-3 Explanation of Display Words and AbbreviationsWord orAbbreviation

Meaning of Word orAbbreviation

Purpose of Word or Abbreviation

A1-A6 Autoscaling error code Appears when an error occurs in the encoder autoscaling process. The numberin the code indicates the type of autoscaling error that has occurred.

ACTIV Active Appears when the USE or SAVE key is pressed, and shows that the programnumber displayed is number of the active program

Add Add Appears briefly on the display when a new bead is added to a pattern

ALMSP Alarm speed Identifies the line-speed setting below which a warning will occur. See alsoMINSP.

ALL All Indicates that all guns have been selected (the default selection) for purging

AUTO Auto-start mode Identifies the auto-start option. Enable the auto-start feature or turn it off formanual startup.

bRITE Brightness Identifies the brightness-adjustment setting for the display

b-TYP Bead type Identifies the bead-type setting. Choose from five bead types: solid bead,stitched bead, dot bead, modulated bead, or random-length bead.

CNT/K Product count dividedby 1000 (K)

Identifies the product-count monitoring option

COPY Copy Appears briefly on the display when using the control’s copy function

dEFLT Default Appears when the USE key is pressed and the default program is selected(Program No. 00)

dELET Delete Appears briefly on the display when the delete function is used

dISAb Disable Identifies the monitoring option that shows the current status of the remote disablecontacts

EGEAR Encoder gearing ratio Used to identify the current value of the encoder gearing ratio

ENAbL Enable Identifies the monitoring option that shows the current status of the remote enableinput (on units with optional I/O board only)

ERROR Error Appears when an autoscaling error occurs during the encoder setup process

FAULT Fault Appears when any type of fault occurs

FLOG Fault log Used with a number from 1−9 to indicate the nine most recent faults. FLOG2, forexample, is the second most recent fault.

FREE Free Indicates that the next unused program number has been selected whilepreparing to save settings

GLUE Glue Identifies the setting for the number of consecutive products to glue when settingup the control for pallet-stabilization applications. Refer also to SKIP.

G-SAV Glue savings Identifies the setting for percentage glue savings when setting up a pattern forstitching

GTO Gun-to-trigger offset Identifies the setting for gun-to-trigger offset (the distance from the gun to itsassigned trigger)

GUN Gun Appears (with a number) when selecting a specific gun to purge

HAMR Hammer Purges gun at a 50 Kz cycle rate

INCFG Remote input Appears when user intends to program specific system functions from remotelocation

INTVL Interval Identifies the setting for the sub-bead interval (the distance between the start ofone sub-bead and the start of the next one) when setting up a gun to produce thestitch bead type, the dot bead type, or the modulated bead type

JOG Jog Identifies one of the methods of autoscaling options (the line-jog method) whensetting up the encoder


Display Words andAbbreviations



237514D02Issued 2/10

Word orAbbreviation

Meaning of Word orAbbreviation

Purpose of Word or Abbreviation

LATCH Latch Identifies the latching option for warnings.

LNGTH Length Appears when it is required to enter the length of product during theproduct-length method of autoscaling.

LOCKd Locked Indicates that the operator panel is locked and that system operation is beingcontrolled by PatternView, the Windows-based software program.

LPSPd Last-product speed Identifies the line speed measured by the controller when the first bead wasapplied to the last product. Use this measurement to set gun compensation whenline speed varies.

MINSP Minimum speed Identifies the line-speed setting below which pattern generation will stop. Seealso ALMSP.

OFF-d Gun-off compensation(distance units)

Identifies gun-off compensation setting in distance units.

OFF-T Gun-off compensation(time units)

Identifies gun-off compensation setting in time units.

ON-d Gun-on compensation(distance units)

Identifies gun-on compensation setting in distance units.

ON-T Gun-on compensation(time units)

Identifies gun-on compensation setting in time units.

OPSET Output contactssetting

Identifies the remote output contact configuration.

P1 and P2 Point 1 and Point 2 Identifies points 1 and 2 on the run-up curve. Enter a line speed and apercentage output for each of these two points.

PASSW Password Identifies the current password setting.

PASTE Paste Appears briefly on the display when pasting the copied settings.

PRESS Pressure Identifies the controller output percentage to the run-up-control device(a pressure transducer or a motor drive).

PROd Product Indicates one of the methods of autoscaling options (the product-length method)when setting up the encoder.

PURGE Purge Appears briefly on the display while performing the purge operation from thecontrol panel.

PW-LV Password Level Identifies the password-level setting.

RATE Rate Identifies the product rate (one of the monitoring options) at trigger 1 or 2.

REMOT Remote Identifies the on/off setting for recall of programs from a remote location.

RUN Run Appears on the display during encoder setup when running the production line isrequired.

RUNPR Run permissive Identifies the monitoring option that shows the current status of the run-permissiveinput to the control.

SKIP Skip Identifies the setting for the number of consecutive products to skip when settingup the control for pallet stabilization applications. Refer also to GLUE.

SPEEd Line speed Used in several ways:

� To indicate one of the methods of autoscaling (the line-speed method) whensetting up the encoder

� To indicate a selected line speed as the monitoring option

� To indicate the line speed that determines gun compensation

� To identify the line speeds at which the two run-up output settings areentered

� To indicate the setting for activating line speed when setting up a pattern forthe modulated bead type.




237514D02Issued 2/10

Table 3-3 Explanation of Display Words and Abbreviations (contd.)START Start Appears on the display during encoder setup when start-up of the production line

is required.

STOP Stop Appears on the display during encoder setup when stopping the production line isrequired.

TIME Gun-on time Identifies the setting for gun-on time when setting up a gun to produce a dot bead.

T-MAX Trigger maximumspacing

Identifies the setting for the maximum distance between trigger events, which isset to receive warnings of possible jams on the production line.

T-MEM Trigger memory Identifies the setting for applying or not applying adhesive to products betweenthe trigger and the gun when the line recovers from a minimum-speed-disablecondition.

T-MIN Trigger minimumspacing

Identifies the setting for the minimum distance between trigger events, which areset to reject false triggers from the package or product.

T-POL Trigger polarity Identifies the trigger polarity setting, information that the control needs for correcttrigger operation.

TRAVL Line travel Used in two ways:

� To indicate that entry of the amount of line travel during the line-jogmethod of encoder setup is required

� To identify a read-only value used to measure GTO distances(gun-to-trigger offset).

TRIG Trigger Used (sometimes with a number) to identify the trigger or a specifictrigger (1 or 2).

UNITS Units Identifies the setting for units of measurement (metric or English).

USEd Used Appears when a used program number has been selected when preparing tosave revised settings. Saving to a used program will overwrite the program withthe new settings.

USER User supplied Identifies the user-supplied method of encoder setup.

VER-C Version of controlboard software

Identifies the monitoring option that shows the current version of themain-control-board software.

VER-O Version ofoperator-panel displayboard software

Identifies the monitoring option that shows the current version of theoperator-panel software (located on the display board).

WAIT Wait Appears briefly on the display at startup, whenever a new program is activated,and whenever a new program is being downloaded from memory.

WARN Warning Appears whenever a warning occurs. For a complete list of warnings andwarning codes, refer to Troubleshooting from Fault and Warning Codes inTroubleshooting.

Display Words andAbbreviations (contd.)



237514D02Issued 2/10

The following figure and table identify the three indicator lights on theoperator panel and explain the function of each one.

5742016A

Fig. 3-5 Indicator Lights on Operator Panel

Table 3-4 Explanation of Indicator Lights

IndicatorLight

Meaning of Light (When Light Is On) Notes

READY light To show that all of the following conditions exist:

� No faults are present.� The unit disable switch (if installed) is not closed (units with optional I/O board

only).� The unit enable switch (if installed) is closed (units with optional I/O board only).� At least one of the four switches used for remote recall of programs is on when the

unit is set for remote recall (units with optional I/O board only).

A, B, C

REMOTElight

To show that program activation is being controlled remotely (units with optional I/Oboard only)

ALARM light To indicate a system fault when it turns on and remains on or to indicate a warningwhen it flashes

D

NOTE A: When the READY light is on, the control will generate patterns if the RUN light is also on and productsare passing through the pattern control system. If the READY light turns off, pattern generation will stopbut the RUN light will remain on (unless the run-permissive switch is open).

B: The unit-enable switch is typically used as an interlock that closes when the hot melt system is ready topump adhesive.

C: If all of the binary remote-recall switches are open, no program is selected and the READY light turnsoff.

D: The light flashes for 30 seconds for warnings and then stops if the problem causing the warning iscorrected. If the latching feature is turned on, however, the light will continue to flash until the warning iscleared (refer to Clearing a Warning in Operation). For faults, the light does not flash but turns on andremains on until the problem causing the fault is corrected and the fault is cleared.

4. Indicator Lights



237514D02Issued 2/10

The keypad has four different types of keys, which are grouped accordingto function:

� SYSTEM SETTINGS keys� PROGRAM SETTINGS keys� Operating keys� Navigation keys

The keys are color-coded. The gray SYSTEM SETTINGS andPROGRAM SETTINGS keys are used primarily for setup tasks while thewhite operating and navigation keys are used primarily for operatingtasks. Figure 3-6 identifies each type of key.

5742017A


ERIES

21 3 4

3

Fig. 3-6 Four Types of Keys on Operator Panel

1. SYSTEM SETTINGS keys2. PROGRAM SETTINGS keys

3. Operating keys 4. Navigation keys

5. Keypad



237514D02Issued 2/10

Each function key has a small indicator light that turns on when the key isactive. If a key is pressed when its light is off, the light turns on, whichindicates that the function (or functions) controlled by that key can nowbe performed. Likewise, if a key is pressed when its light is on, the lightturns off, indicating that the function (or functions) controlled by that keycan no longer be performed.

NOTE: SYSTEM SETTINGS keys and PROGRAM SETTINGS keys canbe password protected. When a key is password protected, userswithout the password can view but not change any setting accessed bythat key.

5742018A

Fig. 3-7 Activating the Purge Function by Pressing the PURGE key



237514D02Issued 2/10

SYSTEM SETTINGS keys are used to enter global settings that apply tothe whole pattern control system.

5742019A

Fig. 3-8 The SYSTEM SETTINGS Keys

Table 3-5 Explanation of SYSTEM SETTINGS Keys

Key Purpose

ENCODER key To set the encoder gearing ratio

GUN key To enter gun-compensation settings for the gunsin the system. Also to enter the gun-to-triggeroffset (GTO) for each gun and its assignedtrigger

SET UP key To enter various other global settings for thesystem. These settings include passwordprotection, units of measure, trigger polarity, andauto-start.

SYSTEM SETTINGS Keys



237514D02Issued 2/10

PROGRAM SETTINGS keys are used to

� customize pattern sets or enter other program-related settings

� save these settings to a specific program (identified by aprogram number)

Basic pattern settings such as bead placement and length can beentered without having to press a PROGRAM SETTINGS key. Anytimethe pattern-definition screen (see Figure 3-2) appears on the display, usethe navigation keys to define or revise a pattern set. For moreinformation, refer to Windows near the beginning of this section.

5742020A

Fig. 3-9 The PROGRAM SETTINGS Keys

Table 3-6 Explanation of PROGRAM SETTINGS Keys

Key Purpose

RUN UP key To enter volume-control settings for one or twotransducers or motor drives (units with optionalI/O board only)

OPTIONS key To customize a pattern with stitching or otherspecial bead types or enter other optionalprogram-related settings

SAVE key To save program settings to a new program or tooverwrite the settings of an existing program

PROGRAM SETTINGS Keys



237514D02Issued 2/10

The operating keys are used to perform the basic tasks of the patterncontrol system. The keypad includes five operating keys, which areidentified and explained in the following figure and table.

Each operating key has a light to show when the key’s function isturned on.

5742021A


ERIES

5 4

1

2

3

Fig. 3-10 Keys Used to Operate the Pattern Control System

Table 3-7 Explanation of Operator Keys

ItemNumber in

Figure3-10

Description Purpose

1 RUN key To start pattern generation (when a trigger signal is received) or to stop patterngeneration.

2 PURGE key To purge (actuate) all guns or to purge a single user-selected gun.

3 MONITOR key To set the display for monitoring the pattern control system. Display also varioustypes of system data, such as current line speed, and the codes for any warningsor faults that may occur.

4 SHIFT key To perform copy, paste, and delete functions provided by the top three navigationkeys. During operation, use the delete function to clear faults and latchedwarnings and to reset the product count to zero. During setup, use copy, paste,and delete functions to speed up programming tasks (see Note A).

5 USE key To activate a stored program prior to either running it or revising its settings.

NOTE A: The delete function can be used to set any value to its minimum setting. For example, if the currentsetting for the low-line-speed alarm (ALMSP) is 50 m/min and it is selected (flashing), change it to 0m/min by pressing the SHIFT key and then the DELETE key.

Operating Keys



237514D02Issued 2/10

The keypad has five navigation keys for easy selection of information toview or change. The following figure and table identify each navigationkey and explain how it works.

5742023A

321

4 5

Fig. 3-11 The Navigation Keys

Table 3-8 Explanation of Navigation Keys

Item No. inFigure 3-11

Name of Key Functions of Key

1 Left key � To move left from one window to another

2 Right key � To move right from one window to another

3 Up key � To increase the number or value shown in the display

� To scroll up through a list of possible selections

4 Down key � To decrease the number or value shown in the display

� To scroll down through a list of possible selections

5 ENTER key � To perform various tasks, such as purging a gun

� To move right from one window to another

� To display the next value to view or change

NOTE A: When the SHIFT key is used, the top three navigation keys can be used to delete, copy and pastefunctions.

Navigation Keys



237514D02Issued 2/10

5742106B

Gun Settings

ON-T

OFF-T

SPEEd

ON-d

OFF-d

Gun-on compensation in time units

Gun-off compensation in time units

Line speed for gun compensation

Gun-on compensation in distance units

Gun-off compensation in distance units

GTO Gun-to-trigger offset distance

Methods of Encoder Setup

JOG

SPEEd

USER

Line-jog method of autoscaling

Line-speed method of autoscaling

User-supplied encoder gearing ratio

PROd Product-length method of autoscaling

Gun Purging Options

GUN 1

GUN 2

GUN 3

GUN 4

Only gun 1

Only gun 2

Only gun 3

Only gun 4

ALL All guns

TRAVL Read-only valve of GTO

LPSPd Read-only valve of line speed

Basic System Settings

PASSW

UNITS

T-POL

T-MEM

REMOT

Password selection

Units of measure (English or metric)

Trigger polarity

Trigger memory

Remote program recall on/off

PW-LV Level of password protection

ALMSP

MINSP

LATCH

AUTO

bRITE

Low-line-speed warning

Minimum-line-speed setting

Latching on/off for warnings

Auto-start mode on/off

Display brightness adjustment

OPSET Output-contacts setting

(to shut off guns)

OPSET

INCFG Remote setting input

HAMR Gun purge at 50 Kz (use with dot−bead mode)

Fig. 3-12 Keypad Reference Chart (Part 1 of 2)

Keypad Reference Chart



237514D02Issued 2/10

5742107A

Program Option Settings

T-MAX

b-TYP

GLUE

Maximum distance between trigger events

Bead type (see NOTE)

Consecutive products glued when palletizing

T-MIN Minimum distance between trigger eventsMonitoring Selections

(2) RATE

(3) RATE

(4) CNT/K

(5) CNT/K

(6) VER-O

Product rate at trigger 1

Product rate at trigger 2

Product count divided by 1000 for trigger 1

Current version of display board firmware

(1) SPEEd Current line speed

(8) RUNPR

(9) ENAbL

(10) dISAb

(11) GLUE

(12) SKIP

Current setting of run-permissive input

Current status of remote enable input

Current status of unit disable input

Consecutive products glued for trigger 1

Consecutive products skipped for trigger 1

(7) VER-C Current version of main control

SKIP Consecutive products skipped when palletizing

NOTE: Additional settings not shown here are requiredwhen selecting stitch, dot or modulated beat type. Refer toUnderstanding Program Options Settings in ProgramSetup.

Run-up Settings

P1-PRESS

P2-SPEEd

LO-LIMIT

Percent output at point 1

Line speed for point 2 on run-up curve

Minimum percent output

P1-SPEEd Line speed for point 1 on run-up curve

HI-LIMIT Maximum percent output

PURGE Output for purging guns

(13) GLUE

(14) SKIP

WARN,FAULT,FLOG

Product count divided by 1000 for trigger 2

when palletizing

when palletizing

Consecutive products glued for trigger 2when palletizing

Consecutive products skipped for trigger 2when palletizing

Refer to Troubleshooting for a completelist of warnings, faults, and fault log codes.

board firmware

P2-PRESS Percent output at point 2

Fig. 3-13 Keypad Reference Chart (Part 2 of 2)



237514D02Issued 2/10


237514D02Issued 2/10

Section 4

Installation

Installation4-0


237514D02Issued 2/10

Installation 4-1


237514D02Issued 2/10

Section 4Installation

This section describes how to install the pattern control system. It isdivided into five major parts:

� Equipment Inspection� System Design� Equipment Mounting� Electrical Installation� Preparation for Setup

For instructions on setting up the equipment after installation, refer to thenext two sections, System Setup and Program Setup.

After unpacking the equipment, make the following checks:

1. Inspect the equipment for any damage that may have occurred duringshipping. Look for any dents and scratches and make sure allfasteners are tight. Report any damage to a Nordson representative.

2. Open the ship-with kit that comes with the main control unit. Thefollowing table shows the items in the kit.

Table 4-1 Contents of Ship-With Kit for Main Control Unit

Description Quantity Purpose

Low-profile DIN rail 1 To mount the main control unit

Rubber standoffs 2 To provide bumpers used with a high-profile DIN rail instead of thelow-profile DIN rail in the ship-with kit

Fuses 3 or 4 To provide a spare fuse for each fuse in the pattern control unit

Small screwdriver 1 To provide a screwdriver for the small screws used on the control’squick-disconnect terminal blocks

Terminal-block quickdisconnects

4 or 6 To connect external components to main control board and (if unitincludes optional I/O board) to I/O board

1. Introduction

2. Equipment Inspection

Installation4-2


237514D02Issued 2/10

3. Locate the Owner’s Record in the box and insert it in the Servicesection or in some other convenient place in this manual.

This part of Section 4 explains how to select the individual componentsfor the system, and to locate and install them so that they deliver the bestperformance. It contains the following procedures:

� Selecting System Components� Finding the Best Range for Encoder Gearing Ratio� Locating System Components

Use this procedure to determine the type and number of systemcomponents required to generate pattern sets.

1. Based upon the pattern sets required for an application, determinethe number of the following system components to be used:

� independently controlled guns� triggers

2. Make sure that the pattern control system can support all thecomponents needed to produce pattern sets. Refer toTable 4-2.

Table 4-2 Minimum and Maximum Number of Components for Pattern Control System

Component MinimumNumber

MaximumNumber

Explanation

Trigger 1 2 At least one trigger is required, and two can be used to generatemore complex pattern sets.

Gun 1 Seeexplanation.

The unit provides four individually controlled outputs for operatingeither pneumatic solenoid valves or electric gun drivers. The unitcan support gun loads of 1.10 amps per output. However, the totalgun load must not exceed what the power supply (or powersupplies) can support. See External power supply in this table.

Externalpower supply

1 2 If a single power supply is used, it must supply enough power tosupport the controller (0.5 amp) plus the total gun load, which canbe as high as 1.10 amps per output. If gun loading is high, use onepower supply to support guns 1 and 2 and use a second powersupply to support guns 3 and 4. Either provide a power supply orchoose from two power supplies that Nordson offers: the PS40power supply (2.5 amps) or the EPS20 power supply (2.5 amps).The EPS20 power supply must be mounted inside an electricalenclosure.

2. Equipment Inspection(contd.)

3. System Design

Selecting System Components

Installation 4-3


237514D02Issued 2/10

Use this procedure to determine the optimum range of encoder gearingratios. Once this range has been determined, install gearing that willoperate within the range. Exact determination of the gearing ratio is notrequired because the autoscaling feature of the pattern control does thisautomatically.

1. Start with the assumption that the encoder gearing ratio will be in therange of 1−20 pulses per millimeter (25.4−508 pulses/inch). For mostapplications, an encoder gearing ratio in this range will provide thecontrol’s rated accuracy of plus or minus I millimeter (0.1 inch) forbead placement and length.

NOTE: If the target range for the encoder gearing ratio is known,determine the approximate gearing to use on the production line. Thestandard encoder for the system produces 500 pulses/revolution. Forexample, an encoder gearing ratio of approximately 5−10 pulses permillimeter (127−254 pulses/inch) would require the encoder to begeared to about 50−100 mm (1.97−3.93 inches) of line travel causedone revolution of the encoder.

EXAMPLE: To calculate the line travel per revolution needed if theencoder resolution and the encoder gearing ratio are know, use thefollowing formula:

Line travel/revolution = encoder resolution ÷ encoder gearing ratio

For a 500-ppr encoder and a gearing ratio of 10/pulses per millimeter, theline travel would be 50 mm:

Line travel/revolution = 500 pulses/revolution ÷ 10 pulses/mmLine travel/revolution = 50 mm

Finding the Best Range forEncoder Gearing Ratio

Installation4-4


237514D02Issued 2/10

2. Make sure that the encoder gearing ratio to be used is not too high forproduction requirements. As the encoder gearing ratio increases, thelength of the beads that can be generated decreases, as does themaximum spacing between them, and the maximum distance fromgun to trigger. Refer to Table 4-3 to make this check.

Table 4-3 Effect of Encoder Gearing Ratio on Bead Length and Spacing

Encoder Gearing Ratio in Pulses/mm

(Pulses/Inch)

Maximum Distance From:� The Trigger to the First Bead (see Note A)� The Start of Any Bead to the End of the Same Bead� The End of Any Bead to the Start of the Next Bead

1 pulse/mm (25.4 pulses/inch) 8192 mm (322.5 in.)

2 pulses/mm (50.8 pulses/inch) 4096 mm (162.3 in.)

4 pulses/mm (102 pulses/inch) 2048 mm (80.6 in.)




NOTE A: Ensure that the proposed trigger location also meets the requirements specified in Tables 4-8 and 4-9.

Finding the Best Range forEncoder Gearing Ratio (contd.)

Installation 4-5


237514D02Issued 2/10

3. Make sure the encoder gearing ratio is high enough for productionrequirements. The combination of a low encoder gearing ratio andhigh gun compensation can cause variation in the placement ofbeads from one product to the next. Table 4-4 shows how muchvariation results from different gun compensations and encodergearing ratios.

Table 4-4 Effect of Encoder Gearing Ratio on Pattern Variation

GunCompensationin Milliseconds

Encoder Gearing Ratio in Pulses/mm (Pulses/Inch)

1 pulse/mm 2 pulse/mm 4 pulse/mm 8 pulse/mm 16 pulse/mm

5 0.13 mm

(0.0049 in.)

0.06 mm

(0.0025 in.)

0.03 mm

(0.0012 in.)

0.02 mm

(0.0006 in.)

0.01 mm

(0.0003 in.)

10 0.25 mm

(0.0098 in.)

0.13 mm

(0.0049 in.)

0.06 mm

(0.0025 in.)

0.03 mm

(0.0012 in.)

0.02 mm

(0.0006 in.)

20 0.50 mm

(0.020 in.)

0.25 mm

(0.0098 in.)

0.13 mm

(0.0049 in.)

0.06 mm

(0.0025 in.)

0.03 mm

(0.0012 in.)

50 1.25 mm

(0.049 in.)

0.63 mm

(0.025 in.)

0.31 mm

(0.012 in.)

0.16 mm

(0.006 in.)

0.08 mm

(0.0031 in.)

100 2.50 mm

(0.0984 in.)

1.25 mm

(0.0492 in.)

0.63 mm

(0.0248 in.)

0.31 mm

(0.0122 in.)

0.16 mm

(0.0063 in.)

150 3.75 mm

(0.148 in.)

1.875 mm

(0.074 in.)

0.938 mm

(0.037 in.)

0.469 mm

0.018 in.)

0.234 mm

(0.009 in.)

200 5.00 mm

(0.197 in.)

2.50 mm

(0.0984 in.)

1.25 mm

(0.0492 in.)

0.63 mm

(0.0248 in.)

0.31 mm

(0.0122 in.)

4. When using the dot-bead feature of the pattern control, use a highencoder gearing ratio in the range of 10−20 pulses/millimeter(254−508 pulses/inch), especially if small dots are required at linespeeds below 20 meters/minute (65 feet/minute).

Installation4-6


237514D02Issued 2/10

Use this procedure to choose locations for system components.

1. Select a location for the main control unit, using the recommendationsin the following table.

Table 4-5 Location Objectives for Main Control Unit

Objective Recommendation or Requirement

To facilitate operation Select a place where the display is easy to see and the keypad is easy to reach. Makesure that the operator has good access to the unit.

To protect unit fromwater and dust

Choose suitable place for IP54 enclosure (splash and dust resistant). Use water-tightconduit fittings to meet IP54 requirements.

To protect unit fromtemperature extremes

Select a place within operating temperature range of unit:

� 0−60 �C (32−140 �F) for the part of unit that is inside enclosure� 0−40 �C (32−104 �F) for the part of unit that is outside enclosure

To facilitate installation Choose location with reach of standard cable lengths:

� encoder: 9.1 m (30 ft)� trigger: 9.1 m (30 ft)

2. When using the optional remote operator panel, select a location forit. Use the recommendations in the following table.

Table 4-6 Location Objectives for Optional Remote Operator Panel


To facilitate operation Select a place where the display is easy to see and the keypad is easy to reach. Makesure that the operator has good access to the unit.

To protect unit fromtemperature extremes

Select a place within operating temperature range of unit:

� 0−60 �C (32−140 �F) for the part of unit that is inside enclosure� 0−40 �C (32−104 �F) for the part of unit that is outside enclosure

To facilitate installation Choose location within reach of standard or optional cable for connecting remote panelto main control unit:

� standard cable length: 3.6 m (12 ft)� optional cable length: 9.1 m (30 ft)

To provide sufficientspace in cabinet formounting panel

Make sure that the cabinet in which the operator panel is mounted has a depth of atleast 75 mm (3 in.). The panel is 230 mm (9.05 in.) wide X 103 mm (4.05 in.) high.

Locating System Components

Installation 4-7


237514D02Issued 2/10

3. Select a location for the encoder, using the recommendationsprovided in the following table as a guide.

Table 4-7 Location Objectives for Encoder


To ensure good encoderperformance

Choose a protected location where the encoder can be securely mounted withminimum vibration.

To protect encoder fromwater and dust

Choose a suitable place for the IP66 (water wash) encoder enclosure. Theencoder cable is either IP66 (water-wash) or IP54 (splash and dust resistant),depending upon which cable is used.

4. Select a location for the trigger (or the two triggers) in the system,using the recommendations in Tables 4-8 and 4-9.

Table 4-8 Location Objectives for Trigger


To protect trigger from waterand dust

Choose a suitable place for the IP54 enclosure (splash and dust resistant).

To ensure good productsensing

Make sure that the distance between the trigger lens and the target is withinrecommended range:

� Diffuse reflective (proximity) type: 51−381 mm (2.0−15 in.)� Retroreflective type (polarized lens): 51−2130 mm (2−84 in.)� Retroreflective type (non-polarized lens): 51−4500 mm (2−180 in.)

To avoid exceeding thecontroller queuing capability

Choose a location that will not permit more than four products between the triggerand the guns at any time.

To ensure proper operation ofpattern control system

Make sure that the distance between the trigger and the first bead for each gun isno greater than the distance specified in Table 4-3. The minimum allowabledistance is 2 mm (0.1 in.), but sufficient spacing for the control must be providedto accomplish gun compensation. Refer to Table 4-9 to determine the minimumallowable distance between the gun and the trigger (GTO) for various line speedsand gun compensation values.

Installation4-8


237514D02Issued 2/10

Table 4-9 Minimum Allowable Gun-To-Trigger Distances in Millimeters (Inches)

Line Speed in Meters/Minute (Feet/Minute)

GunCompensationin Milliseconds

50 m/min

(164 ft/min)

100 m/min

(328 ft/min)

200 m/min

(656 ft/min)

300 m/min

(984 ft/min)

0 2.0 mm

(0.08 in.)

2.0 mm

(0.08 in.)

2.0 mm

(0.08 in.)

2.0 mm

(0.08 in.)

5 4.2 mm(0.16 in.)

8.3 mm

(0.33 in.)

16.7 mm

(0.66 in.)

25.0 mm

(0.98 in.)

10 8.3 mm

(0.33 in.)

16.7 mm

(0.66 in.)

33.3 mm

(1.32 in.)

50.0 mm

(1.97 in.)

20 16.7 mm

(0.66 in.)

33.3 mm

(1.32 in.)

66.7 mm

(2.62 in.)

100.0 mm

(3.94 in.)

50 41.7 mm

(1.61 in.)

83.3 mm

(3.28 in.)

166.7 mm

(6.56 in.)

250.0 mm

(9.84 in.)

NOTE : When generating random-length patterns on products, allow at least 10 mm (0.4 in.) between the triggerand each gun.

5. Select a location for the power supply (or power supplies), using therecommendations provided in the following table as a guide.

Table 4-10 Location Objectives for Power Supply


To protect power supply fromwater and dust

Choose a suitable place based upon the rating of the power supply enclosure:

� PS40 power supply: IP54 (splash and dust resistant)� EPS20 power supply: IP20 (see Note A).

To facilitate operation If the PS40 power supply is used, choose location where the power switch is easyto reach. If the Phoenix power supply is used, make sure that the plant circuitbreaker for the system is easy to reach.

NOTE A: IP20 protects against fingers touching the circuitry inside the enclosure.

Installation 4-9


237514D02Issued 2/10

This part of Section 4 describes how to mount the different componentsof a pattern control system. It includes the following procedures:

� Mounting the Main Control Unit� Mounting a Remote Operator Panel� Mounting the Encoder� Mounting a Trigger� Mounting a Transducer for Run-Up Control� Mounting a Power Supply

For instructions on mounting guns and gun actuators, refer to the productmanual (or manuals) supplied with this equipment.

Use this procedure to mount the main control unit. The procedureapplies to either of the two basic configurations of the pattern controlsystem:

� a main control unit with an integral operator panel� a main control unit with a remote operator panel

Figure 4-1 shows both configurations of the pattern control. Theremaining figures in this procedure show only the control with an integraloperator panel.

5742027A

1 2

Fig. 4-1 Main Control Unit

1. Unit with integral operator panel 2. Unit with remote operator panel

4. Equipment Mounting

Mounting the Main Control Unit

Installation4-10


237514D02Issued 2/10

1. Select a location for the main control unit. For location requirementsand recommendations, refer to Locating System Components in thissection. In addition, provide sufficient space to mount the unit andsufficient clearances to operate and service it. Figure 4-2 shows thedimensions of the unit.

5742028A

246 mm(9.7 in.)

272 mm(10.7 in.)

94 mm(3.7 in.)

41 mm(1.6 in.)

Fig. 4-2 Dimensions of Main Control Unit

2. Mount a 35-mm DIN rail in the selected location. Use the low-profile(7.5-mm depth) DIN rail provided in the ship-with kit or use ahigh-profile (15-mm depth) DIN rail.

NOTE: If using a high-profile DIN rail, use the larger rubber standoffssupplied in the ship-with kit in order to mount the unit so that it isperfectly level on the DIN rail. To install the larger rubber standoffs,remove the two small standoffs and replace them with the largerones.

Mounting the Main ControlUnit (contd.)

Installation 4-11


237514D02Issued 2/10

5742029A

Fig. 4-3 Mounting the Main Control Unit on a DIN Rail

3. Hook the top of the two mounting clips on the back of the unit overthe top of the DIN rail.

4. Slide the unit left or right on the rail as desired to adjust its location.

5. Push the unit flat against the DIN rail to secure the mounting clips.

Installation4-12


237514D02Issued 2/10

If the system has the optional remote operator panel, use this procedureto mount it on the cabinet door of the remote operator station.

1. Open the ship-with kit that came with the remote operator panel andverify that it contains the following items. Some of them may beneeded to mount the unit and some to make wiring connections in alater procedure.

