Eclipse Series EPC-15 Pattern Control Customer Product Manual Part 321 352D02 This equipment is regulated by the European Union under WEEE Directive 2002/96/EC). See www.nordson.com for information about how to properly dispose of this equipment. NORDSON CORPORATION DULUTH, GEORGIA USA www.nordson.com
Nordson Corporation welcomes requests for information, comments and inquiries about its products. General information about Nordson can be found on the Internet using the following address: http://www.nordson.com. Address all correspondence to: Nordson Corporation Attn: Customer Service 11475 Lakefield Drive Duluth, GA 30097 Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2000. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Nordson Corporation. The information contained in this publication is subject to change without notice. Trademarks AccuJet, AquaGuard, Asymtek, Automove, Autotech, Blue Box, CF, CanWorks, Century, Clean Coat, CleanSleeve, CleanSpray, Compumelt, Control Coat, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, Durafiber, Durasystem, Easy Coat, Easymove Plus, Econo-Coat, EPREG, ETI, Excel 2000, Flex-O-Coat, FlexiCoat, Flexi-Spray, Flow Sentry, Fluidmove, Fluidshooter, FoamMelt, FoamMix, Helix, Horizon, Hose Mole, Hot Shot, Hot Stitch, Isocoil, Isocore, Iso-Flo, JR, KB30, Little Squirt, Magnastatic, MEG, Meltex, MicroSet, Millenium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson, OmniScan, Opticoat, Package of Values, PluraFoam, Porous Coat, PowderGrid, Powderware, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, PRX, RBX, Ready Cost, Rhino, S. design stylized, Saturn, SC5, SCF, Select Charge, Select Coat, Select Cure, Shur-Lok, Slautterback, Smart-Coat, Spray Squirt, Spraymelt, Super Squirt, Sure-Bond, Sure Coat, System Sentry, Tela-Therm, Trends, Tribomatic, UniScan, UpTime, Veritec, Versa-Coat, Versa-Screen, Versa-Spray, Watermark, and When you expect more. are registered trademarks of Nordson Corporation. ATS, Auto-Flo, AutoScan, BetterBook, Chameleon, CanNeck, Check Mate, CPX, Control Weave, Controlled Fiberization, EasyClean, Ebraid, Eclipse, Equi=Bead, Fillmaster, Gluie, Ink-Dot, Maxima, MicroFin, Minimeter, Multifil, OptiMix, Pattern View, PluraMix, Primarc, Prism, Process Sentry, PurTech, Pulse Spray, Seal Sentry, Select Series, Sensomatic, Shaftshield, Spectral, Spectrum, Sure Brand, Swirl Coat, Vista, Walcom, and 2 Rings (Design) are trademarks of Nordson Corporation. 2010 Nordson Corporation
Table of Contents i Table of Contents 1. Safety 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 2. System Overview 1. Introduction............................................... 2-1 2. Product Description....................................... 2-1 3. System Components...................................... 2-2 Main Control Unit..................................... 2-3 Operator Panel....................................... 2-3 Trigger.............................................. 2-3 Power Supply........................................ 2-4 Gun................................................ 2-4 2010 Nordson Corporation
ii Table of Contents 2. System Overview (contd) 4. System Capabilities....................................... 2-4 Setup Capabilities....................................... 2-4 Autoscaling.......................................... 2-5 Quick Pattern Definition............................... 2-5 Copy, Paste, and Delete Functions..................... 2-6 Operational Capabilities................................. 2-6 Online Pattern Adjustment............................. 2-6 Remote Inputs....................................... 2-7 Application Capabilities.................................. 2-7 5. Operator Panel Overview.................................. 2-8 Display................................................ 2-8 Keypad................................................ 2-9 Mode Keys......................................... 2-10 Navigation (+ SHIFT) Keys........................... 2-11 Run Key............................................ 2-11 3. Installation 1. Introduction............................................... 3-1 2. Equipment Inspection...................................... 3-1 3. System Design............................................ 3-2 Selecting System Components........................... 3-2 4. Equipment Mounting....................................... 3-3 Mounting the Main Control Unit........................... 3-3 Mounting a Trigger...................................... 3-5 Mounting a Power Supply................................ 3-7 5. Electrical Installation....................................... 3-7 Removing the Terminal Block Cover....................... 3-8 Connecting Inputs and Outputs to the Main Control Board.... 3-9 Connecting Power to the Power Supply................... 3-14 2010 Nordson Corporation
Table of Contents iii 6. Setup Preparation........................................ 3-14 Removing Energy Sources from Equipment Attached to the Pattern Control..................................... 3-15 Adjusting a Trigger..................................... 3-15 Determining Trigger Polarity............................. 3-17 Checking for Correct Gun Output Wiring.................. 3-18 Checking for Correct Remote Input Wiring................ 3-18 Reinstalling the Terminal Block Cover.................... 3-18 4. Setup 1. Introduction............................................... 4-1 2. System Setup............................................. 4-1 System Settings........................................ 4-1 Language........................................... 4-2 Auto Start........................................... 4-2 Units................................................ 4-3 Input Mode.......................................... 4-3 Trigger Polarity....................................... 4-3 GTO s............................................... 4-4 Gun-Trigger Assignments............................. 4-4 Entering System Settings................................ 4-4 3. Program Setup............................................ 4-6 Pattern Definition....................................... 4-6 Understanding Pattern Settings........................... 4-8 Defining Pattern Sets.................................... 4-9 Using Quick Keys to Define Pattern Sets.................. 4-12 To Add a Bead to a Pattern........................... 4-13 To Modify a Bead.................................... 4-13 To Delete a Bead.................................... 4-14 To Copy a Pattern................................... 4-16 To Delete a Pattern.................................. 4-18 2010 Nordson Corporation
