PC-1 0 Pattern Control - Welcome to Nordson...

PC-1 0 Pattern Control

Part 104 500A

NORDSON CORPORATION. AMHERST, OHIO. USA

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

Address all correspondence to

Nordson Corporation 11475 Lakefield Drive

Duluth, GA 30136

Notice

This is a Nordson Corporation publication which is protected by copyright. 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

AquaGuard, Blue Box, Control Coat, Equi=Bead, FloMelt, FoamMelt, FoamMix, Helix, Hot Shot, Hot Stitch, 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, and Package of Values are trademarks of Nordson Corporation.

Manual 57-17 104 500A 0 1988 Nordson Corporation

Issued 9/88 All Rights Reserved

Section

II

III

0 Nordson P&A Division

A t/an ta, Georgia TECHNICAL PUBLICATION 57-17-o1

TABLE OF CONTENTS

Page

LIST OF ILLUSTRATIONS. .......... 57-17-03 LIST OF TABLES .............. 57-17-05 SAFETY SUMMARY .............. 40-l-l

EQUIPMENT FAMILIARIZATION. ........ Functional Description ....

Power Module and Mainframe Board: ...... Sensor Module . ... Timer and Gear-To-Line Modules. .......... DriverModules ........

Compensated and Uncompensated . .

Driver Modules ........ Stitcher Module ........... Run-Up Module ............ Cabinet, Card Cage, and Heat Sinks. .

Feature Variations and Options ...... Multifunction Counter Module. .... Strobe Light Kit. ..........

Specifications ..............

PREPARATION FOR USE. ........... Introduction ............ Unpacking .............. Inspection ............. Installation Electrical Installation

..................

Trigger Installation. . Light Source and Photo-'

....

transistor Pair. ....... Limit Switch .......... Other Triggers .........

Encoder Installation. English System Calibration Friction Wheel Installation:

...........

Gun Installation ..........

OPERATING INSTRUCTIONS . . . . . . . . . . Setup and Initial Operation. . . . . . . .

Pre-Programming Instructions. . . . . Programming and Initial Operation . . Changing Onboard Compensation . . . .

Daily Operation. . . . . . . . . . . . . . Programming for Special Applications . . .

Dual Trigger Applications . . . . Trigger Installation and Sensor

Module Programming . . . . . . Timer and Gear-To-Line Module

Programming. . . . . . . . . .

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TABLE OF CONTENTS (Continued)

Section

IV

V

VI

Invert, Dot, and Inverted Dot Applications. ...........

Invert Mode. .......... Dot Mode ............ Inverted Dot Mode. .......

57-17-48 57-17-48 57-17-49 57-17-50

MAINTENANCE ............... Introduction Preventive Maintenance: ................. Corrective Maintenance. ....... Disassembly and Repair. .......

Power Module Replacement .... Mainframe Board Re.placement. .. Power Transistor and Zener Diode Replacement. ......

57-17-53 57-17-53 57-17-54 57-17-54 57-17-63 57-17-63 57-17-64

57-17-64

DIAGRAMS AND TABLES. ........... 57-17-67

ILLUSTRATED PARTS LIST .......... 57-17-73 Recommended Spare Parts. ......... 57-i7-83184

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Fiaure Number Title

1

2

7

8

9

10

11

12

13

14

15

16

17

18

19

LIST OF ILLUSTRATIONS

Model PC-10 Pattern Control. .....

Block Diagram, PC-10 Pattern Control. ...............

Sensor Module. ............

Timer Module .............

Driver Module. ............

Gear-To-Line Module. .........

Stitcher Module. ...........

Stitcher Module Bead Patterns, PC-10 Pattern Control. ........

Card Cage, PC-10 Pattern Control ...

Dimensions, PC-10 Pattern Control. ..

Dimensions, Incremental Encoder. .....

Input Voltage Selection Switch Settings ...............

Cabinet Input and Output Connections. .............

Friction Wheel Installation Diagram. ...............

(Substrate Diagram). .........




Sample Worksheet ...........

Page

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LIST OF ILLUSTRATIONS (Continued)

Figure Number Title Page

20

21

22

23

24

25

26

27

28

29

30

31 Zener Heat Sink Assembly, PC-lo. . . .

32 Transistor Heat Sink Assembly, PC-lo.................


Output Cycle Time vs. Knob Setting, Timer and Stitcher Modules . . . . . .

Printed Circuit Board, Sensor Module..... . . . . . . . . . . .

Printed Circuit Board, Timer Module... . . . . . . . . . . . . .

Printed Circuit Board, Gear-To-Line Module. . . . . . . . . .

Printed Circuit Board, Compensated Driver Module. . . . . . . . . . . . .

Symbol Key, PC-10 Cabinet and Module Faceplates . . . . . . . . . . . . . .

Mainframe Board and Cabling Chart, PC-10 Pattern Control. . . . . . . . .

Wiring Diagram, PC-lo. . . . . . . . .

Control System, PC-lo. . . . . . . . .

Enclosure, PC-lo, with Power Module, Side View. . . . . . . . . . .

Enclosure, PC-lo, with Power Module, Top View . . . . . . . . . . .

SUPERSEDES

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Table Number

1

2

3

4

5

ISSUED 7/86

LITHO U.S.A.

LIST OF TABLES

Title

TECHNICAL PUBLICATION 57-17-05/06

Modules and Associated Equipment, PC-10 Pattern Control. . . . . . . . .

Programming Worksheet. . . . . . . . .

Onboard Compensation Settings, Gear-To-Line Module

Troubleshooting Chart Summary. . . . .

Troubleshooting Chart. . . . . . . . .

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0 NORDSON CORPORATION 1986 All Rights Reserved

0 Nordson P&A Division Atlanta, Georgia TECHNICAL PUB1 /CArlON 40-l-l

SAFETY SUMMARY

INTRODUCTION

Here you will find safety guidelines for the use of Nordson equipment. equipment,

These guidelines apply to anyone working with Nordson including operations and service personnel. They are

repeated throughout this manual, along with specific warnings and cautions not included in this section. These safety guidelines cover:

l Installation.

. Equipment operation.

l Working with hot melt materials.

= Use of hot melt solvents.

Failure to follow these recommendations may result in personal injury from burns or electrocution and/or equipment and property damage.

EXPLANATION OF TERMS AND SYMBOLS

The following symbols are used in Nordson publications to alert the reader to potential physical harm or equipment damage:

WARNING:

Failure to observe may cause DEATH or PERSONAL INJURY

CAUTION:

Failure to observe can cause DAMAGE TO EQUIPMENT

c

General 0 General

Electrical II

A 3

Nozzle

A e Hot

A

l 0 a* Pressure'

Figure 1 - Nordson Corporation Safety Symbols

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All Rights Reserved LITHO U.S.A.

SAFETY DURING INSTALLATION

TECHNICAL PUl3L/CAllON

ELECTRICAL

A protective electrical ground connection to a reliable earth.ground is essential for safe operation. Without one, all accessible conductive components (including knobs and controls that appear insulated) can render an electric shock.

A disconnect switch with lockout capability must be provided between the power source and the equipment.

The power supply wire gauge and insulation must be sufficient to meet the temperature and power requirements.

Only fuses of the correct type, voltage rating and current rating should be used. Refer to the Nordson equipment parts list for fuse recommendations. Using incorrect or nonrecom- mended fuses can present a fire hazard.

PNEUMATIC

Nordson recommends installing a lockout, three-way, manual valve in the air supply line to the filter/regulator. This valve makes it possible to relieve air pressure and lock out the pneumatic system before undertaking maintenance or repairs.

GAS-SYSTEM (Pertains to FoamMelt @ Applicators and Nitrogen Blanket

Kits Only)

Cylinders of compressed gas are under high pressure and can present significant safety hazards if handled improperly. Refer to OSHA General Industry Standards, paragraphs 1910.101, 1910.166 and 1910.167 for safety precautions that apply to the use, handling and storage of compressed air.

SAFETY DURING OPERATION

Do NOT operate Nordson equipment under the following conditions:

= At a pressure higher than the rated maximum working pressure of any component in the system.

= Near volatile or otherwise explosive gases or materials.

l Without the covers, panels and safety guards properly installed. -

. At temperatures below 20° F (-6O C) or above 120° F (50° C).

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- With hoses enclosed in any material that interferes with heat dissipation. This includes electrical conduit, insulation of any type or tight metal covers.

With large areas of hoses in contact with a cold floor, cold supports or other such surfaces. Cold points along the hose restrict the flow of adhesive inside the hose and can create potential problems during operation.

(If outdoors or in drafty areas) with the applicator guns unshielded from the wind. Rapid heat dissipation due to air movement across the guns may cause operational problems.

With handgun trigger left unlocked while the gun is unattended.

In addition:

m Use only the metal base when attempting to lift or move this equipment. Do not use equipment covers, doors, panels or hose connectors as braces or grips.

. Never use this equipment as a ladder or stepping stool.

= Route all hoses so as to prevent damage from kinking, abrasion and other physical damage. Do not allow a hose to be installed with a bend radius of less than 6 inches (150 mm).

m Never point an applicator handgun at yourself or anyone else.

SAFETY DURING SERVICING

m Do not perform internal service or adjustment on any equipment unless another person capable of rendering first aid and resuscitation is present.

. Only qualified personnel should service Nordson equipment.

. To avoid personal injury, never touch exposed connections and components while power is ON. Dangerous voltages exist at several points in the equipment.

. Disconnect, lock out and tag external electrical power before removing protective panels or replacing electrical components.

. Remove all jewelry (rings, watches, etc.) before servicing equipment.

n If possible, equipment.

stand on a rubber mat when servicing Nordson Do not work on equipment if standing water is

present. Avoid working in a high-humidity atmosphere. Cover exposed terminals and work area with rubber sheeting to avoid accidental contact while the power is ON.

ISSUED 7/86 SUPERSEDES 2/85 LITHO U.S.A.

Q NORDSON’CORPORATION 1986 All Rights Reserved

TECHNICAL PUB1 /CAT/ON

8 Always wear safety glasses, protective gloves (Nordson P/N 902 514 or equivalent) and long-sleeved protective clothing to prevent injury from hot applicator parts, splashed hot melt adhesive and hot gun surfaces,

= To prevent serious injury from molten adhesive under pressure, always relieve system hydraulic pressure (by triggering the handgun, for example) before opening any hydraulic fitting or connection).

l Never use an open torch, drill or broach when cleaning a nozzle.

a Never continue to operate equipment with a known leak in the system.

SAFETY WHEN‘USING HOT MELT ADHESIVES AND SOLVENTS

HOT MELT ADHESIVES

n Use extreme care when working with molten materials. They solidify rapidly at high temperature and present a hazard. Severe burns can occur if the molten materials come in contact with the skin. Even when first solidified, they are still hot.

m Always wear protective clothing and eye protection handling molten material or working near equipment ing hot melt adhesives under pressure.

when contain-

HEATING SOLVENTS

= Do NOT use an open flame or uncontrolled heating device to heat solvents (for example, a small pan on an unregulated hot plate).

Avoid fire hazard by using only a controlled heating device to heat solvents (for example, a small deep fat fryer or thermostatically controlled hot plate).

l DO NOT USE PAINT-TYPE SOLVENTS UNDER ANY CIRCUMSTANCES! These solvents are volatile and may create a fire and/or toxic vapor hazard even at room temperature.

= Always be sure the work area is adequately ventilated. Avoid prolonged or repeated breathing of solvent vapors.

SUPERSEDES 2/8 5

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40-l-5

- HALOGENATED HYDROCARBON SOLVENTS

Halogenated hydrocarbon solvents are dangerous when used to clean aluminum components in a pressurized fluid system. No available stabilizers prevent halogenated hydrocarbon solvents from reacting under all conditions with aluminum components in a pressurized fluid pumping system.

NEVER clean any aluminum component or flush any system using halogenated hydrocarbon solvents. Use Type R solvents or contact your solvent or hot melt supplier for a non-halogenated hydrocarbon solvent for cleaning and flushing.

Halogenated fluids include the following solvents:

Fluorocarbon Solvents: Dichlorofluoromethane Trichlorofluoromethane

Chlorinated Solvents: Carbon Tetrachloride Chloroform Dichloromethane Ethylene Dichloride Methylene Chloride Monochlorobenzene Monochlorotoluene Orthodichlorobenzene Perchloroethylene Trichloroethylene

Brominated Solvents:

Iodinated Solvents:

Ethylene Dibromide Methyl Bromide Methylene Chlorobromide

Ethyl Iodide Methyl Iodide N-butyl Iodide Propyl Iodide

IF MOLTEN MATERIAL COMES IN CONTACT WITH THE SKIN

n Do NOT try to remove molten material from the skin.

. Immediately immerse the affected area in cold, clean water. Keep the affected area immersed until the material has cooled.

. Do NOT try to remove the cooled material from the skin.

8 Cover the affected area with a clean wet compress.

= In cases of severe burns, look for signs of shock. If shock is suspected, have patient lie down, use blankets to preserve body heat and elevate the feet several inches.

. Call a physician immediately.