Table 4-11 Contents of Ship-With Kit for Remote Operator Panel

Description Quantity Purpose

Nuts with external washers 6 To mount the unit to the remote operator station

Fuse 1 To provide an extra fuse for the DC-converter board

Small screwdriver 1 To provide a screwdriver of the correct size for installing wiring atthe quick-disconnect terminal block

Terminal block quickdisconnect

1 To connect 24 VDC power to the remote operator panel

Cable 1 To connect remote operator panel to the main control unit

2. Choose a location for the remote operator panel. Refer to LocatingSystem Components in this section for location requirements andguidelines.

5742030A1 2

Fig. 4-4 Required Cutting and Drilling for Remote Operator Panel(not to scale)

1. Mounting hole 2. Cutout area for panel

Mounting a Remote OperatorPanel

Installation 4-13


237514D02Issued 2/10

3. Drill the six holes shown in Figure 4-4. The holes should be 5.2 mm(0.203 inch) in diameter.

4. Cut out the area for the panel shown in Figure 4-4.

5. Using the six nuts from the ship-with kit, mount the remote operatorpanel in the cabinet.

NOTE: A template for these modifications is provided in the appendix tothis manual.

Use this general procedure to mount the encoder on the production line.The specific procedure will vary according to the method of installation.Gear the encoder to the production line in any of the following threeways:

� friction wheel mounted on a spring-loaded bracket� flexible coupling� timing belt

1. Select a location for the encoder. For location requirements andrecommendations, refer to Locating System Components in thissection.

2. Mount the encoder. Refer to the Figure 4-5 for the mounting-holepatterns for both encoders: one with the metric dimensions and onewith U. S. Standard dimensions.

NOTE: Mount the encoder so that the shaft will turn clockwise (facingthe encoder shaft).

5742101A

0.22 in.diameter

2.064 in.

2.064 in.

48 mm

M3 x 5 mm deep

Fig. 4-5 Mounting Patterns for Encoder with Metric and U. S. StandardDimensions

Mounting the Encoder

Installation4-14


237514D02Issued 2/10

3. Make the appropriate linkage between the encoder shaft and theparent machine. The metric encoder has a shaft that is 10 mm indiameter while the English shaft has a diameter of 3/8 inch.

NOTE: Be sure any coupling or wheel used fits the encoder shaft. Ifa coupling is used, align it with the shaft before tightening it. Thentest the coupling or wheel for smooth rotation.

4. Connect the encoder cable to the encoder.

Use this general procedure to mount the trigger (or triggers, if a secondtrigger is used). The specific procedure will vary according to the type oftrigger to be installed. Any of the following types of photosensors can beused as a trigger:

� a retroreflective sensor (with standard lens)� a retroreflective sensor (with polarized lens)� a diffuse reflective (proximity) sensor� a limit switch

1. Select a location for the trigger. For location requirements andrecommendations, refer to Locating System Components in thissection.

2. Mount the trigger either with the adjustable mounting bracket or withthe mounting nut provided with the trigger. Refer to Figure 4-6 for themounting pattern for the bracket or for the hole size required to usethe mounting nut.

5742102A

20 mm(0.80 in.)

18 mm(0.71 in.)

Fig. 4-6 Mounting Information for Nordson Triggers

Mounting the Encoder (contd.)

Mounting a Trigger

Installation 4-15


237514D02Issued 2/10

3. If the trigger is a retroreflective type, mount the reflector on the otherside of the production line. For best performance, align the sensorand reflector so they are at a slight angle to the product(approximately 70� or 110�) instead of perpendicular to the product(at a 90� angle).

4. Make all fasteners tight. Excessive vibration can cause loss ofalignment or false signals.

5. Repeat this procedure to mount a second trigger.

To use run-up-control capability (if a unit includes the optional I/O board),refer to the instruction sheet shipped with the transducer kit to

� select a location for the transducer

� mount the transducer

� connect an air supply to the input air port of the transducer

� route an air line from the output port of the transducer to pump tobe controlled.

One or two transducers can be connected to the pattern control.

Use this general procedure to mount the external power supply (orsupplies, if a second power supply is used). The specific procedure willvary according to the power supply used. Nordson offers two powersupplies:

� the PS40 power supply� the EPS20 power supply

1. Select a location for the power supply. For location requirements andrecommendations, refer to Locating System Components in thissection.

2. Mount the power supply.

3. If using a second power supply, repeat this procedure.

Mounting a Transducer forRun-Up Control

Mounting a Power Supply

Installation4-16


237514D02Issued 2/10

This part of Section 4 describes how to make all the electricalconnections for the pattern control system, including options. It containsthe following procedures:

� Removing the Terminal Block Cover� Connecting Inputs and Outputs to the Main Control Board� Connecting Inputs and Outputs to the Optional I/O Board� Connecting Inputs to the Remote Operator Panel� Connecting Power to the Power Supply

WARNING: Remove input power from the pattern control priorto performing any service to any part of the glue applicationsystem. Failure to do so can cause the opening of a connectedgun or the applying of high pressure to a connectedrun-up-control system. The result can cause severe personalinjury.

Use this procedure to remove the terminal block cover from the maincontrol unit.

WARNING: Remove input power from the pattern control priorto removing the terminal block cover. Failure to do so cancause the opening of a connected gun or the applying of highpressure to a connected run-up-control system. The result cancause severe equipment damage or personal injury.

1. Remove the three screws that secure the terminal block cover to theunit.

2. Pull the terminal block cover down about 25 mm (1 inch) to disengageits tabs from the unit and remove it from the main control unit.

5. Electrical Installation

Removing the Terminal BlockCover

Installation 4-17


237514D02Issued 2/10

5742061A

Fig. 4-7 Removing the Terminal Block Cover

Use this procedure to connect all external wiring and cabling to themain-control-board terminal blocks.

1. Route all wires and cables from the external components to the maincontrol unit. This includes the following:

� one encoder cable

� wiring from one trigger

� wiring from a second trigger (if used)

� wiring from gun actuators (pneumatic or electric) to 1−4 gunoutputs

� wiring from one power supply

� wiring from a second power supply (if used)

� wiring from a run-permissive switch (if used)

� a ground wire

Connecting Inputs andOutputs to the Main ControlBoard

Installation4-18


237514D02Issued 2/10

WARNING: Risk of electrical shock. The base-panel groundlug must be connected to a reliable earth ground. Failure to doso can result in severe personal injury.

CAUTION: Do not connect any AC lines to the unit or any DClines that exceed 30 VDC. The pattern control unit is designedfor 18−30 VDC inputs, outputs, and contact closures. Turningthe unit on with too much voltage applied can blow fuses ordamage circuit boards.

CAUTION: Do not reverse the two wires that supply power tothe unit at positions 9 and 10 on terminal block X7. Reversingthe voltage to the unit can blow fuses and damage circuitboards.

NOTE: The maximum wire size that can connect to the terminalblocks on the main control board is 1.5 mm2 (16 AWG).

2. Clip (or tape back) the green current-sourcing output (PNP) wire onthe trigger cable.

NOTE: Only current-sinking (NPN) sensor outputs can be used withthis pattern control.

3. Refer to the wiring diagrams in Figures 4-11 and 4-12 and determinethe connections needed between the external components and thetwo main terminal blocks (X7 and X8) on the main control board.Note that some connections are optional and depend on how muchexternal equipment is being installed at this time.

4. Remove the terminal block cover. Refer as needed to the previousprocedure, Removing the Terminal Block Cover.

5. Locate the four conduit holes in the conduit plate at the bottom of thecontrol enclosure. Decide which of these holes to use to connectexternal wiring to the main control board.

Connecting Inputs andOutputs to the Main ControlBoard (contd.)

Installation 4-19


237514D02Issued 2/10

6. Remove the dust plugs from these conduit holes.

7. Install a grommet or conduit fitting in each hole to be used. Tomaintain the IP54 rating of the enclosure, the fitting must meetdust-tight, water-spray requirements. The 22.5-mm (0.886-in.) holesrequire PG16 (0.5-in. trade size) grommets or fittings.

5742062A

Fig. 4-8 Installing a Conduit Fitting at access Hole for Wiring

8. Route the wiring through the conduit fittings and conduit holes.

9. Locate the small screwdriver and the four quick-disconnect terminalblocks in the ship-with kit. The two 8-position terminal blocks are thetop and bottom parts of X7 and the two 7-position terminal blocks arethe top and bottom parts of X8.

Installation4-20


237514D02Issued 2/10

CAUTION: Do not plug the quick disconnects into their baseson the main control board until completing the wiringconnections. Connecting wiring with the quick disconnectsinstalled may damage the circuit board.

10. Connect the wiring to the quick-disconnects before plugging them intotheir bases on the terminal-blocks.

� For connections at X7, refer to Figure 4-12 and Table 4-14.� For connections at X8, refer to Figure 4-11 and Table 4-13.

NOTE: Remove the conduit plate to provide additional working room.

NOTE: Be sure the wires are securely installed between the metalclip and the metal block.

11. Plug the four quick-disconnects into their bases on the main controlboard. Each quick-disconnect is keyed so that it cannot be insertedin the wrong base.

5742063A

Fig. 4-9 Connecting Wiring to Quick-Disconnect Terminal Blocks

12. Route a ground wire from the ground lug below terminal block X7 to ametal support nearby. Installing this ground will provide maximumimmunity from electrical noise.


Installation 4-21


237514D02Issued 2/10

13. Check to see that the terminator plug is present in the X4 connectoras shown in Figure 4-10. If not, look in the ship-with kit for theterminator plug and insert into the connector.

NOTE: Incorrect connection or missing terminator plug will cause a“WARN 65” fault message.

5742064A

X4

Fig. 4-10 Installing Terminator Plug in Connector X4 on Main Control Board

14. If the unit is equipped with any of the optional equipment shown in thefollowing table, go to the appropriate procedure (or procedures) toconnect the wiring or cables for this equipment. If not, go to theprocedure Connecting Power to the Power Supply.

Table 4-12 Procedures to Use for Connecting Optional Equipment

Option Title of Wiring Procedure

I/O Board Connecting Inputs and Outputs to the Optional I/O Board

Remote Operator Panel Connecting Inputs to the Optional Remote Operator Panel

Installation4-22


237514D02Issued 2/10

5742068A

X8TOP

X8BOTTOM

BOARDCIRCUITS

CUSTOMERWIRING

Fig. 4-11 Wiring Diagram for Main-Control-Board Terminal Block X8

NOTE: When making the connections for the encoder, always connect inthis order: #6, #1−#5, then #7.


Installation 4-23


237514D02Issued 2/10

Table 4-13 Wiring Instructions for Main-Control-Board Terminal Block X8

TerminalBlock

Position

Wire Label/Color Installation Comment SeeNote

X8-1 Power +V (red) Connect encoder wire according to label on wire.

X8-2 Signal A (brown) Connect encoder wire according to label on wire.

X8-3 Signal A-not(brown/white)

Connect encoder wire according to label on wire.

X8-4 Signal B (orange) Connect encoder wire according to label on wire.

X8-5 Signal B-not

(orange/white)

Connect encoder wire according to label on wire.

X8-6 Common (black) Connect encoder wire according to label on wire.

X8-7 Shield

(black/white)

Connect both the encoder shield and the trigger shield (or shields ifa second trigger is used).

X8-8 Red Connect power wire from trigger 1. If second trigger is used,connect both trigger power wires to this terminal. If a through-beamtype of sensor is used, connect the power wires from both theemitter and receiver to this terminal. If a limit switch is used, do notconnect any wire to this position.

A

X8-9 White Connect current-sinking output wire from trigger 1. B

X8-10 Black Connect common wire from trigger 1. If a through-beam sensor isused, connect the common wire from the emitter to this terminalalso.

X8-11 White Connect current-sinking output wire from trigger 2 (if used). B

X8-12 Black Connect common wire from trigger 2 (if used). If a through-beamsensor is used, connect the common wire from the emitter to thisterminal also.

X8-13 Unused terminal block position

X8-14 Unused terminal block position

NOTE A: A mechanical limit switch can also be used as a trigger. For trigger 1, connect the limit switch wires toX8−9 and X8−10. For trigger 2 (if used), connect the limit switch wires to X8−11 and X8−12.

B: Clip off (or tape back) the sourcing output wire (the green wire).

Installation4-24


237514D02Issued 2/10

5742097A

X7TOP

X7BOTTOM

1.10 AMPS EACHMAXIMUM

BOARDCIRCUITS

CUSTOMERWIRING

Fig. 4-12 Wiring Diagram for Main-Control-Board Terminal Block X7


Installation 4-25


237514D02Issued 2/10

Table 4-14 Wiring Instructions for Main-Control-Board Terminal Block X7

Terminal BlockPosition

Wire Label/Color Installation Comment SeeNote

X7-1 Various Connect first lead wire from gun actuator for gun 1. A

X7-2 Various Connect second lead wire from gun actuator for gun 1. A







X7-9 Connect wire from power supply for 24 VDC power.

X7-10 Connect wire from power supply for 24 VDC common.

X7-11 Remove jumper if second 24 VDC power supply is required.

X7-12 Connect 24 VDC power wire from second power supply(if required).

X7-13 Connect 24 VDC common wire from second power supply.

X7-14 Remove jumper and connect first wire from a normally closedrun-permissive switch (if used).

X7-15 Connect second wire from run-permissive switch.

X7-16 Unused earth ground connection

NOTE A: The leads from gun actuators (pneumatic or electric types) are usually not polarity sensitive. Whenconnecting polarity-sensitive actuators, positions 1, 3, 5, and 7 of X7 are the more positive sides of theconnection.

Installation4-26


237514D02Issued 2/10

Use this procedure to connect wiring from remote I/O devices and fromone or two run-up-control transducers to terminal block X1 on the I/Oboard.

1. Route all wires and cables to the main control unit from all of theexternal I/O devices and run-up transducers to be installed.

CAUTION: Do not connect any AC lines to the unit or any DClines that exceed 30 VDC. The pattern control unit is designedfor 18−30 VDC inputs, outputs, and contact closures. Turningthe unit on with too much voltage applied can blow fuses ordamage circuit boards.

NOTE: The maximum wire size to connect to the terminal blocks onthe I/O board is 1.5 mm2 (16 AWG).

2. Locate terminal block X1 on the I/O board.

5742067A

Fig. 4-13 Location of Terminal Block X1 on I/O Board

3. Refer to the wiring diagram in Figure 4-14 to determine whichconnections are needed between external components and terminalblock X1 on the I/O board. The number of connections depends onhow much external equipment is installed at this time.

4. Locate the four conduit holes in the conduit plate at the bottom of thecontrol enclosure. Decide which unused conduit hole (or holes) touse for connecting external wiring to the I/O board.

Connecting Inputs andOutputs to the Optional I/OBoard

Installation 4-27


237514D02Issued 2/10

5. Remove the dust plug from each conduit hole to be used.

6. Install a grommet or conduit fitting in each hole to be used. Tomaintain the IP54 rating of the enclosure, the fitting must meetdust-tight, water-spray requirements. The 22.5-mm (0.886-in.) holesrequire PG16 grommets or fittings.

7. Route the wiring through the conduit fittings and conduit holes.

8. Locate the small screwdriver and the two quick-disconnects forterminal block X1 in the ship-with kit.

CAUTION: Complete the wiring connections to the quickdisconnects before plugging them into their bases on the I/Oboard. Connecting the wiring with the quick disconnectsinstalled may apply forces capable of damaging the circuitboard.

9. Before plugging the quick-disconnects into their bases on theterminal-blocks, connect the wiring to them first. Refer to Figure 4-14 and Table 4-15 to find the correct termination point foreach wire to the I/O board terminal blocks.

NOTE: Remove the conduit plate to provide additional working room.

NOTE: Be sure the wires are securely installed between the metalclip and the metal block.

10. Plug the two quick-disconnects into their bases on the I/O board.Each quick-disconnect is keyed so it cannot be inserted in the wrongbase.

Installation4-28


237514D02Issued 2/10

5742085A

X1TOP

X1BOTTOM

BOARDCIRCUITS

CUSTOMERWIRING

Fig. 4-14 Wiring Diagram for I/O Board Terminal Blocks

Connecting Inputs andOutputs to the Optional I/OBoard (contd.)

Installation 4-29


237514D02Issued 2/10

Table 4-15 Wiring Instructions for Optional I/O Board Terminal Blocks

Terminal BlockPosition

Installation Comment See Note

X1-1 Connect one wire from remote device to isolated contacts that are normally open(and close when a low-line-speed warning occurs).

A, C

X1-2 Connect other wire from same remote device.

X1-3 Connect one wire from remote device to isolated contacts that are normally open(and close when a warning or fault occurs).

B, C

X1-4 Connect other wire from same remote device.

X1-5 Connect wire from run-up transducer 1 (if current-type transducer is used).

X1-6 Connect common wire from transducer 1.

X1-7 Connect wire for operating transducer 1 (if voltage-type transducer is used).

X1-8 Connect wire from transducer 2 (if current-type transducer is used).

X1-9 Connect common wire from transducer 2.

X1-10 Connect wire from run-up transducer 2 (if voltage-type transducer is used).

X1-11 Connect first wire for customer use of 24 VDC output.

X1-12 Connect second wire for customer use of 24 VDC output.

X1-13 Terminal block position not used (24 VDC common)

X1-14 Connect line for use with remote program activation. D




X1-18 Connect wire from remote device for use of unit-disable output

X1-19 Remove jumper and connect first wire from remote equipment for use withunit-enable input. This input is activated with 24 VDC.

E

X1-20 Connect second wire from remote equipment for use with unit-enable input.

NOTE A: These contacts can be set to close when any warning occurs. Refer to Understanding Basic SystemSettings in System Setup.

B: These contacts can be set to close only when a fault occurs. Refer to Understanding Basic SystemSettings in System Setup.

C: The contacts are rated for 1 amp @ 30 VDC.

D: Refer to activating a Program Remotely in Operation for the switching logic used to activate programs.These inputs are activated with 24 VDC.

E: This input is typically used to provide a signal to the pattern control that the hot melt system is ready.This signal is a condition for turning on the ready light, which is in turn required to start generatingpattern sets on the production line.

Installation4-30


237514D02Issued 2/10

Use this procedure to connect 24 VDC power and the serial port cable tothe remote operator panel.

1. Route the two wires that provide 24 VDC power from the externalpower supply to the remote operator panel.

2. Locate the small screwdriver and the 3-position terminal block in theship-with kit.

CAUTION: Complete the wiring connections to the quickdisconnect before plugging it into its base on the display board.Failure to do so may allow forces capable of damaging thecircuit board.

3. Connect the 24 VDC power wire to position 3 (shown inFigure 4-15) on the quick disconnect.

4. Connect the 24 VDC common wire to position 2 (shown inFigure 4-15) on the quick disconnect.

5. Install a ground wire at position 1 on terminal block X8 and connect itto a reliable earth ground.

WARNING: Risk of electrical shock. Failure to connect X8-1 toa reliable earth ground can result in severe personal injury.

6. Plug the quick-disconnect into terminal block X8 on the display boardas shown in Figure 4-15.

5742066A

X8

Fig. 4-15 Wiring Connections at Terminal Block X8 (panel assembly shown with clear cover removed)

Connecting Inputs to theOptional Remote OperatorPanel

Installation 4-31


237514D02Issued 2/10

7. Connect the input end of the serial port cable (the end with the arrowpointing to the connector) to terminal X6 on the display board of theremote panel.

8. Route the other end (the output end) of the cable to the main controlunit.

9. Remove one of the remaining dust plugs from the conduit plate andinstall a grommet or a conduit fitting.

10. Route the cable through the fitting and plug the connector intoterminal X5 on the main control board.

Use the following general procedure to connect a source of AC power tothe external power supply (or power supplies, if a second power supply isused). The specific procedure used will depend upon the chosen powersupply.

1. Decide on a source of power to connect to the power supply. The twoNordson power supplies can accept the following input voltages:

� PS40 power supply: 90−132 VAC or 180−264 VAC� EPS20 power supply: 90−264 VAC

2. If using the PS40 power supply with a 120-VAC power line, changethe hardware setting inside the unit, which is set for 240 VACoperation. Open the unit, remove the metal cover that protects thecircuit board, and move the plug from the connector marked 230V tothe connector marked 115V. Then replace the circuit-board cover andclose the unit back up.

3. Disconnect and lock out the source of power.

WARNING: Risk of electrical shock. Failure to disconnect andlock out power can result in injury or death.

WARNING: Applying 24 VDC power to the pattern control canopen guns in the system or pressurize connected run-up-controlequipment. Take precautions to disconnect power sources(pneumatic, hydraulic, and electric) from components of theglue application system and to protect personnel from hazards.Failure to do so can result in severe personal injury.

4. Route a power line to the power supply.

5. Make the appropriate connections at the power-input terminals on thepower supply.

Connecting Power to thePower Supply

Installation4-32


237514D02Issued 2/10

This part of Section 4 describes how to prepare the system for setup. Itincludes the following procedures:

� Removing Energy Sources from Equipment Attached to thePattern Control

� Adjusting a Trigger

� Determining Trigger Polarity

� Checking for Correct Encoder Wiring

� Checking for Correct Gun Output Wiring

� Checking for Correct I/O Board Wiring

� Replacing the Terminal Block Cover

Use this procedure to make the pattern control system safe for theremaining procedures in this section.

WARNING: Applying 24 VDC power to the pattern control canopen guns in the system or pressurize connected run-up-controlequipment. Take precautions to disconnect power sources(pneumatic, hydraulic, and electric) from components of theglue application system and to protect personnel from hazards.Failure to do so can result in personal injury or death. Failure toobserve every precaution in this section can result in personalinjury or death.

1. Remove all sources of power from equipment that pressurize thedevices (guns and run-up-control equipment) connected to thepattern control outputs.

2. Relieve pressure from guns attached to the pattern control.

3. Remove the terminal block cover from the pattern control.

4. Remove the top quick-disconnect terminal block X7 from the maincontrol board.

6. Preparation for Setup

Removing Energy Sourcesfrom Equipment Attached tothe Pattern Control

Installation 4-33


237514D02Issued 2/10

5. Remove the top quick-disconnect terminal block X1 from the I/Oboard (if this option is installed).

6. Turn on the 24-VDC power supply.

7. Apply a closed circuit across the run-permissive terminals(X7−14 and X7−15).

Use this procedure to align a trigger (photosensor) and adjust itssensitivity to the best setting for the system. The system may beequipped with one or two triggers.

1. Direct the light beam at the target (either a reflector, a receiver, or theproduct), which should be positioned so the beam hits it directly andnot at an angle.

2. Remove the back cover (and gasket) located above the cable on thetrigger. Locate the gain control adjustment and the red LED on thetrigger.

5742065A

3

2

1

Fig. 4-16 Location of Trigger Gain Control and LED

1. Gain control2. Red LED

3. Light/dark operate switch (notused)

Adjusting a Trigger

Installation4-34


237514D02Issued 2/10

3. Follow the instructions in Table 4-16 for the type of trigger beinginstalled.

Table 4-16 Instructions for Step 3

Retroreflective Sensor Diffuse Reflective (Proximity) Sensor

Complete the following steps:

a. Turn the gain control fully clockwise. The red LEDon the trigger should flash on and off.

b. Adjust the position and alignment of the trigger forthe fastest flash rate of the LED.

c. Move the product to be sensed past the trigger. Theleading edge of the product will break the lightbeam, and then the beam will again hit the reflectoras the trailing edge of the product passes by thetrigger.

d. Turn the gain control counterclockwise in one-halfturn increments until the LED remains off while theproduct is in front of the trigger. Then turn it anadditional one-half turn counterclockwise. If theLED remains on even after turning the gain controlfully counterclockwise, take steps to reduce thereflectivity of the product or turn the sensor so that itsenses the product less directly.

Complete the following steps:

a. Turn the gain control until the red LED is flashing onand off.

b. Remove the product from front of the trigger.

c. Turn the gain control counterclockwise in one-halfturn increments until the LED turns on only when it“sees” the product but remains off when the productis removed from in front of the trigger. Then turn thegain control an additional one-half turncounterclockwise. If the LED remains on even afterturning the gain control fully counterclockwise, movethe trigger farther away from the product.

4. Replace the back cover on the trigger.

5. If there is a second trigger in the pattern control system, repeat Steps2−5. If not, go to the next procedure, Determining Trigger Polarity.

Adjusting a Trigger (contd.)

Installation 4-35


237514D02Issued 2/10

Use this procedure to determine the polarity (normally open or normallyclosed) of the trigger or triggers not known.

NOTE: This information is needed during system setup. For a normallyopen trigger, change the setting for trigger polarity from the default settingof normally closed (setting = 1) to normally open (setting = 0). Refer toUnderstanding Basic System Settings in System Setup.

1. Make sure there is no product in front of the trigger.

2. Connect the bottom half of the quick-disconnect terminal block X7 tothe main control board.

3. Check that there is a closed circuit across run-permissive terminalsX7−14 and X7−15.

4. Observe the LED for trigger 1 or trigger 2 at the bottom of the maincontrol board. If the LED is on, the trigger has normally closedpolarity. If the LED is off, the trigger has normally open polarity.

5742056A

12

34

OP

EN

X7

DS15

DS14

X8

1

2

Fig. 4-17 Location of Trigger-1 LED (DS14) and Trigger-2 LED (DS15) on Main Control Board

Determining Trigger Polarity

Installation4-36


237514D02Issued 2/10

Use this procedure to determine whether the encoder is correctlyinstalled.

1. Run the production line.

2. Press the MONITOR key. The light on the key will turn on.

3. Observe the line speed in the right window of the display and followthe instructions in Table 4-17.

Table 4-17 Instructions for Step 3

Your Observationin Step 3

Instructions

Line speed is a positive number. a. Stop the production line.

b. Go to the next procedure inthis section.

Line speed is a negative number. a. Stop the production line.

b. Turn off the pattern control.

c. Remove the terminal blockcover.

d. Continue at step 4.

4. Reverse the positions of wire A and wire B at terminal block X8 on themain control board.

5. Reverse the positions of wire A-not and wire B-not at terminalblock X8.

6. Repeat Steps 1−3 to check for correct wiring. If the line speed ispositive, follow the instructions in step 3 and replace the terminalblock cover.

Checking for Correct EncoderWiring

Installation 4-37


237514D02Issued 2/10

Use this procedure to check for correct gun output wiring.

1. Complete steps 1, 2, 3, and 5 in Removing Energy Sources fromEquipment Connected to the Pattern Control.

2. Connect the top half of quick-disconnect terminal block X7 to themain control board.

NOTE: The bottom half of the quick-disconnect terminal block X7should have already been connected in the previous step. If not,connect the bottom half now.

3. Purge gun 1 and check that the gun is being actuated. Refer toPurging a Gun in Operation for instructions on how to purge a gun.

4. Repeat step 3 for each of the other guns in the system.

Use this procedure to check for correct I/O board wiring if the unitincludes the optional I/O board.

1. Complete steps 1, 2, and 3 in Removing Energy Sources fromEquipment Connected to the Pattern Control.

2. Connect the top and bottom halves of the quick-disconnect terminalblock X1 to the I/O board.

Checking for Correct GunOutput Wiring

Checking for Correct I/O BoardWiring

Installation4-38


237514D02Issued 2/10

3. Refer to Table 4-18 and follow the instructions for each external I/Odevice being used.

Table 4-18 Tests for Checking I/O Board Wiring

Type of I/O Wiring Test Procedure

Run-up-control output wiring Apply power to the pattern control. Leave the RUN key off. Energize the run-upequipment. Press PURGE key and then ENTER. If the system has a transducer,check if the output pressure from the transducer changes. If run-up control isconnected to a DC motor drive, check if the pump speed changes duringoperation.

Low-line-speed output wiring Apply power to the pattern control. Change low-speed setting (ALMSP) to anumber other than 0; refer to Understanding Program Options Settings inProgram Setup. Jog the product line manually to produce a trigger signal, andthen stop the line. A low-line speed warning should occur.

Fault/warning output wiring Supply power to the pattern control. Open the remote run-permissive switch.This should cause a fault to occur.

Unit disable input wiring Supply power to the pattern control. The READY light will turn on. Energize thedisable input. The READY light should turn off. De-energize the disable input.The READY light should turn back on.

Unit enable input wiring Supply power to the pattern control. The READY light will turn on. Remove theunit enable condition. The READY light should turn off.

Program recall input wiring Apply power to the pattern control. Enable the pattern control for remoteoperation. Recall programs 1, 2, 4 and i from the remote switch or PLC. Forinstructions on how to do this, refer to Switching Between Local and RemoteProgram activation and Recalling a Program in Operation. Each program will besuccessfully recalled if all the wiring is correct.

NOTE: Recalling these programs will create seven new programs(programs 2−7) with no patterns. Overwrite these programs later when it is timeto create new programs.

Use this procedure to replace the terminal block cover on the maincontrol unit.

1. Insert the tabs of the terminal block cover into the tab slots in the unit.

2. Replace the three screws that secure the terminal block cover tothe unit.

Checking for Correct I/OBoard Wiring (contd.)

Replacing the Terminal BlockCover


237514D02Issued 2/10

Section 5

System Setup

System Setup5-0


237514D02Issued 2/10

System Setup 5-1


237514D02Issued 2/10

Section 5System Setup

This section explains how to set up the pattern control system by usingthe SYSTEM SETTINGS keys. The section is divided into three majorparts:

� Basic System Setup� Encoder Setup� Gun Setup

All system settings are global and are the same for all programs. Thenext section, Program Setup, will explain the different program settingsthat can be entered for each different program created.

NOTE: PatternView, which was shipped with the unit, can be used tofacilitate the setup of the system. PatternView is a Windows-basedsoftware program that runs on a desktop or notebook computer.

NOTE: Enter system settings in the following order: (1) Basic systemsettings (using the SET UP key), (2) Encoder settings (using theENCODER key), (3) Gun settings (using the GUN key). Following thisorder is important. Basic settings, units of measurement and triggerpolarity, may need to be changed before the encoder is initialized.Always complete encoder setup before entering gun settings.

Figure 5-1 identifies the SYSTEM SETTINGS keys. The keypad showsthe light on the ENCODER key is flashing. The flashing light is areminder to determine the encoder gearing ratio for the system beforeputting it into operation. The light will stop flashing upon completion ofone of the four encoder setup procedures.

5742031A

Fig. 5-1 SYSTEM SETTINGS Keys (with light on ENCODER key flashing)

1. Introduction

System Setup5-2


237514D02Issued 2/10

The following procedures describe the purpose of each basic systemsetting and how to enter (or change) the setting.

� Understanding Basic System Settings� Entering Basic System Settings

Use the following table to determine which basic system settings arerequired to change the default settings or revise from previous settings.All basic system settings are global and therefore apply to all programs.

Table 5-1 Explanation of Basic System Settings

Number andAbbreviationof Setting

Name ofSetting

Explanation of Setting DefaultSetting

Possible Settings

(1) PW-LV Level ofpasswordprotection

Set the level of password protection desired.Refer to Password Feature after this table formore information.

0

(no password)

0

(no password)

1

(SYSTEMSETTINGS keys)

2

(all SETTINGSkeys)

(2) PASSW Password Select a numerical password 500 0−999

(3) UNITS Units ofmeasure

Display all measurements in either metric orEnglish units. To obtain the most accuratepatterns, always use metric units(see Note A).

0

(metric)

0

(metric)

1

(English)

(4) T-POL Triggerpolarity

Correct polarity for trigger 1 and (if a secondtrigger is installed) for trigger 2

1

(normallyclosed)

0

(normally open)

1

(normally closed)

(5) T-MEM Triggermemorymode

Apply or do not apply adhesive to productsbetween the trigger and the guns when theline speed recovers from a minimumspeed-disable condition (see Note B)

1

(do not applyglue)

0

(apply glue)

1

(do not apply glue)

(6) REMOT

(see Note C)

Remoteprogramrecall

Enable or disable the pattern control forremote program activation. Refer toProcedures for Remote Operation inOperation. See INCFG Table 5-3 forconfiguration settings for remote control.

0

(disabled)

0

(disabled)

1

(enabled)


2. Basic System Setup

Understanding Basic SystemSettings

System Setup 5-3


237514D02Issued 2/10


Name ofSetting


Possible Settings

(7) OPSET

(see Note D)

Outputcontactssetting

See Table 5-2 below 0 0−3

(8) INCFG

(see Note C)

Remoteinputsetting

See Table 5-3 below 0 0−3

(9) ALMSP

(see Note C)

Lowline-speedalarm

Set a line speed below which a warning willoccur. A setting of zero turns this feature off.