iv Table of Contents 4. Setup (contd) Program Options....................................... 4-18 Pattern Types....................................... 4-19 Trigger Minimum.................................... 4-20 Speed............................................. 4-20 Autoscaling......................................... 4-20 Program Management.................................. 4-22 Activating a Program................................. 4-22 Saving a Program................................... 4-24 Copying a Program.................................. 4-24 Record of Program Settings............................. 4-24 5. Operation 1. Introduction............................................... 5-1 2. Operation Safety.......................................... 5-2 3. Operating Procedures..................................... 5-2 Starting the System..................................... 5-2 Shutting Down the System............................... 5-4 Purging the Guns....................................... 5-4 Activating a Program.................................... 5-6 Running a Program..................................... 5-7 Stopping a Program..................................... 5-7 Making Online Pattern Adjustments....................... 5-8 Understanding the Display Words and Abbreviations....... 5-10 4. Monitoring Procedures.................................... 5-12 Understanding Monitoring Options....................... 5-12 Monitoring System Operation............................ 5-13 Resetting Product Counts to Zero........................ 5-14 5. Remote Operation........................................ 5-15 Determining Remote Input Mode......................... 5-15 Remote Input Set to Off................................. 5-15 Recall (Remote Recall) Remote Operation................ 5-16 Enable (Enable/Disable/Lockout)........................ 5-17 Enable/Disable...................................... 5-17 Lockout............................................ 5-17 2010 Nordson Corporation
Table of Contents v 6. Troubleshooting 1. Introduction............................................... 6-1 2. Troubleshooting from Symptoms............................ 6-2 Power Light Not On..................................... 6-2 Contrast/Blank Screen/Dim Screen........................ 6-3 Faults................................................. 6-4 Unit Disabled........................................... 6-4 All Patterns Missing (All Guns Not Firing).................. 6-4 Single Pattern Missing (One Gun Not Firing)............... 6-6 All Patterns Missing on Some Products.................... 6-7 One or More Beads Always Out of Position................. 6-8 One or More Beads Sometimes Out of Position............. 6-8 One or More Beads Missing on Some Products............. 6-9 One or More Beads Too Short or Too Long................. 6-9 Bead Volume Too Low or Too High........................ 6-9 Settings Not Saved..................................... 6-10 Problems with Auto Scaling............................. 6-11 3. Troubleshooting Checks and Tests......................... 6-12 Checking Gun Power Draw............................. 6-12 Checking the Operation of a Single Gun.................. 6-13 Checking Trigger Operation............................. 6-14 4. Troubleshooting Aids and Reference Materials............... 6-16 Fuse Information....................................... 6-16 Test Voltages.......................................... 6-17 Fault Codes and LED................................... 6-18 Diagrams............................................. 6-19 2010 Nordson Corporation
vi Table of Contents 7. Parts 1. Introduction............................................... 7-1 Using the Illustrated Parts List............................ 7-1 2. Recommended Tools...................................... 7-2 3. Service Parts............................................. 7-2 4. Ship-With Kit............................................. 7-3 5. Main Control Unit Parts List................................. 7-4 6. External Components Parts List............................. 7-6 Recommended Spare Parts.............................. 7-6 8. Technical Data Technical Data................................................ 8-1 Nordson Glossary 2010 Nordson Corporation
Section 1 Safety 2005 Nordson Corporation Issued 11/94 A1EN 02 [XX SAFE] 4
1-0 Safety A1EN 02 [XX SAFE] 4 Issued 11/94 2005 Nordson Corporation
Safety 1-1 Section 1 Safety 1. Operate Safely Safety instructions contained in this section and throughout this document apply to tasks that may be performed with or on the unit. Warnings related to specific safety concerns are included within the text as appropriate. It is very important that these safety instructions are always followed. Failure to do so could result in personal injury and/or damage 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 are related to specific tasks. Store this document within easy reach of personnel operating or maintaining the unit. Wear personal protective equipment and clothing such as safety goggles and gloves. Familiarize yourself with and follow all safety instructions prescribed by your company, general accident-prevention regulations, and government safety regulations. 2005 Nordson Corporation Issued 11/94 A1EN 02 [XX SAFE] 4