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SUPERSEDES 2/85 8 NORDSON CORPORATION 1986

All Rights Reserved

TECHNICAL PURLICATI~N

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SECTION 1

EQUIPMENT FAMILIARIZATION

Figure 1 - Model PC-10 Pattern Control

The Model PC-10 is Nordson's most advanced and most versatile pattern control. It combines state of the art technology with modular construction and so offers simplified operation together with adaptability to a wide variety of applications.

The basic unit consists of an enclosure with a Power Supply Module, a Sensor Module, and a Card Cage and Mainframe Board that will accept up to nine additional modules. ments of the application,

Depending on the require-

or Gear-To-Line Modules, the user may then select up to four Timer

Run-Up, or Multi-Function one to four Driver Modules, and a Stitcher, Counter Module.

Modules and a Stitcher Module, When equipped with Timer

the PC-10 can produce one or more stitched or solid adhesive beads, both solid and stitched beads.

or a bead pattern that includes With Gear-To-Line Modules and a

Run-Up Module, the PC-10 can also be programmed to maintain consistent bead placement and applicator output at varying line speeds from 1 MPM to 300 MPM (3.3 FPM to 1000 FPM).

The Sensor Module will respond to an input signal from an incandescent, infrared, or mechanical trigger and will operate in either a


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PA 173 B

Figure 2 - Block Diagram, PG.10 Pattern Ccntrol




Atlanta, Georgia TECHNICAL PUB1 ICATION 5 7 - 17 - 3

make-light or a break-light mode. The output section of the pattern control will control as many as 16 pneu.matic guns and can handle a total output current draw of up to 4 amps.

The PC-10 is especially designed for ease of installation, programming, and maintenance, All electrical connections are made at the rear of the cabinet via keyed connectors, and the main programming controls are located behind a lockable cover at the front of the unit. Each module is equipped with front panel LED% to provide visual indication of system operation, and the Sensor and Driver Modules have front panel pushbuttons that can be used to initiate a test cycle or troubleshoot the unit.

FUNCTIONAL DESCRIPTION

The PC-10 controls the deposit of adhesive on a moving substrate by activating automatic extrusion guns. (e.g.,

During operation, a trigger a limit switch or a light source and phototransistor pair)

senses the approach of the substrate and sends a signal to the Sensor Module in the PC-lo. On a trigger signal, the Sensor Module activates one or more Timer or Gear-To-Line Modules, each of which controls a pre-set delay and a pre-set duration interval. The delay interval begins with the signal from the Sensor Module and lasts until the targeted area of the substrate arrives under the gun(s). At the end of the delay interval, the Timer or Gear-To-Line Module automatically starts its duration interval and sends an output signal to the Driver Module(s).

The Driver Modules activate gun solenoi,ds which control the flow of adhesive onto the substrate. At the enId of the duration interval, the Timer or Gear-To-Line Module interrupts the signal to the Driver Module(s) and the gun solenoids close, adhesive.

shutting off the flow of

Figure 2 shows the interrelationship be,tween the various modules and the signal path through the PC-lo. The individual modules and their functions are further described in the paragraphs that follow.

POWER MODULE AND MAINFRAME BOARD

The Power Module isolates, transforms, and rectifies input voltage to the pattern control and supplies regulated and unregulated DC card voltage to the printed circui t boards on the individual control modules. It also supplies the Driver Modules with -30 Vdc to actuate pneumatic gun solenoids- The Power Module will accept single phase input voltages of 100/200 or 115/230 VAC, 50/60 Hz. switches on the printed

A pair of

of the two voltage pairs circuit board selects the higher or lower

pair. and the low or high voltage within each



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Input power to the PC-10 is controlled by a magnetic circuit breaker mounted at the right-hand side of the front panel, separate from the other controls. It thus remains accessible even when the cabinet door has been closed and locked to protect the programmed modules against tampering or damage.

An indicator lamp to the left of the circuit breaker lights when the pattern control is turned ON.

The Mainframe Board distributes power to the modules and provides the signal paths from one module to another. It also provides input and output paths to and from the encoder, gun solenoids, trigger(s), and other external components, all of which connect to the Mainframe Board via keyed connectors at the rear of the control cabinet. An onboard switch selects a light source supply voltage of 6.3 VAC or 12 Vdc.

SENSOR MODULE

The Sensor Module has two independent channels and can accept and discriminate between signals from two different triggers. This makes it possible, for example, to control guns on two different

SENSOR

lines or-to sense and trigger off both the leading and the trailing edge of the same substrate.

The two channels will operate either in the same or in different modes (make-light or break- light) and are set by means of slide switches located on the Sensor Module printed circuit board. The four LEDs at the center of the front panel indicate the setting selected for each channel.

Figure 3 - Sensor Module

The two LEDs at the upper left- hand corner of the front panel indicate the presence of an incoming trigger signal. With Channel 1 in the make-light mode,

for example, the LED for Channel 1 is normally dark and lights to indicate a trigger signal. In the break--light mode, the LED is normally on and blinks off to indicate a signal.

The yellow pushbutton (TEST) at the bottom of the front panel is a momentary contact switch. When pressed, manually -- i.e.,

it initiates a test cycle without a signal from the trigger.



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The connections between the Sensor Module and the trigger(s) are made via keyed fittings at the rear of the cabinet. Use of a second trigger requires a special backplate to accommodate the additional input and output connections.

TIMER AND GEAR-TO-LINE MODULES

Timer Modules are normally used in applications where the line moves at a constant speed or where the effects of small variations in line speed on bead placement are relatively unimportant. Each Timer Module controls one delay and one duration interval and is set by means of dual-range counting dials at the top and bottom of the front panel. A pushbutton switch below each dial selects its low range (2-200 ms) or high range (200-2000 ms), and a yellow LED at the upper left-hand side of each dial lights during the portion of the timed interval it controls.

t - YSEc &EOO YSEC

nuulull

TIMER

I

Figure 4 - Timer Module

Like the Timer Modules, the Gear-.To-Line Modules (Figure 6) each have two sets of controls, one f:or the delay and the other for the duration interval. As with the Timer Modules, a yellow LED to the upper left of each set of controls lights during the portion of the cycle it controls. Unlike the Timer Modules, however, the Gear-To- Line Modules are set with 3- digit thumbwheel switches which indicate millimeters (or tenths of an inch) of line travel instead of milliseconds of elapsed time.

The Gear-To-Line Modules will maintain consistency of bead placement at line speeds from 1 MPM to 300 MPM (3.3 FPM to 1000 FPM). If line speed drops below 1 MPM, the Gear-To-Line Modules will automatically inhibit the output signal to the Driver Modules, preventing the guns from firing continuously if the line should stop during a control cycle.

Timer and Gear-To-Line Modules can be set to accept signals from either or both o f the channels on the Sensor Module by means of onboard switches.

DRIVER MODULES

The PC-10 will accommodate up to four Driver Modules, each of which can support from one to four guns.



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Atlanta, Georgia TECHNICAL

All Driver Modules are front-panel programmable by means of pushbutton selector switches and will respond to an output signal from any or all of the Timer or Gear-To-Line Modules. Thus, with all four pushbuttons depressed, a single Driver Module can respond to four separate demands for extrusion from the timing section of the pattern control, each of which will actuate up to four pneumatic guns.

PUB1 ICATION

Figure 5 - Driver Module

h 1 Since the maximum current output of the PC-10 is 4 amps, however, it can actuate only a limited number of guns at one time.

All Driver Modules have a yellow LED at the upper left-hand corner that lights when the driver receives an output signal from any Timer or Gear-To-Line Module. They also have a fifth, momentary contact pushbutton (TEST) beneath the timer selection switches that can be used to activate the module manually for testing or troubleshooting the system.

Compensated and Uncompensated Driver Modules

Since it takes all guns a certain amount of time to respond to electrical signals from the pattern control, it is always necessary to shorten the measured delay and duration intervals slightly to compensate for gun reaction time. When line speed is constant, this is done simply by subtracting fixed amounts of time from the delay and duration settings on the Timer Modules. varies, however,

When line speed the PC-10 must be equipped with Gear-To-Line

Modules and compensated Driver Modules. Working together, the Gear-To-Line and Driver Modules use the encoder input to convert the response time of the guns to millimeters or inches of line travel and adjust the delay and duration intervals accordingly.

As the substrate moves toward the gun, the Gear-To-Line Module uses information from the encoder to calculate the delay interval and adjust it for the response time of the gun solenoid. Thus, the Gear-To-Line Module actually sends its signal to the Driver Module before the gun mus t fire so that the solenoid valve will have time to open before the substrate arrives. In essence, the pull-in



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compensator subtracts the gun response time from the delay interval. For this reason, the delay interval must always be greater than the gun response time.. Otherwise, the gun will have too little time to react after the substrate passes the trigger,

w

and the bead will begin too ILate. If, because of an in-

6 8 3 crease in line speed or a mistake in programming the module, the

@ dela:y interval is too short for the gun to be activated in time,

,B the red LED below the upper set ' of thumbwheel switches on the

Figure 6 - Gear-To-Line Module Gear-To-Line Module will light to signal an error condition.

A similar series of events takes place during the duration interval. As the substrate passes under the open gun nozzles, the Gear-To-Line Module actually signals the Driver Module to deactivate the gun solenoid before the end of the bead so that there will be enough time for the gun to cycle off. Again, the Gear-To-Line Module subtracts the gun response time from the programmed distance interval. For this reason, the duration interval must always be greater than the gun's drop-out time. Otherwise, the duration interval will be zero, there will be no signal to the gun solenoid, and no bead. If this happens, the red LED below the lower set of thumbwheel switches on the Gear- To-Line Module will light to signal an error condition.

The compensation circuitry is set by means of two screwdriver adjustment pots on the front panel of the Driver Modules (Figure r;\

All compensated Driver Modules are equipped with an onboard switch that can be used to modify the driver output for special applications. In one position, the switch 1NVE:RTs the output so that the gun is normally on and turns off on an output signal from the Timer or Gear-To-Line Module(s). In another, the switch produces a minimum deposit or DOT on a duration signal from the timing section of the pattern control. In a third, the switch produces an INVERTED DOT pattern in which the gun is normally on and the dot becomes a short interruption of the bead.

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STITCHER MODULE

When an application calls for a stitched adhesive bead, the PC-10 can be equipped with a Stitcher Module that will respond to an output signal from any or all of the pattern control's Timer Modules.

In-such cases, the overall length of the stitched bead is determined by the duration interval on the Timer Module and the stitch bead and stitch gap are set with counting dials at the top and bottom of the Stitcher Module.

Figure 7 - Stitcher Module

When the output from one of the four Timer Modules is selected by depressing the appropriate pushbutton on the front panel of the Stitcher Module, the Timer output signal is diverted to the Stitcher Module, where it is broken up into stitch beads and gaps. It is then fed to the Driver Module via the Timer output connections. During the stitching process, yellow LEDs to the left of each control knob light alternately to indicate output signals for stitch beads and gaps.

When choosing applications for the Stitcher Module, bear in mind the following points:

1. Although the Stitcher Module can be used with Gear-To-Line Modules, it has no provision for adjusting the stitch bead and stitch gap to compensate for changes in line speed. Thus, F;hile the overall length of the stitched bead will remain the same, the stitch bead and stitch gap will become progressively longer as line speed increases and progressively shorter as line speed decreases.

2. When activated, the Stitcher Module always begins with a stitch bead of the required 1e:ngth and produces a regular stitch pattern until it is switched off. When the stitcher is programmed to respond to an output signal from more than one Timer Mcdule and the output signals overlap, the stitcher will not start a new stitch bead when the signal from the second Timer Module arrives. Instead, it will begin the second sti tched bead at whatever point in its cycle it happens to be at the time. As a result, the set ond bead ( and subse quent stit the d beads, if lap with prev ious outp ut si gnals ) m .ay begin ei gap or a shor tened sti tch b ead ( See Figure 8).

' th ey over- the r with a



PackagIng and Assembly Dlvlslon

Atlanta, Georgia TECHNICAL PUBLICATION 5 7 - 17 - g

STANDARD MODULE

TIMER 1 I ! I I L

I I I

TIMER 2 I 1 i I 1 I I I I I

TIMER 3 I I

I I I

I I 1 I I I

I I I I I I

TIMER 4 I I I 1 I I

I I

I ’ I

STITCH I OUTPUT I I I

I

Timer l'- - - q I

Timer 2 'I, - m m I 1 I I I

1 I I Timer 3 11 D - 4

I I

Shortened / Timer41- - - m stitch bead

Second stitched / bead begins with gap

SPECIAL MODULE

TIMER 1 1 I I I I I

TIMER 2 I I

1

I I I

TIMER 3 I

I I I I

I I

TIMER 4 1 I I

STITCH OUTPUT

Timer 1 '- m

Extended stitch bead

f I II

; I 1 I

Timer 3 M D - (1 I

Timer 4 I- - m (II’

/ Shortened gap.

Figure 8 - Stitcher Module Bead Patterns, PC-10 Patterr, Control



57-17-10 0 Nordson PackagIng and Assembly Dlvlslon

Atlanta, Georgia TECHNICAL PUB1 ICATION

In applications where all stitched beads must begin with a stitch bead of the same length, a special Stitcher Module is available that will restart the stitch pattern each time it receives an output signal from a different Timer Mod-ule. As Figure 8 shows, however, the ongoing stitch pattern will then be interrupted, either by a shortened gap or a prolonged bead.