0 m/min

(0 ft/min) =off

0−300 m/min

(0−990 ft/min)

(10) MINSP Minimumspeeddisable

Set a minimum line speed below which theguns will stop applying adhesive. Setting thisfeature to a speed other than zero prevents apuddle of adhesive from forming when theline stops.

1 m/min

(3 ft/min)

0−50 m/min

(0−165 ft/min)

(11) LATCH Latchingfeatureon/off

Set latching so warning messages will notautomatically be removed if the condition thatcauses the warning goes away. Latchedwarnings must always be cleared.

0

(not latched)

0

(not latched)

1

(latched)

(12) AUTO Auto-startfeature

Select either automatic or manual startup.When the auto start feature is on, the patterncontrol will automatically be placed in the runmode when the unit is turned on.

0

(manual)

0

(manual)

1

(automatic)

(13) bRITE Displaybrightness

Adjust the display brightness. The defaultsetting of 1 is best for most lightingenvironments.

1 0−7

(high to lowbrightness)

(14) HAMR Gun purge Purges gun at a 50 Kz cycle rate. For usewith dot bead mode, in which bead sizeaccuracy can vary based on line speed andencoder gearing.

0 0

(off)

1

(enabled)

NOTE A: Pattern sets are more accurately measured and defined with metric units. Using metric units,1 mm isthe smallest possible increment of measure. Using English units, 0.1 inch (2.54 mm) is the smallestpossible increment.

B: With the memory mode set to 1, the system does not apply glue to any products downstream of thetrigger upon recovery. With the memory mode set to 0, the system applies adhesive to all productsdownstream of the trigger, including any product under the gun.

C: This setting is available only on units with the optional I/O board.

D: This setting is available only on units with the optional I/O board. When using the default setting (0), theremote indication for faults and warnings will be the same.

System Setup5-4


237514D02Issued 2/10

Table 5-2 Closed State of Contact for Output Contact Settings

(7) OPSET Output #1 Output #2

0 Low Line Speed Fault/Warning

1 Warning Fault

2 Run Ready

3 No Warning No Fault

Table 5-3 Functions when Input is Driven with 24 VDC

(8) INCFG Input #1 Input #2 Input #3 Input #4 Input #5 Input #6

0 Program Recall0

Program Recall1

Program Recall2

Program Recall3

Unit Disable Unit Enable

1 Program Recall0

Program Recall1

Program Recall2

Program Recall3

Purge All Unit Enable

2 Purge Gun 1

OR

Program Recall0

Purge Gun 2

OR

Program Recall1

Purge Gun 3

OR

Program Recall2

Purge Gun 4

OR

Program Recall3

Driven with24 VDC: Inputs1-4 are remotepurge inputs

NOT driven with24 VDC: Inputs1-4 are program

recall inputs

Unit Enable

3 Program Recall0

Program Recall1

Program Recall2

Program Recall3

Reset Palletizing Unit Enable

NOTE: Make sure that the 6) REMOT setting on the controller is set to 1 under SystemSettings when using the OPSET or INCFG features.

System Setup 5-5


237514D02Issued 2/10

Password Feature

Use the password feature to prevent unauthorized users from changingsettings. When the password feature is on, select either of two levels ofpassword protection:

� The first level (setting = 1) prevents unauthorized users fromchanging any settings accessed by the three SYSTEMSETTINGS keys.

� The second level (setting = 2) prevents unauthorized users fromchanging any settings accessed by the SYSTEM SETTINGS andthe PROGRAM SETTINGS keys.

All users are still able to make online adjustments to pattern settings andbead volume settings (if equipped with run-up control. However, settingscannot be saved because the SAVE key is one of the PROGRAMSETTINGS keys and thus is password protected.

5742032A2

1

Fig. 5-2 Keys Protected by Password at Level 1 and Level 2

1. Keys protected at level 1 2. Keys protected at level 2

When the password feature is on, users without the password will be ableto view but not change any of the settings accessed by thepassword-protected keys. The following table summarizes how thepassword feature works.

System Setup5-6


237514D02Issued 2/10

Password Feature (contd.)

Table 5-4 How the Password Works

User PasswordStatus

Appropriate Action When Password-ProtectedKey Is Pressed (see Note A)

User Capabilities

User withpassword

When password prompt appears, change numberdisplayed on screen (500) to the password andpress ENTER.

Ability to view or change the settingsaccessed by the password-protectedkey

User withoutpassword

When password prompt appears, press ENTER. Ability to view (but not change) thesettings accessed by thepassword-protected key

NOTE A: For keys that are not protected by a password, the capabilities of users with and without the passwordare the same. All users can both view and change the settings accessed by the key.

When the password is entered, it is temporarily disabled. It is notnecessary to reenter it when using any of the keys on the operator panel.The password will remain disabled for a twenty-minute period that startswith the last keystroke. The twenty minute cycle restarts each time a keyis pressed.

If twenty minutes go by without anyone pressing a key, the password willagain be enabled and will have to be entered again to change anysettings or programs for password-protected keys. To enable thepassword again before twenty minutes has passed, press the SET UPkey twice (to enter and exit the function) and the password willimmediately be turned on. Also enable the password by pressing theSET UP key to view or change any settings. Then press the key again toexit the basic system settings.

Quickly determine whether a password is required by looking at thedisplay. If a password is required for use of any key groups (either thethree SYSTEM SETTINGS keys or the six SYSTEM SETTINGS andPROGRAM SETTINGS keys), the password icon appears on the bottomof the display. When the password is successfully entered, the icondisappears, and no further entry is required. When the password isenabled again, either automatically by the twenty-minute time lapse ormanually by pressing the SET UP key twice, the password iconreappears on the display.

NOTE: Contact a Nordson representative if the password is lost orforgotten.

System Setup 5-7


237514D02Issued 2/10

5742033A

Fig. 5-3 Key Icon that Appears when Password Is Enabled

Use this procedure to change the settings for any of the basic systemsettings.

1. Press the SET UP key. The light on the key will turn on. Refer toUnderstanding Basic System Settings, to determine which settings, ifany, are to be changed.

NOTE: Be sure to check the UNITS and T-POL settings. The UNITSsetting determines whether metric or English units are used on thedisplay. The T-POL setting must be changed if it does not correctlydescribe the polarity of the trigger (or triggers) in the system. Refer toDetermining Trigger Polarity in Installation if polarity is not known.

2. Use the up or down key to display the settings to be changed.

3. Use the navigation keys to select the current value of the setting andchange it.

Entering Basic SystemSettings

System Setup5-8


237514D02Issued 2/10

Password Feature (contd.)

4. Repeat steps 2−3 for each setting to be changed.

5. Press the SET UP key. The light on the key will turn off.

6. Record the new values for the system settings in Record of SystemSettings at the end of this section.

EXAMPLE: Figure 5-4 shows how to change the setting for units ofmeasurement (UNITS) from the metric system (setting = 0) to the U.S.Standard system (setting = 1). It is not required to enter a passwordbecause the password feature is not turned on (setting = 0). If there areno other basic system settings to be changed, press the SET UP key toexit. The light on the SET UP key will turn off.

5742071A

Fig. 5-4 Changing the System Setting for Units of Measurement

System Setup 5-9


237514D02Issued 2/10

This part of Section 5 explains the following procedures for encodersetup:

� Understanding the Encoder Gearing Ratio� Understanding Encoder-Setup Error Messages� Setting Up the Encoder (choose one of four procedures)

NOTE: Enter the basic system settings before encoder setup. Refer toEntering Basic System Settings in this section.

The encoder setup provides the controller with a single piece of requiredinformation called the encoder gearing ratio. The encoder sends 500pulses to the controller with each revolution of the encoder shaft. Usingthe encoder gearing ratio, the controller can continuously track lineposition. The encoder gearing ratio is expressed either in pulses permillimeter (if metric units are used), or in pulses per inch (if U.S. Standardunits are used). For more information, refer to Finding the Best Rangefor Encoder Gearing Ratio in Installation.

Choose from four different methods of setting the encoder gearing ratio.Table 5-5 describes each method and explains the requirements for itsuse. Select the method that is best suited to the production line.

Table 5-5 Encoder Setup Methods

Number andAbbreviationof EncoderSetup Method

Name ofEncoderSetupMethod

Explanation of Encoder Setup Method Requirements for Use ofMethod

(1) PROd Product-lengthmethod

Automatically scale the encoder by runningone (or more) products past the trigger.Refer to To Use the Product-Length Methodin this section.

Must be able to run theproduction line with at least oneproduct on it. Must know (oraccurately measure) the lengthof product.

(2) JOG Line-jogmethod

Automatically scale the encoder to theproduction line by measuring the distanceof line travel. Refer to Use the Line-JogMethod in this section.

Must have a way to measurethe distance the production linehas traveled.

(3) SPEEd Constantline-speedmethod

Scale the encoder by running theproduction line at a known speed. Refer toUse the Constant-Line-Speed Method inthis section.

Must have an accuratemeasurement of line speedduring production runs. Mustalso have minimum variation inline speed.

(4) USER User-suppliedmethod

Set up the encoder by entering a knownvalue. Refer to Use the User-SuppliedMethod in this section.

Must either have an accuratevalue for the encoder gearingratio or be using the Nordsonfriction wheel.

3. Encoder Setup

Understanding the EncoderGearing Ratio

System Setup5-10


237514D02Issued 2/10

During the encoder setup procedure, the word ERROR may display if amistake is made. If this happens, note the error code displayed, thenrefer to the following table for an explanation of the error message and arecommended action.

Table 5-6 Encoder-Setup Error Messages

Error Code Explanation of Error Code Recommended Action

A1 The light on the RUN key is on when theENCODER key is pressed, or the RUN key waspressed during the setup procedure.

Press the RUN key to turn the light on the keyoff and start the procedure again.

A2 The production line was moving at thebeginning of the line-jog-method setupprocedure.

Clear the error message and start theprocedure again, following the steps in Use theLine-Jog Method.

A3 The production line stopped in the middle of thesetup procedure during the line-speed methodof encoder setup.

Clear the error message and then repeatprocedure, making sure the line does not stopbetween start-count and stop-count.

A4 The production line did not move between startand stop instructions of setup procedure.

Clear the error message and repeat procedure,making sure to start and stop line as instructedin the setup procedure.

A5 The production line was started and stoppedbut no products were detected during this time.

Clear the error message and repeat procedure,making sure to send products past the triggeras instructed in the setup procedure.

A6 The production line was not running during theline-speed method of encoder setup.

Clear the error message and repeat procedure,making sure to start the production line asdirected in the procedure.

Clear an Error Message

Use this procedure to clear encoder error messages.

1. Note the error code displayed and refer to Table 5-6 to find the causeof the error message.

2. Press the ENCODER key. The light on the key will turn off and theerror message will be removed from the display.

5742034A

Fig. 5-5 Typical Encoder-Setup Error Message

Understanding Encoder-SetupError Messages

System Setup 5-11


237514D02Issued 2/10

Decide which method of encoder setup to use and refer to one of thefollowing four procedures to set the encoder gearing ratio. Refer also toUnderstanding the Encoder Gearing Ratio for the requirements of eachsetup method.

� Use the Product-Length Method� Use the Line-Jog Method� Use the Constant-Line-Speed Method� Use the User-Supplied Method

NOTE: Enter basic system settings before performing one of theencoder setup procedures. Two of the basic system settings, units ofmeasurement and trigger polarity, may need to change. Refer toUnderstanding Basic System Settings at the beginning of this section.

Use the Product-Length Method

Use this procedure to set the encoder gearing ratio by the product-lengthmethod. The steps of the procedure are shown in Figures 5-6 and 5-7.

1. Obtain an accurate measurement of product length. Convert thismeasurement to millimeters or inches, whichever is selected(converting any fractions of an inch to the nearest 0.1 inch).

2. If the pattern control is in the run mode, press the RUN key to exit therun mode. The light on the key will turn off.

3. Press the ENCODER key. If this is a first time set up of the encoder,the light on the key will change from flashing to steadily on.Otherwise, the light will change from off to on. In either case, theabbreviation PROd will appear on the display.

4. Press ENTER. The abbreviation TRIG will appear on the display,with the number 1 flashing.

5. To use trigger 1 to set up the encoder, press ENTER. To usetrigger 2, use the up key to change the 1 to 2 and press ENTER. Theword START will flash on the display.

6. Press ENTER. The display will flash the word RUN.

7. Introduce a product on the production line.

NOTE: To obtain an accurate measurement, ensure that any possiblesource of false triggering, such as an open flap, is eliminated.

8. If the production line is not running, start the production line now.

Setting Up the Encoder

System Setup5-12


237514D02Issued 2/10

Use the Product-Length Method (contd.)

5742069A

T1

STARTT1

Fig. 5-6 Setting Up the Encoder by the Product-Length Method

System Setup 5-13


237514D02Issued 2/10

9. Allow the complete product, front to back, to move past the trigger.The word STOP will appear on the display. See Figure 5-7.

10. Once the back edge of the product has passed the trigger, stop theproduction line.

11. Press ENTER. The abbreviation LNGTH and a length measurementwill appear on the display.

12. Use the up and down keys to change the length currently shown inthe display to the length of the product and press ENTER. Thecontroller will calculate the encoder gearing ratio (EGEAR) anddisplay it in either pulses/mm or pulses/in.

13. Press the ENCODER key. The light on the key will turn off.

NOTE: Verify that the value for the encoder gearing ratio is accurateby pressing the MONITOR key when the line is running and bychecking the line speed displayed. If it seems too high or low,measure actual line speed with an instrument, or repeat thisprocedure (or use another method of encoder setup) to see if thesame value for the encoder gearing ratio is derived.

Use the Line-Jog Method

Follow this procedure to set the encoder gearing ratio by the line-jogmethod.

1. Stop the production line.

2. If the controller is in RUN mode, press the RUN key to exit. The lighton the key will turn off.

3. Press the ENCODER key. If this is a first time set up of the encoder,the light on the key will change from flashing to steadily on.Otherwise, the light will change from off to on. In either case, theabbreviation PROd will appear on the display.

4. Press the up key. The word JOG (line-jog method) will appear on thedisplay.

5. Press ENTER. The display will flash the word START.

6. Press ENTER again to bring the encoder count to zero. The displaywill flash the word RUN.

System Setup5-14


237514D02Issued 2/10

Use the Line-Jog Method (contd.)

7. Place a piece of masking tape at the start of a measurement of linetravel. Place the tape so that one end of the tape is on the conveyorand the other is on a stationary support or frame.

8. Cut the tape at the point at which it passes from the conveyor to thesupport frame or rail.

5742070A

T1STOP

Fig. 5-7 Setting Up the Encoder by the Product-Length Method

System Setup 5-15


237514D02Issued 2/10

9. Start the production line and then stop it before it has traveled 20 m(66 ft). For best accuracy, it should travel at least 1 m (3.3 ft). Theword STOP will appear on the display.

NOTE: To obtain the most accurate encoder gearing ratio, let the linetravel as far as can be accurately measured.

10. Carefully measure the distance between the two pieces of tape andadd the width of the tape. Convert this measurement to mm or in.(converting any fractions of an inch to the nearest 0.1 inch),whichever is selected.

11. Press ENTER. The display will show the abbreviation TRAVL andflash the distance of 1 mm (or 0.1 in.).

12. Use the up and down keys to change the display to the length oftravel you measured.

13. Press ENTER. The controller will calculate the encoder gearing ratio(EGEAR) and display it in either pulses/mm or pulses/in.


NOTE: Verify that the value for the encoder gearing ratio is accurateby pressing the MONITOR key when the line is running and bychecking the line speed displayed. If it seems too high or low,measure actual line speed with an instrument, or repeat thisprocedure (or use another method of encoder setup) to see if thesame value for the encoder gearing ratio is derived.

Use the Constant-Line-Speed Method

Follow this procedure to set the encoder gearing ratio by theconstant-line-speed method.

1. Start the production line and allow it to run long enough to eliminateline-speed fluctuations. Products need not be on the line.

2. Measure line speed using an accurate measuring instrument.


4. Press the ENCODER key. If this is the first time to set up theencoder, the light on the key will change from flashing to steadily on.Otherwise, the light will change from off to on. In either case, theabbreviation PROd will appear on the display.

System Setup5-16


237514D02Issued 2/10

Use the Constant-Line-Speed Method (contd.)

5. Press the up key twice. The display will show the abbreviationSPEEd (line-speed method).

6. Press ENTER. The display will flash the word START.

7. Press ENTER. The display will flash the word STOP.

8. Wait several seconds and then press ENTER. The display will showthe word SPEEd (line speed) and a value, which will be flashing.

9. Use the up and down keys to change the value to the known linespeed in m/minute or ft/minute.

10. Press ENTER. The controller will calculate the encoder gearing ratio(EGEAR) and display it in either pulses/mm or pulses/in.


To Use the User-Supplied Method

Follow this procedure to set the encoder gearing ratio by theuser-supplied method.


2. Press the ENCODER key. If this is the first time to set up theencoder, the light on the key will change from flashing to steadily on.Otherwise, the light will change from off to on. In either case, theabbreviation PROd will appear on the display.

3. Press the up or down key until the word USER (user-suppliedmethod) appears on the display.

4. Press ENTER. The abbreviation EGEAR (encoder gearing ratio) willappear on the display with the current value of the ratio flashing.

5. Use the up and down keys to change the encoder gearing ratio to theknown ratio in pulses/mm or in pulses/in.

NOTE: When using the Nordson friction wheel (which has a 500-mmcircumference), make sure the encoder gearing ratio (EGEAR) iseither 1.000 pulse/mm or 25.4 pulses/in., depending upon the units ofmeasurement.

6. Press ENTER and then press the ENCODER key. The light on thekey will turn off.

System Setup 5-17


237514D02Issued 2/10

This part of Section 5 contains the following explanation and procedure:

� Understanding Gun Settings� Entering Gun Settings

For each gun, enter two types of settings:

� the gun-to-trigger offset (GTO) distance� the compensation for gun-on and gun-off time delays

NOTE: Enter the GTO settings for the guns before setting guncompensation.

Entering gun-compensation settings ensures more accurate placement ofpattern sets, especially in applications where line speed varies. Thisallows manual entry of the amount of time required for each gun in thesystem to open and dispense adhesive and the amount of time requiredto close and stop dispensing adhesive. The pattern control compensatesfor these time lags by opening or closing guns sooner than it would if itcould send signals and cause pattern generation to start and stopimmediately. Different amounts of compensation for each gun can beentered.

The controller provides two methods to enter this information, referred toas gun compensation. If gun compensation is known, simply enter thetime for each gun to open and dispense adhesive (called the gun-oncompensation) and the time for each gun to close and stop dispensingadhesive (called the gun-off compensation). Typical values for gun-onand gun-off compensation are as follows:

� standard air-operated guns: 8−20 ms

� high-performance air-operated guns (such as Nordson H400Series guns): 5−12 ms

� electric guns: 3−8 ms

If gun compensation is not known, the pattern control provides a methodto quickly determine these times and enter them. Set the guncompensation to zero, enter the line speed, produce a test pattern, andmeasure the distance between the programmed bead placement (thesettings entered in the controller) and the actual bead placement (theposition on the product). When the distance for the start and end of thebead is entered, the control automatically calculates thegun-compensation times.

4. Gun Setup

Understanding Gun Settings

System Setup5-18


237514D02Issued 2/10

Use the following table to see which gun settings to change. Entertime-based gun compensation settings when gun compensation valuesare known. Use the distance-based compensation settings and theline-speed setting to determine unknown gun compensation. Thefollowing pages contain procedures for the two methods of entering guncompensation.

Table 5-7 Explanation of Gun Settings

Abbreviationof Gun Setting

Name of GunSetting

Explanation of Gun Setting DefaultSetting

PossibleSettings

TRAVL Line travel A read-only value that shows the amountof line travel. It can be used to measureGTO.

− − − − N/A

GTO Gun-to-triggeroffset

The distance between each gun and thetrigger, or triggers. The system mayhave one or two triggers.

100 mm

(3.9 in.)

2−10,000 mm

(0.2−393.7 in.)

ON-T Gun-oncompensation(time units)

The time it takes (in milliseconds) tosend a signal to the gun, open the gun,and dispense adhesive on the product.

0.0 ms 0−200 ms

OFF-T Gun-offcompensation(time units)

The time it takes (in milliseconds) tosend a signal to the gun, close the gun,and stop adhesive from being applied tothe product.

0.0 ms 0−200 ms

LPSPd Last-productspeed

A read-only value that shows the linespeed when the first bead is applied tothe last product. It provides a way todetermine line speed (which is requiredto determine gun compensation) ininstallations where line speed varies.

0 m/min

(0 ft/min)

N/A

SPEEd Line speedfor guncompensationvalues

The speed at which the line is runningwhen determining gun compensation.

0 m/min

(0 ft/min)

0−300 m/min

(0−990 ft/min)

ON-d Gun-oncompensation(distance units)

The distance between the programmedand the actual start of a bead (in mm orin.). This distance is due to the systemdelay in opening the gun.

0 mm

(0.0 in.)

0−1000 mm

(0−39.4 in.)

OFF-d Gun-offcompensation(distance units)

The distance between the programmedand the actual end of a bead (in mm orin.). This distance is due to the systemdelay in closing the gun.

0 mm

(0.0 in.)

0−1000 mm

(0−39.4 in.)

Understanding Gun Settings (contd)

System Setup 5-19


237514D02Issued 2/10

Upon completion of the encoder setup procedures, use the followingprocedures to set up the guns. Choose one of the first two procedures todetermine the gun-to-trigger offset (GTO) distances for the system (seeFigure 5-8). Follow the third procedure to enter the GTO distances.Then use either the fourth procedure (known gun compensation) or thefifth procedure (unknown gun compensation) to complete set-up.

� Measure Gun-to-Trigger Offset (GTO) Distances� Determine GTO Distances Using the Controller� Enter GTO Distances� Enter Known Gun-Compensation Values� Determine and Enter Gun-Compensation Values� Copy Gun Settings

If the settings for one gun are the same or almost the same as those ofanother gun in the system, save time by copying the settings from onegun to another. Refer to Copy Gun Settings.

NOTE: Enter gun settings accurately and correctly to ensure accuratebead placement.

5742058A

T1

T2

GTO

G2

GTO

GTO

GTO

G1

Fig. 5-8 GTO Measurements for a System with Two Triggers and Two Guns

Entering Gun Settings

System Setup5-20


237514D02Issued 2/10

Measure Gun-to-Trigger Offset (GTO) Distances

Use this procedure to measure the distance between each gun and eachtrigger in the system. Some installations facilitate easy measurements.For example, if the trigger and the guns are oriented in the samedirection and are the same height above the production line, accuratemeasurements may be obtained by using a tape measure. In otherinstallations, however, measuring GTO distances may be difficult. Thetrigger and the guns may be oriented in different directions, or may beotherwise positioned so that it is difficult to take accurate measurements.If this is the case, go to Determine GTO Distances Using the Controller.

NOTE: Obtain accurate measurements in this procedure. Havingaccurate GTO measurements will increase the accuracy of patterncontrol and reduce the number of adjustments to be made later.

1. Using a tape measure or similar tool, determine the distance betweeneach trigger and each gun in the system. Figure 5-8 shows the fourGTO measurements required in a system with two triggers and twoguns.

2. Record the GTO measurements in the following table. Select mm orin. (to the nearest 0.1 inch).

Table 5-8 Record of GTO Measurements

Gun Number GTO Distances for Trigger 1 GTO Distances for Trigger 2

1

2

3

4

System Setup 5-21


237514D02Issued 2/10

Determine GTO Distances Using the Controller

If it is hard to measure the GTO distances in the production line, use thisprocedure to determine them. This procedure is especially useful onproduction lines where it is difficult to obtain accurate measurementsusing a tape measure or a ruler.

1. Remove the terminal block cover from the main control unit.

2. Remove the top quick-disconnect part (the part with positions 1−8) ofterminal block X7 on the main control board.

WARNING: Failure to disconnect terminal block X7 can resultin injury or death. If the terminal block remains connected, thedispensing guns can discharge hot adhesive during thisprocedure.

3. Place the system in the run mode by pressing the RUN key. The lighton the key will turn on.

4. Press the GUN key. The light on the key will turn on and theabbreviation TRAVL (which stands for line travel) will appear on thedisplay.

5. Use the navigation keys to select the correct trigger (trigger 1 ortrigger 2).

6. Place only one product on the production line at a point that isupstream of (prior to) the trigger that was selected in the previousstep.

7. Jog the production line so that the leading edge of the product passesin front of the trigger. When the trigger senses the leading edge, thecontrol will start counting the amount of line travel.

8. Continue jogging the line until the leading edge of the product isexactly aligned with the nozzle of the first gun in the system. Thealignment must be precise in order to obtain an accurate GTOmeasurement.

NOTE: If the production line cannot be stopped exactly at the gunnozzle, stop it just before the leading edge of the product reaches thenozzle. Then, measure the remaining distance with a tape measureor ruler and add it to the reading obtained in the next step.

9. Read the amount of line travel (TRAVL) from the last window of thedisplay. This is the GTO.

System Setup5-22


237514D02Issued 2/10

Determine GTO Distances Using the Controller (contd.)

5742125A

Fig. 5-9 Display Reading After 130 mm of Line Travel from Trigger 1

10. Record this GTO distance in the appropriate row and column ofTable 5-9.

NOTE: The first gun that the product reaches in the system is notnecessarily gun number 1. Gun number 1 is determined by the wiringconnections at terminal block X7 on the main control board. Refer tothe wiring diagrams in Installation for details.

11. In systems using more than one gun that are not all the samedistance from the trigger, continue jogging the line, stopping theproduct so that it aligns with the nozzle of each gun in the system.Record the distance in Table 5-9.

12. If the system is equipped with a single trigger, go to step 13. If thesystem is equipped with two triggers, repeat steps 5−11 for thesecond trigger.

13. Press the GUN key and then the RUN key. The lights on the keys willturn off.

14. Reconnect the quick-disconnect part of terminal block X7 and replacethe terminal block cover.

Table 5-9 Record of GTO Measurements

Gun Number GTO Distances for Trigger 1 GTO Distances for Trigger 2

1

2

3

4

System Setup 5-23


237514D02Issued 2/10

Enter GTO Distances

Use this procedure to enter the gun-to-trigger offset for each gun in thesystem.

1. Press the GUN key. The light on the key will turn on.

2. If the number of the guns to be set up is not displayed, use thenavigation keys to change the number. Gun number 1 is alwaysdisplayed when the GUN key is first pressed.

3. Use the navigation keys to select the gun-to-trigger offset (GTO)setting and then select the current value of the setting.

4. Enter the distance between the gun and trigger number 1 in mm or in.(to the nearest 0.1 in.), whichever is being used. For systems with asecond trigger, change the trigger number to 2 and enter the distancefrom the gun to the second trigger.

5. Repeat steps 2−4 for each gun in the system.

6. Press the GUN key. The light on the key will turn off.

7. Record the GTO settings in Record of System Settings at the end ofthis section.

EXAMPLE: Figure 5-10 shows how to enter a GTO of 235 mm for gun 1and trigger 1 and a GTO of 187 mm for gun 2 and trigger 1.

System Setup5-24


237514D02Issued 2/10

Enter GTO Distances (contd.)

5742072A

Fig. 5-10 Example of Entering GTO Setting

System Setup 5-25


237514D02Issued 2/10

Enter Known Gun-Compensation Values

Use this procedure to enter known gun-compensation values.


2. Use the navigation keys to select the first gun to be set up.

3. Use the navigation keys to select the following two settings and enterthe gun-on and gun-off compensation in milliseconds:

� ON-T (gun-on compensation in time units)� OFF-T (gun-off compensation in time units)

NOTE: The following settings do not need to have values entered:SPEEd, ON-d, and OFF-d. These settings are used only fordetermining unknown gun compensation. Unless the correct linespeed (the SPEEd setting) has been entered, changing the ON-d andOFF-d values will cause the control to change the time values thatwere entered to incorrect values. To view gun compensation indistance units, the control calculates this automatically when linespeed is entered. If line speed is entered correctly, gun compensationcan be fine-tuned by observing the difference between desired beadplacement and actual bead placement. The next procedure,Determine and Enter Gun-Compensation Values, describes how todo this.

4. For each additional gun in the system, repeat steps 2−3. The systemcan independently control the operation of up to four guns.

5. Press the GUN key to exit the gun setup function. The light on thekey will turn off.

6. Record gun compensation settings in Record of System Settings atthe end of this section.

NOTE: Changing the ON-d and OFF-d values will cause the controlto change the time to incorrect values unless the correct line speedhas been entered.

System Setup5-26


237514D02Issued 2/10

Determine and Enter Gun-Compensation Values

Use this procedure to determine the gun-on and gun-off compensationfor the guns and enter these values.

NOTE: Purge the guns before starting this procedure. This action willremove any char that may have formed around the nozzle area.

1. Create a test pattern set to use for setting gun compensation. Mostinstallations can use the pattern set in the default program (program00) for this purpose. When the default program runs, each gun willgenerate a single 25-mm (1.0-in.) bead that is 25 mm (1.0 in.) fromthe leading edge of the product (see Figure 5-11). For installations inwhich this pattern set will not work, refer to Defining a Pattern Set inProgram Setup to create a suitable test pattern.

2. Using one product, mark the position where the bead from each gunshould be applied.

5742035A

1

2

3

4

25 mm(1.0 in.)

25 mm(1.0 in.)

Fig. 5-11 The Pattern Set Generated by the Default Program (Program 00)


4. To set the compensation of gun 1, go to the next step. To set thecompensation of a gun other than gun 1, use the navigation keys toselect it.

System Setup 5-27


237514D02Issued 2/10

5. Make sure that the values for both the gun-on time (ON-T) and thegun-off time (OFF-T) are zero (0 ms). To change the value of ON-Tor OFF-T to zero, use the navigation keys to select the current valueand then use the down key or press the SHIFT and the DELETE keysto change the value to zero.

6. Start the production line. To obtain the most accurategun-compensation values, run the line at the fastest operating speedrange.

7. Press the RUN key. The light on the key will turn on.

8. Place the product that was marked in step 2 on the production lineand allow it to pass through the pattern control system. The testpattern will be generated on the product.

9. Determine and enter the production line speed by one of the twomethods described in Table 5-10.

Table 5-10 Two Methods for Determining and Entering Line Speed

Constant Line-Speed Method Variable Line-Speed Method

a. Using the navigation keys,select the line speed setting(SPEEd), then select thevalue for this setting in theright window of the display.

b. While the line is still running,press the SHIFT key and thenthe COPY key(see Figure 5-12). The controlwill capture the current linespeed and show it in the rightwindow of the display.

c. Press ENTER to accept thisline speed.

a. Using the navigation keys,select the last-productspeed (LPSPd), which is aread-only value that showsthe instantaneous linespeed when the gunopened to apply the firstbead to the last product.Read the line speed shownin the right window of thedisplay.

b. Using the navigation keys,select the line speed setting(SPEEd) and then selectthe value for this setting.

c. Use the up and down keysto change the value for thissetting to the last-productspeed determined in step a.

System Setup5-28


237514D02Issued 2/10

Determine and Enter Gun-Compensation Values (contd.)

5742073A

Fig. 5-12 Example of Capturing a Constant Line Speed of 191 m/min

System Setup 5-29


237514D02Issued 2/10

10. Compare the bead position of the test pattern with the bead positionmarked on the sample product. Measure the distance from the startof the marked bead to the start of the actual bead. This is the gun-oncompensation in distance units for the gun that generated this bead.In the example shown in Figure 5-13, this measurement is 2 mm (0.1in.).

11. Measure the distance from the end of the marked bead to the end ofthe actual bead. This is the gun-off compensation in distance unitsfor the gun that generated this bead. In the example shown inFigure 5-13, this measurement is 3 mm (0.1 in.).

EXAMPLE: Figure 5-13 shows the difference between the programmedposition of a bead (shown in dotted lines) and the actual position of thebead (shown in black). Due to the gun-on delay, the bead starts2 mm (0.1 in.) farther away from the leading edge than it is programmedto do. Due to the gun-off delay, the bead ends 3 mm (0.1 in.) fartheraway from the leading edge than it was programmed to do. When thesemeasurements are entered into the pattern control (along with the correctline speed), the bead will be generated in the programmed position.

5742036A

2 mm 3 mm(0.1 in.) (0.1 in.)

1

2 3

Fig. 5-13 Determining the Gun-Compensation Distances to Enter

1. Leading edge of product2. Position of bead as defined in test

pattern

3. Actual bead

System Setup5-30


237514D02Issued 2/10

Determine and Enter Gun-Compensation Values (contd.)