1-2 Safety 2. Safety Symbols The following symbols are used to warn against dangers or possible sources of danger. Become familiar with them! Failure to heed a warning could lead to personal injury and/or damage to the unit or other equipment. WARNING: Failure to observe may result in personal injury, death, or equipment damage. WARNING: Risk of electrical shock. Failure to observe may result 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 the symbols shown. WARNING: Risk of explosion or fire. Fire, open flames, and smoking prohibited. WARNING: System or material pressurized. Relieve pressure. Failure to observe may result in serious burns. CAUTION: Failure to observe may result in equipment damage. CAUTION: Hot surface. Failure to observe may result in burns. A1EN 02 [XX SAFE] 4 Issued 11/94 2005 Nordson Corporation
Safety 1-3 3. Qualified Personnel Qualified personnel is defined here as individuals who thoroughly understand the equipment and its safe operation, maintenance, and repair. Qualified personnel are physically capable of performing the required tasks, familiar with all relevant safety rules and regulations, and have been trained to safely install, operate, maintain, and/or repair the equipment. It is the responsibility of the company operating the equipment to see that its personnel meet these requirements. 4. Intended Use The unit is designed and intended to be used only for the purpose described in the Description section. Uses not in accordance with that section or as described in this document are considered unintended uses and not in accordance with governing regulations. WARNING: Use of this equipment in ways other than described 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, but not all, examples of unintended use which would permit Nordson to claim it is not responsible for personal injury or property damage arising from such 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 out by unqualified personnel Use of inappropriate or incompatible foreign materials or auxiliary equipment Failure to observe workplace safety rules or regulations issued by government authorities or safety councils 2005 Nordson Corporation Issued 11/94 A1EN 02 [XX SAFE] 4
1-4 Safety 5. Installation and Electrical Connections WARNING: Failure to follow the safety procedures can result in injury or death. All electrical, pneumatic, gas, and hydraulic connections and installations of hot melt equipment may only be carried out by qualified personnel. Be sure to observe installation instructions for components and accessories. Equipment must be properly grounded and fused according to its rated current consumption (see ID plate). Cables which run outside the unit must regularly be checked for wear or damage. Power supply wire gauge and insulation must be sufficient to handle rated current consumption. Cables must never be squeezed or pinched. Do not locate cables or hoses in high traffic areas. 6. Operation The unit should be operated by qualified personnel in accordance with the instructions presented in this document. WARNING: Failure to follow the safety procedures can result in injury or death. Never allow the unit to be operated by personnel under the influence of substances which reduce their reaction times, or who are not able to operate the equipment for physical reasons. Prior to each start-up of the unit, check protection and warning devices and make sure they are fully functional. Do not operate the unit 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-connected immediately upon completion of the work. Prior to start-up of the unit, check to make sure all safety guards and safety equipment are in place and functioning properly. A1EN 02 [XX SAFE] 4 Issued 11/94 2005 Nordson Corporation
Safety 1-5 6. Operation (contd) In a humid environment, only equipment featuring a corresponding class 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 not wear loose articles of clothing when operating or servicing units with rotating parts. Take off wrist watches, rings, necklaces, or similar pieces of jewelry and pin up or cover long hair before performing any work on or with the unit. To carry out measurements on work pieces, switch off the unit and wait until it comes to a standstill. Never point hand guns or applicator nozzles at yourself or other persons. Less-Obvious Dangers WARNING: An operator or service technician working with the unit should be aware of less-obvious dangers that often cannot be completely minimized at production sites: Exposed surfaces of the unit which cannot be practically safeguarded. They may be hot and take time to cool after the unit has been operating. The possibility that electrical potentials may remain in the unit after the 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 Action in the Event of Unit Malfunction 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. 2005 Nordson Corporation Issued 11/94 A1EN 02 [XX SAFE] 4
1-6 Safety Danger of Burns Contact with hot melt materials or hot areas of the unit may produce a severe skin burn. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and/or heat-protective gloves depending on the symbols shown. Be extremely careful when using hot melt material. Even solidified material may still be very hot. Always wear protective clothing which safely covers all exposed parts of 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. 7. Maintenance/Repair Allow only qualified personnel to perform the procedures described in this document. When performing such tasks, wear protective clothing, and equipment. WARNING: Even when the circuit breaker or main power switch is OFF, the unit is still electrically energized. Complete the following steps prior to maintenance or repair: Disconnect, lock out, and tag external power supply. To ensure the external power supply is disconnected, attempt to operate the unit. If the unit does not energize, proceed with maintenance or repair work. If the unit energizes, repeat the disconnect, lock out, and tag procedure. Re-test the unit. A1EN 02 [XX SAFE] 4 Issued 11/94 2005 Nordson Corporation