RUN-UP MODULE

The Run-Up Module controls air pressure to the applicator pump and is used to maintain consistent bead thickness when line speed increases or decreases. It is normally installed with Gear-To-Line Modules and uses the line-speed encoder together with a current-to- pressure transducer and pressure multiplier to control applicator output.

When line speed changes, the Run-Up Module sends an electrical signal to the transducer, which translates the signal into a change in pressure at the pressure multiplier. The pressure multiplier then uses the transducer output to adjust inlet pressure to the applicator air motor or piston pump and thus to increase or decrease applicator output.

CABINET, CARD CAGE, AND HEAT SINKS

The Card Cage consists of a series of parallel channels that guide the keyed terminal strips at the the Mainframe Board.

rear of the modules into place on Altogether, the cage contains ten sets cf

channels or slots, of module.

each of which is reserved for a particular type As Figure 9 shows, the four slots on the left-hand side

of the cabinet are reserved for Driver Modules, the first slot cn the right-hand side for the Sensor Module, and the three slots on its left for Timer or Gear-To-Line Modules. slots, No.

The remaining twc 5 and No.

module. 6, will accommodate more than one type of

Slot No. 6 will accept the Stitcher Module, the Run-Up Module, or an optional Multifunction Counter Module (See Feature Variations and Options). Slot No. 5 is normally used for a fourth Timer or Gear-To-Line Module but will also accept the Run-Up Module for applications where both a Stitcher and a Run-Up Module are needed.

To prevent the modules from being installed in the wrong slots, the keyed terminal strips at the rear of the modules will seat only in the slot or slots ling the modules,

for which they were intended. To aid in instal- the lower left-hand corner of each module is

marked with an identifying symbol which alsc appears on the lower ledge of the cabinet beneath the slots that will accept the module.


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--~ --,

till

--___ --__- ~ --

, w w W W L?J W -1 6

v4V3V2Vl+ l 4m3m2mlo 1

SLOT NO. SYMBOL MODULE

1 Sensor Module

PA 173 I

2 Timer Module Gear-to-Line Module



5 Timer Module Gear-to-Line Module Run-Up Control Module

6 Stitcher Module Run-Up Control Module Multifunction Counter

Module

‘7 v 30V Driver Module

8 v 30V Driver Module



ISSUED lo/82 LITHO U S.A.

Figure 9 - Card Cage, PC-10 Pattern Control


All Rights Reserved

57-17-12 0 Nordson Packagtng and Assembly Dwwon


The rear of the cabinet serves as a mounting board for the power transistor and zener heat sinks, which also incorporate keyed connectors for the gun cables, encoder, run-up output, and trigger. Connections between the rear of the cabinet and the modules are made via cables that plug into keyed receptacles on the back of the Mainframe Board.

When the PC-10 is assembled at the factory, the modules ordered with the unit are inserted in their proper places and the appropriate heat sinks are attached to the rear of the cabinet. Any remaining openings at the rear of the cabinet are then closed with cover plates and blank modules are inserted in all unoccupied slots in the Card Cage.

FEATURE VARIATIONS AND OPTIONS

The basic PC-10 consists of a cabinet equipped with a Power Module, Card Cage, Mainframe Board, and a zener heat sink with keyed connectors for the light source and receiver. Additional modules and accessories are then ordered and installed according to the requirements of the individual application.

Table 1 lists the available modules and their associated equipment. Further feature variations, if any, are noted to the right of the appropriate table entry together with additional comiments on the installation of the equipment.

In addition to the modules listed in Table 1, the following modules or accessories are also available on a special order basis.

MULTIFUNCTION COUNTER MODULE

The Multifunction Counter Module installs in Slot No. 6 and acts both as a cycle counter and as a tool for checking line speed, timer intervals, and encoder output during setup and troubleshooting. An 8-digit LED display at the bottom of the front panel counts impulses from the trigger and can be reset with a pushbutton switch immediately below the display. A second, 4-digit LED display at the top of the front panel registers either line speed in feet or meters per minute or the delay or duration interval for each of the Timer Modules. The various readouts are selected by means of six pushbutton switches located below the display panel.

STROBE LIGHT KIT

The Strobe Light Kit is used as a diagnostic ularities in bead

tool to check for irreg- timing and mechanical or electrical malfunctions

of the guns. The strobe light is equipped with its own power supply and the necessary cabling to attach it to the pattern ccntrol.

ISSUED lo/82 SUPERSEDES LITHO U.S.A.


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Atlanta, Georgia TECHNICAL PUB1 /CATION 5 7 - 17 - 13

TABLE 1

MODULES AND ASSOCIATED EQUIPMENT, PC-10 PATTERN CONTROL

PART NO. DESCRIPTION MAX QTY/ NOTES UNIT

296 000 Enclosure w/Power Module 1 Includes zener heat sink with connectors for light source and phototransistor/receiver.

296 065 Sensor Module 1 Use of dual trigger requires receptacle panel (P/N 296 151 or 296 153) with fittings for second light source and receiver.

Triggers other than standard light source and receiver require 3-wire shielded cable (P/N 296 171) to connect trigger to fittings at rear of cabinet.

296 051 Timer Module 4

296 069 Gear-To-Line Module 4 Module is equipped with a 1 KHz clock and can be used at constant line speeds without an encoder. In applications where line speed varies, module must be installed with a line- speed encoder.

296 055 Stitcher Module 1

296 063 30V Driver Module 4 Each Driver Module must be ordered with a transistor heat sink assembly (P/N 296 047)

296 096 30V Driver Module 4 and at least one gun cable (P/N 296 092) w/compensation

When a single driver provides power for more than one gun, installation requires an expander box (P/N 273 289) and additional gun cables (P/N 296 092).

296 105 Run-Up Module 1 Installation requires line-speed encoder on all units not already so equipped.

All installations require Current to Pressure Transducer, 1:6 Pressure Multiplier, and Run-Up Control Output Cable (P/N 296 170). Components may be bought in kit form by ordering P/N 296 172.

296 101 Multi-Function Counter 1 Module

Strobe Light Kit 1 Installation requires signal expander box (P/N 273 289) and 115 VAC, 50/60 Hz, 1 9 external power source.

-- ___-----_

296 162 200 PPR Line Speed Encoder w/Cable 1 Requires receptacle panel (P/N 296 080) for encoder input connection. A friction wheel

296 163 500 PPR Line Speed Encoder w/Cable 1 (P/N 296 144) is available for establishing positive contact with the conveyor when direct drive is impossible or undesirable. For metric calibration, use friction wheel with 500 PPR encoder; for English system calibration use with 200 PPR encoder.


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Atlanta. Georgia

SPECIFICATIONS*

PC-10 PATTERN CONTROL

Dimensions

Input Trigger

Input Trigger Requirements (1) Resistance Type

(2) Voltage-Output Type

TECHNICAl PUB1 /CATION

See Figure 10

Light source/phototransistor pair, limit switch, solid state relay, retroreflector, or proximity switch.

Low level input: less than 8,000 ohms

High level input: greater than 500,000 ohms

Supply current requirement: less than 250 mA at 12 Vdc

Non-grounded common

Low level output: less than 3.0 Vdc

High Level output: 9.0 Vdc to 12.0 Vdc

Supply current requirement: less than 250 mA at 12 Vdc

Non-grounded common

(3) Solid-State Output Type

Open collector NPN transistor Supply current requirement:

less than 250 mA at 12 Vdc Non-grounded common

Electrical Requirements 100/115/200/230 VAC, 50/60 Hz ,r single phase, 185 watts ma2timum

Driver Output 4 amps at 30 VDC

Timer Modules Low Range 2 to 200 ms

k l0 percent

High Range 200 to 2000 ms t l0 percent

Repeat Accuracy Error + 0.5 ms

Temperature Drift + l percent over operating temperature range (0°C to 55OC)

* Due to possible technological and/or quality improvements, equipment specifications are subject to change without notice.


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Atlanta, Georgia TECHNiCAl PUBL /CATION 5 7 - ’ 7 - ’ 5

SPECIFICATIONS (Continued)

Gear-To-Line Modules Maximum Count

Count Repeat Accuracy

Pull-In and Drop-Out Compensation

999 pulses

+ 1 cou:nt

0.1 ms to 30 ms

Stitcher Module Stitch Bead Range

Stitch Gap Range

Repeat Accuracy Error

2 to 200 ms f 10 percent

2 to 200 ms t 10 percent

2 0.5 ms

Temperature Drift

INCREMENTAL ENCODER

Dimensions

Supply Voltage

Pulses per Revolution

Shaft Loading Radial

Axial

Rated Speed

Operating Temperature


& 1 percent over operating temperature range (OOC to 55OC)

See Figure 11

12 Vdc

200/500

100 lb (45.3 kg) maximum at end of shaft

40 lb (18.1 kg) maximum

3000 rpm at maximum shaft loading

O°C to 65OC (32OF to 149'F)

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All Rights Reserved

57-17-16 0 Nordson Packaglng and Assembly Dlvlsion

Atlanta, Georgta TECHNICAL PURL ICATION

16.0)

Dimensions in inches (centimeters).

Figure 10 - Dimensions, PC-10 Pattern Control



0 Nordson Packaging and Assembly Dwrslon

Atlanta, Georgia TECHNICAL PUBLICATION 57-17-17,‘18

l-A-1

PA 173 K

3.00 in. (7.6 cm) LSO in. (3.8 cm) 1.62 in. (4.1 cm) 3.25 in. (8.3 cm) 1.25 in. (3.2 cm) 2.50 in. (6.4 cm) 1.31 in. (3.3 cm) 2.63 in. (6.7 cm)

3.12 in. (7.9 cm) 1.50 in. (3.8 cm) 0.75 in. (1.9 cm) 4.64 in. (11.8 cm) 0.38 in. (1.0 cm) 2.12 in. (5.4 cm) 1.19 in. (3.0 cm) 0.25 in. (0.6 cm)


Figure 11 - Dimensions, Incremental Encoder


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0 Nordson Packaging and Assembly Dwlslon

Atlanta, Georgia TECHNICAl PUBLICATION 5 7 - 17 - 19

SECTION II PREPARATION FOR USE

INTRODUCTION

The following paragraphs describe procedures for unpacking, inspecting, and installing the Model PC-10 Pattern Control. For parts identification, refer to Section VI.

UNPACKING

The PC-10 Pattern Control is shipped with the control modules installed in the cabinet. The equipment accompanying the unit (interconnection cables, light source and phototransistor pair, encoder, etc.) is packed in individual compartments molded into the foam packing surrounding the cabinet.

To unpack the PC-lo, remove the equipment from the compartments in the foam packing and set it aside. Then remove the top half of the packing and carefully lift the cabinet out of the carton.

0 Handle all equipment with care. Do not drop the components, place them on hot surfaces, or expose them to strong magnetic fields. Do not remove the modules from the cabinet. If spare modules are shipped with the unit, read the instructions for storage and handling of digital circuit boards in Section IV before removing the modules from their packing.

INSPECTION

After unpacking the PC-lo:

1. Check the contents of the shipment carefully against the packing slip enclosed in the carton.

2. Inspect all components for dents, scratches, or other evidence of damage.

3. Inspect all fasteners for tightness.

4. Store the carton and all packing materials, including the spare conductive plastic bags for the modules, in a safe place. The packing materials must be used if it becomes necessary to return the unit or the modules for repair.

lSSUE0 lo/82 LITHO U.S.A.


All Rights Reserved

57-17-20

INSTALLATION

Packaging and Assembly Division

Atlanta, Georgta TECHNICAL PUBLICATION

The PC-10 should be mounted right side up in a location free from large amounts of vibration and from ambient temperatures above 120°F (5OOC) or below 32OF (OOC). To minimize electrical noise in the input and output cables, the cabinet should be as close to the line as possible. The terminals at the rear of the cabinet should be readily accessible and there should be enough clearance at the front of the cabinet so that the door can be fully opened.

0 Do not install the PC-10 inside another enclosure, directly above the hot melt applicator, or in any position that will interfere with the ability o.f the transistor heat sinks to dissipate heat.

0 Do not install the unit where it will be exposed to excessive moisture, large amounts of dust, or corrosive materials.

NOTE: Beneath the rubber feet on the base of the cabinet are are bolt holes (M6) that may be used to mount the PC-10 permanently in its installed position. holes to secure the cabinet,

When using the bolt leave the rubber feet in place

to serve as vibration insulators.

ELECTRICAL INSTALLATION

A

The Model PC-10 Pattern Control contains electrical poten-

t

tials that are dangerous and can be fatal. Exercise extreme caution when installing, operating, and servicing the equipment. Only qualified personnel should install and service the PC-lo.

A

To prevent electrical shock during installation and serv-

's

ice, Nordson recommends installation of a circuit breaker in the service line to the pattern control. This is man- datory where required by local electrical codes.

The PC-10 must be connected to a reliable earth ground.

1. Remove the four screws from the access panel at the rear of the Power Module and remove the panel.

2. Route a 100, 115, 200, or 230 VAC service line through the cord connector to the left of the access panel and connect the incoming power leads to the Power Module at the input terminal block.