12. Use the navigation keys to select the following two settings and enterthe measured gun-on and gun-off compensations either in mm orin.(to the nearest 0.1 inch):

� ON-d (gun-on compensation in distance units)� OFF-d (gun-off compensation in distance units)

Upon entry of these values, the control will automatically calculate thecorrect times for the gun-on and gun-off compensation of the gun.View these times by displaying the ON-T and OFF-T settings.

13. Repeat steps 4−12 for each gun in the system.

NOTE: To check the accuracy of the gun-compensation settings,send one product through the pattern control system with the linerunning at the low end of the operating speed range. Then sendanother product through the system with the line running at the highend of the operating speed range. Compare the two samples. If thebeads on both samples are in the same position, your guncompensation values are good. If the bead edges on the slow-speedsample are closer to the leading edge of the product than they are onthe fast-speed sample, you need to add more gun compensation. Ifthe bead edges on the slow-speed sample are farther from theleading edge of the product than they are on the fast-speed sample,decrease the gun compensation.

14. When gun compensation settings are satisfactory, press the GUN keyto exit the gun setup function. The light on the key will turn off.

15. Record gun compensation settings in Record of System Settings atthe end of this section.

System Setup 5-31


237514D02Issued 2/10

Copy Gun Settings

This procedure will replace all of the existing settings (whether they arethe default settings or previously entered settings), including the settingfor gun-to-trigger offset, which may be different for each gun in thesystem.


2. If the number of guns to receive the copied settings is not displayed,use the navigation keys to change the gun number.

3. Press the SHIFT key. The light on the key will turn on.

4. Press the COPY key. The word COPY will briefly appear in thedisplay and the gun settings will be copied. The light on the SHIFTkey will turn off.

5. Use the up or down key to select the number of the gun into which toinsert the copied settings. The number of the gun will flash.


7. Press the PASTE key. The word PASTE will briefly appear in thedisplay and the copied settings will be inserted for the selected gun.The light on the SHIFT key will turn off.

8. Press the GUN key. The light on the key will turn off.

System Setup5-32


237514D02Issued 2/10

Use the following tables to record system settings. For more informationabout these settings, refer to Basic System Setup, or Encoder Setup, orGun Setup in this section.

Table 5-11 Basic System SettingsNumber andAbbreviation ofSetting

Name of Setting Possible Settings Your Setting

(1) PW-LV Level of password protection 0(no password)

1(SYSTEM SETTINGS keys)

2(all SETTINGS keys)

(2) PASSW Password 0−999

(3) UNITS Units of measure 0 (metric)

1 (English)

(4) T-POL Trigger polarity for trigger 1 0 (normally open)

1 (normally closed)

Trigger polarity for trigger 2 0 (normally open)

1 (normally closed)

(5) T-MEM Trigger memory for triggers 1 and 2 0 (apply glue)

1 (do not apply glue)

(6) REMOT Remote program recall (only on unitswith optional I/O board)

0 (disabled)

1 (enabled)

(7) OPSET Output setting for I/O contacts (only onunits with optional I/O board)

0−3

See Table 5−2

(8) INCFG Remote input setting 0−3

See Table 5−3

(9) ALMSP Setting for low-line-speed alarm (only onunits with optional I/O board)

0−300 m/min

(0−990 ft/min)

(10) MINSP Setting for minimum line speed 0−50 m/min

(0−165 ft/min)

(11) LATCH Warning latch feature 0 (not latched)

1 (latched)

(12) AUTO Auto start mode enable 0 (manual)1 (automatic)

(13) bRITE Display brightness 0−7(high to low brightness)

(14) HAMR Gun purge (with dot bead mode) 0 (off)

1 (enabled)

5. Record of SystemSettings

System Setup 5-33


237514D02Issued 2/10

Table 5-12 Setting for the Encoder Gearing RatioEncoder SetupMethod(check one)

ProductLength(PROd)

Line Jog(JOG)

Constant LineSpeed(SPEEd)

User Supplied(USER)

Encoder Gearing inpulses/mm orpulses/inch

Table 5-13 Gun SettingsAbbreviation ofSetting

Name of Setting Settings for Gun1

Settings for Gun2

Settings for Gun3

Settings for Gun4

GTO Gun-to-triggeroffset for trigger 1

Gun-to-triggeroffset for trigger 2

ON-T

(See Note A)

Gun-oncompensation(time units)

OFF-T

(See Note A)

Gun-offcompensation(time units)

SPEEd Line speed if guncompensationvalues are indistance units

ON-d

(See Note A)

Gun-oncompensation

(distance units)

OFF-d

(See Note A)

Gun-offcompensation(distance units)

NOTE A: Gun-on and gun-off compensation can be recorded in either time or distance units. It is not necessary to recordboth settings. For distance units used in the setup procedure, the pattern control will calculate the time units.

System Setup5-34


237514D02Issued 2/10


237514D02Issued 2/10

Section 6

Program Setup

Program Setup6-0


237514D02Issued 2/10

Program Setup 6-1


237514D02Issued 2/10

Section 6Program Setup

This section describes how to set up pattern-control programs. It isdivided into four major parts:

� Pattern Definition� Setup of Program Options� Setup of Run-Up Control� Program Management

The instructions in Pattern Definition describe how to define pattern setswith solid beads, and Program Management includes instructions on howto save pattern settings as programs.

The other parts of this section explain how to create more complexpattern sets. Setup of Program Options provides instructions on how toproduce four custom bead patterns (stitched bead, dot bead, modulatedbead, and random-length bead), how to set up the system for palletstabilization, and how to enter settings for detecting jams and minimizingfalse triggers. Setup of Run-Up Control explains how to ensure constantbead volume if the system is equipped with the optional I/O board andthe required run-up-control equipment.

The control simplifies the task of defining patterns. Anytime thepattern-definition screen appears on the display, as it does in Figure 6-1,select individual guns, triggers, and beads and specify bead lengths andpositions by using the navigation keys. Detailed instructions are providedin Pattern Definition.

5742026A


ERIES

Fig. 6-1 The Pattern-Definition Screen

1. Introduction

Program Setup6-2


237514D02Issued 2/10

This part of Section 6 describes how to define the pattern sets. Itcontains the following explanations and procedures:

� Understanding Pattern Control Terminology� Understanding Pattern Settings� Defining a Pattern Set� Using Quick Keys to Define Pattern Sets

Become familiar with the terms this manual uses to describe patterns andpattern control equipment. The following table and figure will help toexplain these key terms. For a more comprehensive list of the technicaland specialized terms used in this section, refer to the glossary at theend of the manual.

5742037A

1

2

GE

F

C

B

H

A

D

1−11−2

2−2 2−1

Fig. 6-2 Illustration for Key Terms Used to Describe Pattern Sets

2. Pattern Definition

Understanding Pattern ControlTerminology

Program Setup 6-3


237514D02Issued 2/10

Table 6-1 Definitions of Key Pattern Control Terms

Term IdentifyingLetter InFigure 6-2

Example or Examples inFigure 6-2

Definition of Term

Bead A � bead 1-1 (from gun 1)� bead 1-2 (from gun 1)� bead 2-1 (from gun 2)� bead 2-2 (from gun 2)

A continuous segment of adhesive or, in thecase of a stitched, dot, or modulated bead,a segment of adhesive that has beendivided into sub-beads

Pattern None � beads 1-1 and 1-2� beads 2-1 and 2-2

All of the beads that are generated by anysingle gun

Pattern set None � all beads from guns 1 and 2 All of the patterns generated by all of theguns

Bead offset B and C � distance B� distance C

The distance from the leading edge of theproduct to the start of the bead.

Bead length D � distance D The distance from the start to the end of thebead

Gun E and F � gun 1� gun 2

The dispensing device (or devices) used toapply a single pattern

Trigger G � trigger 1 A photosensor that detects products asthey move on the production line

Gun-to-triggeroffset (GTO)

H � distance H The distance between the gun and thetrigger that is associated with the gun

Program Setup6-4


237514D02Issued 2/10

Use the following figure and table to see how to define a pattern set. AsFigure 6-3 shows, each window of the display is used for a differentselection or setting. Decide which settings to change from the defaultsettings or to revise from previous settings.

5742038A541 2 3 6

Fig. 6-3 Information Shown On Display when Defining Pattern Sets

Table 6-2 Information Shown in Display Windows

WindowNumber

InformationDisplayed inWindow

PossibleValues

Explanation or Comment

1 Programnumber

00, 01−49,and - -

Shows the active program number for the pattern setdisplayed. Any change to the active program will changethe program number to two dashes (- -) to show that theprogram has been changed. Double zero (00) is afactory-test program that cannot be overwritten.

2 Number of gun 1−4 Select the gun used to generate a pattern

3 Trigger number 1 or 2 Assign or select the trigger that provides the input for eachgun. The system can be equipped with one or two triggers.

4 Bead number 1−24 Select any single bead in a pattern

5 Bead offset See Note A. Set the position of each bead relative to the leading edge ofthe product. The offset distance is measured from theleading edge of the product to the starting point of the bead.

6 Bead length See Note B. Set the length of each bead

NOTE A: The minimum offset is 0 mm (0.0 inch) for the first bead and 1 mm (0.1 inch) past the end of thepreceding bead for all other beads.

B: The minimum bead length is 1 mm (0.1 inch).

Understanding PatternSettings

Program Setup 6-5


237514D02Issued 2/10

Use this procedure to create a basic pattern set. Before starting, be surethat basic system settings have been entered and that encoder and gunsetup procedures in System Setup have been completed.

NOTE: If some patterns are the same or similar, save time by using thecopy and delete functions. Refer to Using Quick Keys to Define PatternSets in this section.

1. Take the measurements that define the pattern set. Refer as neededto Understanding Pattern Settings in this section.

2. Activate the program that is most like the one to be created. Refer asneeded to the procedure Activating a Program in this section.

NOTE: Use program 01 when creating the first program as thestarting point.

NOTE: If the light on the RUN key is on and the production line isrunning, any changes made to the program will immediately takeplace on the production line.

3. Make sure the pattern-definition screen, shown in Figure 6-4, appearson the display. If it does not, one of the following keys is active (asindicated by its light being on): one of the SYSTEM SETTINGS keys,one of the PROGRAM SETTINGS keys, the PURGE key, or theMONITOR key. Press the key. Its light will turn off and thepattern-definition screen will appear on the display.

5742128A

Fig. 6-4 Pattern-Definition Screen (default pattern set shown)

4. Use the up or down key to select the number of the gun (1, 2, 3, or 4)that will be used to generate the defined pattern. Each gun canproduce one of the patterns in a pattern set.

5. For the selected gun, use the navigation keys to select the trigger(number 1 or 2) that will provide input to the pattern control.

Defining a Pattern Set

Program Setup6-6


237514D02Issued 2/10

6. For the selected gun, use the navigation keys to define each bead inthe pattern with the following information. Each bead generated bythe gun will have

� a bead number (starting with bead number 1 and increasingsequentially)

� a bead offset (the distance from the leading edge of the product tothe start of the bead)

� a bead length.

Enter the bead offsets and lengths in mm or in., depending on theunit’s display settings, converting any fractions of an inch to thenearest 0.1 in.

NOTE: The pattern control will not allow beads to overlap or permitother incorrect settings. If the control will not increases or decreasesin length or a change to an offset distance past a certain number,check the offset or length of the previous or next bead.

NOTE: As soon as a change is made to the selected program as thebasis for the new program, the program number will change to twodashes (- -) to show that the program has been changed. There isnow a new, temporary, and unsaved program.

7. Repeat Steps 4−6 for each gun that is used to generate the patternset being defined.

NOTE: To test and adjust the temporary program on the productionline before saving, refer to Making Online Pattern Adjustments inOperation.

8. To save the pattern set, refer to Saving a Program in this section.

9. Record pattern settings. Refer to Record of Program Settings at theend of this section.

EXAMPLE: Figure 6-5 shows how to enter a bead offset of 31 mm and abead length of 190 mm for bead 1.

Defining a Pattern Set (contd.)

Program Setup 6-7


237514D02Issued 2/10

5742074A

Fig. 6-5 Example of Defining the Bead Offset and Length of Bead 1

Program Setup6-8


237514D02Issued 2/10

Use any of the following procedures to speed up the process of definingpattern sets.

� Delete a Bead� Copy a Pattern� Delete a Pattern

Figure 6-6 shows the keys used to delete and copy beads and patterns.

5742011A

1

2 3 4

Fig. 6-6 Quick Keys

1. SHIFT key2. DELETE key

3. COPY key4. PASTE key

Delete a Bead

Use this procedure to delete one or more beads from a pattern set.Revise a pattern set with this procedure or correct a mistake whencreating a new pattern set.

1. Activate the bead program to be deleted Refer as needed toActivating a Program in this section.

2. Use the navigation keys to select the number of the gun that is usedto generate the bead to be deleted.

3. Use navigation keys to move to the window that displays the beadnumber. The bead number will flash.

Using Quick Keys to DefinePattern Sets

Program Setup 6-9


237514D02Issued 2/10

4. Use the up or down key to change the current bead number to thenumber of the bead to be deleted.


6. Press the DELETE key. The abbreviation dELET will briefly appearon the display, the bead will be deleted, and the light on the SHIFTkey will turn off.

NOTE: If the deleted bead was not the last one in the pattern, theremaining beads will be renumbered. If the deleted bead was the lastone in the pattern, the bead length will change to four dashes (- - - -),and the bead offset will change to the minimum offset at which a newbead can be started.

7. To delete additional beads from the pattern set, repeat Steps 2−6.

8. To save the revised pattern set, refer to Saving a Program in thissection.

EXAMPLE: Figure 6-7 shows how to delete bead 3 in a pattern thatincluded four or more beads. Note that the beads are renumbered whendeleting a bead that is not the last one in the pattern. Here the bead thatwas bead 4 has become bead 3.

5742099A

Fig. 6-7 Example of Deleting Bead 3 in a Four-Bead Pattern

Program Setup6-10


237514D02Issued 2/10

Copy a Pattern

A pattern produced by one gun can be copied to make it the pattern ofanother gun. If the gun to which the pattern copied has an existingpattern, the copied pattern will replace (overwrite) the existing pattern. Apattern can be copied from one gun to another gun in the same programor from a gun in one program to a gun in another program. Thecontroller retains the copy until the copy function is used again or until theunit is turned off.

NOTE: If the pattern to be copied is set to produce a stitched, dot,modulated, or random-length bead pattern, copy only the settings forbead lengths and positions with this procedure. To copy the settings forcustom bead types, refer to Copying Bead-Type Settings in this section.

1. If the program containing the pattern to be copied is not active, makeit active. Refer as needed to Activating a Program in this section.

2. Use the navigation keys to select the gun that is used to produce thepattern to be copied.


4. Press the COPY key. The word COPY will briefly appear in thedisplay, the pattern produced by the gun will be copied, and the lighton the SHIFT key will turn off.

5. Use the up or down key to select the number of the gun to which tocopy the pattern.

NOTE: To paste the copied pattern to a gun in another program, referto Activating a Program in this section to activate the program towhich to copy. Then follow Steps 5−7 of this procedure.


7. Press the PASTE key. The word PASTE will briefly appear in thedisplay, the copied pattern will be pasted to the selected gun, and thelight on the SHIFT key will turn off.


EXAMPLE: Figure 6-8 shows how to copy the pattern of gun 3 andpaste it to gun 4. Note that the existing pattern of gun 4 is overwritten.

Program Setup 6-11


237514D02Issued 2/10

5742075A

Fig. 6-8 Example of Copying a Pattern from Gun 3 to Gun 4

Program Setup6-12


237514D02Issued 2/10

Delete a Pattern

Use this procedure to delete one or more patterns from a pattern set.Deleting a pattern will remove all the beads in the pattern.

1. If the program containing the bead to be deleted is not active, make itactive. Refer as needed to Activating a Program in this section.

2. Use the navigation keys to select the number of the gun that is usedto produce the pattern to be deleted.


4. Press the DELETE key. The abbreviation dELET will briefly appearin the display, all beads generated by the gun will be deleted, and thelight on the SHIFT key will turn off. Define new beads at this time.

5. To delete additional patterns from the pattern set, repeat Steps 2−4.


This part of Section 6 describes how to set up program options for

� producing special bead patterns (stitched, dot, modulated, orrandom length)

� handling pallet-stabilization applications

� detecting jams

� minimizing the occurrence of false triggers

It contains the following explanations and procedures:

� Understanding Program Options Settings� Changing Program Options Settings� Creating Custom Bead Patterns� Removing Custom Bead Settings from a Pattern� Creating Random-Length Bead Patterns� Copying Bead-Type Settings

3. Setup of ProgramOptions

Program Setup 6-13


237514D02Issued 2/10

Use the following table to determine the program options settings to bechanged from the default settings or to be revised from previous settings.

Table 6-3 Explanation of Program Options Settings


Name ofSetting

Explanation of Setting Default Setting Possible Settings

(1) T-MIN Minimumdistancebetweentriggerevents

Set the minimum allowable distance(generally the product length) betweentrigger events for trigger 1 and (if used)for trigger 2. This feature is used toignore unwanted triggers from theproduct.

- - - - (if no setting isentered, thetotal patternlength is used)

- - - - to 10,000 mm

(- - - - to393.7 in.)

(2) T-MAX Maximumdistancebetweentriggerevents

Set the maximum allowable distancebetween trigger events for trigger 1 and(if used) for trigger 2. The pattern controlprovides a warning when this maximumis exceeded, indicating a possible jam onthe production line(see Note A).

- - - - - - - - or 100 mmto 10,000 mm

(3.94 in. to 393.7 in.)

(3) b-TYP Bead type Select one of five different bead types foreach gun: solid bead, stitched bead, dotbead, modulated bead, andrandom-length bead.NOTE: For more information, refer toStitched Bead Patterns, Dot BeadPatterns, Modulated Bead Patterns, orRandom-Length Bead Patterns after thistable.

0

(solid bead)

0

(solid)

1

(stitched)

2

(dot)

3

(modulated)

4

(random-length)

(4) G-SAV

(see Note B)

Glue savings Specify the percentage of glue to save ifa stitched bead pattern is selected as thebead type

50 % 10−90 %

(4) TIME

(see Note C)

Gun-on time Specify the gun-on time if selecting a dotbead pattern as the bead type

10.0 ms 0.5−1999.9 ms


Understanding ProgramOptions Settings

Program Setup6-14


237514D02Issued 2/10


Name ofSetting

Explanation of Setting Default Setting Possible Settings

(4) SPEEd

(see Note D)

Activatingline speed

Set a line speed at which the controlbegins producing a modulated bead ifselected as the bead type

200 m/min

(660 ft/min)

0−300 m/min(0−990 ft/min)

(5) INTVL

(see Note E)

Bead interval Specify the interval from the start of onesub-bead to the start of the nextsub-bead if either stitched, dot, ormodulated bead is selected as the beadtype

25 mm

(1.0 in.)

1 mm−10,000 mm

(0.1 in.− 394 in.)

(6) GLUE

(see Note F)

Palletizing

gluesequence

Specify how many consecutive productsto apply adhesive to in pallet-stabilizationapplications. Set a glue sequence fortrigger 1 or trigger 2, or for both triggers.

1 1−1000

(7) SKIP

(see Note F)

Palletizingskipsequence

Determine how many consecutiveproducts to skip (not apply glue to) inpallet-stabilization applications. Set askip sequence for trigger 1 or trigger 2,or for both triggers.

0

(off)

0−1000

NOTE A: If the production line starts running without products on it, T-MAX for Trigger No. 1 will be exceeded(and receive a Warning 13) and/or for Trigger No. 2 (and receive a Warning 14).

B: This option is displayed only when the bead type setting is changed (b-TYP) to 1 (stitched bead).

C: This option is displayed only when the bead type setting is changed (b-TYP) to 2 (dot bead).

D: This option is displayed only when the bead type setting is changed (b-TYP) to 3 (modulated bead).

E: This option is displayed only when the bead-type setting is changed to 1, 2, or 3.

F: To reset the glue/skip count to zero, press the RUN key to take the system out of the run mode and thenpress the RUN key again to re-enter the run mode. The next product that passes the trigger will startthe glue count at one.

Understanding ProgramOptions Settings (contd.)

Program Setup 6-15


237514D02Issued 2/10

Stitched Bead Patterns

Stitched bead patterns provide a way to reduce adhesive usage andincrease bond strength. Enter the percentage of glue savings (G-SAV)wanted and, if desired, a stitch interval (INTVL). The controllerautomatically determines the stitch pattern that will provide the desiredsavings. It does this by dividing each original solid bead of a pattern intosub-beads with spaces between them. Either set a stitch interval (thedistance from the start of one sub-bead to the next sub-bead), or acceptthe default interval of 25 mm (1.0 in.).

For example, if the adhesive savings for a bead pattern is set to 30percent, the stitched beads will be produced with 70 percent of theadhesive used to produce the original non-stitched beads. The patterncontrol always places a sub-bead at the beginning of the original solidbead and as close as possible to the end of the bead.

If the resulting pattern does not have sufficient bond strength, a quickadjustment to the percentage savings can be made. Adjust thepercentage to the maximum possible adhesive savings without loss ofbond strength.

The stitched bead type can be turned on or off for individual programsand for individual guns within each program. For setup instructions, referto Creating Custom Bead Patterns in this section.

5742104A

178 mm (7.0 in.) G−SAV

0%

10%

30%

50%

70%

90%

INTV = 25 mm (1.0 in.)

Fig. 6-9 Effect of Increasing Glue Savings from 0 Percent (top) to 90 Percent (bottom)

Program Setup6-16


237514D02Issued 2/10

Dot Bead Patterns

Dot bead patterns produce patterns of constant-weight (constant-volume)dots of adhesive spaced apart by a user-determined distance. Controlthe dot weight by specifying gun-on time (TIME). Control the distancebetween dots by specifying the dot-interval distance (INTVL). A constantdot weight and interval can be produced over the entire range of linespeed without using external run-up equipment. The dot-bead featurecan be used with run-up control to obtain highly consistent dot placementand weight.

Turn the dot bead type on or off for individual programs and for individualguns within each program. For setup instructions, refer to CreatingCustom Bead Patterns in this section.

5742105A

178 mm (7.0 in.) TIME

10 ms

5 ms

2 ms

INTV = 25 mm (1.0 in.)SPEED = 30.5 m/min (100 ft/min)

Fig. 6-10 Effect on Dot Size of Decreasing Gun-On Time from 10 ms (top) to 2 ms (bottom)

When using dot bead mode, bead size accuracy can vary based on linespeed and encoder gearing. Table 6-4 shows the expected amount ofbead size variation (jitter) based on given line speeds and encodergearing.

Table 6-4 Bead Size Variance Based on Line Speeds and Encoder Gearings

LineSpeed

(m/min)

Expected Dot Time Jitter (ms) for a set Encoder Gearing Ratio in Pulses/Millimeter (p/mm)

0.25 p/mm 0.5 p/mm 1 p/mm 2 p/mm 4 p/mm 10 p/mm 15 p/mm 20 p/mm

1 60.00 ms 30.00 ms 15.00 ms 7.50 ms 3.75 ms 1.50 ms 1.00 ms 0.75 ms








Program Setup 6-17


237514D02Issued 2/10

Modulated Bead Patterns

Modulated bead patterns provide a nearly constant bead volume below aset line speed. Suppose, for example, that an emergency stop isrequired. When the production line slows down to a user-selected speed(SPEEd), the control begins dividing the beads into smaller, spacedsub-beads to prevent the bead volume from increasing. At any given linespeed, the total gun-on time to produce the modulated bead remains thesame as the total gun-on time to produce the solid bead at the set linespeed, so that the divided modulated contains the same amount ofadhesive as the solid bead. As the line speed decreases, the sub-beadsget shorter and their thickness increases. Specify the interval (INTVL)desired between sub-beads, and the control will always place a sub-beadat the beginning of the bead length defined and one as close as possibleto the end of the bead length.

The modulated bead feature can be used to prevent pooling or puddlingof adhesive when the production line slows to a stop.

The modulated bead type can be turned on or off for individual programsand for individual guns within each program. The bead-modulationfeature can be used in systems with or without run-up control. For setupinstructions, refer to Creating Custom Bead Patterns in this section.

5742103A

178 mm (7.0 in.) LINE SPEED

38.1 m/min (125 ft/min)

30.5 m/min (100 ft/min)

22.9 m/min (75 ft/min)




INTV = 25 mm (1.0 in.) SPEED = 30.5 m/min (100 ft/min)

Fig. 6-11 Effect on Modulated Bead Pattern as Production Line Drops Below Activating Line Speed of 30.5 m/min (100 ft/min)

Program Setup6-18


237514D02Issued 2/10

Random-Length Bead Patterns

The random-length bead mode provides a way to mix products ofdiffering length on the production line during the same production run.For example, when alternating between short and long products on theproduction line, the control will produce continuous beads that fit eachproduct. The control automatically determines the length of each productas it passes the trigger and then sizes the beads to fit the product.Although each bead is continuous, a bead margin can be specified ateach end of the product where adhesive will not be applied.

The random-length bead mode can be turned on or off for individualprograms and for individual gun outputs within each program. For setupinstructions, refer to Creating Random-Length Bead Patterns in thissection.

5742045A

1

2

AB

Fig. 6-12 Random-Length Bead Pattern

A. Leading-edge margin B. Trailing-edge margin

Program Setup 6-19


237514D02Issued 2/10

Use this procedure to change any of the following program optionssettings:

� the minimum distance between trigger events (T-MIN)� the maximum distance between trigger events (T-MAX)� palletizing settings (GLUE and SKIP)

To change any of the other program-options settings, refer to one of thefollowing two procedures, Creating Custom Bead Patterns or CreatingRandom-Length Bead Patterns.

1. Press the OPTIONS key. The light on the key will turn on.

2. Refer to Understanding Program Options Settings in this section todetermine the settings to change and the possible values that can beentered for each setting.

3. Use the up or down key to display the setting to be changed.

4. Use the navigation keys to change the current value of the setting.

5. Repeat steps 2−4 for each option to be changed.

6. Press the OPTIONS key. The light on the key will turn off.

7. Record options settings. Refer to Record of Program Settings at theend of this section.

Use this procedure to customize bead patterns by changing the beadtype to stitched bead, dot bead, or modulated bead. For instructions ofsetting up random-length bead patterns, refer to the following procedure,Creating Random-Length Bead Patterns.

1. If the program that generates the custom bead pattern is not theactive program, refer to Activating a Program in this section.

2. Define the pattern set to be customized. Refer to Defining a PatternSet for instructions on creating pattern sets.


4. Use the up or down key to display the setting for bead type (b-TYP).

5. Select the number of the gun (1, 2, 3, or 4) that will generate thecustomized bead pattern. When the bead-type setting is firstdisplayed, gun number 1 will always be selected.

Changing Program OptionsSettings

Creating Custom BeadPatterns

Program Setup6-20


237514D02Issued 2/10

6. Change the setting for bead type to 1 (stitched bead), 2 (dot bead), or3 (modulated bead) and press ENTER.

NOTE: When setting a gun for stitched bead, dot bead, or modulatedbead, the stitch icon will appear under the gun number, indicating thatthe pattern generated by that gun is a type of stitched bead. This iconwill appear any time pattern settings are being viewed or changed anda gun set for a stitched bead, dot bead, or modulated bead isselected.

7. Depending upon the setting chosen in the previous step, one of thefollowing three settings will be displayed. Use the navigation keys toenter the desired value for the setting.

Table 6-5 Settings for Different Custom Bead Patterns

Abbreviationof Setting

Name ofSetting

Explanation of Setting Default Setting PossibleSettings

G-SAV Glue savings Specify the percentage of glue to besaved if stitched bead has beenselected as the bead type

50 % 10-90 %

TIME Gun-on time Specify the gun-on time if dot beadhas been selected as the bead type.

10.0 ms 0.5−1999.0 ms

SPEEd Activating linespeed

Set a line speed at which the controlbegins producing a modulated bead ifmodulated bead has been selected asthe bead type.

200 m/min

(660 ft/min)

0−300 m/min

(0−990 ft/min)

8. The sub-bead interval setting (INTVL) will be displayed. Decidewhether to change the interval (the distance from the start of onesub-bead to the start of the next one) from the default setting of25 mm (1.0 in.). If a new interval is desired, use the up or down keyto change the interval and press enter. When setting up the controllerto generate a stitched bead pattern (b-TYP = 2), refer to Table 6-6 tofind the minimum interval for different gun-compensation values. If nochange of interval is desired, press ENTER.

Creating Custom BeadPatterns (contd.)

Program Setup 6-21


237514D02Issued 2/10

NOTE: The pattern control will determine the best bead pattern forthe application based upon the requirements entered in Steps 7 and8. The bead pattern will always have sub-beads at the beginning ofeach bead in the pattern and as close as possible to the end of eachbead in the pattern. It is possible, however, to set requirements thatcannot be met. In some cases, WARN 26 (Warning No. 26) may flashon the display, indicating that the control memory has been exceeded.If so, increase the interval. In other cases, the bead patterngenerated on the production line is solid instead of divided. If so,decrease the interval to obtain the desired bead type.

Table 6-6 Minimum Recommended Stitch-Bead Interval in Millimeters (Inches) forDifferent Gun-Compensation Values

Maximum Operating Speed of Production Line

GunCompensation

in ms

10 m/min

(33 ft/min)

50 m/min

(164 ft/min)

100 m/min

(328 ft/min)

200 m/min

(656 ft/min)

300 m/min

(984 ft/min)

2 1 mm

(0.0 in.)

3 mm

(0.1 in.)

7 mm

(0.3 in.)

13 mm

(0.5 in.)

20 mm

(0.80 in.)

5 2 mm

(0.1 in.)

8 mm

(0.3 in.)

17 mm

(0.7 in.)

33 mm

(1.3 in.)

50 mm

(2.0 in.)

10 3 mm

(0.1 in.)

17 mm

(0.7 in.)

33 mm

(1.3 in.)

67 mm

(2.6 in.)

100 mm

(3.9 in.)

15 5 mm

(0.2 in.)

25 mm

(1.0 in.)

50 mm

(2.0 in.)

100 mm

(3.9 in.)

150 mm

(5.9 in.)

20 7 mm

(0.3 in.)

33 mm

(1.3 in.)

67 mm

(2.6 in.)

133 mm

(5.2 in.)

200 mm

(7.9 in.)

30 10 mm

(0.4 in.)

50 mm

(2.0 in.)

100 mm

(3.9 in.)

200 mm

(7.9 in.)

300 mm

(11.8 in.)

50 17 mm

(0.7 in.)

83 mm

(3.3 in.)

167 mm

(6.6 in.)

333 mm

(13.1 in.)

500 mm

(19.7 in.)

Program Setup6-22


237514D02Issued 2/10

9. To customize another pattern in the pattern set, repeat steps 4−8.

10. Upon completion of setting up the custom bead requirements for theprogram, press the OPTIONS key. The light on the key will turn off.

11. To save the revised program, refer to Saving a Program in thissection.

NOTE: Test the custom bead settings before saving them by running thetemporary program (indicated by - - in the left window of the display) onthe production line. Using the procedure Making Online PatternAdjustments in Operation, to fine-tune the custom bead settings. Whensuccessful results are achieved, save the settings by saving thetemporary program to a specific program number.

1. Follow Steps 1−5 of the previous procedure, Creating Custom BeadPatterns.

2. Set the bead type (b-TYP) to 0.

3. Remove custom bead settings from other patterns in the samepattern set by repeating these steps.

4. When all the changes are complete, press the OPTIONS key. Thelight on the key will turn off.

Use this procedure set up one or more guns to generate random-lengthbeads.

NOTE: The gun-to-trigger offset (GTO) must be at least 10 mm (0.4 in.)to produce a random-length bead pattern.

1. If the program to set for a random-length bead pattern is not theactive program, refer to Activating a Program in this section to make itactive.


3. Use the up or down key to display the bead-type setting (b-TYP).

4. Use the navigation keys to select the gun to be set for random-lengthbeads.

5. Change the bead type-setting to 4.

6. Repeat steps 4−5 for each gun that is to be set for random-lengthbeads.

7. Press the OPTIONS key. The light of the key will turn off.

Creating Custom BeadPatterns (contd.)