Safety 1-7 7. Maintenance/Repair (contd) Follow the specific instructions provided in this manual to relieve the system pressure in the entire unit. Secure pneumatically- or hydraulically-operated equipment against uncontrolled movement. Only use parts which do not compromise the safety of the unit. Only use genuine Nordson parts. Always use tools with insulated handles when removing or installing components. 8. Cleaning NOTE: Always refer to the material manufacturer s Material Safety Data Sheet (MSDS) or material information sheet before working with any material. WARNING: Never clean any aluminum part or flush any system using halogenated hydrocarbon fluids. Examples of common halogenated hydrocarbons are: dichloromethylene, 1,1,1-trichloroethylene, and perchloroethylene. Halogenated hydrocarbons may react violently with aluminum parts. WARNING: Fire, open flame, and smoking are prohibited when cleaning fluids are used. Observe all explosion prevention regulations. Cleaning fluids may only be heated using temperature-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 hot melt material being used in the unit. Never use paint fluids under any circumstances. Note the flash point of the cleaning fluid used. Only use a controlled heating method to heat fluids. Ensure sufficient room ventilation to draw off generated vapors. Avoid prolonged breathing of vapors. 2005 Nordson Corporation Issued 11/94 A1EN 02 [XX SAFE] 4
1-8 Safety 9. Thermoplastic Hot Melt Material NOTE: Always refer to the material manufacturer s Material Safety Data Sheet (MSDS) or material information sheet before working with any hot melt material. Ensure the work area is adequately ventilated. Do not exceed recommended processing temperatures. Doing so creates a danger to personnel due to decomposition of the material. 10. Equipment and Material Disposal Dispose of equipment and materials used in operation and cleaning according to local regulations. A1EN 02 [XX SAFE] 4 Issued 11/94 2005 Nordson Corporation
Section 2 System Overview 2010 Nordson Corporation
2-0 System Overview 2010 Nordson Corporation
System Overview 2-1 Section 2 System Overview 1. Introduction This section describes the Eclipse Series EPC-15 pattern control and includes: Product Description System Components System Capabilities Operator Panel Overview NOTE: The glossary at the end of this manual will define technical terms. 2. Product Description The EPC-15 pattern control is designed for constant line speeds and has an accuracy of 1 ms (1 mm at 60 m/min or 0.1 in. at 500 ft/min). It can receive input from up to three triggers, control four independent outputs, produce up to eight beads per output, and store as many as 25 programs. In addition, the EPC-15 pattern control can handle normal, random-length, and stitched bead patterns, automatically determine line speed, and accept entered values in time or distance. 5742129A Fig. 2-1 Eclipse Series EPC-15 Pattern Control 2010 Nordson Corporation
2-2 System Overview 3. System Components A typical EPC-15 pattern control system includes the following components: one main control unit one, two, or three triggers one external power supply guns and solenoid valves for up to four outputs 4 1 3 32 5742130A Fig. 2-2 Components Used With the EPC-15 Pattern Control 1. Main control unit 2. Trigger (photosensor) with reflector 3. Gun and solenoid valve 4. Power supply 2010 Nordson Corporation
System Overview 2-3 Main Control Unit The main control unit consists of a main control board and surrounding enclosure, a base plate that is mounted to a standard DIN rail, and an operator panel. Operator Panel The operator panel is used to set up, operate, and monitor the EPC-15 pattern control. Refer to Operator Panel Overview later in this section for more details. 1 2 4 4 3 5742131A Fig. 2-3 Parts of the Operator Panel 1. Liquid crystal display 2. RUN key 3. Navigation and SHIFT keys 4. Mode keys Trigger A trigger, or photosensor, detects products as they move along the production line, and provides input to the EPC-15 pattern control. Three triggers can be equipped for complex patterns or dual-gluing applications. Nordson offers the following types of triggers: a retroreflective photosensor a retroreflective photosensor with polarized lens a diffuse-reflective photosensor through-beam emitter/receiver photosensor The type of trigger to be used depends on the reflectivity of the product being sensed and the lighting conditions within the sensing area. 2010 Nordson Corporation
2-4 System Overview Power Supply The EPC-15 pattern control requires an external power supply to convert from AC to DC power. Nordson offers two different power supplies: a 2.5 A power supply in an IP54 sealed enclosure a 2.5 A power supply in an unsealed enclosure Both are autoranging units that can accept power from 90 to 135 VAC or from 175 to 264 VAC and convert it to a regulated 24 VDC. The power supply must be sized to handle the total load of all guns plus the load of the EPC-15 pattern control. For information on selecting a power supply for your system, refer to System Design in Installation. Gun The EPC-15 pattern control operates one or more adhesive-dispensing guns, up to four guns total. Use either pneumatic solenoid valves or electric gun drivers, depending on the type of guns used. 4. System Capabilities The EPC-15 pattern control incorporates some advanced features and new technology that include: Setup Capabilities Operational Capabilities Application Capabilities Setup Capabilities Several time saving features include: autoscaling quick pattern definition copy, paste, and delete functions 2010 Nordson Corporation
System Overview 2-5 Autoscaling The EPC-15 pattern control s autoscaling feature determines the line speed based on a product s length. The pattern can then be entered in terms of distance instead of time. This saves setup time by avoiding a manual computation of line speed. Quick Pattern Definition Measure the length of each bead and the distance from the leading edge of the product to the start of the bead. Then select the beads by gun and bead number, and enter the measurements in either time (default option), millimeters, or inches to define patterns. The following figure shows a typical bead (bead 2 from gun 1) and the measurements required to define it. bead offset 120 mm (4.7 in.) bead length 30 mm (1.2 in.) Enter these bead measurements into the system as indicated below: 120 mm 30 mm 5742152A Fig. 2-4 Entering Bead Measurements for Bead Number 2 2010 Nordson Corporation