0 Input voltage must be nomina:Lly 100, 115, 200, or 230 VAC, 50/60 Hz, 1 jZ. Connecting any other voltage supply to the PC-10 will result in improper operation of the unit and may damage the components.

ISSUED IO/82 LITHO U.S.A.


0 Nordson PackagIng and Assembly Dwlslon

A tlanta, Georgia TECHNICAL PUB1 ICATION 5 7 - 17 - 2 1

3. To avoid accidental damage to the printed circuit boards, all units are set at the factory for an input voltage of 230 VAC. If the service line voltage is other than 230 VAC, consult the diagram in Figure 12, and set the two switches beside the input terminal block for the correct voltage.

0 Setting the switches incorrectly may result in damage to the unit.

4. Connect the ground stud inside the access panel to a reliable earth ground. tion.

Use a ring-tongue terminal to make the connec-

POWER MODULE PRINTED CIRCUIT BOAR0

\”

/ I

II

RECESSED PORTION OF SWITCH

1

PA 173 L

i------r-- 1 / VOLTAGE ) POSITION /

Figure 12 - Input Voltage Selection Switch Settings

5. Reinstall the access panel and tighten down the gland packing cn the cord connector until the service line is fully captured.

TRIGGER INSTALLATION

NOTE: For dual trigger installations, see PROGRAMMING FOR SPECIAL APPLICATIONS in Section III.

The trigger must be securely mounted and located so that each substrate on its

will initiate its own timed sequence as it passes the trigger way to the guns. In general, the trigger should be located

as close to the gun installation as possible to minimize the effect of slippage between the substrate and the line. located, however,

It should not be

from the guns. so that it will be exposled to splashed adhesive





Light Source and Phototransistor Pair

The light source and phototransistor should be mounted so that the passing substrate will interrupt the light beam between the two modules. Choose an area where strong ambient light will not affect the phototransistor and where dust, paper fiber, and other foreign material will not cover the light source or receiver. the light source should be below the

If possible, substrate and aimed upward

toward the phototransistor to reduce false signals from ambient lighting.

For best results, the light source and phototransistor should be as close together as possible, especially in high speed applications. Under no conditions should the two be more than 5 ft (1.5 m) apart.

To connect the light source and phototransistor pair:

1. Select a suitable location for the trigger point, install the necessary mounting hardware, alignment visually.

and bring the pair into rough

2. Route the cables from the light source and receiver to the cabinet and connect them at the two keyed fittings below the heat sink behind slots No. 3 and 4. The cable from the light source attaches to the connector on the right-hand side of the heat sink, the cable from the phototransistor to the connector on the left-hand side (See Figure 13). Snap the latches into place over the connectors and check to be sure the cables are fully secured.

0 All cables should be routed so that they are well away from vehicle and pedestrian traffic, moving machine parts, and areas with high temperature and excessive moisture. Once routed, with suitable fasteners.

they should be held in place

3. Switch on external power to the pattern control and turn the unit ON at the circuit breaker on the front panel. The indicator: lamp should glow and the light source should come on.

4. Use a piece of black cardboard placed in front of the phototransistor to check for proper alignment of the light source. If necessary, adjust the light source until the beam of light shines directly into the phototransistor receiver.

5. Fasten both elements securely and recheck for alignment.

6. Test the trigger for proper operation by interrupting the beam of light to the phototransistor. The yellow LEDs at the upper left of the front panel should wink on or off when the beam is interrupted.

lSSlJE0 IO/ 8 2 LITLiT) IISA



Atlanta. Georgia TECHNICAL PUBfICATlON 57-17-23

Figure 13 - Cabinet Input and Output Connections



57-17-24 0 Nordson Packaging and Assembly Dwwon


7. Switch the pattern control OFF at the front panel.

Limit Switch

Limit switches used as triggers should be wired in the normallv closed (NC) position and connected to the cabinet with a shiel&ed cable (P/N 296 171) at the fitting normally used for the phototransistor. To connect the limit switch, clip the red lead cn the shielded cable flush with the end of the cable and attach the black and clear leads to the terminals on the switch. shield at the switch.

DO NOT ground the

Other Triggers

The Sensor Module in the PC-10 is designed to be used with triggers that change from a short circuit to an open circuit in the break-light mode and from an open circuit to a short circuit in the make-light mode. In addition to the standard light sourc~J phototransistor pair or a limit switch, various other kinds cF triggers may be used. Nordson offers two types of retroflcctor (P/N 296 201 and P/N 296 203) and two types of proximity switches (P/N 296 202 and P/N 296 204). For further information on these triggers, see manual 59-32. The customer may supply his o\;n trigger device as long as it meets the specifications listed in Section I under Input Trigger Requirements.

Installation of triggers other than those described above is the responsibility of the user and may void the warranty on the unit.

For convenience in connecting triggers other than a limit switch or the standard light source and phototransistor pair, the light source supply voltage can be converted from 6.3 VAC to 12 Vdc. open collector output triggers requiring a +12 Vdc supply voltage can then be connected directly to the fitting for the phototransistor/ receiver.

To change light source supply voltage::

1. Ensure that the pattern control is turned OFF at the main circuit breaker on the front panel.

2. Remove the four screws securing the zener heat sink assembly (17, Figure 30) and tilt the assembly outward from the rear panel to gain access to the voltage selection switch on the Mainframe Board.

3. Change the switch to the 12 Vdc position and re-install the zener heat sink assembly.

To install an open collector output trigger:



All RIghIs Reserved

0 Nordson Packagmg and Assembly Dwlslon

Atlanta, Georgia TECHNICAL PUBLICATION 57-17-2 5

1. Connect a shielded cable (P/N 296 17l) to the cabinet at the fitting normally used for the phototransistor/receiver.

2. Connect the clear cable lead to the trigger collector (+), the black lead to the emitter (common), and the red lead to the terminal marked +12 Vdc. On applications where input voltage to the trigger is not required, clip the red lead flush with the end of the cable.

ENCODER INSTALLATION

The encoder must be mounted on the parent machine and installed in such a way that it registers accurately the speed of the substrate on the line. In most cases, this involves selecting an idler shaft on the parent machine and using it to drive the encoder via a gear or belt drive system.

Generally, timing gears driven by a notched timing belt produce the best results, although a chain drive with a tensioner will also work well. V-belts and pulley arrangements or flat belt drives should be avoided since slippage of any kind will adversely affect the accuracy of the encoder and can result in erratic bead placement.

If necessary, the encoder may also be driven by a rubber-faced friction wheel, provided that positive contact with the line is maintained.

The moving parts of any encoder drive system should be covered with a protective guard to prevent injury to personnel working near the machine.,

To install the encoder (P/N 296 162 only)::

1. Select an appropriate mounting site and install the encoder so that 200 mm of line travel will produce one revolution of the encoder shaft. Begin by determining how many revolutions the drive shaft on the parent machine makes for every 200 mm of line travel. Then select a gear or pulley system that will produce the required encoder shaft speed. drive components,

To select the proper use a reliable tachometer to measure both the

line speed (in MPM) and the speed of the shaft that will be used to drive the encoder. Then use the following equation to calculate the proper gear ratio for the encoder drive system:

ISSUED 3184 LITHO U.S.A.

Gear Ratio = Drive Shaft Speed (RPM) Line Speed (MPM) x 0.20


All Rights Reserved

57-17-26 0 Nordson PackagIng and Assembly Division


If, for example, the drive shaft turns at 1750 rpm when the line speed is 100 MPM, the proper gear ratio for the encoder drive system is 1750 x 0.20 or 3.5:1.

100

With the encoder installed as described above, the settings on the thumbwheel switches at the Gear-To-Line Modules will read in millimeters and will control delay and duration intervals of 1 to 999 millimeters.

English System Calibration

Generally, metric system calibration is preferable to English system calibration since it produces more precise control over bead placement. however,

If English system calibration is required, install the encoder so that 20 inches of line travel

will produce 1 revolution of the encoder shaft. Use the following equation to calculate the gear ratio for the encoder drive system:

Gear Ratio = Drive Shaft Speed (RPM) Line Speed (FPM) x 1.66

With the encoder installed as described above, the settings on the thumbwheel switches will read in tenths of an inch with an interval range of 0.1 inch to 99.9 inches.

NOTE: If necessary, the encoder can also be calibrated so that the thumbwheel switches register multiples or frac- tions of the actual distance intervals. Increasing the drive system gear ratio by a factor of 2, for example, will produce a bead twice the length indicated on the thumbwheel switches. Decreasing the gear ratio by a factor of 2 will produce a bead half the length shown on the switches.

2. Route the interconnection cable f:rom the encoder to the cabinet and attach it to the keyed fitting on the right-hand side of the panel behind Slots No. 1 and 2. over the connector,

Snap the latch into place and check to be sure the cable is fully

secured.

0 The cable should be routed so that it is well away from vehicle and pedestrian traffic, moving machine parts, and areas with high temperature, and excessive moisture. Once routed, the cable should be held in place with suitable fasteners.



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PackagIng and Assembly Dwlslon

Atlanta, Georgia TECHNICAL PUB1 ICATION 5 7 - 17 - 2 7

Friction 'Wheel Installation

When a friction wheel (P/N 296 144) is used to drive the encoder, the contact area between the friction wheel and the drive surface must be sufficiently large to prevent slippage and erratic readings (Figure 14). Do not attempt to drive the friction wheel by point contact with a metal shaft or other smooth surface.

For best results, the encoder should be mounted on a hinged bracket and held in place against the drive surface with adjustable spring tension. The pressure applied should be sufficient to prevent skipping and false readings but safely below the radial shaft loading limits for the encoder. (Note that the larger the contact area, the less radial pressure is required.)

CONTACT

AREA CONTACT

AREA

PA 173 N

Figure 14 - Friction Wheel Installation Diagram

For metric calibration, the friction wheel should be installed together with a 500 pulse encoder (P/N 296 163). the thumbwheel

The settings on switches at the Gear-To-Line Modules will then read

in millimeters and to 999 millimeters.

will control delay and duration intervals of 1

For English system calibration, the friction wheel should be installed with the standard, 200 pulse encoder. The thumbwheel switches at the Gear-To-Line Modules will then read in tenths of an inch and will control interval ranges of 0.1 inch to 99.9 inches.



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57-17-28 0 Nordson Packaging and Assembly Dwislon


GUN INSTALLATION

All guns must be mounted securely and located the same distance from the substrate.

In applications with pneumatically actuated guns, the solenoid valves should be located as close to the guns as possible to minimize mechanical delays in activating and deactivating the guns. Air pressure to the solenoids should be 50-70 psig (34-48 kPa) and the air supply lines and fittings must be free of leaks and/or restrictions that would affect gun actuation time.

NOTE: Use only 24 Vdc solenoids. 120 VAC/24 Vdc --

Dual voltage solenoids -- e.g., have different operating characteristics

from single voltage solenoids and may operate erratically in high speed applications.

To connect the guns to the PC-lo:

1.

2.

3.

4.

Route the gun cables from the gun solenoids to the rear of the cabinet. Do not connect them to the cabinet at this time.

When the cables have been routed and fastened in place, cut each cable to length, cable,

strip the wires at the gun end of the and attach them to the solenoid leads.

If signal expander boxes are being used in the application, connect the gun cables to the expander box. Then connect the expander box to the driver output fitting at the rear of the cabinet. Otherwise, the output fittings.

connect the gun cables directly to The connection for each Driver Module

is located on the heat sink assembly directly behind the module.

The PC-10 is now ready for programming and initial operation. Refer to SECTION III, OPERATING INSTRUCTIONS.


@ NORDSON CORPORATION 1982 All Rights Reserved

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SECTION III OPERATING INSTRUCTIONS

SETUP AND INITIAL OPERATION

The following procedures apply only to programming and initial operation of the PC-lo. For normal daily operation, refer to the instructions under DAILY OPERATION.

Setup and programming instructions for dual trigger, dot, inverted, and inverted dot applications are described separately in the sub- section headed PROGRAMMING FOR SPECIAL APPLICATIONS.

PRE-PROGRAMMING INSTRUCTIONS

1. Draw a diagram of the substrate like the one in Figure 15, sho-wing the direction of line travel, the bead pattern on the substrate, the

and the location of the trigger and guns. Note that leading edge of the substrate should be aligned with the

trigger if the Sensor Module will be set in the break-light mode. If the Sensor Module will be set in the make-light mode, draw the diagram so that the trailing edge of the substrate is aligned with the trigger (Figure 17).

TRIGGER GUNS I I

id--- A- l I

/SSUED IO/82 SUPERSEDES LITHO U.S.A.

I

I I

*’

LINE TRAVEL ;

Figure 15

PA 173 0



57-17-30 Atlanta, Georgia TECHNKA L PUBLICATION

2. Determine how many Timer or Gear-To-Line Modules it will take to produce the bead pattern and write the number of the controlling Timer or Gear-To-Line Module over each bead on the substrate diagram.

Remember that each Timer or Gear-To-Module can control only one delay and one duration interval. Thus, it will take one module for each bead on the substrate -- unless the deposit pattern includes two or more beads that start and stop the same distance from the leading edge. In that case, a single Timer or Gear-To-Line Module can be used to produce both beads since both call for the same delay and duration intervals.