Removing Custom BeadSettings from a Pattern

Creating Random-Length BeadPatterns

Program Setup 6-23


237514D02Issued 2/10

8. If gun 1 is not set for random length beads, use the navigation keys toselect the first gun to be set for random length beads. The displaywill appear as shown in Figure 6-13.

5742046A1 2

Fig. 6-13 Display Showing Random-Length Settings

1. Setting for leading-edge margin 2. Setting for trailing-edge margin

9. Use the navigation keys to enter the setting for the leading-edgemargin. If a leading-edge margin is not wanted, leave the setting at(or change it to) zero.

10. Use the navigation keys to enter the setting for the trailing-edgemargin. If a trailing-edge margin is not wanted, leave the setting at(or change it to) zero.

NOTE: The trailing-edge margin must always be smaller than theGTO (gun-to-trigger distance).

11. Repeat steps 9−11 for each gun to have a defined margin (ormargins).

12. To save the revised program, refer to Saving a Program in thissection.

Use this procedure to copy settings for bead type from one gun toanother. When copying stitch settings, copy both the interval setting andone of the following settings, depending upon the bead type to be copied:

� glue savings (for stitched bead settings)� gun-on time (for dot bead settings)� activating line speed (for modulated bead settings)� margins (for random-length bead settings)

Copy the settings either to a gun in the same program or to one inanother program.

Copying Bead-Type Settings

Program Setup6-24


237514D02Issued 2/10

1. Press the OPTIONS key. The light on the key will turn on. Theprogram number of the active program will appear in the left windowof the display.

2. Use the down key to select the bead-type setting (b-TYP). Thenumber of the currently selected gun will appear in the gun window.

3. To copy the settings of a gun other than the one currently selected,use the up or down key to change the gun number.


NOTE: When setting a gun for stitched bead, dot bead, or modulatedbead, the stitch icon will appear under the gun number, indicating thatthe pattern generated by that gun is a type of stitched bead. This iconwill appear any time when viewing or changing pattern settings and agun set for a stitched bead, dot bead, or modulated bead is selected.

5. Press the COPY key. The word COPY will briefly appear on thedisplay, the bead-type settings will be copied in the controller memory,and the light on the SHIFT key will turn off.

6. Use the navigation keys to select the number of the guns to which tocopy the settings.


8. Press the PASTE key. The word PASTE will briefly appear on thedisplay, the bead-type settings will be copied to the selected gun, andthe light on the SHIFT key will turn off.

9. To copy the same setting to another gun, repeat Steps 6−8.

10. When finished copying and pasting bead-type settings, press theOPTIONS key. The light on the key will turn off.

11. To save the revised program, refer to Saving a Program inthis section.

Copying Bead-Type Settings (contd.)

Program Setup 6-25


237514D02Issued 2/10

This part of Section 6 contains the following explanation and twoprocedures to setup run-up control:

� Understanding Run-Up-Control Settings� Entering Run-Up-Control Settings� Copying Run-Up-Control Settings

If the pattern control is equipped with the optional I/O board and therequired run-up-control equipment has been installed , then run-upcontrol is available. The controller can provide a 4−20 mA analog signalto an I/P transducer, which in turn controls the air pressure to (andtherefore the adhesive flow from) a piston pump. Or the controller canprovide a 0−10 VDC analog signal to a DC motor drive, which in turncontrols the speed of (and therefore the output from) a gear pump. Thecontroller has the ability to control the output of two separate pumps.

To obtain the bead volume wanted on the production line, create a run-upcurve that defines the correct controller output for any given line speed.To create the curve, specify output percentages (PRESS) at two differentline speeds (SPEEd). When these two points (P1 and P2) are defined,run the production line at any line speed and the control will provide thecorrect output for constant bead volume. To increase or decrease thebead volume, change the output percentages at points 1 and 2 on therun-up curve. Figure 6-14 shows a typical run-up curve.

5742047A

200 400 600 800

50 100 150 200 250 300

LINE SPEED IN M/MIN

LINE SPEED IN FT/MIN

CONTROLOUTPUT TO

TRANSDUCER

P1

P2

100%

90%

80%

70%

60%

50%

40%

30%

20%

10%

0%

ORMOTOR DRIVE

HI/LIMIT

LO/LIMIT

Fig. 6-14 Typical Run-Up-Control Curve

4. Setup of Run-Up Control

Understanding Run-Up-ControlSetup

Program Setup6-26


237514D02Issued 2/10

Use the following table to determine the run-up-control settings to bechanged from the default settings, or revise from previous settings.

Table 6-7 Explanation of Run-Up-Control Settings

Abbreviationof Setting

Name ofSetting


PossibleSettings

P1/SPEEd Line speed atpoint 1 onrun-up curve

Used to enter the lower of the two linespeeds at which the desiredpressure-control is specified

0 m/min

(0 ft/min)

0−300 m/min

(0−990 ft/min)

P1/PRESS Percentageoutput at point 1for pressurecontrol

Used to set the percentage output at theline speed for point 1 on the run-upcurve. P1 must be a lower line speedand a lower percentage output than thevalues used for P2.

10 % 0−100 %

P2/SPEEd Line speed atpoint 2 onrun-up curve

Used to enter the higher of the two linespeeds at which the desiredpressure-control is specified

100 m/min

(330 ft/min)

0−300 m/min

(0−990 ft/min)

P2/PRESS Percentageoutput at point 2for pressurecontrol

Used to set the percentage output at theline speed for point 2 on the run-upcurve. P2 must be a higher line speedand a higher percentage output than thevalues used for P1.

100 % 0−100 %

LO/LIMIT Minimum output Used to set a minimum output. Theoutput will not drop below this setting,even if the line slows down to a very lowspeed or stops.

0 % 0−100 %

HI/LIMIT Maximumoutput

Used to set a maximum output. Theoutput will not increase beyond thissetting, no matter how much the linespeed increases.

100 % 0−100 %

PURGE Percentageoutput for thepurge operation

Used to adjust the pressure for the gunpurging operation to the desired setting

50 % 0−100 %

UnderstandingRun-Up-Control Setup (contd.)

Program Setup 6-27


237514D02Issued 2/10

If the pattern control is equipped for run-up control, use this procedure toenter run-up settings.

NOTE: If the settings for one program have been entered and they willbe the same for another program, copy the settings from one program toanother. Refer to the next procedure, Copying Run-Up-Control Settings.

1. Turn the hot melt system on and start the production line.

2. Press the RUN UP key. The light on the key will turn on.

NOTE: If the light on the key does not turn on when the RUN UP keyis pressed, the pattern control unit is not equipped with the optionalI/O board that provides run-up-control capability.

3. Use the navigation keys to select the number of the run-up output(1 or 2) to be set up.

5742048A1 2 3 4 5 6

Fig. 6-15 Information Provided in Display Windows when Entering Run-UpSettings (typical information shown)

1. Program number2. Output number3. Blank window

4. Abbreviation for point 1 or 25. Abbreviation of setting6. Value of setting

4. Slow the production line down to the low end of the operating-speedrange. Allow it to run long enough to eliminate any line-speedfluctuations.

5. Using the navigation keys, select the line-speed setting (P1/SPEEd)for the lower point on the run-up curve and then select the currentvalue for this setting in the right window of the display.

6. Press the SHIFT key and then the COPY key. The control willcapture the current line speed and show it in the right window of thedisplay.

Entering Run-Up-ControlSettings

Program Setup6-28


237514D02Issued 2/10

7. Press the RUN key on the pattern control and start the products onthe production line.

8. Using the navigation keys, select the current value for therun-up-control output percentage (P1/PRESS).

9. Use the up and down keys to change the output percentage until thedesired bead volume is achieved.

10. Increase line speed to the high end of the operating-speed range.Allow it to run long enough to eliminate any line-speed fluctuations.

11. Using the navigation keys, select the line-speed setting (P2/SPEEd)for the higher point on the run-up curve and then select the currentvalue for this setting in the right window of the display.

12. Press the SHIFT key and then the COPY key. The control willcapture the current line speed and show it in the right window of thedisplay.

13. Using the navigation keys, select the current value for therun-up-control output percentage (P2/PRESS).

14. Use the up and down keys to change the output percentage until thedesired bead volume is achieved.

15. To set a minimum output percentage (LO/LIMIT) or a maximumoutput percentage (HI/LIMIT), use the navigation keys to select thesesettings and enter the values desired.

NOTE: If the minimum output is set above the maximum output,WARN 37 will appear on the display. To remove this warning, set theminimum output below the maximum output setting.

16. Use the navigation keys to select the purge output percentage(PURGE). The default setting is set at 50 percent, but can bechanged if desired.

17. If a second run-up-control system is connected to the pattern control,repeat steps 3−15 for the second output. If the settings are the sameas those for the first output, copy the settings for output number 1.Refer to Copying Run-Up-Control Settings.

Entering Run-Up-ControlSettings (contd.)

Program Setup 6-29


237514D02Issued 2/10

18. Press the RUN UP key. The light on the key will turn off.

19. To save the run-up-control settings, refer to Saving a Program in thissection.

20. Record the run-up-control settings. Refer to Record of ProgramSettings at the end of this section.

Copy all of the run-up settings from one output to another output (whenusing two run-up control systems) or from one program to anotherprogram. If the output to which the settings are copied has existingsettings, the copied settings will replace (overwrite) the existing settings.

1. If the program containing the pattern to be copied is not active, makeit active. Refer as needed to Activating a Program in this section. Ifthe light on the RUN UP key is not on, press the RUN UP key. Selectthe output that has the settings to be copied. The number of theoutput (1 or 2) will flash.


3. Press the COPY key. The word COPY will briefly appear in thedisplay and the settings of the run-up output will be copied. The lighton the SHIFT key will turn off.

4. Use the up or down key to select the output at which to insert thecopied settings. The number of the output will flash.

NOTE: Other options include exiting the current program, activatinganother program, and pasting the copied run-up settings in the newprogram.


6. Press the PASTE key. The word PASTE will briefly appear in thedisplay and the copied settings will be inserted for the selectedoutput. The light on the SHIFT key will turn off.

7. To save this change, refer to Saving a Program in this section.

Copying Run-Up-ControlSettings

Program Setup6-30


237514D02Issued 2/10

This part of Section 6 contains the following procedures on how tomanage programs:

� Activating a Program� Changing a Program� Saving a Program� Copying a Program� Overwriting a Program� Recording Program Settings

For instructions on using programs from a remote location, refer toActivating a Program Remotely in Operation.

Use this procedure to change the active program from the one that iscurrently active to the one to be used. Determine the active program bychecking the left window of the display. If this window is blank, the activeprogram will be displayed by pressing the USE key.

NOTE: To do this procedure, the REMOTE light on the operator panelmust be off. If it is on, the USE key will be locked and programs cannotbe changed from the operator panel. To obtain access to the USE key,refer to Switching Between Local and Remote Program Activation inOperation.

1. If the light on the RUN key is on, press the key. The light will turn offand, if the production line is running, the system will stop generatingpattern sets.

NOTE: If the production line is running before exiting the run mode,the unit will start generating the pattern set of the activated program inthe middle of the production run.

2. Press the USE key. The light on the key will turn on and the numberof the active (ACTIV) program will flash in the left window of thedisplay.

3. To activate another program, use the up or down key to change theflashing number to the number of the stored program to be activated.

4. Press ENTER. The display will flash the word WAIT while theprogram is loaded. Then the number of the program selected willappear in the left window of the display and the pattern-definitionscreen will appear on the display. The light on the USE key will turnoff.

5. Program Management

Activating a Program

Program Setup 6-31


237514D02Issued 2/10

5. Once a program is active, the following objectives can be achieved:

Table 6-8 Different Objectives Achieved with an Active Program

Objective Where to Find Instructions

Run the program Refer to Running a Program inOperation.

Modify the program settings (andsave the new settings)

Refer to Pattern Definition in thissection.

Use the program as the basis forcreating a new program

Refer to Pattern Definition in thissection.

Make online adjustments to theprogram

Refer to the procedures formaking online adjustments inOperation.

5742076A

Fig. 6-16 Example of Activating Program Number 3

Program Setup6-32


237514D02Issued 2/10

Use the procedures in Program Setup to make changes to any storedprograms. As soon as the first change to any program is made, theprogram number in the left window of the display will change from thenumber of the program activated to two dashes (- -). The dashesindicate that the program has been changed and that a modified,temporary, and unsaved program is now being displayed. Continue tomake changes to the program as needed. Upon completion:

� Save the temporary program as a new program by saving it in thenext free program number (which allows the activated program toretain its original settings), or

� Replace the program activated with the temporary program byoverwriting the active program (and saving the temporary programto the number of the active program number), or

� Erase the temporary program from memory by making any storedprogram active.

Use this procedure to save a changed program or to copy a storedprogram and save it to a different program number.

1. Press the SAVE key. The light on the key will turn on.

2. Check the display and refer to the following table for the appropriateaction.

Table 6-9 Instructions for Entering Password

Status of Display Action

The left window of the displayflashes the number of the active(ACTIV) program.

Go to step 3.

The display prompts passwordentry (PASSW).

Change the number displayed onthe screen (500) to the passwordand press ENTER. The leftwindow of the display will flashthe number of the active (ACTIV)program. Go to step 3.

Changing a Program

Saving a Program

Program Setup 6-33


237514D02Issued 2/10

3. Use the revised or stored program to

� overwrite an existing program, or� create a new program

4. Take one of the following actions shown in Table 6-10:

Table 6-10 Different Ways to Save a Program

Objective Action

Overwrite a program Take no action to overwrite the active(ACTIV) program. To overwrite anotherstored (USEd) program, use the navigationkeys to select it.

Create a new program Press the up key until the word FREE isdisplayed.

5. Press ENTER. The word WAIT will briefly flash in the display. Thenewly saved program will become the active program and thepattern-definition screen will appear on the display.

Use this procedure to make a copy of an existing saved program.

1. Make the program to be copied active. Refer to Activating a Programin this section.

2. Press the SAVE key. The light on the key will turn on, theabbreviation ACTIV will show in the display, and the number of theprogram that was activated will flash in the left window of the display.

3. Press the up key until the word FREE shows on the display. Thenumber flashing in the left window of the display is the first freeprogram number.

4. Press ENTER. The word WAIT will appear briefly on the display andthe existing program will be copied and given the free programnumber. The new copy of the existing program (with its new number)will now be the active program. The pattern-definition screen willappear on the display.

Copying a Program

Program Setup6-34


237514D02Issued 2/10

Use this procedure to overwrite an existing program.

NOTE: When overwriting an existing program, all settings will be lost.

1. If the program to be overwritten is not active, activate it at this time.Refer to Activating a Program in this section.

2. Make any changes to this program. The program number will changeto two dashes (- -) to show that the active program has beenmodified.

3. Press the SAVE key. The light on the key will turn on.

4. Use the up or down key to select the program to be overwritten.

5. Press ENTER. The word WAIT will appear briefly on the display andthe program selected will be overwritten with the settings of the activeprogram. The pattern-definition screen will appear on the display.

To record settings, refer to Record of Program Settings at the end of thissection.

Overwriting a Program

Recording Program Settings

Program Setup 6-35


237514D02Issued 2/10

Use the following chart to record program settings. If settings for morethan one program are to be recorded, make copies of these pages. IfPatternView software is installed on a personal computer, usePatternView to record and print settings.

Table 6-11 Pattern SettingsPattern Generated By Gun No. 1 Trigger Assigned to Gun No. 1 =

Bead Number BeadOffset

BeadLength

BeadNumber

BeadOffset

BeadLength

BeadNumber

BeadOffset

BeadLength

1 9 17

2 10 18

3 11 19

4 12 20

5 13 21

6 14 22

7 15 23

8 16 24

Pattern Generated By Gun No. 2 Trigger Assigned to Gun No. 2 =


BeadLength

BeadNumber

BeadOffset

BeadLength

BeadNumber

BeadOffset

BeadLength

1 9 17

2 10 18

3 11 19

4 12 20

5 13 21

6 14 22

7 15 23

8 16 24


6. Record of ProgramSettings

Program Setup6-36


237514D02Issued 2/10



BeadLength

BeadNumber

BeadOffset

BeadLength

BeadNumber

BeadOffset

BeadLength

1 9 17

2 10 18

3 11 19

4 12 20

5 13 21

6 14 22

7 15 23

8 16 24



BeadLength

BeadNumber

BeadOffset

BeadLength

BeadNumber

BeadOffset

BeadLength

1 9 17

2 10 18

3 11 19

4 12 20

5 13 21

6 14 22

7 15 23

8 16 24

NOTE A: Store up to 50 programs in memory. Make a copy of this form for recording the pattern set of each program createdand saved.

Table 6-12 Run-Up-Control SettingsAbbreviation ofRun-Up Setting

Name of Run-Up Setting

(See Note A)

Settingsfor

Run-Up Output 1

Settingsfor

Run-Up Output 2

P1/SPEEd Line speed for first point on run-up curve

P1/PRESS Output percentage for first point on run-up curve

P2/SPEEd Line speed for second point on run-up curve

P2/PRESS Output percentage for second point on run-upcurve

LO/LIMIT Minimum output percentage

HI/LIMIT Maximum output percentage

P/PURGE Output percentage for purging guns

NOTE A: Run-up control is an optional feature. Record run-up settings only if the unit is equipped with this option.

6. Record of ProgramSettings (contd.)

Program Setup 6-37


237514D02Issued 2/10

Table 6-13 Program Options SettingsNumber andAbbreviation ofSetting

Name of Setting Possible Settings Your Setting

(1) T-MIN Minimum distance between trigger events fortrigger 1

- - - - to 10,000 mm

(- - - - to 393.7 in.)

Minimum distance between trigger events fortrigger 2

- - - - to 10,000 mm

(- - - - to 393.7 in.)

(2) T-MAX Maximum distance between trigger events fortrigger 1

- - - - or 100 mm to 10,000mm

(3.94 in. to 393.7 in.)

Maximum distance between trigger events fortrigger 2

- - - - or 100 mm to 10,000mm

(3.94 in. to 393.7 in.)

(3) b-TYP Bead type 0 (solid)

1 (stitched)

2 (dot)

3 (modulated)

4 (random-length)

(4) G-SAV Percentage glue savings 10−90 %

(4) TIME Gun-on time for producing dot beads 0.5−1999.9 ms

(4) SPEEd Activating line speed for modulated beads 0−300 m/min (0−990ft/min)

(5) INTVL Bead interval for stitched, dot, or modulated beads 1 mm−10,000 mm

(0.1 in.−394 in.)

(6) GLUE Consecutive glue sequence for palletizing 1−1000

(7) SKIP Consecutive skip sequence for palletizing 0−1000

Program Setup6-38


237514D02Issued 2/10


237514D02Issued 2/10

Section 7

Operation

Operation7-0


237514D02Issued 2/10

Operation 7-1


237514D02Issued 2/10

Section 7Operation

This section describes how to operate the pattern control system. It isdivided into three major parts:

� Operating Procedures� Monitoring Procedures� Procedures for Remote Operation

The first two parts of this section contain procedures that apply to allunits. The third part contains one procedure that applies to all units,Stopping the System Remotely (with Fault Notification). The rest of theprocedures in this part apply only to units with the optional I/O board.The optional I/O board provides the capability for remote activation ofprograms and remote monitoring of faults and warnings.

5742060A

ÄÄÄÄÄÄÄÄÄÄÄÄ

ÄÄÄÄÄÄÄÄÄÄ

Fig. 7-1 Operator at Pattern Control Operator Panel

1. Introduction

Operation7-2


237514D02Issued 2/10

Observe the following warnings when operating the pattern controlsystem.

WARNING: Proceed with caution after connecting,disconnecting, or making any type of change to wiring orequipment connected to the pattern control unit. After makingany modifications to wiring or devices connected to the patterncontrol, follow the checkout procedures in Preparation for Setupin Installation. Failure to follow these procedures as well asother procedures required for attached equipment can result inpersonal severe injury.

WARNING: Proceed with caution after activating or revisingany program stored in the pattern control for the first. Proceedwith caution after making any changes to or replacing anyequipment attached to the pattern control unit. Changes toprograms or equipment can produce unexpected results. Takeprecautions to protect personnel from harm or injury prior torunning any new or changed program or equipment for the firsttime. This precaution is required to uncover any undesirableand potentially dangerous conditions created by these changes.

Make several precautionary runs of new or changed programs andequipment before fully enabling attached equipment and power sources.These trial runs should include the following checks:

1. Running the program through all conditions and modes of operationwith sources of hydraulic energy removed and pressure relieved fromthe system. During this checkout, make sure that triggers aredetected and guns open and close as expected.

2. Running the program through all conditions and modes of operationwith energy disconnected from devices attached to the fourpattern-control gun outputs.

3. Conducting any additional trial runs needed for the safe and thoroughcheckout of the system that the pattern control is used in.

WARNING: Failure to observe precautions before running anew or changed program for the first time can result in severepersonal injury.

2. Safety in Operation

Operation 7-3


237514D02Issued 2/10

This part of Section 7 contains the following procedures:

� Starting the System� Shutting Down the System� Purging the Guns� Activating a Program� Running a Program� Stopping a Program� Making Online Pattern Adjustments� Making Online Volume Adjustments� Making Online Adjustments to Bead-Type Settings

To operate the pattern control from a remote location, refer to Proceduresfor Remote Operation in this section.

Use this procedure to start the pattern control system after it has beenshut down.

1. Apply power to the pattern control system in one of the followingways:

� Turn on the power switch (if one is present) on the external powersupply.

� Close the circuit breaker for the pattern control system.

After a system test of the display and lights, the word WAIT will flashbriefly on the display while the settings of the active program aretransferred to the operator panel. Then, if no faults or warnings exist,the pattern-definition screen (the default screen) will appear on thedisplay. It will show the number of the active program and some ofthe pattern settings for the program.

NOTE: If auto-start has already been set up in the system, the lighton the RUN key will turn on automatically and the system will beready to generate pattern sets as soon as the READY light turns onand the production line starts. To see a list of conditions necessaryfor the READY light to turn on, refer to Indicator Lights in OperatorPanel Overview.

3. Operating Procedures

Starting the System

Operation7-4


237514D02Issued 2/10

5742059A

Fig. 7-2 Turning On the Pattern Control at the Power Supply

2. To run a program other than the one that is currently active, activatethis program now. Refer as needed to Activating a Program in thissection.

NOTE: The active program at startup will always be the program thatwas active when the unit was shut down.

3. Prepare each gun in the system for operation as follows:

� Air-operated guns: turn on the operating air.� Electric guns: turn on the gun driver.

4. Wait for the READY light to turn on.

5. Press the RUN key. The light on the key will turn on.

Starting the System (contd.)

Operation 7-5


237514D02Issued 2/10

5742049A

Fig. 7-3 Pressing the RUN Key

6. Start the production line. Pattern generation will begin when the firstproduct that the trigger has sensed reaches the guns.

Use this procedure to shut down the pattern control system.

1. Stop the production line.

2. To purge the guns to relieve pressure in the hot melt system, refer toPurging the Guns.

NOTE: If the auto-start feature is in use, skip steps 3 and 4. The unitwill start automatically when the next production run starts and theREADY light turns on. If steps 3 and 4 are skipped, the entire patterncontrol system will start automatically.

3. Turn off the gun actuators (the pneumatic solenoid valves or theelectric gun drivers).

4. Turn the unit off at the external power supply.

Shutting Down the System

Operation7-6


237514D02Issued 2/10

Use this procedure to purge all guns or the gun connected to any singleoutput. Purging removes trapped air or char from a gun if thehot-melt-system pump is operating, and it relieves pressure at the gun ifthe pump is not operating.

NOTE: Before purging, the READY light must be on and the light on theRUN key must be off.

1. Press the PURGE key. The light on the key will turn on and thenumber 1 will flash on the display.

2. To purge gun 1, go to step 3. To purge another gun, use the up keyto display the gun number of the gun to be purge. To purge all gunsat once, display the number 0.

Table 7-1 Options for Purging

Gun or Guns to be Purged Number To Display in theGun-Number Window

Gun 1 1

Gun 2 2

Gun 3 3

Gun 4 4

All guns 0

3. Start the purge by pressing and holding the ENTER key. The wordPURGE will appear on the display while the purge operation takesplace. Release the key to stop the purge operation.

NOTE: Between the time that the key is pressed and the purgingstarts, there is typically a delay of approximately one-half a second.

Purging the Guns

Operation 7-7


237514D02Issued 2/10

4. Press the PURGE key. The light on the key will turn off.

5742050A

Fig. 7-4 Purging All Guns

Use this procedure to change the active program from the one that iscurrently active to the one program to be used. The active program canbe determined by checking the left window of the display. If this windowis blank, the active program will be displayed when the USE key ispressed.

NOTE: The REMOTE light on the operator panel must be off. If it is on,the USE key will be locked and programs cannot be changed. To obtainaccess to the USE key, refer to Switching Between Local and RemoteProgram Activation in this section.

NOTE: If the light on the RUN key is on, press the key to exit the runmode before starting this procedure. If the production line is running withproducts on it before exiting the RUN mode, the unit will start generatingthe pattern set of the program that was activated in the middle of theproduction run.

1. Press the USE key. The light on the key will turn on and the numberof the active program will flash in the left window of the display.

Activating a Program

Operation7-8


237514D02Issued 2/10

2. To activate another program, use the up or down key to change theflashing number to the number of the stored program to be activated.

3. Press ENTER. The display will flash the word WAIT while theprogram is loaded. Then the number of the program selected willappear in the left window of the display, the pattern-definition screenwill be displayed. The light on the USE key will turn off.

4. Once a program is active:

Table 7-2 Different Objectives for Activating a Program

Objective Where to Find Instructions

Run the program Refer to Running a Program inthis section.

Modify the program settings (andstore the new settings)

Refer to Program Setup.

Use the program as the basis forcreating a new program

Refer to Program Setup.

Make online adjustments to theprogram

Refer to one of the procedures formaking online adjustments in thissection.

EXAMPLE: Figure 7-5 shows how to change the active program fromProgram No. 1 to Program No. 3.

Activating a Program (contd.)

Operation 7-9


237514D02Issued 2/10

5742076A

Fig. 7-5 Example of Activating a Program

Operation7-10


237514D02Issued 2/10

Use this procedure to run a program from the operator panel.

1. Make sure that the READY light is on.

5742051A

Fig. 7-6 The READY Light Turned On

2. If the program to be run is active, press the RUN key. If the programto be run is not active, refer to the previous procedure, Activating aProgram, and change the active program to the one to be run. Thenpress the RUN key.

3. If the production line is not running, start the production line. Patterngeneration will begin when the first product that the trigger hassensed reaches the guns.

5742049A

Fig. 7-7 Pressing the RUN Key to Enter the Run Mode

Running a Program

Operation 7-11


237514D02Issued 2/10

Use this procedure to stop the program that is running.

1. If the production line is running, stop it (or stop the flow of products onthe line).

NOTE: If the system is set up to receive a warning when theminimum distance between trigger events is exceeded (to detectjams) and the flow of products stops while the line is running, theALARM light will flash, indicating a warning (WARN 13 or WARN 14).The reason for the warning is that no trigger signals are beingreceived. For more information, refer to Understanding ProgramOptions Settings in Program Setup.

2. Press the RUN key. The light on the key will turn off and the systemwill stop generating pattern sets, even if the production line continuesto run.

NOTE: Depending upon the objective, maintain the system in runmode. The control will not generate pattern sets unless the line ismoving and a trigger is activated.

5742052A

Fig. 7-8 Pressing the RUN Key to Exit the Run Mode

Stopping a Program

Operation7-12


237514D02Issued 2/10

Use this procedure to adjust bead positions and bead lengths while theproduction line is running. Use the copy and delete functions to makeonline adjustments to a pattern set. Refer as needed to PatternDefinition in the previous section, Program Setup.

1. Make sure the pattern-definition screen, shown at the top ofFigure 7-9, appears on the display. If the pattern-definition screen isnot on the display, one of the following keys is active (as indicated byits light being on): one of the SYSTEM SETTINGS keys, one of thePROGRAM SETTINGS keys, or the PURGE key. Press the key toturn it off. Its light will turn off and the pattern-definition screen willappear on the display.

2. Use the navigation keys to change the position or length of anybeads. Within seconds, the pattern control will

a. implement changes on the production line

b. change the active program number in the left window of thedisplay to two dashes (- -) to indicate that the active program hasbeen changed and that a modified, temporary, and unsavedprogram is now being displayed (see Figure 7-9)

c. flash the light on the SAVE key as a reminder that temporaryprogram settings have not yet been saved

3. Continue making adjustments to the temporary pattern set until alladjustments have been made.

4. Upon completion of online adjustments, the following objectives canbe achieved by taking the appropriate action.

Table 7-3 Different Options After Making Online Adjustments

Objective Action

Continue running the temporaryprogram

None

Return to the original program Press the USE key and then theENTER key. Temporary programsettings will be lost.

Store the temporary program as anew program or overwrite thesettings of an existing program

Store the program. Refer toSaving a Program in the previoussection, Program Setup.

Stop running the temporaryprogram

Press the RUN key. The light onthe key will turn off. Thecontroller will retain temporarysettings until activating anotherprogram or turning the unit off.

Making Online PatternAdjustments

Operation 7-13


237514D02Issued 2/10

EXAMPLE: Figure 7-9 shows how to decrease the length of beadnumber 3 from 20 mm to 15 mm while the production line is running. Theprogram number changes to two dashes to show that the programsettings have not been saved.

5742077A

Fig. 7-9 Example of Making an Online Adjustment to Bead Number 3

Operation7-14


237514D02Issued 2/10

If the unit includes the optional I/O board and the required run-up-controlequipment is installed, use this procedure to adjust bead volume whilethe production line is running.

1. Make sure the pattern-definition screen, shown at the top ofFigure 7-10, appears on the display. If the pattern-definition screen isnot on the display, one of the following keys is active (as indicated byits light being on): one of the SYSTEM SETTINGS keys, one of thePROGRAM SETTINGS keys, the SHIFT key, or the PURGE key.Press the key to turn it off. Its light will turn off and thepattern-definition screen will appear on the display.

2. Press the up key until the second screen shown in Figure 7-10appears on the display. Note that the icon shown in the secondwindow has changed from the gun icon to the run-up icon, indicatingthat the control is ready to adjust bead volume.

3. If the number of the run-up output to be selected is not shown, pressthe up or down key once more to select the output that is controllingthe bead volume.

4. Use the navigation keys to increase or decrease the currentpercentage output. Within seconds, the pattern control will

a. change the bead volume in the patterns being generated

b. change the active program number in the left window of thedisplay to two dashes (- -) to indicate that the active program hasbeen changed and that a modified, temporary, and unsavedprogram is now being displayed (see Figure 7-10)

c. flash the light on the SAVE key as a reminder that temporaryprogram settings have not yet been saved.

NOTE: An increase in bead volume will take effect faster than adecrease in bead volume.

EXAMPLE: Figure 7-10 shows how to change the bead volume ofrun-up output 1 from 66 percent to 59 percent while the production line isrunning. The program number changes to two dashes to show that theprogram settings have not been saved.

Making Online VolumeAdjustments

Operation 7-15


237514D02Issued 2/10

5742078A

Fig. 7-10 Example of Making an Online Adjustment to Bead Volume

Operation7-16


237514D02Issued 2/10

5. Upon completing online adjustments, any of the following objectivescan be achieved by taking the appropriate action.


Objective Action


None


Store the temporary program as anew program or overwrite thesettings of an existing program(see Note A)

Store the program. Refer toSaving a Program in ProgramSetup.


Press the RUN key. The light onthe key will turn off. Thecontroller will retain the settings ofthe temporary program untilactivating another program orturning the unit off.

NOTE A: Be aware that changing the output percentage shifts theentire run-up curve and therefore changes the settings forpoint 1 (P1) and point 2 (P2) on the curve. Refer to Setup ofRun-Up Control in Program Setup for more information.

Making Online VolumeAdjustments (contd.)

Operation 7-17


237514D02Issued 2/10

Use this procedure to make online adjustments to bead-type settings.

1. Press the OPTIONS key. If the password feature is enabled for thiskey, enter the password to change any settings.

2. Use the procedure Creating Custom Bead Patterns in the previoussection, Program Setup, to make any change to the bead-typesettings. Within seconds, the pattern control will

a. implement changes on the production line

b. change the active program number in the left window of thedisplay to two dashes (- -) to indicate that the active program hasbeen changed and that a modified, temporary, and unstoredprogram is now being displayed

c. flash the light on the SAVE key as a reminder thattemporary-program settings have not yet been saved.