2-6 System Overview Copy, Paste, and Delete Functions By pressing the SHIFT key, the top three navigation keys are enabled to perform various copy, paste, and delete operations, which will: copy a pattern from one gun to another delete a bead delete a pattern NOTE: The delete function is also used to quickly return any setting to its minimum possible value and to clear trigger counts. 1 2 3 4 5742011A Fig. 2-5 Copy, Paste, and Delete Function Keys 1. SHIFT key 2. DELETE key 3. COPY key 4. PASTE key Operational Capabilities The EPC-15 pattern control simplifies system operation by providing access to real-time data about system variables for on-the-spot adjustments to patterns or bead volume when needed. The different operational capabilities of the system are described below. Online Pattern Adjustment Online pattern adjustment fine-tunes patterns as they are generated on the production line. For example, to increase the length of a particular bead by two millimeters, select the appropriate gun number and bead number and press the up key twice to add 2 mm. The program number will change to two dashes ( ) to show that the active program has been changed. Return to or overwrite the original program with the revised settings at any time. 2010 Nordson Corporation
System Overview 2-7 Remote Inputs The EPC-15 pattern control can control the system remotely with three inputs. These inputs can be connected to a switch box or a PLC. The inputs can either be configured as a remote recall so that programs 1 7 can be run, or they can be used to enable, disable, and lock the system. Application Capabilities The EPC-15 pattern control can handle a variety of applications to meet different production requirements. The following table explains the most significant of these features. Capability Purpose Description Auto-start option Fast startup or shutdown The EPC-15 pattern control automatically starts in RUN mode when it is turned on NOTE: This eliminates the need for the operator to press the RUN key. PURGE key Purges any or all guns manually Purges air or debris from the melter Product count display Provides real-time data about system operation Shows the current product count on the display for each trigger Trigger status Identifies the status of a specific trigger (1, 2, or 3) ON: OFF: Product under the photoeye No product under the photoeye Remote input status Random-length pattern type Stitched pattern type Multiple pattern processing Provides real-time data about system inputs Provides the ability to generate patterns on products of differing lengths without changing the program Provides a way to reduce adhesive usage and increase bond strength Provides the ability to install the sensor farther from guns or space products closer together Identifies the status of the three remote inputs Process both short and long products on the production line by placing patterns on the edges of the product The controller automatically determines the stitch pattern that will provide the desired savings by dividing each original solid bead of a pattern into sub-beads with spaces between them Enables simultaneous tracking of up to four products past each trigger 2010 Nordson Corporation
2-8 System Overview 5. Operator Panel Overview The operator panel has two major parts: Display Keypad 1 2 5742186A Fig. 2-6 Parts of the Operator Panel 1. Display 2. Keypad Display The display provides information required to set up, operate, and monitor the EPC-15 pattern control. Various words, abbreviations, and icons are used to explain the information. For example, on the PATTERN screen, information such as the status of the pattern generation, the number of the active program, and the number of the selected gun are available. 1 2 3 4 5742135A Fig. 2-7 Information Contained on the EPC-15 Pattern Control Display 1. Pattern Generation Status 2. Active Program Number Stop: Trigger inputs ignored, no (Two consecutive dashes display pattern produced ( ) if program changes are not Run: Patterns produced with saved) triggers 3. Current Mode Disable: Trigger inputs ignored, no Includes: Pattern, Monitor, Purge, patterns produced (due to remote Use, Save, Options, or System inputs) 4. Parameters and Values being set within the current mode 2010 Nordson Corporation
System Overview 2-9 Keypad The keypad is used to customize patterns and programs, and consists of: Mode keys (programming and operating) Navigation keys (+ SHIFT) RUN key 3 1 1 Fig. 2-8 Keypad Components 1. Mode keys 2. Navigation and SHIFT keys 2 3. RUN key 5742187A 2010 Nordson Corporation
2-10 System Overview Mode Keys Mode keys select the desired mode. The system remains within that mode until another key is pressed. Key Key Name Function SYSTEM Sets system or global parameters Examples: trigger polarity, GTO, units OPTIONS NOTE: SHIFT must be pressed in order to enter this mode. SAVE Sets program parameters Examples: pattern type and line speed Saves a program permanently PATTERN Sets and modifies pattern lengths and offsets USE Loads a program from permanent memory MONITOR Displays real-time system status Examples: product counts, trigger status PURGE Purges or opens any or all of the guns manually NOTE: ENTER key must be pressed to purge 2010 Nordson Corporation