The bead pattern shown in Figure 16, for example, can be pro- duced with only two Timer or Gear-To-Line Modules, one for each set of parallel beads. The bead pattern in Figure 15, on the other hand, will require three modules, one for each bead.

TRIGGER GUNS I I

k--A-

TIMER 2 TIMER 1 -

TE2 TlMERf

w’ LINE TRAVEL ;

Figure l6

NOTE: When parallel beads are the same length but are offset


cl 1

II

2 a PA 173 P

by a fixed distance, it is often possible to locate the guns at different distances from the trigger and so reduce the number of Timer or Gear-To-Line Modules required to produce the bead pattern (Figure 17).


All Rlqhts Reservc,cl

TRIGGER GUNS I I I /4-- A __-___

E

-4

-f- I

I I w I LINE TRAVEL

II II

- x-- 1

-a x--P, 2

II

Figure 17

3. Determine how many Driver Modules it will take to produce the bead pattern and write the number of the controlling Driver Pkodule next to each gun on the substrate diagram.

In some cases, a different Driver Module will be required for each gun, especially in high speed applications where precise bead placement is required. down identical

When two or more guns are to lay bead patterns on the substrate, however, they

may be controlled by the same Driver Module. (Figure 18)

ISSUED LO/82 LITHO U.S.A.

TRIGGER GUNS

TIMER 2 TIMER I ;

*’ LINE TRAVEL I

1 OR

DRIVER 1

DRIVER 2

DRIVER 3

DRIVER 4

PA 173 R

Figure 18


57-17-32 PackagIng and Assembly Dwlsron


ISSUED M/82 LITHO U.S.A.

SUPERSEDES @ NORDSON CORPORATION 1982 All Rlqhts Reserved

Packaging and Assembly Dlvlslon

Atlanta, Georgia TECHNICAL PUBLICATION 57-17-33

4. Measure the distance from the trigger to the guns (Distance "A" in Figure 15) and enter the measurement in the first column on the Programming Worksheet (Table 2).

NOTE: If the guns are mounted at different distances from the trigger, measure the distance from each gun to the trigger and enter the measurement in the first column of Table 2 opposite the Timer or Gear-To-Line Module(s) that will control the gun.

5. Measure the distance from the leading edge of the substrate to the beginning of each bead and enter the measurement in Column 2 of the Programming Worksheet opposite the Timer or Gear-To- Line Module that will control the bead (Figure 19). Notice that Column 2 of the worksheet has two1 blank spaces for each Timer or Gear-To-Line Module. Enter the measurement in the upper space only.

NOTE: For applications where the Sensor Module will be set in the make-light mode, enter the distance from the trailing edge of the substrate to the beginning of the bead and change the plus sign between Columns 1 and 2 to a minus (-).

6. Determine the required length of each bead and enter the measurement in Column 2 of the Programming Worksheet opposite the Timer or Gear-To-Line Module that will control the bead (Figure 19).

7. Reading across the entries for each Timer or Gear-To-Line Module, add the measurements in Columns 1 and 2 and enter the result in Column 3, "Total Interval Length" (Figure 19).

If the bead pattern includes a stitched bead, enter the length of the STITCH BEAD and the STITCH GAP in the spaces provided.

8. Timer Modules Only:

a. Use the following equation to co:nvert the delay and duration lengths in Column 3 to milliseconds:

Interval (ms) = 5000 x Interval Length (in.) Line Speed (FPM)

If, for example, the delay length in Column 3 is 2 inches and the line speed is 200 FPM, the delay interval will be 5000 x 2 or 50 ms.

200


@ NORDSON CORPORA All Rights Reserved

TION 1982



TRIGGEIR GUNS I I

k- 6”

TIMER 2 TIMER 1 ;

TIMER 2 TIMER 1 1

WI

UNE TRAVEL ;

I

l’imer or Gear-To- Column 1 Column 2 Line Module No. Trigger To Gun(s) Trigger To Bead/

Bead Length -

DELAY 6 in/mm + 1 in/mm =

1 DURATION in/mm =

DELAY 1 6 in/mm + I 6 in/mm =

2 DURATION in/mm =

- DELAY in/mm + in/mm =

3 DURATION in/mm =

I -

DELAY in/mm + in/mm =

4 DURATION in/mm =

STITCHER CONTROLLING STITCH BEAD MODULE TIMER

MODULE(S) STITCH GAP

Figure 19 - Sample Worksheet


SUPERSEDES

Column 3 Total Interval

Length

7 in/mm

2 in/mm

12 injmm

2 in/mm

in/mm

in/mm

in/mm

in/mm

in/mm

PA 173 S

LS = 200 FPM

ms ;;< 775

50 ms LRQ’ 255 HRO ---l--l 300 ms LJ-J& 50

50 ms ;;f 255

ms LRO HRO

ms LRO HRCJ

ms LRO HRO

ms LRO HRO

ms I

ms

0 NORDSON CORPORATION 1c)B.i’

All Rlqhts Resc~rvccl

0 Nordson

For metric equation:

Packaging and Assembly Dlvlslon

Atlanta. Georgia TECHNICAL PUBlICATlON 57 -17 -35

system installations, use the following

Interval (ms) = 60 x Interval Length (mm) Line Speed (MPM)

b. Enter the delay and duration intervals for each Timer Module in Column 4, "Output Cycle Time".

c. lJse the graphs in Figure 20 to find the proper knob setting for each delay and duration interval.

To use the graphs, find the output cycle time on the vertical axis and draw a horizontal line to the solid line on the graph as shown in Figure 20. (NOTE: Be sure to use the correct line in the Low Range graph. The two lines are calibrated to include pull-in or drop-out compensation time for the guns.) Next, find the correct knob setting by drawing a vertical line from the point of intersection to the horizontal axis of the graph.

d. Enter the knob settings in Column 5 of the Programming Worksheet and indicate which graph was used by checking the box marked LR (Low Range) or HR (High Range).

NOTE : If the bead pattern includes a stitched bead, use the DURATION line on the Low Range graph to find the setting for the stitch bead and the DELAY line to find the knob setting for the stitch gap.

9. The PC-10 is now ready for programming.

PROGRAMMING AND INITIAL OPERATION

Before removing any module from the control cabinet, read the precautions for the handling and storage of digital logic circuit boards at the beginning of Section IV.

1. Check to be sure the PC-10 is turned OFF at the main switch.

2. Remove the Sensor Module from the cabinet and use Figure 21 to locate switches S2 and S3. To select the make-light mode for Channel 1, set S2 to the position furthest toward the front panel; to select the break-light mode, set it to the position furthest toward the keyed connector strip at the rear of the printed circuit board. Placing the switch in the middle position disables the channel and turns off the mode indicator lights on the front panel.

For single trigger applications, tion.

leave S3 in the middle posi- For dual trigger applications, see PROGRAMMING FOR

SPECIAL APPLICATIONS.

ISSUED 3184 SUPERSEDES lo/82 @ NORDSON CORPORATION 1984

LITHO U.S.A. All Rights Reserved

0 Nordson 57-17-36

PackagIng and Assembly Dlvlswn

Atlanta, Georgia TECHNICAl PUB1 ICATION

I 0

ilWI1 313A3 lndlnO

I --T-l

3WIl 113A3 lndlnO

Figure 20 - Output Cycle Time vs. Knob Setting, Timer and Stitcher Modules





Figure 21 - Printed Circuit Board, Sensor Module

When the mode selection switches have been set, reinstall the module in the cabinet, turn the unit ON, and check the indicator lights on the front panel to be sure they register the settings that have been selected.

Turn the unit off at the main circuit breaker.

3. Timer Modules

a. Remove each of the Timer Modules from the cabinet and use Figure 22 to locate switch S3. Check to be sure S3-1 is closed and S3-2 is OPEN. If necessary, use a pencil point to change the switch setting.

b. Reinstall the modules in the cabinet and use the information in Column 5 of the Programming Worksheet to set each of the modules. Select the low or high range for each delay or duration interval; then adjust the interval control knobs for the settings shown on the worksheet.

Figure 22 - Printed Circuit 13oard, Timer Module

ISSUED 3 / 8 7 SUPERSEDES lo / 8 2 LITHO U.S.A. 0 NORDSON CORPORATION 1987

All Rights Reserved

Gear-To-Line Modules

NOTE: The instructions below pertain only to Gear-To-Line Modules without memory capability. If the PC-10 is equipped with Gear-To-Line Modules with memory capability refer to Instruction Sheet 57-22 in the bac:k of this manual.

a. Remove each of the modules from the cabinet and use Figure 23 to locate switches Sl, S2, and S3.

b. Check to be sure that:

n Sl is in the TACH position.

n The first three DIP switches on S2 (labeled 1, 2 and 3) are OPEN and the last one (labeled 4) is CLOSED.

NOTE: IF the response time of the gun is known to be more than 20 ms (an integral slot nozzle, for example), or if the viscosity of the adhesive is extremely high, set switch 4 OPEN.

n S3-1 is closed and S3-2 is OPEN.

If necessary, use the point on a small pencil to change the switch settings.

Figure 23 - Printed Circuit Board,. Gear-To-Line Module

C. Reinstall the modules in the cabinet and set the thumbwheel switches on each module for the distances shown in Column 3 of the Programming Worksheet.

NOTE: With English system calibration, multiply the distances shown in Column 3 by 10 to arrive at the correct thumbwheel switch settings.

57-17mIssued 9/88mONordson Corporation 1988

57-17-39

4. Stitcher Module Only

If the bead pattern includes a stitched bead, adjust the control knobs on the Stitcher Module for the settings shown in Column 5 on the Programming Worksheet.

NOTE: The top dial controls the stitch bead, the bottom dial controls the stitch gap. Be careful not to confuse the two.

Refer to the space marked CONTROLLING TIMER(S) on the Pro- gramming Worksheet and use the white pushbuttons on the module faceplate to select the Timer Module(s) the Stitcher Module will respond to.

5. Use the white pushbuttons on the Driver Modules to select the Timer or Gear-To-Line Module(s) each Driver Module will respond to.

For ease in programming the Driver Modules, refer to the substrate diagram and find the gun the Driver Module controls. Then read along the bead pattern the gun will produce and engage the appropriate pushbuttons on the Driver Module. Repeat the process for each gun until all the Driver Module(s) have been programmed.

6. Refer to the substrate diagram and check to be sure each Driver Module is connected electrically to the gun or guns it must control. If necessary, exchange gun cables at the rear of the cabinet and/or rewire the gun solenoids.

7. Compensated Driver Modules Only

When used with Timer Modules: Zero the compensation circuitry on each module by turning both screwdriver adjustment pots twenty-two full turns clockwise.

When used with Gear-To-Line Modules: Preadjust the pull-in compensation on each module by turning the upper screwdriver adjust twenty-two full turns clockwise, then five full turns counterclockwise. Preadjust the drop-out compensation by turning the lower screwdriver adjust twenty-two full turns clockwise, then ten full turns counterclockwise.

8. Turn the pattern control ON at the main switch. The indicator lamp next to the switch will light.

9. Check to be sure that the applicator, hoses, and gun are at operating temperature and that there is full air pressure to the guns.

57-17mIssued 9/88+Nordson Corporation 1988

57-17-40

10. Timer Modules

Bring the line up to speed and run two or more sample substrates past the trigger and gu:ns. Then stop the line and check each bead in the deposit pattern for proper placement and length. If necessary, adjust the settings on the Timer Modules to obtain the correct bead length and placement on the substrate:

n To move the bead closer to the leading edge of the substrate, decrease the setting at the delay section of the controlling Timer Module. To move the bead further away from the leading edge, increase the setting.

. To increase bead length, increase the setting at the duration section of the controlling Timer Module. To decrease bead length, decrease the setting.

When Adjusting Timer Modules Installed With Compensated Driver Modules: Begin by correcting the placement of the controlled bead that must be moved furthest toward the leading edge of the substrate. Then adjust the position of the remaining beads controlled by the same Timer by turning the pull-in compensation potentiometer on the appropriate Driver Module counterclockwise one turn at a time until bead placement is correct.

To correct bead length, begin by adjusting the bead that must be shortened most. Then adjust the length of the remaining beads controlled by the same Timer by turning the drop-out compensation potentiometer on the appropriate Driver Module counterclockwise one turn at a time until bead length is correct.

After adjusting each Timer Module, check the bead pattern on the substrate. When bead length and placement are correct, lock the settings into the dials by engaging the lock on the right hand side of the dial.

11. Gear-To-Line Modules

With the line running at low speed, run two or more sample substrates past the trigger and guns and check each bead in the deposit pattern for proper placement and length.

a. Bring bead length and placement into rough adjustment by changing the settings on the thumbwheel switches.

n To move the bead closer to the leading edge of the substrate, decrease the setting on the thumbwheel switches at the delay section of the controlling Gear-To-Line Module. To .move the bead further away away from the leading edge, increase the setting.

57-17Ussued 9/88=ONordson Corporation 1988

57-17-41

= To increase bead length, increase the setting on the thumbwheel switches at the duration section of the controlling Gear-To-Line Module. To decrease bead length, decrease the setting.

m If the bead moves closer to the leading edge of the substrate, turn the upper screwdriver adjust counterclockwise one turn at a time until the bead placement remains c:onstant at all line speeds.