3. Upon completing nline adjustments, press the OPTIONS key. Thelight on the key will turn off.

4. The following objectives can be achieved by taking the appropriateaction.


Objective Action


None


Store the temporary program as anew program or overwrite thesettings of an existing program

Store the program. Refer toSaving a Program in the previoussection, Program Setup.


Press the RUN key. The light onthe key will turn off. Thecontroller will retain temporaryprogram settings until activatinganother program or turning theunit off.

Making Online Adjustments toBead-Type Settings

Operation7-18


237514D02Issued 2/10

EXAMPLE: Figure 7-11 shows how to change the percentage of gluesavings from 25 percent to 30 percent while the production line isrunning. The program number changes to two dashes to show that theprogram settings have not been saved.

5742079A

Fig. 7-11 Example of Making Online Adjustments to Glue Savings

Making Online Adjustments toBead-Type Settings (contd.)

Operation 7-19


237514D02Issued 2/10


� Understanding Monitoring Options� Monitoring System Operation� Resetting the Product Count to Zero� Monitoring Bead Volume� Checking Faults and Warnings� Clearing a Fault� Clearing a Warning� Checking Program or System Settings

To monitor the pattern control system from a remote location, refer toProcedures for Remote Operation in this section.

5742053A


ERIES

Fig. 7-12 Display Set to Monitor Line Speed

4. Monitoring Procedures

Operation7-20


237514D02Issued 2/10

Use the display to monitor line speed, product count, and other systemconditions that change. The following table provides a complete list ofmonitoring options and explains each one.

Table 7-6 Monitoring Options

Number andAbbreviation of

MonitoringOption

Name of Monitoring Option Explanation of Option

(1) SPEEd Current production line speed Shows current production line speed in meters/minute (orfeet/minute) as measured by the encoder

(2) RATE Current product rate at trigger 1 Shows the current product rate at trigger 1 in pieces perminute

(3) RATE Current product rate for trigger 2 Shows the current product rate at trigger 2 (if used) inpieces per minute

(4) CNT/K Current total product count fortrigger 1

Shows the current total product count for trigger 1 dividedby 1000. To obtain the product count, multiply the numberon the screen by 1000.

(5) CNT/K Current total product count fortrigger 2

Shows current product count for trigger 2 (if installed)divided by 1000. To obtain the product count, multiply thenumber on the screen by 1000.

(6) VER-O Current version ofoperator-panel firmwareinstalled

Shows the current version of firmware installed on thedisplay board of the operator panel

(7) VER-C Current version ofmain-control-board firmwareinstalled

Shows the current version of firmware installed on the maincontrol board

(8) RUNPR Status of remote run-permissiveinput

Displays 0 if the unit is not permitted to run (input switch isopen). Displays 1 if the unit is permitted to run (input switchis closed)

(9) ENAbL

(units withoptional I/Oboard only)

Remote-enable status (typicallyused on units with I/O boardoption to indicate that the hotmelt system is ready)

Displays 0 if unit is not remotely enabled. Displays 1 if theunit is remotely enabled (or if the enable feature is notinstalled)


Understanding MonitoringOptions

Operation 7-21


237514D02Issued 2/10

Number andAbbreviation of

MonitoringOption

Name of Monitoring Option Explanation of Option

(10) dISAb

(units withoptional I/Oboard only)

Remote unit-disable status Displays 0 if the guns and triggers are not remotely disabled(or if the enable feature is not installed). Displays 1 if theguns and triggers are remotely disabled.

(11) GLUE Current count of consecutiveproducts glued (counted bytrigger 1)

Shows current count of consecutive products glued whenprogram is set up for palletizing. To reset the glue/skipcount to zero, press the RUN key to take the system out ofthe run mode and then press the RUN key again to re-enterthe run mode. The next product that passes the trigger willstart the glue count at one.

(12) SKIP Current count of consecutiveproducts skipped (counted bytrigger 1)

Shows current count of consecutive products skipped whenprogram is set up for palletizing. To reset the glue/skipcount to zero, press the RUN key to take the system out ofthe run mode and then press the RUN key again to re-enterthe run mode. The next product that passes the trigger willstart the glue count at one.

(13) GLUE Current count of consecutiveproducts glued (counted bytrigger 2)

Shows current count of consecutive products glued whencontrol is set up for palletizing. To reset the glue/skip countto zero, press the RUN key to take the system out of the runmode and then press the RUN key again to re-enter the runmode. The next product that passes the trigger will start theglue count at one.

(14) SKIP Current count of consecutiveproducts skipped (counted bytrigger 2)

Shows current count of consecutive products skipped whencontrol is set up for palletizing. To reset the glue/skip countto zero, press the RUN key to take the system out of the runmode and then press the RUN key again to re-enter the runmode. The next product that passes the trigger will start theglue count at one.

Operation7-22


237514D02Issued 2/10

Use this procedure to monitor the operation of the pattern control system.Refer to Understanding Monitoring Options to see a complete list ofmonitoring options and an explanation of each.

1. If the light on the MONITOR key is not on, press the MONITOR key.The light will turn on and the monitoring icon will appear on thedisplay (see Figure 7-13).

2. Use the up or down key to select the monitoring option.

3. Monitor system operation for as long as necessary. The monitorscreen will remain on the display unless

� one of the eight function keys below the display is pressed� the PURGE key is pressed� the system is shut down and then turned back on

The display will exit the monitoring mode in any of these situations. Ifthe MONITOR key is pressed again, the display will show the defaultmonitoring option, line speed (SPEEd). For other monitoring options,use the up or down key to select them.

4. To exit the monitor mode, press the MONITOR key. The light on thekey will turn off.

EXAMPLE: Figure 7-13 shows how to select the product count at trigger1 to monitor. The current count displayed is 1392 products.

Monitoring System Operation

Operation 7-23


237514D02Issued 2/10

5742080A

Fig. 7-13 Example of Selecting a Monitoring Option

Operation7-24


237514D02Issued 2/10

Use this procedure to reset the product count to zero.

1. Display the product count to be reset (monitoring option 4 or 5).Refer as needed to the previous procedure, Monitoring SystemOperation.


3. Press the DELETE key. The letters dELET will appear briefly on thedisplay and the count will reset to 0.000. The light on the SHIFT keywill turn off.

EXAMPLE: Figure 7-14 shows how to reset the product count at trigger1 to zero.

5742081A

Fig. 7-14 Resetting the Product Count to Zero

Resetting the Product Count toZero

Operation 7-25


237514D02Issued 2/10

If the unit has the optional I/O board and the required run-up-controlequipment is installed, use this procedure to monitor the current outputpercentage for controlling bead volume.

1. Make sure the pattern-definition screen appears on the display. If thepattern-definition screen is not on the display, one of the followingkeys is active (as indicated by its light being on): one of the SYSTEMSETTINGS keys, one of the PROGRAM SETTINGS keys, or thePURGE key. Press the key to turn it off. Its light will turn off and thepattern-definition screen will appear on the display.

2. Press the up or down key until the screen shown in Figure 7-15appears on the display. Note that the icon shown in the secondwindow has changed from the gun icon to the run-up icon, indicatingthat the control is ready to monitor (or adjust) bead volume.

5742108A

Fig. 7-15 Screen for Monitoring Bead Volume

3. Check the second window of the display to see if the number of therun-up output to be monitored is selected. If it is not shown, press theup or down key once more to select the output that is controlling thebead volume.

Monitoring Bead Volume

Operation7-26


237514D02Issued 2/10

When the ALARM light turns on, a fault or a warning has occurred. Thelight will

� flash to indicate a warning� turn on and remain on to indicate a fault

NOTE: With all faults and some warnings, the control will stopgenerating pattern sets. With other warnings, pattern generationcontinues but with the pattern sets may be flawed due to the problemcausing the warning.

Use the following procedure to determine the cause of a fault or warning.To clear a warning or a fault, refer to Clearing a Warning or Clearing aFault in this section.

1. If the light on the MONITOR key is not on, press the MONITOR key toswitch the display to the monitor screen.

2. See whether the word FAULT or WARN appears on the display andnote the number shown.

NOTE: In checking the display for faults or warnings, the abbreviationFLOG, which stands for Fault Log, may appear. The fault log is ahistory of special faults and fault codes that is intended for Nordsontechnicians in troubleshooting situations. For more information on thefault log, refer to Troubleshooting from Fault Log Codes inTroubleshooting.

3. Determine the cause of the fault or warning by referring toTroubleshooting from Fault and Warning Codes in Troubleshooting.

4. If more than one fault or warning exists, use the up or down key todisplay any additional faults or warnings.

Checking Faults and Warnings

Operation 7-27


237514D02Issued 2/10

When a fault occurs, the ALARM light will turn on and remain on andpattern generation will stop. If a fault occurs when the pattern control isnot running, generating patterns cannot commence.

Use this procedure to clear a fault.

1. Correct the problem that caused the fault. To find the cause of thefault, refer as needed to Checking Faults and Warnings in thissection.

2. If the light on the MONITOR key is not on, press the MONITOR key toswitch the display to the monitor screen. The display will show thefault and a number that identifies the cause of the fault.

NOTE: If the display is not currently showing the fault message, usethe up or down key to scroll until the word FAULT appears on thedisplay.


4. Press the DELETE key. The word FAULT will be removed from thedisplay and the light on the SHIFT key will turn off.

5. To resume operation, press the RUN key. Pattern generation willbegin when products start passing through the pattern control system.

Clearing a Fault

Operation7-28


237514D02Issued 2/10

With one exception, all warnings are displayed for at least 30 seconds. Ifthe problem causing the warning has corrected itself or is not a recurringproblem, the warning will be removed after 30 seconds and the ALARMlight will turn off unless the latching feature is turned on (refer toUnderstanding Basic System Settings in System Setup). If the latchingfeature is turned on, the warning and flashing light will remain until theyare cleared.

The low-line-speed warning is an exception. As soon as line speedrecovers to exceed the line-speed setting for this warning, the warningclears unless the latching feature has been set to latch all warnings. Thefollowing procedure details how to clear the warning.

1. Correct the problem causing the warning. Refer as needed toTroubleshooting from Fault and Warning Codes in Troubleshooting.When the problem has been corrected, the warning will be removed(and the ALARM light will stop flashing) unless the latching feature isturned on. If the latching feature is on, continue at step 2.

2. If the light on the MONITOR key is not on, press the MONITOR key toswitch the display to the monitor screen.

3. The display will show the most recent warning that has not beencleared. If there is more than one uncleared warning, use the up ordown key to display any additional warnings.

4. When the display is showing the warning to be cleared, press theSHIFT key. The light on the key will turn on.

5. Press the DELETE key. The message will be cleared and the light onthe SHIFT key will turn off. The word WARN will no longer bedisplayed and the ALARM light will stop flashing.

NOTE: The ALARM light will continue to flash if

� the problem or condition causing the warning has not beencorrected

� the problem or condition has recurred

� more than one warning was present and only one warning hasbeen cleared

EXAMPLE: Figure 7-16 shows how to clear a latched warning whenthe ALARM light starts flashing.

Clearing a Warning

Operation 7-29


237514D02Issued 2/10

5742082A

Fig. 7-16 Clearing a Latched Warning

Operation7-30


237514D02Issued 2/10

Use this procedure to view any settings. View any program or systemssettings even if the keys that provide access to these settings require apassword to change the settings.

1. Press any key in the SYSTEM SETTINGS or PROGRAM SETTINGSareas of the operator panel. The light on the key will turn on.

2. If the display asks the password (by displaying the abbreviationPASSW), press ENTER. The display will show the first setting.

3. Use the navigation keys to display any other settings to be viewed.

4. When finished, press the function key that was pressed in step 1.The light on the key will turn off.

Checking Program or SystemSettings

Operation 7-31


237514D02Issued 2/10


� Stopping the System Remotely (with Fault Notification)� Disabling the Unit Remotely� Switching Between Local and Remote Program Activation� Recalling a Program� Stopping a Program Remotely� Monitoring Faults and Warnings� Operating the System from a Personal Computer

The first procedure applies to all units. The next four procedures applyonly to units that are equipped with the optional I/O board and include therequired I/O devices. The last procedure provides information aboutusing a personal computer to operate the pattern control system.

Use this procedure to stop the generation of pattern sets and remove theunit from the run mode.

1. Turn on the run-permissive switch at the remote switch location.

2. To resume operation, turn off the run-permissive switch.

Use this procedure to disable the unit from a remote location. Whendisabled, the system is prevented from operating the guns. The status ofthe RUN light will not change. If the READY light was on, it will turn off.

1. Apply 24 VDC to terminal 18 on the I/O board. The unit will bedisabled from operation.

2. To resume operation, open the switch. If the production line isrunning and the RUN light is on, the unit will start generating patternsets.

5. Procedures for RemoteOperation

Stopping the System Remotely

Disabling the Unit Remotely

Operation7-32


237514D02Issued 2/10

Use this procedure to change from local to remote control of programactivation. Switching to remote control provides the ability to recallprograms 1−15. Control system operation can still be monitored from theoperator panel, but the USE key will be locked out.

1. Press the SET UP key. The light on the key will turn on.

2. If the display asks for the password (by displaying the abbreviationPASSW), enter the password.

3. Using the navigation keys, select the setting for remote I/Oenable (REMOT).

5742083A

Fig. 7-17 Switching to Remote Program Activation

4. To switch from local to remote operation, change the setting from 0 to1. The REMOTE light will turn on. To switch from remote to localoperation, change the setting from 1 to 0. The REMOTE light will turnoff.

5742084A1 2

Fig. 7-18 Remote Status Indicator Light

1. Remote recall of programsdisabled

2. Remote recall of programsenabled

Switching Between Local andRemote Program Activation

Operation 7-33


237514D02Issued 2/10

NOTE: When enabling the system for remote activation of programs,programs can no longer be activated from the operator panel with theUSE key.

5. Press the SET UP key again. The light on the key will turn off.

Use this procedure to recall a program from a remote location. TheREMOTE light on the unit must be on to recall programs remotely. If it isnot on, refer to Switching Between Local and Remote Program Activationin this section.

1. If pattern sets are being generated on the production line, do one ofthe following:

� stop the production line

� stop the flow of products on the line

� press the RUN key on the operator panel (the light on the key willturn off)

NOTE: If a new program is recalled when the unit is in the run modeand the production line is running with products on it, the patterncontrol will (1) stop generating pattern sets on the products betweenthe trigger and the guns and (2) start generating the pattern sets ofthe new program on products upstream of the trigger (after a delay ofa few seconds).

Recalling a Program

Operation7-34


237514D02Issued 2/10

2. Refer to the following table to set the binary switching deviceconnected to terminals X1-14, X1-15, X1-16, and X1-17 on theoptional I/O board.

Table 7-7 Binary Switch Settings for Recalling Programs Remotely

Objective Setting of Switches Connected to I/OBoard Terminals (see Note A)

X1 -17 X1 -16 X1 -15 X1 -14

Stop the program that isrunning

Off Off Off Off

Recall program 01 Off Off Off On

Recall program 02 Off Off On Off

Recall program 03 Off Off On On

Recall program 04 Off On Off Off

Recall program 05 Off On Off On

Recall program 06 Off On On Off

Recall program 07 Off On On On

Recall program 08 On Off Off Off

Recall program 09 On Off Off On

Recall program 10 On Off On Off

Recall program 11 On Off On On

Recall program 12 On On Off Off

Recall program 13 On On Off On

Recall program 14 On On On Off

Recall program 15 On On On On

NOTE A: When theses switches are on, 24 VDC is supplied to theinputs on the I/O board.

3. Resume production by the appropriate means, depending on how theproduction line was stopped in step 1. The pattern set of the recalledprogram will be generated.

Recalling a Program (contd.)

Operation 7-35


237514D02Issued 2/10

Use this procedure at the remote panel to stop a remotely activatedprogram. The REMOTE light on the operator panel must be on to do thisprocedure.

1. Set all of the switches connected to terminals X1-14 through X1-17 ofthe I/O board to off. If a pattern set was being generated, the unit willstop generating it. The RUN light on the operator panel will remainon but the READY light will turn off.

2. Stop the production line as desired. To resume operation, refer toRecalling a Program in this section.

Faults and warnings can be monitored at a remote location if remotedevices are connected to the appropriate terminals on the optional I/Oboard. The I/O board provides two sets of output contacts (defaults) thatcan be set up to:

� monitor the occurrence of a low-line-speed warning with a remotedevice

� monitor the occurrence of any warning or fault with anotherremote device.

Setting up the outputs for the other monitoring option can

� monitor the occurrence of any warning with a remote device� monitor the occurrence of any fault with another remote device.

For information on installing the remote I/O devices, refer to ConnectingInputs and Outputs to the Optional I/O Board in Installation. Forinformation on how to change the output settings, refer to UnderstandingBasic System Settings in System Setup.

Stopping a Program Remotely

Monitoring System OperationRemotely

Operation7-36


237514D02Issued 2/10

The system can be operated from a personal computer. To do this, installPatternView, the Windows-based software that was shipped with thepattern control, and connect the computer to the main control unit withthe cable supplied by Nordson. Instructions for installing and usingPatternView are provided in the PatternView User’s Guide.

When PatternView is used to control system operation, the abbreviationLOCKd appears on the display (see Figure 7-19). It indicates that all ofthe keys on the operator panel except the MONITOR key are locked.Any of the monitoring options can still be selected, but control functionscannot be performed at the operator panel.

5742126A

Fig. 7-19 Display Indication That Control Functions of Operator Panel AreInactive

Operating the System from aPersonal Computer


237514D02Issued 2/10

Section 8

Troubleshooting

Troubleshooting8-0


237514D02Issued 2/10

Troubleshooting 8-1


237514D02Issued 2/10

Section 8Troubleshooting

This section explains how to troubleshoot the pattern control system.Indications for troubleshooting include:

� symptoms of abnormal operation (such as a missing pattern), or

� notification from the controller (displayed as a warning or fault) ofsome abnormal condition.

Troubleshooting advice for these two situations is provided in the first twomajor parts of this section:

� Troubleshooting from Symptoms� Troubleshooting from Fault and Warning Codes

The section also contains three other major parts:

� Troubleshooting from Fault Log Codes� Troubleshooting Checks and Tests� Troubleshooting Aides and Reference Material

The first of these parts is intended only for the use of Nordson personnelin troubleshooting situations. The second part includes various checksand tests to help determine whether a suspected cause of a problem is infact the actual cause. The last part contains wiring diagrams and otherreference material that can be useful for troubleshooting.

1. Introduction

Troubleshooting8-2


237514D02Issued 2/10

This part of Section 8 explains how to find the cause of some basicpattern control symptoms. It includes the following troubleshootingprocedures:

� READY Light Not Turning On� All Patterns Missing (All Guns Not Firing)� Single Pattern Missing (One Gun Not Firing)� All Patterns Missing on Some Products� One or More Beads Always Out of Position� One or More Beads Sometimes Out of Position� One or More Beads Missing on Some Products� One or More Beads Too Short or Too Long� Bead Volume Too Low or Too High� Pools of Adhesive Forming When Line Stops� Settings Not Saved

2. Troubleshooting fromSymptoms

Troubleshooting 8-3


237514D02Issued 2/10

Use the following table to determine the cause of the READY light notturning on.

Table 8-1 Troubleshooting for the READY Light Not Turning On

Warning Code Explanation Recommended Action

1. Unit has been disabled(or not enabled) byremote device (unitswith optional I/O boardonly).

One of the following situations hasoccurred:

� The unit disable switch(if installed) is closed.

� The unit enable switch (ifinstalled) is not closed (typicallybecause the interlocked hotmelt system is not in the readystate)

� The unit is enabled for remoterecall of program (the REMOTElight is on), but all of the remoteprogram-setting switches areopen.

Press the MONITOR key to check thestatus of the enable and disableswitches (refer to Monitoring SystemOperation in Operation). If these arecorrectly set, check all four of the remoterecall switches. Press the MONITORkey to check the status of the enableand disable switches (refer to MonitoringSystem Operation in Operation). Ifthese are correctly set, check to see ifall four of the remote recall switches areopen.

2. Warning number 27 hasoccurred.

Programming error

NOTE: All warnings will causethe ALARM light to flash on andoff, but a warning number 27 isthe only warning that will causethe READY light to turn off.

Press the MONITOR key to see ifWARN 27 is displayed. If so, refer toTroubleshooting from Fault and WarningCodes in this section, and follow therecommended action.

3. Fault has occurred. Various possible causes. Any faultwill cause the controller to turn off theREADY light and turn on the ALARMlight.

Press the MONITOR key to check thefault code number. Then refer toTroubleshooting from Fault and WarningCodes in this section and follow therecommended action.

READY Light Not Turning On

Troubleshooting8-4


237514D02Issued 2/10

Use this procedure to determine the cause of all patterns missing. If onlyone gun is being used to produce the pattern set, refer also to SinglePattern Missing (One Gun Not Firing) for possible causes of the problem.

1. To help isolate the cause of the problem, observe the gun-outputLEDs (shown in Figure 8-3) on the main control board. Note whetherthey are turning on and off when the guns should be firing.

2. If the LEDs are not turning on, see Table 8-2 for:

� Problem with program setup� Operational problem� Problem on production line� Problem in pattern control

If the LEDs are turning on, see Table 8-2 for:

� Problem in hot melt system

Note that status of the LEDs does not help to isolate some of thepossible causes that are included in Table 8-2.

Table 8-2 Troubleshooting for All Patterns Missing

Possible Cause (General) Possible Cause (Specific) Recommended Action

1. Problem in hot meltsystem

Adhesive not yet melted Wait for system-ready light on hot meltapplicator to turn on.

Pump not running Check pump air pressure. Make surepump is turned on.

Presence of fault Check hot melt system for presence offault.

Empty tank Check tank level.

Defective hot melt unit Refer to manual shipped with unit fortroubleshooting advice.

2. Problem with programsetup

Wrong trigger associated with guns Display the pattern-definition screen andcheck trigger number window to see thatcorrect trigger is assigned to each gun.

Some other setup error Run default program (programnumber 00) to see if the systemgenerates pattern sets. If there is apattern, look for an error in programsetup.

All guns are set to generaterandom-length beads but the endmargins overlap.

Compare end-margin settings to thelength of the product. Shorten marginsif they overlap.


All Patterns Missing (All GunsNot Firing)

Troubleshooting 8-5


237514D02Issued 2/10

Table 8-2 Troubleshooting for All Patterns Missing (contd.)


3. Operational problem Pattern control not turned on Check to see that power is on atexternal power supply.

System not in run mode Make sure light on RUN key is on.

Serious warning exists. Refer to Troubleshooting from Fault andWarning Codes in this section.

READY light not on Refer to READY Light Not On in thissection.

Air supply to guns not turned on orset too low

Check air pressure setting for guns.

4. Problem withinstallation

Loose connection Check tightness of all connections tomain control board.

Encoder wired backwards Refer to Checking for Correct EncoderWiring in Installation and followprocedure.

Other wiring problem Refer to wiring diagram in Installationand check for correct connections.

Too much power draw from one ormore guns

Refer to Checking Gun Power Draw inthis section.

5. Problem on productionline

Line speed has dropped below theminimum-speed setting (MINSP).

Check line speed and either increasespeed or reduce the value entered forthis setting. Refer to UnderstandingBasic System Settings in System Setup.

6. Problem with systemsetup

GTO incorrect for all guns Check GTO (gun-to-trigger distance)settings. If they are much too large orsmall, the pattern may be generated offthe product.

Incorrect encoder gearing ratio Check the encoder gearing ratio. If it ismuch too large or small, the pattern maybe generated off the product.

7. Problem in encoder Defective encoder, incorrect encoderwiring, or loose encoder wiring

Press MONITOR key and check linespeed. Look for a speed that seems toohigh, too low, or erratic. Also check fornegative speed.

8. Problem in trigger Various possible causes Refer to Checking Trigger Operation inthis section.

9. Problem in externalpower supply

Defective power supply Check power supply.

10. Problem in patterncontrol

Blown fuse Refer to Fuse Information in this sectionand check for blown fuse.

Defective main control board orDC-converter board

If no other problem can be found,replace the main control boardassembly. Refer to the Service sectionfor the part number.

Troubleshooting8-6


237514D02Issued 2/10

Use this procedure to determine the cause of a single pattern missing.Refer also to All Patterns Missing (All Guns Not Firing).

1. If there is a missing pattern, refer to Table 8-3 for a similar possiblegeneral cause and start troubleshooting there; otherwise, go to Step2.

2. Refer to Checking the Operation of a Single Gun in this section. Thisprocedure will help to isolate the cause of these problems:

a. the gun or gun actuatorb. the pattern controllerc. some other part of the pattern control system

3. When the cause of the problem has been better defined, return toTable 8-3 for specific troubleshooting advice.

Table 8-3 Troubleshooting for Single Pattern Missing


1. Problem in gun Clogged nozzle Refer to gun manual.

Defective gun RTD

Defective gun heater

Defective gun module

2. Problem in programsetup

A trigger that is not installed isassigned to gun. Trigger 1 or trigger2 can be assigned to any gun.

Display the pattern-definition screen andcheck trigger number window to see thatcorrect trigger is assigned to gun.

Incorrect pattern setup Run test program (program number 00)to see if same pattern is missing in testprogram. If a pattern exists, look for amistake in the pattern definition.

Bead size is set for a smaller beadthan the system can produce

Increase bead size to see if problemgoes away. Small beads are harder toproduce as line speed increases,especially if the gun compensation ishigh.

Gun is set to generate arandom-length bead but the endmargins overlap.

Compare end-margin settings to thelength of the product. Shorten marginsif they overlap.


Single Pattern Missing (OneGun Not Firing)

Troubleshooting 8-7


237514D02Issued 2/10

Table 8-3 Troubleshooting for Single Pattern Missing (contd.)


3. Problem in gun actuator(pneumatic type only)

Defective solenoid valve Press the manual test button on thesolenoid valve. If the gun does notdispense adhesive, look for a problem inthe gun. If it does dispense adhesive,assume the gun is working properly andrefer to Checking the Operation of aSingle Gun. This procedure will help toisolate the problem to the solenoidvalve, the pattern control, or some otherarea.

4. Problem in gun actuator(electric gun driver only)

Defective gun driver Refer to electric gun driver manual. Orrefer to Checking the Operation of aSingle Gun in this section.

5. Problem in hot meltsystem

Gun heating zone set too low orturned off

Check zone temperature and adjust asneeded.

Hose heating zone set too low orturned off

Check zone temperature and adjust asneeded.

Defective hose Refer to hot melt system manual.

6. Problem in trigger Various possible causes If the same trigger is associated with allguns and some of these guns areproducing good patterns, eliminate thetrigger as the cause of the problem. Butif two triggers are installed and one isdedicated to the gun that is notgenerating a pattern, refer to CheckingTrigger Operation in this section.

7. Problem withinstallation

Incorrect or loose wiring Check for loose or incorrect wiring.Refer to Connecting Inputs and Outputsto Main Control Board in Installation.

Air line(s) to gun incorrectly installed(air-operated guns only)

Refer to gun manual and check forincorrectly installed air lines.

Loose or incorrect connectionbetween gun driver and gun (electricguns only)

Refer to gun manual and check for looseor incorrectly installed wiring.

Troubleshooting8-8


237514D02Issued 2/10

Use Table 8-4 to determine why the pattern control generates patternssets on some products but not on others. If it is not generating patternsets on all products, refer to All Patterns Missing.

Table 8-4 Troubleshooting for All Patterns Missing on Some Products


1. Incorrect trigger setup Trigger alignment or sensitivity isborderline, causing the trigger tosense some products and not others.

Refer to Adjusting a Trigger inInstallation and check trigger alignmentand sensitivity.

2. Incorrect setting forT-MIN

This setting (for the minimumdistance between trigger events) istoo high.

Check setting for T-MIN. It must be lessthan product spacing (pitch) to preventthe controller from ignoring someproducts. The control will ignore asecond trigger event that occurs beforethis minimum amount of line travel hasoccurred. Refer to UnderstandingProgram Options Settings in ProgramSetup.

3. Incorrect gun-to triggeroffset (GTO) valuesentered

Controller will ignore some products ifGTO values are set much lower thanthe actual distances (in combinationwith bead offset distances that aretoo high)

Check accuracy of GTO and patternsettings.

4. Program is set forpalletizing.

Controller skips the number ofproducts entered when it is set forpalletizing.

Remove palletizing settings. Refer toUnderstanding Program OptionsSettings in Program Setup.

5. Production rate exceedssystem capabilities.

More than four products are betweenone of the guns and its assignedtrigger.

Press MONITOR key and see if warningcode 1, 2, 3, or 4 is displayed. If so,refer to Troubleshooting from Fault andWarning Codes in this section forrecommended action.

6. Encoder not operatingcorrectly

Slippage in encoder gearing Check encoder mounting for possibleslippage.

Intermittent connection in encodercable

Check for secure connections at bothends of encoder cable.

All Patterns Missing on SomeProducts

Troubleshooting 8-9


237514D02Issued 2/10

Use this procedure to determine why one or more beads are out ofposition when they are consistently in the same incorrect position. Ifthe bead placement is unpredictable, however, refer to the procedureOne or More Beads Sometimes Out of Position.

1. Determine whether the problem affects

� a single bead� all the beads generated by one gun (a single pattern)� all beads generated by all guns (the entire pattern set)

NOTE: If one of the patterns has just one bead, check thetroubleshooting in Table 8-5 for both a single bead and all beads inone pattern.

2. Use the following troubleshooting table to determine the possiblecause of the problem and a recommended course of action.

Table 8-5 Troubleshooting for One or More Beads Always Out of Position


1. Single bead too close toleading edge or trailingedge

Incorrect setting used for bead offset Re-check setting for bead offset.

2. All beads in one patterntoo close to leadingedge or trailing edge

Incorrect trigger assigned to gun Make sure correct trigger (1 or 2) isassigned to gun. Triggers are assignedto guns on the pattern definition screen.

Incorrect gun compensation valuesentered

Refer to Checking Gun Compensation inthis section.

Incorrect gun-to-trigger distance(GTO) entered

Measure GTO again and change ifnecessary. An incorrect GTO will shiftthe pattern produced by the gun.

3. All beads in entirepattern set too close toleading or trailing edge

Incorrect value for encoder gearingratio

Note whether beads are too short andtoo close to leading edge or whetherthey are too long as well as too close tothe trailing edge. An encoder gearingratio that is 20% too high, for example,will produce beads that are 20% toolong and shifted toward the trailing edgeby 20%. To change the gearing ratio,refer to Setting Up the Encoder inSystem Setup.


One or More Beads Always Outof Position

Troubleshooting8-10


237514D02Issued 2/10

Table 8-5 Troubleshooting for One or More Beads Out of Position (contd.)


4. Some beads are tooclose to leading edgewhile others are tooclose to trailing edge.

Wrong program is running. Check the program number in the leftwindow of the display. Verify that theactive program is the desired program.

Active program has been changed. Check the program number in the leftwindow of the display. If two dashes (- -)appear in the window, the activeprogram has been changed.

5. Entire pattern set isgenerated off theproduct

Trigger polarity is incorrectly set,causing trigger to sense trailing edgeinstead of leading edge

Check for correct trigger polarity. Referto Determining Trigger Polarity inInstallation.

GTO setting is incorrect for all guns Measure gun-to-trigger distances againand revise GTO if needed.

Incorrect encoder gearing ratio Perform encoder setup again to checkcurrent gearing ratio. View the currentsetting by pressing the ENCODER keyand selecting the user-supplied (USER)method of encoder setup.

One or More Beads AlwaysOut of Position (contd.)

Troubleshooting 8-11


237514D02Issued 2/10

Use the following table to determine the cause of inconsistent patternplacement. If the control is producing patterns that are consistently in thewrong position, however, refer to One or More Beads Always Out ofPosition or One or More Beads Too Short or Too Long. If the beads areout of position only when line speed changes, refer to Checking GunCompensation in this section.

Table 8-6 Troubleshooting for One or More Beads Sometimes Out of Position


1. Mechanical or otherphysical problemsimpair systemperformance

Slippage occurring on production line Make sure that products do not getskewed as they pass through the patterncontrol system.

Partial clogging in nozzle Check for nozzle clogging.

Slippage in encoder gearing Check encoder mounting for possibleslippage.

2. System performance notmaximized

Encoder gearing ratio too low Check encoder gearing ratio. Anencoder with a gearing ratio of at least 1pulse/mm (25.4 pulses/in.) must beinstalled to obtain rated performance ofpattern control.