System Overview 2-11 Navigation (+ SHIFT) Keys The keypad has five navigation keys to maneuver to different parts of the display and select information to review or revise. The following figure and table identifies each navigation key and how it works. 5742023A Fig. 2-9 Navigation Keys Key Function To move left from one field to another To delete (when the SHIFT key is also pressed) To move right from one field to another To copy (when the SHIFT key is also pressed) To increase the number or value shown in the field (the parameter or value that is flashing) To scroll through the possible selections To paste (when the SHIFT key is also pressed) To decrease the number or value shown in the field (the parameter or value that is flashing) To scroll through the possible selections To perform various tasks, such as purging a gun or using and saving a program To provide a shortcut to the next parameter Run Key The RUN key starts and stops pattern generation. 5742148A Fig. 2-10 RUN Key 2010 Nordson Corporation
2-12 System Overview 2010 Nordson Corporation
Section 3 Installation 2010 Nordson Corporation
3-0 Installation 2010 Nordson Corporation
Installation 3-1 Section 3 Installation WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. 1. Introduction This section describes how to install the EPC-15 pattern control, including: Equipment Inspection System Design Equipment Mounting Electrical Installation Setup Preparation 2. Equipment Inspection 1. Inspect the equipment for any damage that may have occurred during shipping, including any dents, scratches and loose fasteners. Report any damage to a Nordson representative. 2. Open the ship-with kit that comes with the EPC-15 pattern control. Refer to the following table for a list of the items included in the kit. Description Quantity Purpose Low-profile DIN rail 1 To mount the main control unit Rubber standoffs 2 For use with a high-profile DIN rail instead of the low-profile DIN rail in the ship-with kit Fuse 1 A spare fuse for the main fuse in the pattern control Small screwdriver 1 For the control s quick-disconnect terminal blocks Terminal-block quick-disconnects 3 To connect external wiring to the main control board 2010 Nordson Corporation
3-2 Installation 3. System Design This section explains how to select individual components and how to locate and install them for optimal performance. Selecting System Components 1. Based on the pattern sets required, determine the required number of each of the following system components: independently controlled guns triggers 2. Make sure the EPC-15 pattern control can support all the required components for pattern sets. Refer to the following table. Component Minimum Number Maximum Number Explanation Trigger 1 3 At least one trigger is required and up to three can be used for more complex pattern sets. Gun 1 See explanation External power supply The EPC-15 provides four individually controlled outputs for operating either pneumatic solenoid valves or electric gun drivers. The unit can support gun loads of 1.10 A per output. However, the total gun load must not exceed what the power supply (or supplies) can support. Refer to External power supply below. 1 1 The power supply must supply enough power to support the controller (0.5 A), plus the total gun load, plus the load of the photoeyes. Provide a power supply or choose from the two power supplies that Nordson offers: PS-40 (2.5 A) EPS-20 (2.5 A) NOTE: The EPS-20 power supply must be mounted inside an electrical enclosure. NOTE: Limit the total current of all loads to 3.5 A. 4. Equipment Mounting This part of the section includes: Mounting the Main Control Unit Mounting a Trigger Mounting a Power Supply For instructions on mounting guns and gun actuators, refer to the gun product manual (or manuals) supplied with the equipment. 2010 Nordson Corporation
Installation 3-3 Mounting the Main Control Unit 1. Select a location for the main control unit, referring to the following table for requirements and recommendations. NOTE: Provide sufficient space to mount, operate, and service the unit. Objective Ease of use Water and dust protection Avoid temperature extremes Ease of installation Recommendation or Requirement Select a location where the display is easy to see and the keypad is easy to reach, ensuring proper access to the unit. Choose a suitable place for the IP54 enclosure (which is splash and dust resistant). Water-tight conduit fittings must also be used. Select a place within the 0 50 C (32 122 F) operating temperature range of the unit. Choose a location within reach of the trigger cable (9.1 m [30 ft]). 246 mm (9.7 in.) 41 mm (1.6 in.) 205 mm (8.1 in.) 272 mm (10.7 in.) 94 mm (3.7 in.) 5742157A Fig. 3-1 Dimensions of Main Control Unit 2010 Nordson Corporation
3-4 Installation Mounting the Main Control Unit (contd) 2. Mount a 35-mm DIN rail in the selected location. Use either the low-profile (7.5-mm depth) DIN rail provided in the ship-with kit or provide a high-profile (15-mm depth) DIN rail. NOTE: When using a high-profile DIN rail, use the large rubber standoffs supplied in the ship-with kit to mount the unit so that it is perfectly leveled on the DIN rail. Remove the two small standoffs and replace them with the larger standoffs. 5742144A Fig. 3-2 Mounting the Main Control Unit on a DIN Rail 3. Hook the top of the two mounting clips on the back of the unit over the top of the DIN rail. 4. Slide the unit left or right on the rail to adjust it. 5. Push the unit against the DIN rail to secure the mounting clips. 2010 Nordson Corporation
Installation 3-5 Mounting a Trigger The type of trigger to be installed determines the procedure to be followed. A limit switch can be installed, or any of the following types of photosensors can be used as a trigger: a retroreflective sensor (with standard lens) a retroreflective sensor (with polarized lens) a diffuse reflective (proximity) sensor 1. Select a location for the trigger as directed by the objectives in the following table. Objective Protect trigger from water and dust Ensure good product sensing NOTE: The sensor should be placed 2 in. from product. This prevents outside sources from triggering the sensor (false triggering). Avoid exceeding the controller queuing capability Ensure proper operation of pattern control Maximize accuracy Recommendation or Requirement Choose a suitable place for the IP54 enclosure (which is splash and dust resistant). Make sure the distance between the trigger lens and the target is within recommended range: Diffuse reflective (proximity) type: 51 381 mm (2 15 in.) Retroreflective type (polarized lens): 51 2130 mm (2 84 in.) Retroreflective type (non-polarized lens): 51 4500 mm (2 180 in.) Choose a location that will not permit more than four products between the trigger and guns at any time. Make sure the time between the trigger and the first bead of each gun is greater than 2 milliseconds plus the time for gun to fire adhesive. NOTE: For random-length operation, the trigger must be farther from the gun than the longest pattern length (i.e., the distance from trigger to gun is greater than the distance from the start of the box to the end of the last bead). With pattern control operation in mind, install the trigger as close to the guns as possible to minimize the effects of line speed variance. Farther mounting distance of the trigger requires more stable line speeds. 2010 Nordson Corporation