If the bead moves further away from the leading edge of the substrate, turn the screwdriver adjust clockwise one turn at a time until bead placement remains constant.

. If bead length increases, turn the lower screwdriver adjust clockwise one turn at a time until bead length remains constant at all line speeds.

If bead length decreases with an increase in line speed, turn the lower screwdriver adjust counterclockwise one turn at a time until bead length remains constant.

b. Recheck bead length and placement and readjust the settings on the thumbwheel switches as necessary.

12. When bead length and placement are approximately correct, adjust the pull-in and drop-out compensation on each driver module as indicated by the charts on the following pages:

57-17mIssued 9/88@Nordson Corporation 1988

57-17-41A 0 Nordson P&A Division

Atlanta, Georgia TECHNICAL PUB1 /CATION

A. Increase line speed and monitor the red LED below thumbwheel for setting the delay interval on the Gear-To-Line module.

NOTE: If duration LED comes on, ignore it for the present. This indicates that on-board compensation may be greater than the duration interval. Some applications work perfectly even with this LED on. Delay LED.

Duration LED-

Delay LED OFF

o 7 Proceed to Step B.

On-board compensation is larger than delay interval. Correct problem by:

1) Starting bead farther from leading edge to increase delay interval,

and/or

2) Move trigger farther from gun to increase delay interval,

and/or

3) Reduce onboard compensation (see Table 3, page 57-17-416).

ISSUED 7/8 6 SUPERSEDES

LITHO U.S.A. G, NORDSON CORPORATION 1986

All Rights Reserved


Atlanta, Georgia TECHNICAL PUBLICATION 57-17-41B

B. With the line still running at the increased line speed, observe where the bead starts relative to where it started at the lower line speed.

Step E.

0 Moves: 0 --

0 +- - w. / -I

Closer to lezding edge Away fromyeading edge

I I Proceed to Step D. Proceed to Step C.

ISSUED 7/8 6

LITHO U.S.A.

SUPERSEDES 0 NORDSON CORPORATION 1986

All Rights Reserved

0 Nordson P&A Division 57017041c Atlanta, Georgia TECHNICAL PUB1 /CATION

C. Turn pull-in compensation screw one full turn clockwise and observe bead placement. Continue turning this screw one turn clockwise each time until bead starts at desired position.

Driver module with compensation

ISSUED 7/8 6

LITHO U.S.A.

desired position -- even with screw turned fully

Turn PC-10 off; turn pull-in compensation screw fully clockwise, then five turns counterclockwise. Increase onboard compensation (Table 3, page 57-17-41-G). Repeat procedure starting with Step A.

0 NORDSON CORPORATION 1986 All Rights Reserved

57-17-41D

D. Turn pull-in compensation screw one turn counterclockwise and observe bead placement. Continue this adjustment (one fuli turn at a time ) until bead starts at desired position.

Driver module with compensation

7 Proceed to Step E

Bead cannot be moved to desired

Turn PC-10 OFF; turn pull-in compensation screw fully clockwise, then five turns counterclockwise. Decrease onboard compensation (Table 3, page 57-17-41G).

Repeat procedure starting with Step A.

57-17=Issued 1/87=0Nordson Corporation 1987

57-17-41E

E. Check placement of end of bead re:Lative to where it was at slower line speed.

Away from leading edge

Turn drop-out compensation screw one full turn clockwise and observe bead placement. Continue turning screw clockwise until bead ends at desired location. The PC-10 is ready for normal operation.

PC-10 ready for normal operation. Bead position and and length should be constant for all line speeds.

Closer to leading edge --

Turn drop-out compensation screw one full turn counterclockwise and observe bead placement. Continue turning- screw counterclockwise until bead ends at desired location. PC-10 is ready for normal operation.

57-17mIssued 9/88=ONordson Corporation 1988


A tianta, Georgia TECHNICAL PUB1 /CATION 57-17-41F

CHANGING ONBOARD COMPENSATION

To change the onboard compensation settings, follow the procedure below:

1. Turn the PC-10 off at the circuit breaker on the front panel.

2. Remove the Gear-To-Line Module.

3. Locate switch S2 on the innermost of the two printed circuit boards. Its location is shown in Figure 23. It may be necessary to remove the two slot-head screws securing the outer board and swing it out of the way in order to see and change the S3 setting.

4. Note that S2 has four (4) DIP switches. 2, 3 and 4.

They are labeled 1, These switches may be set as OPEN or CLOSED.

In the illustration below, switches 1 and 4 are shown as OPEN and 2 and 3 are CLOSED.

5. The settings of these switches determines the amount of on-board compensation. The amount of compensation for each possible setting is shown in Table 3 (page 57-17-41G). For example, the setting in the illustration above will produce 24 milliseconds of compensation. The total range of settings is from 0 ms to 40 ms (on older PC-10 models, the range is from 0 ms to 20 ms and there are only three switches instead of four).

6. The onboard compensation can be decreased or increased by changing the positions of one or morle of the four switches.



All Rights Reserved

57-17041G 0 Nordson P&A Division

Atlanta, Georgia

TABLE 3

TECHNICAl PUB1 /CATION

DIP Switch Block S2, switches Compensation 1 2 3 4 in milliseconds

Closed Open Closed Closed Open Open Closed Closed Open Open Closed Closed Open Open Closed Open

Closed Closed Open Closed Open Closed Open Closed Open Closed Open Closed Open Closed Open Open

Closed Closed Closed Open Closed Open Open Closed Open Closed Closed Open Closed Open Open Open

Closed 0 Closed 5 Closed 7 Closed 9 Closed 12 Closed 14 Closed 16 Open 19 Closed 21 Open 24 Open 26 Open 28 Open 31 Open 33 Open 35 Open 40

DAILY OPERATION

Once the PC-10 has been installed and set up properly, no further adjustments are necessary unless a change in the application makes it necessary to reprogram the unit.

For normal daily operation, it is necessary only to turn the unit ON at the beginning of a production run and OFF when it will not be in use for an extended period of time.

ISSUED 7/8 6

LITHO U.S.A. 0 NORDSON CORPORATION 1986

All Rights Reserved


Atlanta, Georgia TECHNICAL PUBLICATION 57-17-41H

This Page Left Blank Intentionally.

ISSUED 7/86

LITHO U.S.A. 0 NORDSON CORPORA All Rights Reserved

TION 1986


Atlanta, Georgia TECHNICAl PUB1 ICATION

PROGRAMJ4ING FOR SPECIAL APPLICATIONS

Contained in this section are setup and programming instructions for dual trigger, dot, inverted, and inverted dot applications. The instructions cover representative setups of each type but are not intended to be exhaustive. For further assistance, consult a Nordson representative.

DUAL TRIGGER APPLICATIONS*

Several different types of dual trigger applications are possible with the PC-lo, including those that allow the pattern control to be triggered:

(1) Separately from the leading or trailing edge of two substrates on the same or different lines (Dual Substrate).

(2) From the leading and the trailing edge of the same substrate (Lead/Lag).

(3) Twice from the leading or trailing edge of the same substrate (Lead/Lead or Lag/Lag).

Lead/Lag, Lead/Lead, and Lag/Lag applications each reuse the delay and duration intervals on a single Timer or Gear-To-Line Module. For this reason they are most often used to minimize the number of modules required for complex patterns. Lead/Lag setups, however, can also be used to deposit beads of equal length on the leading and trailing flaps of cartons of varying length. Dual substrate setups are used primarily in conjunction with folder gluers or other types of automated machinery that bring up two substrates at a time. Under certain conditions, however, they can also be used to control two lines or two stations on the same line from one pattern control.

Each of the following pages contains a diagram of a typical dual trigger application, together with programming instructions and sample calculations for determining th!e location of the two triggers. General instructions for programming the Sensor, Timer, and Gear-To-Line Modules are contained in the pages following the diagrams. I

*All dual trigger applications require a special receptacle panel (P/N 296 151 or 296 153) with connectors for a second light source and receiver. The encoder and run-up control panels can-be modi- fied to provide dual trigger capabilities (information available from your Nordson representative).



All Rights Reserved

0 Nordson PackagIng and Assembly DIVISIOI~

Atlanta, Georgia TECHNICAl PUB1 ICATION 5 7 - 17 - 4 3

DUAL TRIGGER APPLICATION DIAGRAM

TRIGGER MODE SELECTION

For setup shown, both triggers must be in the break-light mode. With other setups, select the break-light mode if the trigger is set to detect the leading edc~c~ of the substrate, the make- light mode rf it is set to detect the trailing edqe.

TIMER 2 TIMER 1

DUAL SUBSTRATE

TRIGGER 1 GUNS

)I

LINE TRAVEL

DRIVER 1

TRIGGER 2 GUNS

TIMER 4 TIMER 3 DRIVER 2

TIMER/GTL MODULE PROGRAMMING

Set Timer/GTL Modules 1 and 2 to respond to input signals from Trigger 1 only. Set Modules 3 and 4 to respond to signals from Trigger 2 only.

NOTE: The same type of setup may be used to control guns at two different stations on the same line or on two different lines if the lines move at constant speed (Timer Modules) or vary at a fixed rate relative to each other (Gear-To- Line Modules). The PC-10 cannot be used to control lines that change speed independently of each other.



All Rights Reserved


57-17-44 Atlanta, Georgia TECHNICAl PUBLICATION


LEAD/LAG

TRIGGER 2 TRIGGER 1 GUNS TRIGGER MODE SELECTION I I

I I II Trigger 1 Break-Llqht Trlgqer 2 Make-Llqht

+.-- x --+- A

I I -)/I I

I I

D/

I

62 c C I

Bl 1

I I

LINE TRAVEL

Condition 1: The delay and duration intervals required to produce both beads must be the same.

A + Bl = X + A - (B2 + C) X= Bl + B2 + C

Condition 2: The signal from Trigger 2 must not arrive at the Timer or Gear-To-Line Module until the delay interval

Trigger Placement

initiated by Trigger 1 has elapsed. X + A < B2 f 2C +D A<C+D-Bl

1. Locate Trigger 1 as close to the guns as practical but under no conditions further away than (1 + D - Bl (the bead length plus the distance between the two beads minus the distance from the leading edge to the first bead).

2. Calculate the distance from Trigger 1 to Trigger 2 using the equation X = Bl + B2 + C

Example: If Bl = 1" Then A a: 1/2 + 4 - 1 < 3% C = &If

= $1 and X := 1 + 1 + 1/2 = 23

D B2 = 1"

NOTE: Lead/Lag programming can also be used to apply adhesive beads of equal length to the leading and trailing flaps of cartons that vary in length. In such cases, use the smallest value for the distance between the two beads when calculating distance A.

lSSUE0 lo/82 LITHO U.S.A.

SUPERSEDES 0 NORDSON CORPORATION 1982 All Riqhts Rcsrrve~l


Atlanta, Georgia TECHNICAl PUBLICATION 57-17-45


LEAD/LEAD

TRIGGER MODE SELECTION

Trigger 1 Break-Light Trigger 2 Break-Light

TRIGGER 1 GUNS TRIGGER 2 I I I I

I

It-A- l I I

k-X ----A I

I I I I

I w

Set Trmcr/GTL Xodule to respond

LINE TRAVEL to input signals from both Trlqqer 1 and Triqger 2.

TIXR/GTL MODULE PROGRAMMING

Condition 1: The delay and duration intervals required to produce both beads must be the same,

A + Bl = Bl i- C -+ D - (X - A) X= C+D

Condition 2: The signal from Trigger 2 must not arrive at the Timer or Gear-To-Line Module until the delay interval initiated by Trigger 1 has elapsed.

X- A > Bl A<C+D-Bl

Trigger Placement

1. Locate Trigger 1 as close to the gun(s) as practical but under no conditions further away than C + D - Bl (the bead length plus the distance between the two beads minus the distance between the leading edge and the first bead).

2. Calculate the distance from Trigger 1 to Trigger 2 using the equation X = C + D.

Example: If Bl = 1" Then A ( 1/2 + 4 - 1 ( 3% C = &II and X = 1/2 + 4 = 4% D = &I

B2 = 1"






LAG/LAG

TRIGGER 1 TRIGGER 2

I I I

It 1

TRIGGER MODE SELECTION ' I

Trigger 1 It---X----+

Make-Light I Trlgqer 2 Make-Light I I

I I

GUNS

A -____)

Condition 1:

Condition 2:

Condition 3:

The delay and duration intervals required to produce both beads must be the same.

A- (B2 + 2C + D) = A - X - (B2 + C) X=C+D

The signal from Trigger 2 must not arrive at the Timer or Gear-To-Line Module until the delay interval initiated by Trigger 1 has elapsed.

A -X<B2+2C+D A < B2 + 3C + 2D

The delay interval must be greater than zero. A- (B2 + 2C + D) > 0 A>B2+2C+D

Trigger Placement

1. Locate Trigger 1 as far away from the guns as practical but not further away than B2 + 3C + 2D and under no conditions nearer than B2 + 2C + D.