Guns with slow response time areinstalled, requiring high guncompensation settings.

Use faster guns, especially if encodergearing ratio is low. Refer to SystemDesign in Installation for informationabout the effect of gun speed on theconsistency of pattern placement.

3. System performanceexceeded

NOTE: This problem isoften the result of acombination of factorslisted in the specific-causecolumn.

Line speed too fast Keep line speed below 300 m/min (984ft/min). Increasing line speed placesincreasing demands on the control’sprocessor.

Beads too short and/or beads spacedtoo close together

Increase bead length and/or spacingbetween beads, especially if guncompensation is high and the line speedis high.

Trigger too close to one or more guns Avoid setting trigger too close to guns,especially when line speed and guncompensation are high. Refer toLocating System Components inInstallation for table showing minimumgun-to-trigger distance (GTO) withdifferent line speed andgun-compensation settings.

One or More Beads SometimesOut of Position

Troubleshooting8-12


237514D02Issued 2/10

Use Table 8-7 to determine the cause of one or more beads missing onsome products.

Table 8-7 Troubleshooting for One or More Beads Missing on Some Products


1. Gun speed too slow forhigh-performanceapplication

Required gun-compensation settingtoo high for fast line speeds incombination with short bead lengthsand/or short distance between beads

Reduce the line speed. If this works,either operate at this lower speed or useguns with a faster response time.

NOTE: Warning code 5, 6, 7, or 8 maybe displayed. If so, refer toTroubleshooting from Fault andWarning Codes.

2. Partially clogged nozzle Partial clogging is causing adhesiveto be intermittently applied.

Check for nozzle clogging and clean orreplace as needed.

One or More Beads Missing onSome Products



237514D02Issued 2/10

Use the following procedure to determine the cause of one or morebeads being too short or too long. If one of the patterns has just onebead, check the troubleshooting in Table 8-5 for both a single bead andall beads in one pattern.

1. Determine whether the problem affects

� a single bead� all the beads generated by one gun (a single pattern)� all beads generated by all guns (the entire pattern set)

2. Use the following troubleshooting table to determine the possiblecause of the problem and a recommended course of action.

Table 8-8 Troubleshooting for One or More Beads Too Short or Too Long


1. Single bead too short ortoo long

Incorrect bead-length setting Re-check bead-length setting.

2. All beads in one patterntoo short or too long

Incorrect gun-compensation value (orvalues) entered

Refer to Checking Gun Compensation inthis section.

3. All beads in entirepattern set too short ortoo long

Incorrect value entered for encodergearing ratio

Note whether beads are also too closeto leading edge as well as too short orwhether they are too close to the trailingedge as well as too long. If so, recheckencoder setup. Check the valueoriginally entered by choosing another ofthe four possible methods of encodersetup.

One wire from encoder not connected See if beads and spacing betweenbeads are twice as long as they aredefined in the program. If so, refer tothe wiring diagram in Installation andcheck the connections at X8 on the maincontrol board.

One or More Beads Too Shortor Too Long

Troubleshooting8-14


237514D02Issued 2/10

Use the following table to determine the cause of low or high beadvolume.

Table 8-9 Troubleshooting for Low or High Bead Volume


1. Bead volume too low Pump pressure too low in system withpiston pump

Increase pump pressure.

Pump pressure too high in systemwith gear pump

Decrease pump pressure.

Adhesive temperature too low insystem with piston pump

Increase adhesive temperature.

Nozzle or filter partially clogged Clean or replace nozzle or filter.

Run-up setting too low (only forsystems with optional I/O board andrun up equipment installed)

Increase run up setting. Refer toMaking Online Volume Adjustments inOperation.

Run-up curve not set up correctly(only for systems with optional I/Oboard and run up equipmentinstalled)

Redefine run-up curve. Refer toUnderstanding Run-Up Settings inProgram Settings.

2. Bead volume too high Pump pressure too high in systemwith piston pump

Decrease pump pressure.

Pump pressure too low in system withgear pump

Increase pump pressure.

Adhesive temperature too high insystem with piston pump

Decrease adhesive temperature.

Run-up setting too high (only forsystems with optional I/O board andrun-up equipment installed)

Decrease run-up setting. Refer toMaking Online Volume Adjustments inOperation.

Run-up curve not set up correctly(only for systems with optional I/Oboard and run-up equipmentinstalled)

Redefine run-up curve. Refer toUnderstanding Run-Up Settings inProgram Settings.

Bead Volume Too Low or TooHigh



237514D02Issued 2/10

Use this procedure to troubleshoot the problem of adhesive pools orpuddles forming when the line stops.

1. Press the SETUP key, display the MINSP setting (minimum-speedgun disable), and check the line speed below which the patterncontrol stops applying adhesive. If this setting is zero or a very lowline speed, increase the setting. If the results are satisfactory whenoperation is resumed, the problem is solved. If the results are notsatisfactory, go to step 2.

2. Set the pattern control to produce modulated beads below a certainline speed. For instructions, refer to Understanding Program OptionsSettings in the Program Setup section.

Use the following table to determine why the controller did not savesettings.

Table 8-10 Troubleshooting for Settings Not Saved


1. System setting (orsettings) not saved

Controller was turned off too soonafter the change was made.

If a change to a system setting has justbeen made, wait ten seconds beforeshutting the system down. Otherwise,the change will not be saved.

2. Change in programnumber not saved

Controller was turned off too soonafter the new program was activated.

If program has been activated to be theactive program at the next startup, waitten seconds before shutting the systemdown. Otherwise, the new program willnot be saved.

3. Program setting (orsettings) not saved

Change to program was not savedwith the SAVE key.

Always press the SAVE key to save anychanges to a program. Anytimechanges are made to a program, theprogram number will change to twodashes (− −) to show that the programhas been revised but not saved.Changes will be lost if they are notsaved before activating a new programor shutting the system down.

Pools of Adhesive FormingWhen Line Stops

Settings Not Saved

Troubleshooting8-16


237514D02Issued 2/10

Use Table 8-11 to determine the cause of any warning and therecommended course of action. For information on how to display a faultor warning code, refer to Checking Faults and Warnings in Operation.For information on how to clear a fault or warning, refer to Clearing aFault or Clearing a Warning in Operation.

NOTE: If a warning not listed in the following table should appear on thedisplay, call Nordson.

Table 8-11 Explanation of WarningsWarning Code Explanation Recommended Action

WARN-1 More than four products are between gun 1and its associated trigger. The system willnot generate pattern sets on the additionalproducts between the gun and trigger.

Increase distance between products, or decreasedistance between trigger and gun and revise GTOsettings. Refer to Understanding Gun Settings inSystem Setup.







WARN-5 Pattern generation error caused by gun 1 notturning on or off (or both) soon enough.Bead start point or end point has alreadypassed when signal is sent to gun actuator.

Reduce line speed or increase bead lengths,distances between beads, or gun-to-trigger distance,especially if high gun compensation is required. Usinga faster gun is also a possible solution. For moreinformation, refer to System Design in Installation.







WARN-9 Short circuit has been detected on gunactuator for gun 1. The gun will stopoperating until the problem is corrected.

Check the gun load. Refer to Checking Gun PowerDraw in this section.




3. Troubleshooting fromWarning Codes



237514D02Issued 2/10






WARN-13 Distance between products has exceededthe maximum setting (T-MAX) for trigger 1.For an explanation of this setting, refer toUnderstanding Program Options Settings.

Look for possible jam on production line.

WARN-14 Distance between products has exceededthe maximum setting (T-MAX) for trigger 2.For an explanation of this setting, refer toUnderstanding Program Options Settings.

Look for possible jam on production line.

WARN-15 Data in main controller is corrupt. Call a Nordson representative.

WARN-17 The line speed has dropped below thesetting for the low-line-speed warning(ALMSP), or the production line was stoppedwhen the pattern control was turned on.

Increase line speed or decrease setting for thelow-line-speed warning. Refer to Understanding BasicSystem Settings in System Setup.

WARN-18 Missing an encoder signal. Check for secure connection at both ends of encodercable. Make sure cable is not routed nearnoise-producing equipment, such as a motor. Makesure encoder is not driven at frequency above 100kHz (kHz = encoder rpm x 500 pulses/rev x1 min/60 sec).If so, slow the line down or change the encodergearing to reduce the gearing ratio. If problemremains, replace the cable, and if this does not work,replace the encoder and/or cable.


Troubleshooting8-18


237514D02Issued 2/10

Table 8-11 Explanation of Warnings (contd.)Warning Code Explanation Recommended Action

WARN-19 Communications error between the maincontrol board and operator panel (or the PC,if used) has occurred.

Turn the power off and back on and see if the warninggoes away. If it does not, verify that the serial portcable between the main control board and the displayboard is securely connected at both ends. Make surethat the serial-port terminator at X4 on the main controlboard is installed and secure or, if a personalcomputer is being used, that the cable is securelyconnected to X4 and the computer. Make sure alsothat the personal computer software (PatternView) isrunning.

WARN-22 Error has occurred while trying to activate orstore a program or while turning on the unit.The system will not let you use or store aparticular program.

If error occurred during store operation, try to storeprogram to another program number. If problemoccurred during the use or power-up operation, try touse the program or power it up again. Also, try tocreate another program that has the desired settings.If problem persists, check the serial port cable to see ifit is securely connected at both ends. If the cable issecure, replace the firmware on the main controlboard.

WARN-23 Encoder signal is not detected. The encoder did not move while the system was in therun mode and at least two trigger signals werereceived. If this is the case, avoid causing triggerevents. Other possible causes are a loose encodercable, a defective encoder, a defective DC-converterboard, or a defective main control board.

WARN-25 Processing error caused by watchdog circuittiming out has occurred. Unit may gothrough a power cycle.

Ignore warning if it does not recur. If problem persists,replace the main control board.

WARN-26 During program setup, the memory forcustom bead types has been exceeded(stitched, dot, or modulated beads).

Increase the interval (the distance from the start ofone sub-bead to the start of the next sub-bead).

WARN-27 During program setup, the allowablemaximum has been exceeded for

� distance from trigger to first bead

� total length of any bead

� distance between any two beads

Or some other programming error has beenmade.

Refer to Finding the Best Range for the EncoderGearing in Installation to determine maximumallowable distances for the system. Either decreasethe distance that is too long, decrease the total patternlength, or decrease the encoder gearing. Then, whilethe warning appears on the display (press theMONITOR key if the warning is not currently on thedisplay), press the SHIFT and then the DELETE keysto clear the warning.


3. Troubleshooting fromWarning Codes (contd.)



237514D02Issued 2/10

Warning Code Recommended ActionExplanation

WARN-33

WARN-34

WARN-35

WARN-36

Data in main controller is corrupt. Contact a Nordson representative.

WARN-37 The run-up minimum output setting(L0/ LIMIT) has been set above themaximum output setting (HI/LIMIT).

Change these settings so that the maximum outputsetting is greater than the minimum output setting.

WARN-38 Data in main controller is corrupt. Contact a Nordson representative.

WARN-65 Communications has stopped between maincontrol board and operator panel or betweenmain control board and PatternViewsoftware.

If the cable for operating with PatternView isconnected at X4 on the main control board, make surethat the computer is on, that PatternView is running,and that the correct communications port is selected inthe options menu. If the PatternView cable is notconnected, turn power off and back on and see if thewarning goes away. If it does not, make sure theterminator plug at connector X4 on the main controlboard is secure. If it is, make sure the serial portcable between the display board and connector X5 onthe main control board is secure. If the red LED (DS5)near connector X4 is on, replace the main controlboard.

5742127A

X7

1

2

3

4

12

DS5

Fig. 8-1 Location of fault LED DS5 (from WARN-65)

1. Main control board LED (DS5)

Troubleshooting8-20


237514D02Issued 2/10

This part of Section 8 explains fault log codes, which are displayed onlyto help Nordson personnel troubleshoot controller problems. The faultlog codes that can appear on the display are explained in Table 8-12 forreference only.

The controller memory can store up to nine faults in the log and show theorder of occurrence. The second most recent fault, for example, will bedisplayed as FLOG2. In addition, a numerical code will be displayed inthe right window that can be used to determine the cause of the fault.

5742054A1 2 3

Fig. 8-2 Display Showing Typical Fault Log Code

1. Abbreviation for fault log2. Position in fault history

3. Fault log code number

Table 8-12 Troubleshooting for Fault Log Codes

Fault Log Code Description of Fault Recommended Action

FAULT-2 This code is not used except infactory testing.

None

FAULT-3 The microprocessor on the maincontrol board is overloaded.

Possible solutions include decreasingline speed, decreasing the encodergearing ratio, increasing bead lengths,increasing the spacing between beads,or some combination of the above.

FAULT-4 Unrecoverable flash write error hasoccurred.

Turn the unit off and back on. If theproblem recurs, replace the main controlboard.

FAULT-5 Illegal interrupt has occurred. Engine board hardware problem;replace engine board.

FAULT-6 Application checksum failure hasoccurred.

Replace software chip on the maincontrol board.

FAULT-65 Error has occurred in display-boardmicroprocessor.

Turn the unit off and back on. If faultreturns, replace the display board.

FAULT-66 Processing error caused by anincorrect instruction has occurred.

Turn the unit off and back on. If faultreturns, replace the display board.

NOTE: Once nine faults have occurred, the controller always retains the nine most recent faults. The fault log cannot be cleared.

4. Troubleshooting fromFault Log Codes



237514D02Issued 2/10

This part of Section 8 contains procedures for isolating the cause ofcertain symptoms or for testing key parts of the pattern control system. Itincludes the following procedures:

� Checking Gun Power Draw� Checking the Operation of a Single Gun� Checking Trigger Operation� Checking Gun Compensation

Use this procedure to determine whether a gun is drawing too muchpower. When a gun actuator in the system draws too much power orthere is a short somewhere in the gun circuit, one of the followingwarnings appears on the display: WARN 9 (gun 1), WARN 10 (gun 2),WARN 11 (gun 3), or WARN 12 (gun 4).

1. Remove the terminal block cover from the unit.

2. Unplug the top part of terminal block X7 on the main control board.

3. Measure the resistance across appropriate terminals for the gun inquestion:

� gun 1: measure across positions 1 and 2� gun 2: measure across positions 3 and 4� gun 3: measure across positions 5 and 6� gun 4: measure across positions 7 and 8

4. Refer to the following table to interpret the results of the test.

Table 8-13 Recommended Actions for Different Test Results

Test Results Recommended Action

Resistance is 24 ohms or more. None. The gun is drawing anormal amount of power.

Resistance is less than 24 ohmsbut more than 4 ohms.

The gun is drawing too muchpower. Reduce the load on thispattern control output.

Resistance is at or near 0 ohms There is a short in the gun circuit.Find and fix short.

5. Plug the top part of terminal block X7 back into the bottom part.

6. Replace the terminal block cover on the unit.

5. Troubleshooting Checksand Tests

Checking Gun Power Draw

Troubleshooting8-22


237514D02Issued 2/10

When a single gun fails to dispense adhesive, use this procedure toisolate the cause of the problem. The procedure will help you isolate thecause to one of three places:

� the gun or gun actuator� the controller� some other part of the system.

Return to Single Pattern Missing (One Gun Not Firing) in this section forspecific troubleshooting advice.

1. Verify that the control is sending 24 VDC to the output for the gun asfollows:

a. Remove the terminal block cover.

b. Make sure the gun-test DIP switch for the gun in question is on.

c. Press the test button.

d. See if the gun dispenses adhesive.

e. Note whether the green gun-output LED turns on.

f. Note whether the red gun-short LED turns on.

g. Replace the terminal block cover.

2. Use Table 8-14 to isolate the cause of the problem.

Checking the Operation of aSingle Gun



237514D02Issued 2/10

5742055A

12

34

OP

EN

X7

1

2

3

4

1

2

3

4

Fig. 8-3 Location of Gun LEDs, DIP switches, and Test Button

1. Gun DIP switches2. Gun test button

3. Red gun-short LED 4. Green gun-output LEDs

Table 8-14 Recommended Action Based upon Results of Gun Test

Observation Conclusion Recommended Action

Gun dispensedadhesive and LEDturned on.

The gun, gun actuator, and gun circuitryare working properly.

Look for cause of problem in other parts ofsystem. Refer to Single Pattern Missing(One Gun Not Firing) in this section.

Gun failed to dispenseadhesive but LEDturned on.

Problem is in gun actuator (pneumaticsolenoid valve or electric gun driver), ingun circuit wiring, in hot melt system, orin gun itself.

See troubleshooting for these parts of thesystem in Single Pattern Missing (One GunNot Firing) in this section.

Gun failed to dispenseadhesive and LED failedto turn on.

24 VDC power is not being sent to gun. Make sure that power is turned on, thatfuses F1 and F2 on main control board aregood, and that power input connections atX7 are secure. If problem is not found,replace the main control board.

Red gun-short LEDturned on.

Gun is drawing too much power or shorthas occurred in gun circuit.

Refer to Checking Gun Power Draw in thissection.

Troubleshooting8-24


237514D02Issued 2/10

Use this procedure to check for proper trigger operation. The systemmay be equipped with one or two triggers (photosensors).

1. Verify that the control is receiving an input signal from the trigger asfollows:

a. Remove the terminal block cover from the pattern control unit.

b. Locate the LEDs for trigger 1 (DS14) and trigger 2 (DS15) nearterminal block X8.

c. Run products past the trigger in question.

d. Observe whether the LED is turning on and off (or off and on).

e. If the LED is transitioning, a signal from the trigger is beingreceived. This indicates that the trigger is probably installedcorrectly and is not defective (but see the following note). If theLED is not transitioning, continue at step 2.

NOTE: When the trigger is sending signals, it is possible that thesignal is intermittent if the alignment or sensitivity setting is marginal.If the pattern control is not consistently generating a pattern set onevery product, refer to All Patterns Missing on Some Products in thissection.

5742056A

12

34

OP

EN

X7

DS15

DS14

X8

1

2

Fig. 8-4 Location of Trigger LEDs on Main Control Board

Checking Trigger Operation



237514D02Issued 2/10

2. Check the lens on the trigger. If it is dirty, clean it.

3. Check the alignment and sensitivity setting of the trigger. Refer toAdjusting a Trigger in Installation and correct any problem.

4. Check the continuity of the trigger wiring and correct any problem.Refer to Connecting Inputs and Outputs to Main Control Board inInstallation for a wiring diagram.

5. Check for proper trigger voltage. Refer to Test Voltages in thissection.

6. If no input signal from the trigger is found, replace the trigger or tryanother type of trigger. The trigger may be having difficulty sensingproduct, especially if there is not much difference in reflectivitybetween the products and the background.

7. If the LEDs will not transition with the new trigger installed, replacethe main control board. Refer to the Service section for the partnumber of the board service kit.

Troubleshooting8-26


237514D02Issued 2/10

Use this procedure to check the gun compensation values for any gun.Note that three possible gun-compensation problems exist for anypattern:

� Incorrect pull-in compensation only: the beads end where theyshould but do not start where they should

� Incorrect drop-out compensation only: the beads start where theyshould but do not end where they should

� Incorrect pull-in and drop-out compensation: the beads neither startnor end where they should

For more information on how gun compensation works, refer toUnderstanding Gun Settings in System Setup.

NOTE: In general, having the correct gun compensation is more criticalin variable speed applications. If gun compensation is set incorrectly, theeffect will be greater as line speed increases.

NOTE: Typical gun-on and gun-off compensation values are 8−20 ms forstandard air-operated guns, 5−12 ms for high-performance air-operatedguns (such as the Nordson H400 Series guns), and 3−8 ms for electricguns. The amount of gun compensation needed can change after asystem is in operation. If a new gun or gun module is installed, it mayoperate faster (or slower) than the original one. And if a gun is not wellmaintained, char formation and nozzle clogging can gradually decreaseits speed of operation.

1. To set gun compensation correctly, the gun-to-trigger distance (GTO)must be entered correctly. If it is difficult to set gun compensation fora particular gun, check the GTO setting and correct it if it is wrong. Ifit is correct, continue at step 2.

2. Look at the total pattern generated by the gun in question. If theproblem is incorrect gun compensation, it should affect all beads inthe pattern the same way. If this is the case, continue at step 3. If itis not, refer to the procedure One or More Beads Sometimes Out ofPosition.

3. Run the production line at the slowest operating speed and observethe position of the beads in the pattern.

4. Run the line at the fastest operating speed and note whether theposition of the beads changes. Look at both the start and end pointsof the beads. If the start and end points of the beads do not change,the gun compensation settings are correct. If they change (or if justthe start or end points change), continue to the next step.

Checking Gun Compensation



237514D02Issued 2/10

5. Refer to the following table to determine the type of adjustmentneeded to the gun compensation settings.

Table 8-15 Effect of Incorrect Gun Compensation as Line Speed Increases

What Happens as YouIncrease Line Speed

Cause of Bead Movement Recommended Action

Start point of beads movetoward leading edge

Too much pull-in compensation Decrease pull-in compensation (ON-T)

Start point of beads movetoward trailing edge

Not enough pull-in compensation Increase pull-in compensation (ON-T)

End point of beads movetoward leading edge

Too much drop-out compensation Decrease drop-out compensation(OFF-T)

End point of beads movetoward trailing edge

Not enough drop-out compensation Increase drop-out compensation(OFF-T)

6. Adjust the gun compensation until bead placement is the same at thelower and the higher line speeds. If it is difficult finding the rightadjustment, check the gun-on time (ON-T) and gun-off time (OFF-T)for the gun. If either of these times is more than 30 milliseconds, thegun response time is too slow. A slow-operating gun makes it difficultto fine-tune gun compensation, especially at high line speeds.Consider installing a faster operating gun or at least cleaning thecurrently installed gun to improve its response time.

NOTE: Change the gun compensation in either of two ways. If thepattern requires only minor adjustments, change the guncompensation as products run on the production line and observe theeffect of each change. If the pattern requires major changes, refer toand start at the beginning of Determine and Enter Gun-CompensationValues in System Setup.

Troubleshooting8-28


237514D02Issued 2/10

This part of Section 8 provides reference materials that will help introubleshooting the pattern control system. It contains:

� Fuse Information� Test Voltages� Controller Block Diagram� Controller Input/Output Wiring Diagram

Use the following table to determine fuse locations and to troubleshoot ablown fuse. For fuse part numbers, refer to Service Parts in Service.

Table 8-16 Troubleshooting for a Blown Fuse

Fuse Labeland Location

Rating(Amps)

Effect When Fuse Blows Possible Causesof Blown Fuse

F1 on main control board 5 A No power to operatorpanel or (if a remoteoperator panel is used) nocommunication betweenmain control board andremote panel

Voltage too high fromexternal power supply,input power linesreversed, or short on maincontrol board

F2 on main control board 5 A Power to I/O board andguns 3 and 4 is lost. Also,a run-permissive fault(FAULT 1) occurs.

Voltage too high fromexternal power supply,input power linesreversed, or short on maincontrol board

F1 on DC-converter board 3 A No power to operatorpanel or (if a remoteoperator panel is used) nocommunication betweenmain control board andremote panel

Voltage too high fromexternal power supply orshort on DC-converterboard

F1 on optional I/O board 1 A 24 VDC power providedon I/O board is lost.

Connected customerdevices drawing too muchpower (more than 1 amp)

6. Troubleshooting Aidesand Reference Materials

Fuse Information



237514D02Issued 2/10

Use the Tables 8-17 and 8-18 to determine the normal voltage at anyposition on any of the pattern control’s input/output terminal blocks: X7or X8 on the main control board or X1 on the optional I/O board.

Table 8-17 Test Voltages for Terminal Blocks X7 and X8 on Main Control BoardConnectorPosition

Description Voltage Expected Measured withrespect to:

X8-1 12 VDC to encoder 10−14 VDC 12 VDC common

X8-2 A+ input from encoder 0−1 VDC or 10−14 VDC, square wave 12 VDC common

X8-3 A− input from encoder 0−1 VDC or 10−14 VDC, square wave 12 VDC common

X8-4 B+ input from encoder 0−1 VDC or 10−14 VDC, square wave 12 VDC common

X8-5 B− input from encoder 0−1 VDC or 10−14 VDC, square wave 12 VDC common

X8-6 12 VDC common 0 VDC 12 VDC common

X8−7 Shield (earth ground) Not applicable Not applicable

X8-8 24 VDC to trigger sensors 18−30 VDC 24 VDC common

X8-9 Trigger 1 Input 0−1 or 18−30 VDC, square wave 24 VDC common


X8-11 Trigger 2 input 0−1 or 18−30 VDC, square wave 24 VDC common


X8-13 Not used Not applicable Not applicable

X8-14 Not used Not applicable Not applicable

X7-1 24 VDC to gun 1 18−30 VDC 24 VDC common

X7-2 Gun 1 switched output 0−1 or 18−30 VDC, square wave 24 VDC common







X7-9 24 VDC input 1 18−30 VDC 24 VDC common

X7-10 24 VDC common 0 V 24 VDC common

X7-11 24 VDC output 1: used to drive 24VDC input 2 for single power-supplyapplications

18−30 VDC 24 VDC common

X7-12 24 VDC input 2 18−30 VDC 24 VDC common


X7-14 Run permissive (−) 0 V 24 VDC common

X7-15 Run permissive (+) 0 V: run-permissive contact closed or

18−30 VDC: run-permissive contactopen

24 VDC common

X7-16 Earth ground Not applicable Not applicable

NOTE: All measurements to 24 VDC common assume run-permissive jumper is installed. If it is not installed, power isremoved from 24 VDC circuits.

Test Voltages

Troubleshooting8-30


237514D02Issued 2/10

Table 8-18 Test Voltages for Terminal Block X1 on Optional I/O Board

ConnectorPosition

Description Voltage Expected Measured withrespect to:

X1-1 Low-line-speed output relaycontacts

Contacts close (< 2 ohm) when below lowline speed set point

X1-2

X1-2 X1-1

X1-3 Warning/fault output relaycontacts

Contacts close (< 2 ohms) when a warning orfault condition is present

X1-4

X1-4 X1-3

X1-5 4 to 20 mA current output forrun-up channel 1

4 to 20 mA into a 500 ohm or less load 24 VDC common


X1-7 0−10 VDC voltage output forrun-up channel 1

0 to 10 VDC into a 500 ohm or greater load 24 VDC common

X1-8 4 to 20 mA current output forrun-up channel 2

4 to 20 mA into a 500 ohm or less load 24 VDC common


X1-10 0−10 VDC voltage output forrun-up channel 2

0 to 10 VDC into a 500 ohm or greater load 24 VDC common

X1-11 24 VDC output 18−30 VDC 24 VDC common



X1-14 Program recall input 0 0−1 VDC (inactive) or 18−30 VDC (active) 24 VDC common




X1-18 Unit disable input 0−1 VDC (inactive) or 18−30 VDC (active) 24 VDC common

X1-19 Unit enable input 0−1 VDC (inactive) or 18−30 VDC (active) 24 VDC common


Test Voltages (contd.)



237514D02Issued 2/10

5742057A

OPERATOR PANEL

X3

DISPLAYBOARD X11

X8

24 VDC INPUT(REMOTE OPERATOR PANEL ONLY)

SERIALPORT CABLE STATUS LEDs (STANDALONE CONTROL UNIT ONLY)

X2

X3

DC CONVERTERBOARD

X1 24 VDCINPUT

5 VDC, 12 VDC5 VDC OUTPUT DS3

X2CPUDATABUS

OPTIONALI/O BOARD

X3

24 VDCINPUT

X8 X7

X4X1

ENCODER ANDTRIGGER INPUTS UNIT POWER INPUT

AND GUN OUTPUTS

SERIAL

COMPUTERCONNECTION

REMOTE I/OFUNCTIONS

PORT

X6

X5

MAIN CONTROLBOARD

Fig. 8-5 Controller Block Diagram

Controller Block Diagram

Troubleshooting8-32


237514D02Issued 2/10

5742086A

X8 ONMAINCONTROLBOARD

X7 ONMAINCONTROLBOARD

X1 ONOPTIONALI/OBOARD

X8TOP

X8BOTTOM

X7TOP

X7BOTTOM

1.10 AMPS EACHMAXIMUM

X1TOP

X1BOTTOM

Fig. 8-6 Controller Input/Output Wiring Diagram

Controller Input/Output WiringDiagram


237514D02Issued 2/10

Section 9

Service

Service9-0


237514D02Issued 2/10

Service 9-1


237514D02Issued 2/10

Section 9Service

This section explains how to service the pattern control system. Itincludes

� a list of recommended tools� a list of available service kits� illustrated parts lists for ordering parts not contained in service kits� recommendations for stocking spare parts

Only three tools are needed to service the pattern control:

� the number 0 flat-head screwdriver shipped with the controller� a number 2 Phillips-head screwdriver� a 5-mm (3/16-in.) flat-bladed screwdriver

If conduit is needed to protect the wiring connections for the patterncontrol system, a crescent wrench may be required.

To make servicing the pattern control system easy, Nordson providesservice kits. The kits are designed to minimize downtime by providing allthe needed parts in a single package. Instructions are included in thekits.

Service kits are available for basic tasks like upgrading firmware orreplacing a fuse. Kits are also available for the key parts of the system,such as circuit boards and the operator panel assembly. Table 9-1 listsall of the service kits for the pattern control system, describes thepurpose of each kit, and provides the kit part number. Use the table tofind the kit needed.

If the required part is not offered in a service kit, refer to Other Parts inthis section. Use the illustrated parts lists in Other Parts to orderindividual parts of the pattern control system.

1. Introduction

2. Recommended Tools

3. Service Parts

Service9-2


237514D02Issued 2/10

Table 9-1 List of Service Kits

Service Kit Purpose of Kit Part Number Where to FindInstructions

Firmware kit To upgrade the pattern-control firmware tolatest version. Includes the display-board andcontrol-board firmware chips and achip-removal tool.

772 022 Included in kit

Fuse kit To make all fuses used in the unit available inone kit so any fuse can be replaced(see Note A)

772 025 No instructionsneeded

Main control boardkit

To provide the main control board, theDC-converter board, and all connecting cablesalready assembled and installed on the unit’smounting plate


DC-converterboard kit

To supply the DC-converter board, the 4-pinand 20-pin connectors, and the mountinghardware in a single kit


Operator panel kit To provide the operator panel, the attachedboards, the serial port cable, and the panelenclosure in a single assembly. This kit is forunits with the integral operator panel.


Quick-disconnectkit

To make all quick-disconnect terminal blocksavailable in one kit (see Note B)


I/O board kit To replace an I/O board or to add theI/O-board option in the field


Din rail kit To provide the mounting hardware for themain control unit (standard DIN rail, rubberstandoffs, screws, and mounting clips)


Hardware test kit To verify that the circuit boards and otherhardware in the main control unit are workingproperly.


Voltage converteroscillator kit

To make the run-up signal (0−10V) from thepattern controller compatible with the controlsystem of Nordson DO gear pump units withMPC.


NOTE A: This kit includes a fuse for the optional I/O board. If the pattern control does not include this option, the1-amp fuse in the kit is not needed.

B: This kit includes the quick-disconnects used on the optional I/O board. If the pattern control does notinclude this option, these two parts are not needed.

3. Service Parts (contd.)

Service 9-3


237514D02Issued 2/10

Use the illustrated parts lists in this section to find the part number of thepart needed. If the part is inside the pattern control unit, refer to thefollowing procedure, Replacing a Part in the Pattern Control Unit.

Use this procedure to replace a part that is either not in a service kit or isin a service kit that does not include instructions. Some parts can bereplaced without having to complete steps 4 and 5 of this procedure.

1. Disconnect and lock out power to the pattern control system.

WARNING: Risk of electrical shock or burns. Servicing the unitwith power applied can open guns or pressurize connectedrun-up-control equipment. Failure to disconnect and lock outpower can result in severe personal injury or death.

2. Remove the three screws used to secure the terminal block cover tothe unit.

3. Pull the terminal block cover down about 13−25 mm (0.5−1 in.) todisengage its tabs from the top (operator-panel) cover. When thetabs are free of the top cover, rotate the bottom of the terminal blockcover toward you and remove it from the unit.

4. Remove the two flat-head screws that secure the top cover to themounting plate.

5. Rotate the bottom of the top cover up.

4. Other Parts

Replacing a Part in the PatternControl Unit

Service9-4


237514D02Issued 2/10

CAUTION: Be careful not to move the operator panel too farfrom the main control unit. Damage to the cables that connectthe operator panel to the main control unit may occur.