3-6 Installation Mounting a Trigger (contd) 2. Mount the trigger on either the adjustable mounting bracket or the mounting nut provided with the trigger. Mounting patterns for the bracket and the hole size required to use the mounting nut are shown below. 18 mm (0.71 in.) 20 mm (0.80 in.) 5742102A Fig. 3-3 Mounting Information for Nordson Triggers 3. If the trigger is a retroreflective type, mount the reflector on the other side of the production line. Align the sensor and reflector so they are at a slight angle to the product (70 or 110 ) instead of perpendicular to the product (at a 90 angle). 4. Tighten all fasteners. Excessive vibration can cause loss of alignment or false signals. Repeat this procedure to mount multiple triggers. 2010 Nordson Corporation
Installation 3-7 Mounting a Power Supply Nordson offers two power supplies: the PS40 power supply the EPS-20 power supply 1. Select a location for the power supply, referring to the following table for requirements and recommendations. Objective Protect power supply from water and dust Recommendation or Requirement Choose a suitable place based on the rating of the power supply enclosure: PS-40: IP54 (splash and dust resistant) EPS-20: IP20 (touch-proof, no water/dust protection) Ease of operation PS40: choose a location where the power switch is easy to reach. EPS-20: make sure the plant circuit breaker for the system is easy to reach. 2. Mount the power supply according to instructions included with the power supply. 5. Electrical Installation This part contains the following procedures: Removing the Terminal Block Cover Connecting Inputs and Outputs to the Main Control Board Connecting Power to the Power Supply 2010 Nordson Corporation
3-8 Installation Removing the Terminal Block Cover 1. Remove the three screws that secure the terminal block cover to the unit. 2. Pull the terminal block cover down about 25 mm (1 in.) to disengage its tabs from the unit and remove it. 5742147A Fig. 3-4 Removing the Terminal Block Cover 2010 Nordson Corporation
Installation 3-9 Connecting Inputs and Outputs to the Main Control Board Use this procedure to connect all external wiring and cabling to the main control board s terminal blocks. NOTE: Make sure the terminal block cover is removed. Refer to the following illustration for details. POWER LED GUN LED S 1 2 FAULT LED X1 3 4 CONTRAST F1 X2 CONTRAST FUSE TERMINAL BLOCKS TRIGGER LED s TERMINAL BLOCK 5742179A Fig. 3-5 Diagram of Components Needed to Access Main Control Board 1. Route all wires and cables from the external components to the main control unit. This includes wiring: from one trigger to three triggers from the gun actuators (pneumatic or electric) to 1 4 gun outputs from the external power supply from a ground wire to the remote inputs (optional) 2010 Nordson Corporation
3-10 Installation Connecting Inputs and Outputs to the Main Control Board (contd) WARNING: Risk of electrical shock. The base-panel ground lug must be connected to a reliable earth ground. Failure to do so can result in personal injury or death. CAUTION: Do not connect AC lines to the unit or any DC lines that exceed 30 VDC. The EPC-15 pattern control unit is designed for 24 VDC inputs, outputs, and contact closures. Powering the unit with too much voltage applied can blow fuses and/or damage the unit. CAUTION: Do not reverse the two wires that supply power to the unit at positions 1 and 2 of X1. Reversing the voltage to the unit can blow fuses and/or damage the unit. Position 1 is the positive input and position 2 is the common input. NOTE: The maximum wire size that can be used to connect to the terminal blocks on the main control board is 1.5 mm (16 AWG). 2. Clip off or tape back the current-sourcing output (PNP) wire on the trigger cable. NOTE: Only current-sinking (NPN) sensor outputs will work with the EPC-15 pattern control. Nordson provides a trigger conversion service kit for triggers with only a sourcing output or voltage other than 24 VDC. Refer to the Parts section. 2010 Nordson Corporation
Installation 3-11 3. Refer to the following figure to determine the connections needed between the external components and the two main terminal blocks (X1 and X2) on the main control board. EPC 15 ENGINE 5A +24V 24V COM +24V 24V COM +24V 24V COM +24V +24V Remote in #1 Remote in #2 Remote in #3 +24V Trigger 1 24V COM +24V 24V COM +24V 24V COM +24V Trigger 2 24V COM +24V Trigger 3 24V COM LCD Contrast X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 X2 + _ 24 VDC 1 2 <1.25 Amps EA Base Panel Lug Earth Ground, Enable Disable Lockout or Remote Recall Trigger 1 1 +V 3 4 2 +V 3 +V or <1.25 Amps EA or Trigger 2 Trigger 3 or 5742180A Fig. 3-6 Wiring Diagram for Main Control Board Terminal Block X1 NOTE: Some connections are optional, based on the external equipment to be used. 4. Locate the four conduit holes in the conduit plate at the bottom of the control enclosure. Decide which holes to use to connect external wiring to the main control board. Remove the dust plugs from these conduit holes. 5. Install a grommet or conduit fitting into each hole used. To maintain the IP54 rating of the enclosure, the fitting must meet dust-tight, water-spray requirements. The 22.5 mm (0.9 in.) holes require PG16 (0.5 in. trade size) grommets or fittings. 5742146A Fig. 3-7 Installing a Conduit Fitting at Access Hole for Wiring 2010 Nordson Corporation