2. Calculate the distance from Trigger 1 to Trigger 2 using the equation X = C + D.

Example: If Bl = 1" C = $1,

Then A < 1 + 3(1/,) + 2(4) < 10%

D = $1 A > .1 + 2(k) + 4 > 6

B2 = 1" and X = !b + 4 = 4%



All Rights Reserved

0 Nordson Packaging and Assembly DwtsI0.n

A tlanta, Georgia TECHNICAL PUB1 ICATION 5 7 - 17 -4 7

Trigger Installation and Sensor Module Programming

1. Install Trigger 2 as described in SECTION II under TRIGGER INSTALLATION. Connect the trigger cable(s) to the keyed fittings marked Light Source and Eteceiver 2 at the rear of the cabinet.

2. Turn the unit OFF at the main circuit breaker, remove the Sensor Module from the cabinet, and use Figure 21 to locate switches S2 and S3.

3. Depending on the requirements of the application, select either the make-light or break-light mode for Trigger 1 and Trigger 2.

S2 controls Channel 1; S3 controls Channel 2. To select the make-light mode for either channel, move the selection switch to the position closest to the front panel; to select the break-light mode, move the switch to the position furthest toward the keyed connector strip at the rear of the printed circuit board. When both selection switches have been set, reinstall the module in the cabinet, turn the unit ON, and check the indicator lights on the front panel to be sure they register the settings that have been selected.

4. Turn the unit OFF at the main circuit breaker.

Timer and Gear-To-Line Module Programming

Each Timer or Gear-To-Line module must be programmed to respond either to Trigger 1 alone, Trigger 2 alone, or to both Trigger 1 and Trigger 2. This is done by means of switch S3 at the rear of the Timer and Gear-To Line Module printed circuit boards (See Figures 22 and 23).

To program the modules:

1.

2.

3.

4.

Turn the unit OFF at the main circuit breaker on the front panel.

Remove the Timer or Gear-To-Line module(s) that will respond to Trigger 1 only, and check to be sure that S3-1 is closed and S3-2 is OPEN. This ensures that the module(s) will respond to input signals from Trigger 1 but not from Trigger 2. Reinstall the module(s) in the cabinet.

Remove the Timer or Gear Trigger 2 only,

-To-Line module(s) that will respond to and set S3 so that S3-1 is OPEN and S3-2 is

closed. This ensures that the module(s) will respond to input signals from Trigger 2 but not from Trigger 1. Reinstall the module(s) in the cabinet.

Remove the Timer or Gear-To-Line modules that will respond to both Trigger 1 and Trigger 2, and set S3 so that both S3-1 and S3-2 are closed. Reinstall the module(s) in the cabinet.

ISSUED lo,‘82 LITHO U.S.A.


All Rights Reserved

0 Nordson PackagIng and Assembly Owls/on

57-17-48 Atlanta. Georgia TECHNICAL PUB1 ICATION

INVERT, DOT, AND INVERTED DOT APPLICATIONS

All three special output modes are selected by means of a single onboard switch.

To select any of the three modes:

1. Turn the unit OFF at the main circuit breaker.

2. Remove the compensated Driver Module(s) that will be used to generate the special output signal and locate S3 on the module printed circuit board (Figure 24).

3. Using the chart in Figure 24, set S3 for the desired output mode .

4. Reinstall the Driver Module(s) and instructions for the mode that has

follow the programming been selected.

INVERT MODE

DOT MODE -1 1

INVERT DOT MODE

Figure 24 - Printed Circuit Board, Compensated Driver Module

Invert Mode

'With S3 in the INVERT position, the gun(s) continousl-7

the Driver Module supplies power to y except on an input signal from one of the

Timer or Gear-To-Line Modules. continuous bead,

The pattern it produces is thus a interrupted by a gap whose length is determined by

the duration setting on the controlling Timer or Gear-To-Line Module.

To program the PC-10 for invert applications:

1. Calculate the required delay and duration intervals by measuring (1) the distance from the trigger ruption in

to the beginning of the inter- the bead and (2) the length of the interruption.

2. Timer Modules

Use the graph in Figure 20 to find the knob setting for the delay and duration intervals calculated in Step 1.




Atlanta, Georgia

NOTE: When using the Low Range graph to arrive at dial settings for Timer Modules, use the DELAY line to find the duration setting and vice versa.

Gear-To-Line Modules

Enter the delay and duration settings on the upper and lower thumbwheel switches, respectively. Preadjust the pull-in compensation on the Driver Module by turning the upper screwdriver adjust twenty-two full turns clockwise, then five full turns counterclockwise. Preadjust the dropout compensation by turning the lower screwdriver adjust twenty- two full turns clockwise, then ten full turns counterclockwise.

NOTE: With one or more Driver Modules in the invert mode, the guns will remain activated so long as the PC-10 is ON at the main circuit breaker. This is true whether the line is running or not. To avoid un- wanted deposits of adh=e on the substrate or machine webbing, the pattern control must be switched so that it is automatically deactivated when the line stops moving.

Dot Mode

With the Driver Module in the dot mode, an input signal from the duration section of the controlling Timer or Gear-To-Line module produces a short dot instead of the programmed bead. The length of the dot is controlled by the pull-in compensation circuit on the Driver Module.

To program the PC-10 for dot mode applications:

1. Calculate and set the delay interval according to normal programming procedures.

2. Set the duration interval on the controlling Timer or Gear-To- Line Module for any value greater than zero.

Gear-To-Line Modules Only

Turn the unit OFF at the main circuit breaker, remove the Gear- To-Line Module(s) that will be used to produce the dot pattern, and use Figure 23 to locate switch S2. Check to be sure that DIP switches 1 and 2 on S2 are OPEN; DIP switches 3 and 4 should be CLOSED. Reinstall the module(s) in the cabinet.

3. With the line running at normal speed, check the placement of the dot and adjust the delay interval setting on the Timer or Gear-To-Line Module as necessary.

4. Adjust the length of the dot as necessary by turning the pull-in compensation potentiometer o:n the Driver Module counterclockwise to lengthen the dot, clockwise to shorten it.

ISSUED T/a 6 SUPERSEDES :3/84

LITHO U.S.A. 0 NORDSON CORPORATION 1986

All Rights Reserved

57-17-50 P&A Division

A tkmta, Georgia TECHNICAl PUB1 ICATION


Decrease line speed and observe the dot for changes in placement. If the dot moves unacceptably closer to or further away from the leading edge of the substrate as line speed changes, it may be necessary to increase or decrease pull-in compensation at the Gear-To-Line Module.

To change the pull-in compensation setting:

Turn the unit OFF at the main circuit breaker and remove the Gear-To-Line Module. In Step 2 above, the onboard pull-in compensation was preset to 12 ms. If the dot moves closer to the leading edge of the substrate as line speed decreases, choose the next highest setting for S2 from Table 3 and repeat the test. If the dot moves further away from the leading edge, choose the next lowest setting. Continue adjusting S2 until the setting is found at which the dot moves least with changes in line speed,

NOTE: The size of the dot will change as line speed changes even when the pull-in compensation is correctly set.

Inverted Dot Mode

With S3 in the inverted dot position, the Driver Module keeps the gun on continuously except for a short interruption in the bead that occurs on an input signal from the duration section of the Timer or Gear-To-Line Module. As with the dot mode, the length of the interruption is controlled by the pull-in compensation potentiometer on the Driver Module.

To program the PC-10 for inverted dot mode applications:

1. Determine the required delay interval by measuring the distance from the trigger to the interruption in the bead.

2. Calculate and set the delay interval according to normal programming procedures,

Timer Modules

When using the Low Range graph in Figure 20 to arrive at dial settings, use the DURATION line to find the delay setting.

3. Set the duration interval on the controlling Timer or Gear-To- Line Module for any value greater than zero.

SUPERSEDES 1.0/G 2 ISSUED 7/8 6 LITHO U.S.A.

c NORDSON CORPORATION 1986 All Rights Reserved


Atlanta, Georgia TECHNICAL PUBLICATION 57-l’+=/=


Turn the unit OFF at the main circuit breaker, remove the Gear- To-Line Module(s) that will be used to produce the dot interruption, and use Figure 23 to locate switch S2. Check to be sure that DIP switch 1 on S2 is OPEN; DIP switches 2, 3 and 4 should be CLOSED. This presets compensation at the Gear-To-Line Module to 5 ms.

4. Adjust the placement and length of the dot interruption as described in Steps 3 and 4 of the programming instructions for dot mode applications.

ISSUED 7/a 6 LITHO U.S.A.

SUPERSEDES 3/84 0 NORDSON CORPORATION 1986

All Rights Reserved


Atlanta, Georgia TECHNiCAL PUBLKATION 57-17-53

SECTION IV MAINTENANCE

INTRODUCTION

The following page nance. Preventive inspection and cle shooting, removal system components.

s cover both preventive and car rective mainte- maintenance includes procedure s such as periodic aning. Corrective maintenance covers trouble- and reinstallation of assemblie s, and repair of

The Model PC-10 Pattern Control contains electrical potentials that are dangerous and can be fatal. Exercise extreme caution when working wit!2 this equipment. Only qualified personnel should service the PC-lo.

The input terminal block and the terminals on the main circuit breaker behind the front panel remain energized even when the PC-10 is turned OFF at the circuit breaker. Disconnect and lock out external power to the unit before performing any maintenance that requires removal of the cabinet cover or inspection of components inside the electrical access panel.

The large capacitors in the Power Module remain charged for a short time after the unit :has been turned off. After turning the unit off, allow at least 30 seconds for the capacitors to discharge before starting to work on the Power Module or related components. Failure to observe this precaution could result in fatal personal injury.

0 Digital logic circuit boards are highly sensitive to static electricity, high temperature, and foreign sub- stances. To avoid damage to the boards, always observe the following precautions when handling, storing, or transporting modules:

1. Turn the power OFF at the main circuit breaker on the front panel before insertin,g or removing modules.

2. Use the handle at the top of the module faceplate when removing the modules from the cabinet and when carrying them from place to place. If it is necessary to handle the printed circuit boards, do so by the edges only. Do not place fingers on the surface of the board, as skin oils affect the components and can degrade the performance of the board.

3. Do not place modules on hot surfaces, near heavy electrical equipment or strong magnetic fields, or on ungrounded surfaces of any .kind.

4. To avoid damage to the boards from static electricity, all personnel should ground themselves while handling the modules.


SUPERSEDES @ NORDSON CORPORATION 1982 A!I Rights Reserved



5. All digital circuit boards must be stored and trans- ported in the special, conductive plastic bags provided in the shipping carton. Never place the modules in conventional plastic bags or trays. For shipping, use the foam packing materials provided with the unit.

PREVENTIVE MAINTENANCE

Like all solid state devices, little periodic maintenance.

the PC-10 Pattern Control requires The unit should be checked on a

regular basis for loose or missing hardware, frayed or pinched cables, and physical damage to the components. In applications where the PC-10 is exposed to adverse environmental conditions -- i.e., large amounts of dust, moisture, and airborne material -- the cabinet, cables, and other components should be wiped down as a part of regular plant maintenance procedures. Do not hose down the unit.

NOTE: Satisfactory performance of the pattern control depends on proper maintenance of the applicator, hoses, and guns. Refer to the appropriate equipment manual(s) for recommended preventive maintenance procedures.

CORRECTIVE MAINTENANCE

The corrective maintenance section of this manual consists of a troubleshooting chart (Table 5) and a troubleshooting chart summary (Table 4).

To use the troubleshooting chart, first locate the fault condition in the chart summary. To the right of each fault condition is a list of possible causes together with references to specific locations in the troubleshooting chart. If the general cause of the failure is apparent, refer to the appropriate step in the troubleshooting chart for the proper corrective action. Other- wise, begin with the first possible cause and work your way through the procedural steps in the troubleshooting chart one by one until you have isolated the cause of the problem.

Each set of procedures in the troubleshooting chart is followed by a NORMAL INDICATION you should observe after carrying out the steps it describes. If the indication is normal, follow the instructions below the description of the NORMAL INDICATION. Otherwise, follow the instructions in the right-hand column under ABNORMAL INDICATION.

Obvious causes of malfunctions such as broken wires or missing fasteners are generally not included in the troubleshooting chart. When troubleshooting, check carefully for failures of this type and correct them before proceeding.




Atlanta, Georgia TECHNICAL PUBLICATION 5 7 - 17 - 5 5

TABLE 4

Troubleshooting Chart Summary

FAULT CONDITION POSSIBLE CAUSE REFERENCE

CIRCUIT BREAKER ON MAIN SWITCH TRIPS AND WILL NOT STAY ON WHEN RESET

Short circuit in gun solenoid, interconnection cables, or other external components.

Short circuit in control module(s) or Power Module.

Al

A2

NO ADHESIVE DEPOSIT OR MISSING BEAD IN DEPOSIT PATTERN

Faulty gun connections or gun solenoid(s).

Cold hose(s) or gun(s), clogged gun nozzle(s), no adhesive in applicator, other problems external to pattern control.

Bl

B2

Malfunction of Driver Module and/or power transistor.

Loss of high voltage supply from Power Module.

B3

B5

Malfunction of trigger.

Malfunction of Sensor Module.

Malfunction of Power Module.