6. Remove the part to be replaced and install a new one.

7. Reverse steps 1−5 of this procedure to reassemble the unit and placeit back in operation.

5742090A

Fig. 9-1 Opening the Pattern Control Unit (shown with optional I/O board)

Replacing a Part in the PatternControl Unit (contd.)

Service 9-5


237514D02Issued 2/10

This page left intentionally blank

Service9-6


237514D02Issued 2/10

Item Part Description Quantity Note

— - - - - - - Pattern control unit (top-level parts list) — A

1 772 032 � Main control board service kit 1 B

2 249 690 � Enclosure 1

3 331 885 � Gasket (upper enclosure) 1 C

4 277 905 � Operator panel assembly 1 D

6 982 698 � Screw, flat-head, M4 x 13 mm 2

7 249 691 � Terminal block cover 1

8 982 769 � Screw, hex-head, w/lockwasher, M4 x 12 mm 3

11 249 675 � Nut, hex, M3, with external tooth washer 6

16 772 073 � Cable terminator 1

19 307 128 � Label, terminal-block-wiring 1

20 277 857 � Cable (display board to main control board) 1

21 277 880 � Cable (power board to display board) 1

NOTE A: For a pattern control unit without the optional I/O board, order part 772 003; for a pattern control unitwith the optional I/O board, order part 772 004.

B: This kit includes the main control board and the DC-converter board already assembled to the unit’smounting plate.

C: This part is attached to the enclosure (item 2) with adhesive.

D: Order the operator-panel service kit, part 772 021. This kit includes the operator panel, the attachedboards, and the panel enclosure as a single assembly.

Main Control Unit Parts List(Unit with Integral OperatorPanel)

Service 9-7


237514D02Issued 2/10

5742091A

3

7

8

4

6

2

20

1

11

21

16

Fig. 9-2 Main Control Unit Parts (Unit with Integral Operator Panel)

Service9-8


237514D02Issued 2/10


— - - - - - - Pattern control unit (top-level parts list) — A

1 772 032 � Main control board service kit 1 B

2 249 690 � Enclosure 1

3 331 885 � Gasket (upper enclosure) 1 C

4 307 137 � Monitor panel 1

5 277 887 � Cable (LED board to main control board) 1

6 982 698 � Screw, flat-head, M4 x 13 mm 2

7 249 691 � Terminal block cover 1


10 277 882 � LED board 1

11 249 675 � Nut, hex, M3, with external tooth washer 6

14 249 688 � Spacer 2

16 772 073 � Terminator, serial-port 1

17 982 017 � Screw, pan-head, M3 x 8 mm 2

19 307 128 � Label, wiring 1

20 - - - - - - � Cable (unit to remote operator panel) 1 D

28 249 682 � Gasket (panel) 1 E

NOTE A: For a pattern control unit without the optional I/O board, order part 772 000; for a pattern control unitwith the optional I/O board, order part 772 001.

B: This kit includes the main control board and the DC-converter board already assembled to the unit’smounting plate.

C: This part is attached to the enclosure (item 2) with adhesive.

D: For a 3.6 m (12 ft) cable, order part 772 071; for a 9.1 m (30 ft) cable, order part 772 072.

E: This part is attached to the panel (item 4) with adhesive.

Main Control Unit Parts List(Unit with Remote OperatorPanel)

Service 9-9


237514D02Issued 2/10

5742095A

3

7

8

4

6

2

20

1

11

5

16

1710

14

28

Fig. 9-3 Main Control Unit Parts (Unit with Remote Operator Panel)

Service9-10


237514D02Issued 2/10


— - - - - - - Main control board assembly — A

1 331 882 � Mounting plate 1

2 306 016 � Ground lug 1

3 326 947 � Mounting clips 2

4 331 887 � Rubber standoff 2 B

5 182 300 � Plug-in connector (20-pin) 1

6 182 301 � Plug-in connector (4-pin) 1 or 2

7 - - - - - - � Main control board 1 C

8 983 426 � Lockwasher, M3 2 or 3

9 331 883 � Conduit plate 1

10 331 886 � Gasket (conduit plate) 1 D

11 982 308 � Screw, hex-head, M4 x 10 mm 2

12 900 745 � Dust plug 4

13 772 031 � Power-supply-board service kit 1 E

14 235 484 � Spacer 4 or 7



17 - - - - - - � I/O board (optional) 1 F

18 982 017 � Screw, pan-head, M3 x 8 mm 11 or 15

19 331 884 � Gasket (base) 1

NOTE A: Order the main-control-board service kit, part 772 032. The kit includes this entire assembly.

B: If you use the high profile DIN rail, you should use the larger bumpers, part 277 921. This part isincluded in the ship-with kit.

C: To replace a main control board, order the main-control-board service kit, part 772 032.

D: This part is attached to the conduit plate (item 9) with adhesive.

E: This kit includes items 5 and 6 in addition to the board.

F: To replace an I/O board, order the I/O board service kit, part 772 030. The kit includes item 6, item 16,and the mounting hardware in addition to the board. This kit can also be used to add an I/O board tothe pattern control in the field.

Main Control Board AssemblyParts List

Service 9-11


237514D02Issued 2/10

5742089A

18

1413

57

18

16

18

14

18

17

610

15

12

9

4

11

31

19

15

2

15

6

8

18

8

Fig. 9-4 Main Control Board Assembly Parts

Service9-12


237514D02Issued 2/10


— - - - - - - Operator panel assembly — A

1 307 127 � Membrane panel 1

2 249 682 � Gasket 1 B

3 - - - - - - � Display board 1 C

4 249 688 � Spacer 5

5 982 017 � Lockwasher, M3 2


NOTE A: Order the operator-panel service kit, part 772 021, for a kit that includes the operator panel, theattached display board, and the panel enclosure (item 2 in Figure 9-2) already assembled.

B: This part is attached to the panel (item 1) with adhesive.

C: To replace a display board, order the operator-panel service kit, part 772 021.

5742087A

5

6

2

1

4

3

Fig. 9-5 Operator Panel Assembly Parts

Operator Panel Assembly PartsList

Service 9-13


237514D02Issued 2/10


— 772 002 Remote operator panel — A

1 277 905 � Operator panel assembly 1

2 772 031 � DC-converter board service kit 1 B


4 277 893 � Cover 1



8 307 129 � Label, wiring 1

9 983 426 � Lockwasher, M3 1

10 - - - - - - � Cable (unit to remote operator panel) 1 C

NOTE A: All parts are included in the remote operator panel kit, part 772 021.

B: This kit includes items 5 and 6 in addition to the board.

C: For a 3.6 m (12 ft) cable, order part 772 071; for a 9.1 m (30 ft) cable, order part 772 072.

5742088A

3

4

3

1

83

2

6

3

5

9

Fig. 9-6 Remote Operator Panel Assembly Parts

Remote Operator Panel PartsList

Service9-14


237514D02Issued 2/10

Component Part Description Quantity Note

Encoder

772 050 Metric encoder, 500 ppr, 10-mm shaft 1

772 051 U.S. Standard encoder, 500 ppr, 3/8-in.shaft

1

772 052 Cable, 9.1 m (30 ft), IP54-rated 1

772 053 Cable, 9.1 m (30 ft), IP66-rated(waterwash)

1

296 144 Friction wheel, 500-mm circumference(for mounting on 3/8 in. shaft)

1

Trigger (Sensor)

131 474 Trigger (retroreflective sensor) 1

131 475 Trigger (retroreflective sensor withpolarized lens)

1

131 476 Trigger (diffuse reflective sensor) 1

Power Supply

131 739 PS40 power supply 1

772 061 EPS20 power supply 1

Transducer (for Run-Up Control)

772 033 Transducer kit 1

154 890 Transducer kit, IP66-rated (waterwash) 1

PC Software

772 090 PatternView Kit (Windows-based PCsoftware)

1

772 131 Cable, control-unit-to-computer,3.6 m (12 ft)

1

772 133 Cable, control-unit-to-computer,9.1 m (30 ft)

1

When using a single pattern control unit, Nordson recommends stockingone fuse service kit, part 772 025.

When using more than one pattern control unit, or if a short period ofdowntime is critical in the production environment, contact Nordson todetermine an approach to stocking required spare parts.

External Components PartsList

5. Recommended SpareParts

Template for Remote Operator Panel2


237514D02Issued 2/10

Template for Remote Operator Panel 3

� 2010Nordson CorporationAll rights reserved

237514D02Issued 2/10

AppendixTemplate for Remote Operator Panel

This appendix provides a template for the cutting and drilling required tomount a remote operator panel in a customer electrical cabinet. If usingthe remote-panel option, remove this sheet from the manual and use thetemplate on the opposite side to modify the electrical cabinet.

NOTE: The remote operator panel is approximately 230 mm (9.05 in.)wide, 103 mm (4.05 in.) high, and 75 mm (2.95 in.) deep.

For instructions on installing a remote operator panel, refer to thefollowing two procedures in Installation:

� Mounting a Remote Operator Panel� Connecting Inputs to the Optional Remote Operator Panel

1. Introduction

2. Related Information

Template for Remote Operator Panel4


237514D02Issued 2/10

5742109A

HOLE DIAMETER:5.2 mm (0.203 IN.)

CENTERLINE FORDRILLINGMOUNTING HOLES(6 REQUIRED)

OUTLINE OFCUTOUT AREAFOR PANEL

NOTE: ROTATETEMPLATE 90 DEGREESBEFORE DRILLINGAND CUTTING.

TEMPLATE FOR MOUNTINGOPTIONAL REMOTE OPERATOR PANEL

(SCALE = 1:1)


237514D02Issued 2/10

Nordson Glossary

Glossary 0


237514D02Issued 2/10

Glossary 1


237514D02Issued 2/10

Nordson Glossary

Use this glossary to understand the technical and specialized termsfound in this manual.

Determines the encoder gearing ratio without doing calculations. Choosefrom three different methods of autoscaling: the product-length method,the line-jog length method, or the line-speed method. The encodergearing ratio can also be entered if it is already known.

An optional setting that automatically places the pattern control in the runmode when power is applied. When selected, the pattern control systembegins generating patterns as soon as the READY light turns on and thefirst product that the trigger has sensed reaches the guns. If notactivated, manually press the RUN key to start the generation of patternsets.

A continuous line of adhesive or, in the case of a custom bead (astitched, modulated, or dot bead), a line of adhesive that has beendivided into sub-beads. Refer also to Sub-Bead.

The distance from the start of the bead to the end of the bead inmillimeters or inches (measured to the nearest 0.1 inch).

The distance from the leading edge of the product to the beginning of thebead. Refer also to Leading Edge.

A setting that includes five different bead types: solid bead (the defaultsetting), stitched bead, dot bead, modulated bead, and random-lengthbead.

The area on the operator panel where information for setting up,operating, and monitoring the pattern control is shown. The displaycontains six windows.

One of the four different custom bead types the pattern control cangenerate. The dot bead feature produces patterns of constant-weight(constant-volume) dots of adhesive spaced apart by a user-determineddistance. Control the dot weight by specifying the gun-on time. Controlthe distance between dots by specifying the dot-interval distance. Aconstant dot weight and interval can be produced over the entire range ofline speed without using external run-up equipment.

Autoscaling

Autostart

Bead

Bead Length

Bead Offset

Bead Type

Display

Dot Bead Type

Glossary 2


237514D02Issued 2/10

A device that tracks line position. Using the pulse count from an encoder,the pattern control can generate highly accurate pattern sets as linespeed varies. The pattern control system uses a quadrature-typeencoder with a resolution of 500 pulses per revolution.

A type of message displayed when an encoder-setup error occurs. Theword ERROR and an error code beginning with the letter A (such as A1)appear on the display.

The ratio of encoder shaft rotation to line travel. Encoder shaft rotation ismeasured in pulses per revolution and line travel is measured inmillimeters or inches. The encoder gearing ratio is expressed in pulsesper millimeter or inch.

Notification that a serious defect or problem has occurred in the patterncontrol system. When a fault occurs, the word FAULT and a fault codeappear on the display, the ALARM light turns on, and, if the system isrunning, the pattern control will stop generating patterns. Faults cannotbe cleared until the problem causing the fault is fixed.

Gun-to-Trigger Offset, which is the distance from the centerline of the gunnozzle to the centerline of the trigger lens. Enter the GTO between eachgun in the system and the trigger (or triggers).

The dispensing device that applies adhesive to products. Sometimescalled a head or an applicator, a gun can have a single dispensingmodule or it can have multiple modules. Refer also to Gun Actuator andOutput.

The device, either a pneumatic solenoid valve or an electric gun driver,that opens and closes the gun.

The ability of the pattern control to produce accurate patterns bycompensating for the delay, large or small, in gun-response time. Foreach gun for which gun-on compensation can be entered, which is thetime lag between sending a signal to open and actually applyingadhesive on the surface of the product. Also enter gun-off compensation,which is the time lag between sending a signal to close and actuallystopping the application of adhesive to the product. The control canfactor line speed into the compensation so that it produces accuratepatterns over the whole range of line speeds.

Refer to GTO.

Refer to Gun Compensation.

Refer to Gun Compensation.

Encoder

Encoder Error Message

Encoder Gearing Ratio

Fault

GTO

Gun

Gun Actuator

Gun Compensation

Gun-to-Trigger Offset

Gun-On Time

Gun-Off Time

Glossary 3


237514D02Issued 2/10

A button on the main control board that, when pressed, test-fires the gunconnected to any of the four pattern-control outputs. Use this button, andassociated DIP switches, to activate one output or any combination of thefour outputs.

A light on the operator panel that shows when a condition has occurredor when a function is active. The panel has lights for indicating that thesystem is ready, that an alarm (a fault or warning) has occurred, and thatprogram activation is being controlled from a remote location. In addition,each function key has an indicator light to show when the key’s functionis active.

The distance from the start of one bead to the start of the next bead or, inthe case of custom bead types (stitched beads, dot beads, or modulatedbeads), the distance from the start of one sub-bead to the start of thenext sub-bead.

An optional circuit board that permits remote program recall, operation oftwo independent run-up controls, integration of parent machine functions,and monitoring for low line speed and other warnings and faults. Thisoption can be either factory or field installed.

A setting that requires an operator to clear each warning. When notused, warnings automatically clear thirty seconds after the conditioncausing the warning is removed.

The edge or face of the product that the trigger senses first on theproduction line. This edge is also used as the starting point for thebead-offset measurement. Refer also to Trailing Edge and Bead Offset.

Because pattern control allows use of one or two triggers, two differentedges of a product can be sensed in cases where it has a more complexshape than a case or a box.

The enclosure that contains the circuit boards for the pattern controlsystem. The primary board, called the main control board, contains themain microprocessor for the pattern control and the system memory. Itreceives input from the encoder and triggers and provides the power todrive the outputs. The main control unit also includes a DC-converterboard and, on some units, an optional I/O board. It can have an integraloperator panel or be connected by a cable to a remote operator panel.Refer also to Operator Panel.

An area at either end of the product where adhesive is not applied whengenerating random-length beads. Independently set the size of themargin at both the leading and trailing edges of product. Refer also toRandom-Length Bead Type.

Gun Test Button

Indicator Light

Interval

Input/Output (I/O) Board

Latching Feature

Leading Edge

Main Control Unit

Margin

Glossary 4


237514D02Issued 2/10

One of the four different custom bead types the pattern control cangenerate. The modulated-bead provides a nearly constant bead volumebelow a set line speed. When the production line shows down to auser-selected speed, the control starts dividing each bead into shortersub-beads to prevent bead volume from increasing. At any given linespeed, the total gun-on time to produce each divided bead remains thesame as the total gun-on time to produce the original solid bead, so thebead volume remains the same. Use this feature either with or withoutrun-up control.

The ability of the pattern control to simultaneously track the position of upto four products as they move from the trigger to the guns. This featureallows installation of the sensor farther from the guns, space productscloser together, and run the production line faster. In systems equippedwith two triggers, the controller can track four products sensed by trigger1 while tracking four more products sensed by trigger 2.

A feature of the pattern control that allows you to make quick adjustmentsto a pattern set as your products run on the production line. Using onlinepattern adjustment, you can set up your patterns faster and makeon-the-spot corrections when you have irregular patterns caused bymachine or product variations.

A feature of the pattern control that allows the adjustment of bead volumeas products run on the production line. Using online volume adjustment,run-up settings and on-the-spot corrections in bead volume caused byequipment or adhesive variations can be made quickly.

The panel that contains the display, keys, and indicators used in settingup and operating the pattern control. The pattern control is available withan operator panel that is integrated into the main control unit or with onethat can be mounted separately in a remote operator station.

A current or voltage sent from the pattern control for the purpose ofoperating a gun actuator, transducer, or DC motor drive. The patterncontrol has four independent outputs for controlling the operation of gunactuators and (if the unit is equipped with an I/O board) two independentoutputs for controlling the operation of either transducers or DC motordrives.

A feature of the pattern control that allows it to handle pallet-stabilizationapplications. Use this feature to set the number of consecutive productsthat receive adhesive and the number of consecutive products that areskipped before pattern generation starts again.

Modulated Bead Type

Multiple Pattern Processing

Online Pattern Adjustment

Online Volume Adjustment

Operator Panel

Output

Palletizing

Glossary 5


237514D02Issued 2/10

The screen that must appear on the display before you a pattern can beset or revised. It displays all of the settings that are used to define apattern set: the program number, the gun number, the bead number, thebead offset, and the bead length. The pattern-definition screen isdisplayed whenever all of the function keys (except the RUN key) are off.The RUN key can be either on or off.

All of the beads produced by a single gun. Up to 24 beads per patterncan be entered. Refer also to Pattern Set.

All of the patterns generated by a single program. Because the patterncontrol has four outputs for controlling gun operation, up to four differentpatterns on any product can be generated.

A Windows-based software program that can be used with the patterncontrol to facilitate setup and operation. With PatternView installed on anotebook or desktop PC, programs can be set up and download quicklyto the pattern control. Programs from the controller to the PC can also beuploaded.

A piece of equipment that converts a plant’s AC line voltage to DCvoltage and supplies it to the pattern control. The power supply isexternal to the pattern control and connected to it by wiring.

Any item on which the controller generates pattern sets. A product canbe a manufactured or an assembled item, such as a desk, or it can be apackage, such as a carton or a case.

All of the pattern settings and associated parameters for applyingadhesive during a single production run. Each program is identified by aprogram number and is stored in the controller memory. A programincludes the measurements that define a pattern set and may includevolume-control settings (if the run-up feature is purchased and installed),optional settings such as the low-line-speed warning, and custom beadsettings such as stitching or modulation.

In general, program settings vary from one product to the next. Systemsettings, on the other hand, are global and do not change from product toproduct.

The capability of activating programs 1−15 from a remote location if yourunit is equipped with the optional I/O board.

The process of removing trapped air or char from the hot melt system orof relieving system pressure by turning the gun (or guns) on. Purge oneor more guns from the operator panel of the pattern control by pressingthe PURGE key and the ENTER key.

Pattern-Definition Screen

Pattern

Pattern Set

PatternView

Power Supply

Product

Program

Program Recall

Purge

Glossary 6


237514D02Issued 2/10

The DELETE, COPY, and PASTE keys. Take advantage of differentshortcuts when entering or revising pattern settings, gun compensationsettings, or run-up-control settings by pressing the SHIFT key and thenone of these keys. The DELETE key is also used to clear latchedwarnings and perform other functions.

One of the four different custom bead types the pattern control cangenerate. The random-length feature provides a continuous bead ofadhesive applied to products of different length. Set a margin at theleading and trailing edges of the product where adhesive will not beapplied.

An operator panel that can be mounted in a remote operator station orcontrol panel. It is connected to the main control board by a cable.

The operating mode used to start pattern generation. Place the controllerin the run mode by manually pressing the RUN key when the light on theRUN key is off and or by applying power to the unit when the autostartfeature is enabled.

A set of contacts that can be used to remove the pattern control from therun mode, provide notification of a fault, and deactivate any inputs to theoptional I/O board. To use this feature, install a remote switch andconnect it to the appropriate terminals on the main control board.

A method of pattern control that varies pump output as line speedchanges to provide a consistent bead volume. To achieve this result, thepattern control sends a 4−20 mA current signal to a transducer or a 0−10VDC signal to a DC motor drive. A transducer is used to regulate the airpressure to a piston pump, which in turn adjusts adhesive output. Amotor drive is used to control the speed of a gear pump, which variesadhesive output accordingly.

Refer to Trigger.

One of the four different custom bead types the pattern control cangenerate. The stitching feature provides a reduction of adhesive usageby entering the percentage of glue savings desired. The pattern controlautomatically determines the correct length and spacing of the sub-beadsin the bead pattern. Also available is the option of setting a sub-beadinterval (the distance from the start of one sub-bead to the next). Referalso to Sub-Bead.

A bead that results when the pattern control divides a continuous beadinto smaller, spaced beads. Sub-beads are used in the generation ofcustom bead types (stitched beads, dot beads, and modulated beads).

Quick Keys

Random-Length Bead Type

Remote Operator Panel

Run Mode

Run-Permissive Contacts

Run-Up Control

Sensor

Stitched Bead Type

Sub-Bead

Glossary 7


237514D02Issued 2/10

The product edge that causes the trigger to stop sensing the product asthe product passes by the trigger. Although the trailing edge is not usedto position beads on the product, it provides information that the patterncontrol uses to perform a variety of functions. These include generatingrandom-length beads and scaling the encoder by the product-lengthmethod. Refer also to Leading Edge.

A device that receives an analog current signal from the pattern controland uses it to regulate air pressure. A transducer is used only in systemsequipped for run-up control. Refer also to Run-Up Control.

A photosensor that detects products as they travel along the productionline. Equip the pattern control with one or two triggers, depending uponthe application requirements.

A user-determined setting (T-MEM) that allows either apply or not applyadhesive options to products between the trigger and the guns when linespeed recovers after falling below minimum-speed setting (MINSP). Thepattern control will stop generating patterns whenever the line speed fallsbelow a minimum−speed setting.

Notification that an operational problem has occurred in the patterncontrol system. When a warning occurs, the abbreviation WARN and awarning code (such as 3) appear on the display and the ALARM lightstarts flashing. Warnings are less serious that faults and clearautomatically when the problem causing the problem is fixed (unless thelatching feature is turned on). Refer also to Fault and Latching Feature.

One of the six separate areas of the display. Each window of the displayprovides specific information about the task being performed.

Trailing Edge

Transducer

Trigger

Trigger Memory Mode

Warning Message

Window

Glossary 8


237514D02Issued 2/10


237514D02Issued 2/10

Index

Index0

237514D02Issued 2/10


Index 1


237514D02Issued 2/10

Index

A

abbreviations, used on display, 3-6

activating a programfrom a remote location, 7-33from the operator panel, 7-7

adjusting bead volume, procedure for, 7-14

adjusting custom bead settings, procedure for, 7-17

adjusting patterns online, procedure for, 7-12

ALARM light, 3-9how it shows faults, 7-27how it shows warnings, 7-28

auto−start featureexplanation of, 5-3purpose of, 2-12

autoscaling, description of, 2-8

B

basic system settings, procedure for entering, 5-7

beaddefinition of, 6-3how to delete, 6-8

bead offset, definition of, 6-3

bead type, different settings for, 6-13

bead volume, how to monitor, 7-25

beadshow to adjust position of, 7-12how to adjust volume of, 7-14

brightness of display, how to change, 5-3

C

checking faults and warnings, procedure for, 7-26

Cleaning, Safety instructions, 1-7

clearing a fault, procedure for, 7-27

clearing a warning, procedure for, 7-28

copy functions, list of, 2-10

copying a pattern, 6-10

copying a program, 6-33

copying bead−type settings, 6-23

copying run−up control settings, 6-29

custom bead settings, how to adjust online, 7-17

D

delete functions, list of, 2-10

deleting a bead, 6-8

deleting a pattern, 6-12

diagnostic codesfor faults, 8-16for wanings, 8-16

disabling the pattern control system, procedure for,7-31

displayabbreviations, 3-6icons, 3-4windows of, 3-2

dot bead patternexplanation of, 6-16how to set up, 6-19

dot bead type, purpose of, 2-13

E

electrical installation, 4-17

encoderdescription of, 2-4finding a good location for, 4-7how to mount, 4-13procedure for checking wiring of, 4-36

encoder gearing ratioeffect on bead length and spacing, 4-4effect on dot patterns, 4-5effect on pattern variation, 4-5explanation of, 5-9how to find best range for, 4-3

encoder setupERROR messages, 5-10using the line−jog method, 5-15using the log−jog method, 5-13using the product−length method, 5-11

Index2

237514D02Issued 2/10


using the user−supplied method, 5-16

ERROR messagesexplanation of, 5-10how to clear, 5-10

F

false triggering, how to reduce, 6-13

fault log codes, 8-20

faultshow to check for, 7-26how to clear, 7-27

fuse information, 8-28

G

glue savings, how to achieve, 6-15

GTOexplanation of, 5-18minimum allowable, 4-8procedure for entering, 5-23

gunprocedure for checking wiring of, 4-37test button, 8-22

gun compensationdifferent methods for entering, 5-17explanation of, 5-17how to determine, 5-17how to enter a known, 5-25how to fine−tune, 5-30, 8-26typical values for, 5-17

gun settingsexplanation of, 5-17how to copy and paste, 5-31

gun setup, description of, 2-9

gun−to−trigger offset, explanation of, 5-18

guns, how to purge, 7-6

I

I/O boardinstructions for wiring, 4-26procedure for checking wiring of, 4-37purpose of, 2-5

icons, explanations of, 3-4

J

jam detection, how to set up for, 6-13

K

keyENTER, 3-15RUN, 3-14SHIFT, 3-14

keypadcolor code for, 3-10reference chart, 3-16

keysnavigation, 3-15operating, 3-14PROGRAM SETTINGS, 3-13SYSTEM SETTINGS, 3-12types of, 3-10

L

latching feature for warnings, how to set, 5-3

LEDsfor checking gun operation, 8-22for checking trigger operation, 8-24

lightALARM, explanation of, 3-9indicator, types of, 3-9READY, explanation of, 3-9REMOTE, explanation of, 3-9

lights, on keys, purpose of, 3-11

low−line−speed alarm, how to set, 5-3

M

main control unitdescription of, 2-3finding a good location for, 4-6how to mount, 4-9with integral operator panel, 2-6with remote operator panel, 2-6

minimum speed disable, explanation of, 5-3

modulated bead patternexplanation of, 6-17how to set up, 6-19

modulated bead type, purpose of, 2-13

monitoring options, explanation of, 7-20

monitoring system operation, procedure for, 7-22

monitoring system operation remotely, procedure for,7-35

Index 3


237514D02Issued 2/10

monitoring system variables, procedures for, 7-19

multiple pattern processing, purpose of, 2-13

N

navigating on the display, 3-15

O

online pattern adjustment, description of, 2-11

online volume adjustment, description of, 2-11

operator panel, parts of, 3-1

output contacts, different settings for, 5-3

overwriting a program, 6-34

P

palletizing, settings for, 6-14

palletizing feature, description of, 2-13

part numbersfor external components, 9-14for remote operator panel, 9-13

parts, how to replace, 9-3

password, settings for, 5-2

password feature, explanation of, 5-5

patterndefinition of, 6-3how to copy, 6-10how to delete, 6-12

pattern controldescription of, 2-1standard components for, 2-3

pattern definition, description of, 2-9

pattern setdefinition of, 6-3procedure for defining, 6-5

pattern sets, how to define, 6-4

pattern−definition screen, 3-2function of, 6-1how to display, 6-5illustration of, 6-1

patterns, how to adjust online, 7-12

PatternViewdescription of, 2-7requirements for, 2-16setup with, 5-1

power supplydescription of, 2-4finding a good location for, 4-8instructions for sizing, 4-2

procedures, operating, 7-3

program, number, 6-4

program options settingsexplanation of, 6-13how to change, 6-19

programshow to activate, 7-7how to copy, 6-33how to overwrite, 6-34how to revise, 6-32how to run, 7-10how to save, 6-32how to stop the active program, 7-11, 7-35place to record, 6-34procedures for management of, 6-30

purge pressure, how to set, 6-26

purging the guns, procedure for, 7-6

R

random−length bead pattern, explanation of, 6-18

random−length bead patterns, how to set up, 6-22

random−length patterns, purpose of, 2-13

READY light, 3-9purpose of, 2-12

recalling a programhow to set up the system for, 7-32procedure for, 7-33

REMOTE light, 3-9

remote operation, procdures for, 7-31

remote operator panelfinding a good location for, 4-6how to mount, 4-12instructions for wiring, 4-30

remote program recall, how to enable, 5-2

remote recall, switch settings for, 7-34

repair procedures, 9-3

resetting the product count, procedure for, 7-24

run−permissive switchexplanation of, 2-11how to use, 7-31

run−up controlprocedure for setting up, 6-27purpose of, 2-13, 6-25settings for, 6-26

Index4

237514D02Issued 2/10


run−up curve, 6-25

run−up−control output, how to monitor, 7-25

running a programfrom a remote location, 7-33from the operator panel, 7-10requirements for. See READY light

S

SafetyCleaning, 1-7Installation and electrical connections, 1-4Maintenance/Repair, 1-6Operation, 1-4Symbols, 1-2Thermoplastic, 1-8

safetycheckout, 4-32, 7-2in operation, 7-2procedures, 4-32

saving aprogram, 6-32

screen, pattern−definition, 3-2

scrolling, 3-15

sensors. See triggers

service kitscontents of, 9-2list of, 9-2part numbers of, 9-2purpose of, 9-2

settings, how to view password−protected settings,7-30

ship−with kit, contents, 4-1

shutdown, daily, 7-5

software. See PatternView

specifications, system, 2-14

startup, daily, 7-3

stitch bead pattern, how to set up, 6-19

stitched bead pattern, explanation of, 6-15

stitched bead type, purpose of, 2-13

stopping a programfrom a remote location, 7-31, 7-35from the operator panel, 7-11

sub−bead interval, how to set, 6-20

switching to remote recall, procedure for, 7-32

system data, how to monitor, 7-19

system settings

explanation of, 5-2your record of, 5-32

T

terminologySee also glossaryused to describe patterns, 6-2

test voltages, 8-29

testing procedurefor gun power draw, 8-21for proper gun compensation, 8-26for proper gun opeation, 8-22for proper trigger operation, 8-24

transducer, purpose of, 2-5

triggerfinding a good location for, 4-7how to adjust, 4-33how to mount, 4-14

trigger memory mode, explanation of, 5-2

trigger polarityhow to determine, 4-35how to set, 5-2

triggersnumber required, 4-2types of, 2-4

troubleshootingadhesive pooling when line stops, 8-15all patterns missing, 8-4bead volume too low or high, 8-14beads out of position, 8-9beads sometimes missing, 8-12beads sometimes out of position, 8-11beads too short or too long, 8-13from fault and warning codes, 8-16from symptoms, 8-2operation of run−up control, 8-14poor trigger performance, 4-33READY light not on, 8-3single pattern missing, 8-6some patterns missing, 8-8

turning off, the pattern control system, 7-5

turning on, the pattern control system, 7-3

U

unit disable switch, how to use, 7-31

units of measurement, how to change, 5-2

using a program, 7-7

V

volume, how to adjust online, 7-14

Index 5


237514D02Issued 2/10

W

warningshow to check for, 7-26

how to clear, 7-28

windows, functions of, 3-2

wiring, instructions for connecting, 4-17

words, used on display, 3-6

Index6

237514D02Issued 2/10


EC Declaration of Conformityfor Adhesive and Sealant Application Equipment

conforming to European Council Directives

PRODUCT:

Eclipse� Pattern Controllers

APPLICABLE DIRECTIVES:

Low Voltage Directive: 2006/95/ECElectromagnetic Compatibility Directive: 2004/108/EC

STANDARDS USED TO VERIFY COMPLIANCE:

EN 55011EN 61000-6-2EN 61010-1

PRINCIPLES:

This product has been manufactured according to good engineering practice.

The product specified conforms to the directives and standards described above.

Date: 10/June/2010

Peter Lambert, Vice PresidentAdhesives Dispensing Systems

DOC008R6

Nordson Corporation � 28601 Clemens Road � Westlake, Ohio

Technical File Contact:

Dieter Ziesmer

Nordson Engineering GmbH

Lilienthalstrasse 6

21337 Lueneburg

GERMANY

eclipse series epc-30 pattern control -...

Documents