3-12 Installation Connecting Inputs and Outputs to the Main Control Board (contd) 6. Route the wiring through the conduit fittings and conduit holes. 7. Locate the small screwdriver and three quick-disconnect terminal blocks in the ship-with kit. Connect the wiring to the quick-disconnects before plugging them into their bases on the terminal blocks. 5742063A Fig. 3-8 Connecting Wiring to Quick-Disconnect Terminal Blocks CAUTION: Do not plug the quick-disconnects into their bases before completing the wiring connections. Connecting wiring onto installed quick-disconnects may apply force capable of damaging the circuit board. NOTE: Remove the conduit plate to provide additional working room. Be sure the wires are securely installed between the metal clip and the metal block. 8. Plug the three quick-disconnects into their bases on the main control board. Each quick-disconnect is keyed so that it cannot be inserted into the wrong base. 9. Route a ground wire from the ground lug to a metal support nearby. Installing this ground will provide maximum immunity from electrical noise. 2010 Nordson Corporation
Installation 3-13 Terminal Block Installation Comment Note Position X1-1 Wire from power supply for 24 VDC power X1-2 Wire from power supply for 24 VDC common (or negative) X1-3 First lead wire from gun actuator for gun 1 A X1-4 Second lead wire from gun actuator for gun 1 A X1-5 First lead wire from gun actuator for gun 2 A X1-6 Second lead wire from gun actuator for gun 2 A X1-7 +24 V to activate remote inputs X1-8 +24 V to activate remote inputs X1-9 Remote input #1 (remote recall or enable) B X1-10 Remote input #2 (remote recall or disable) B X1-11 Remote input #3 (remote recall or lockout) B X1-12 Power wire from trigger 1. If a through-beam type of sensor is used, connect the C power wires from both the emitter and receiver to this terminal. If a limit switch is used, do not connect any wire to this position. X1-13 Current-sinking output wire from trigger 1 D X1-14 Common wire from trigger 1. If a through-beam sensor is used, connect the D common wire from the emitter and receiver to this terminal. X2-1 First lead wire from gun actuator for gun 3 A X2-2 Second lead wire from gun actuator for gun 3 A X2-3 First lead wire from gun actuator for gun 4 A X2-4 Second lead wire from gun actuator for gun 4 A X2-5 Power wire from trigger 2. If a through-beam type of sensor is used, connect the C power wires from both the emitter and receiver to this terminal. If a limit switch is used, do not connect any wire to this position. X2-6 Current-sinking output wire from trigger 2 D X2-7 Common wire from trigger 2. If a through-beam sensor is used, connect the D common wire from the emitter and receiver to this terminal. X2-8 Power wire from trigger 3. If a through-beam type of sensor is used, connect the C power wires from both the emitter and receiver to this terminal. If a limit switch is used, do not connect any wire to this position. X2-9 Current-sinking output wire from trigger 3 D X2-10 Common wire from trigger 3. If a through-beam sensor is used, connect the common wire from the emitter and receiver to this terminal. D NOTE A: The leads from gun actuators (pneumatic or electric) are usually not polarity sensitive. However, when connecting polarity-sensitive actuators, positions 3 and 5 of X1 and positions 1 and 3 of X2 are the more positive sides of the connection. B: These inputs are activated with +24 V and terminal block positions X1-7 and X1-8 can be used to provide that power. C: A mechanical limit switch can be used for a trigger instead of a photosensor. Connect the switch between current-sinking input and common. The use of mechanical limit switches is not recommended for random-length operation or for systems that need high speeds or accuracy. D: Clip off (or tape back) the sourcing output wire. If the trigger will not sink current at 24 VDC, see the Trigger Conversion service kit in the Parts section. 2010 Nordson Corporation
3-14 Installation Connecting Power to the Power Supply 1. Decide on a source of power to connect to the power supply. Nordson power supplies accept the following input voltages: PS40 power supply: 90-132 VAC or 180 264 VAC EPS-20 power supply: 90 264 VAC 2. When using the PS40 power supply and a 120 VAC power line, change the hardware setting inside the unit from 240 VAC operation. Open the unit, remove the metal cover that protects the circuit board, and move the plug from the connector marked 230V to the connector marked 115V. Replace the circuit board cover and close the unit. WARNING: Risk of electrical shock. Failure to disconnect and lock out power can result in injury or death. 3. Disconnect and lock out the source of power at a circuit breaker. 4. Route a power line to the power supply. 5. Make the appropriate connections at the power-input terminals on the power supply. 6. Setup Preparation This part of the section includes the following procedures: Removing Energy Sources from Equipment Attached to the EPC-15 Pattern Control Adjusting a Trigger Determining Trigger Polarity Checking for Correct Gun Output Wiring Checking for Correct Remote Input Wiring Replacing the Terminal Block Cover Removing Energy Sources from Equipment Attached to the Pattern Control WARNING: Before applying power, disconnect power sources (pneumatic, hydraulic, and electric). Failure to do so can result in personal injury or death. 1. Remove all sources of power from equipment that pressurize guns and that are connected to the EPC-15 pattern control. 2. Relieve pressure from the guns. 3. Remove the terminal block cover from the EPC-15 pattern control. 4. Turn on the 24 VDC power supply. The green power LED should turn on and introduction screens should display in the LCD. If not, remove power immediately and recheck the power supply wiring. 2010 Nordson Corporation