Malfunction of Timer Module.

Malfunction of Gear-To-Line Module.

B6

B7

B9

B6

B6

Faulty encoder or malfunction of encoder drive system.

B12

Malfunction of Stitcher Module B6

IRREGULAR BEAD LENGTH/PLACEMENT

Cl



All Rights Reserved



TABLE 5 - Troubleshooting Chart

CIRCUIT BREAKER ON MAIN SWITCH TRIPS AND WILL NOT STAY ON WHEN RESET

Al. Check for short circuit in interconnection cables and other external components.

1. Remove all connector cables from rear of cabinet.

2. Turn unit ON at main circuit breaker.

NORMAL INDICATION: Main circuit breaker stays on when activated. TURN UNIT OFF AND RECONNECT THE CABLES ONE AT A TIME, BEGINNING WITH THE CABLES FROM THE TRIG- GER AND WORKING TOWARD THE GUNS. RETEST THE CIRCUIT BREAKER AFTER CONNECTING EACH CABLE. WHEN THE CIRCUIT BREAKER TRIPS, CHECK FOR A SHORT CIRCUIT IN THE CABLE THAT WAS CONNECTED LAST AND IN ALL COMPONENTS CONNECTED TO THE CABLE.

ABNORMAL INDICATION: Go to Step A2.

A2. Check for short circuit in modules.

1. Open the cabinet door and pull all modules out until they are disconnected from the keyed receptacles on the Mainframe Board (about 1 inclh).

2. Turn unit ON at main circuit breaker.

NORMAL INDICATION: Main circuit breaker stays ON when activated. TURN UNIT OFF AND REINSERT MODULES ONE AT A TIME, BEGIN- NING WITH THE SENSOR MODULE AND WORKING TOWARD THE DRIVER MODULES. RETEST THE CIRCUIT BREAKER AFTER INSERTING EACH MODULE.

ABNORMAL INDICATION: Re- place Power Module.

0 After testing the circuit breaker, turn the unit OFF before inserting the next module. DO NOT insert modules while unit power is ON. Failure to observe this precaution may result in permanent damage to the modules.

lSSUED lo,'82 LITHO U.S.A.


0 Nordson Packaging and Assembly Owls/on


TABLE 5 - TROUBLESHOOTING CHART (Continued)

WHEN THE CIRCUIT BREAKER TRIPS, REPLACE THE MODULE THAT WAS INSERTED LAST AND CHECK FOR PROPER SYSTEM OPERATION.

REINSTALL THE REMAINING MODULES.

NO ADHESIVE DEPOSIT OR MISSING BEAD IN DEI?OSIT PATTERN

Bl. Place a piece of scrap material under the guns to protect the line and fire the guns manually by pushing the TEST button on the Driver Module(s).

NORMAL INDICATION: All guns fire. ABNORMAL INDICATION: Go GO TO STEP B6. to next step.

B2. Test fire the inoperable guns manually at the gun solenoid(s).

NORMAL INDICATION: Guns fire and ABNORMAL INDICATION: If extrude adhesive. guns fire without ex-

1.

2.

3.

B3

If other guns controlled by same Driver Module were operable from console, CHECK ELECTRICAL CONNECTIONS TO INOPERABLE GUN FOR CONTINUITY AND GUN SOLENOID FOR PROPER OPERATION.

truding adhesive, check for clogged gun nozzles, cold hoses or guns, and other problems with the hot melt equipment.

If guns will not fire, check mechanical operation of gun solenoid(s) and air supply to gun(s).

If all guns controlled by the same Driver Module were inoperable from console and remaining Driver Modules operate properly, GO TO STEP B3.

If all guns were inoperable from console, GO TO STEP B5.

Check for malfunction of Driver Module.

1. Turn unit OFF at main circuit breaker.

2. Remove Driver Module from cabinet and insert another Driver Module in its place.



All Rights Reserved




3. Turn the unit ON and push the TEST button on the replacement Driver Module.

NORMAL INDICATION: Gun(s) fire. ABNORMAL INDICATION: Go REPLACE ORIGINAL DRIVER MODULE. to next step.

B4. Check for faulty gun cable or gun solenoid.


2.. Exchange gun cables at rear of cabinet and attempt to fire guns from a different station.

NORMAL INDICATION: Guns fire. REPLACE TRANSISTOR BEHIND ORIGINAL DRIVER MODULE.

ABNORMAL INDICATION: Check gun solenoid for proper operation and gun cable for continuity.

B5. Check for presence of -30 Vdc at Mainframe Board.

NOTE: If only one Driver Module is installed in the unit, check the gun cable for continuity and the gun solenoid for proper operation before performing the following test.

1. Disconnect and lock out external power to the unit.

The input terminal block and the terminals on the main circuit breaker behind the front panel remain energized even when the PC-10 is turned OFF at the circuit breaker. Disconnect

2,

A 5

and lock out external power to the unit before removing the cabinet cover or inspecting components inside the electrical access panel. Failure to observe this precaution may result in fatal personal injury.

Remove the cabinet cover and locate power supply high voltage connector Pl (Figure 26).

The large capacitors in the Power Module remain charged for a short time after the unit has been turned off. After turning the unit off, allow at least 30 seconds for the capacitors to discharge before starting to work on the Power Module or related components. Failure to observe this precaution could result in fatal personal injury.




Atlanta, Georgia TECH#ICAl PUB1 ICATION 5 7 - 17 - 5 9


3. Unplug connector Pl from the Mainframe Board and insert voltmeter probes at pins No. 2 and No. 3.

4. Restore external power to the unit, turn unit ON at main circuit breaker, and read voltage at meter.

Exercise extreme caution when performing this test. Do not touch any components inside the cabinet while the power is on or for at least 30 seconds after it has been turned off. Be sure the probes are securely fixed in the connector and away from contact with uninsulated surfaces and each other. Do not hold the probes when measuring voltage.

NORMAL INDICATION: -30 Vdc *3 Vdc ABNORMAL INDICATION: Re- REPLACE DRIVER MODULE place Power Module. AND TRANSISTOR.

B6. 1. Place a piece of scrap material under the guns to protect the line and initiate a test cycle manually by pushing the TEST button on the Sensor Module.

2. Observe the sequence of lights on the front panel and compare the result to the normal sequence.

NORMAL INDICATION: LEDs light in the following sequence and all guns fire:

ba: Sensor Module Delay section, Timer/Gear- To-Line Module

C. Duration section, Timer/ Gear-To-Line Module

d. Bead section, Stitcher Module (when applicable)

e. Gap section, Stitcher Module

f. Driver Module(s)

CHECK TRIGGER FOR PROPER ALIGNMENT AND OPERATION. LIGHT SOURCE SHOULD HAVE 6.3 VAC or 12 Vdc FROM POWER SUPPLY. RESISTANCE IN RECEIVER/ CABLE SHOULD BE INFINITY WHEN LIGHT IS INTERRUPTED AND NEAR ZERO WHEN ACTIVATED BY LIGHT SOURCE.


SUPERSEDES

ABNORMAL INDICATION: Re- fer to Test Summary below for the next step. When using the summary, iselect the abnormality in the light sequence that occurs first - e.g., "No light at Sensor Module" before "No light 'at delay section of Timer/Gear-To-Line lModule,'f etc.



57-17-60 Atlanta, Georgia TECHNICAl PUB1 ICATION


NOTE: Set ohmmeter on highest available scale when testing resistance in activated receiver/ cable.

TEST SUMMARY

TEST RESULT

No light at Sensor Module.

No light at delay section of Timer Module.

No light at duration section of Timer Module.

No light at delay section of Gear-To-Line Module (Line running).

No light at duration section of Gear-To-Line Module.

No light at stitch bead section of Stitcher Module.

No light at stitch gap section of Stitcher Module.

No light at Driver Module(s).

0 Bef 'ore rem .oving rea d the p recaut of digital logic of this se ction.

STEP NO.

B7

BlO

Replace Timer Module

Bll

Replace Gear-To-Line Module

B13

Replace Stitcher Module

Replace controlling Timer/ Gear-To-Line Module(s)

any module from the co ntrol ions for th .e han .dling and s circuit bo ards at the begi

t: nn

abinet, rage ing

B7. Check indicator lamp at main switch.

NORMAL INDICATION: Lamp on. ABNORMAL INDICATION: GO TO NEXT STEP. Check input power

to unit.



0 Nordsom Packaging and Assembly Owlston

Atlanta, Georgia TECHNICAl PUB1 ICATION 5 7 - 17 - 6 1


B8. Check for logic voltage at Sensor Module:


2. Remove module to left of Sensor Module.

3. Turn unit ON and check red LED a-t rear of Sensor Module printed circuit board.

NORMAL INDICATION: Red LED on. ABNORMAL INDICATION: Go REPLACE SENSOR MODULE. to next step.

B9. Check for system logic voltage:


2. Remove module to left of first Timer/Gear-To-Line Module.

3. Turn unit ON and check red LED at rear of Timer/Gear- To-Line Module.

NORMAL INDICATION: Red LED on. REPLACE SENSOR MODULE.

ABNORMAL INDICATION: Re- place Power Module.

BlO. Check for proper operation of remaining Timer or Gear-To- Line Modules.

NORMAL INDICATION: Remaining Timer/ AB:NORMAL INDICATION: Re- Gear-To-Line Modules operate place Sensor Module. normally. REPLACE TIMER MODULE.

Bll. Check for proper operation of remaining Gear-To-Line Modules.

NORMAL INDICATION: Remaining Gear-To-Line Modules operate normally. REPLACE GEAR-TO- LINE MODULE.

AB:NORMAL INDICATION: Go to next step.

B12. Check for encoder malfunction.




All Rights Reserved

57-17-62 0 Nordson Packaging and Assembly Dlvislon



2. Remove Gear-To-Line Module and move switch Sl to 1 KHz position.

3. Reinstall module, turn unit ON, and repeat test.

NORMAL INDICATION: Module functions properly. CHECK ENCODER DRIVE SYSTEM, ENCODER CABLES/CONNECTIONS, AND OUTPUT VOLTAGE TO ENCODER (12 VDC). IF NECESSARY, REPLACE ENCODER.

ABNORMAL INDICATION: Re- place Sensor Module.

B13. Check for malfunction of Timer Module control circuitry.

1. Program Stitcher Module to respond to any of remaining Timer Modules.

2. Repeat test.

NORMAL INDICATION: LED at stitch bead section lights and module performs normally. REPLACE FAULTY TIMER MODULE.

ABNORMAL INDICATION: Re- place Stitcher Module.

IRREGULAR BEAD LENGTH/PLACEMENT

Cl. Irregular bead length and bead placement can result from various causes, most of which lie outside the pattern control. If the entire bead pattern is irregular or out of place, check first for variations in line speed (Timer Modules) or malfunctions of the encoder drive system (Gear- To-Line Modules). Slippage between the substrate and the line, erratic or inadequate air supply to the gun solenoids, fluctuations in the temperature of the adhesive, and loose mounting hardware on the trigger will also produce irregu- larities in bead length and/or placement, regardless of the type of control modules installed.

If one bead only is irregular, check the air line to the gun solenoid for restrictions and leakage, the gun solenoid for proper operation, and the gun for correct operating temperature and freedom from clogging. When all other causes have been eliminated, check for incorrectly adjusted pull-in and drop-out compensation (Gear-To-Line Modules)

as a last resort, %e Module(s).

malfunction of the Timer or Gear-To-




Atlanta, Georgia TECHNICAl PUB1 ICATION 5 7 - 17 - 63

DISASSEMBLY AND REPAIR

0 Before removing modules from the cabinet, read the instructions for handling, storage, and transporting digital logic circuit boards at the beginning of this section.

Except for the Power Module, all modules are removed from the front of the unit by disengaging the module handle from the upper lip of the cabinet and pulling the card free from its mounting on the Mainframe Board. For removal of the Power Module, Mainframe Board, power transistors, and zener diode, see below.

The modules in the PC-10 are not field serviceable. If found to be defective, they must be removed and replaced with a new or rebuilt module.

When returning modules, always use the special non-conductive plastic bags and foam packing materials provided with the unit. Pack the modules carefully to avoid damage in transit.

POWER MODULE REPLACEMENT


A ‘I The input terminal block and the terminals on the main circuit breaker behind the front panel remain energized even when the PC-10 is turned OFF at the main circuit breaker. Disconnect and lock out external power to the unit before removing the cabinet cover or opening the electrical access panel at the rear of the cabinet. Failure to observe this precauticn may result in fatal personal injury.


2. Remove the electrical access panel and disconnect the two incoming power leads from terminals Ll and L2 and the ground wire from the ground stud.

3. Loosen the two captive screws at each side of the cabinet cover and lift the cover off the unit.

4. Disconnect wires Ll, L2, 9, and 10 from the circuit breaker on the front panel and wires 7 and 8 from the indicator light.

5. Unplug the power supply high and low voltage cables from connectors Jll and 521 on the Mainframe Board (See Figure 26).




57-17-64 Atlanta. Georgia TECHNICAL PUB1 ICATION

6. Remove the four screws securing the Power Module to the cabinet base and lift the module out of the cabinet.

7. Reinstall the Power Module by reversing Steps 1 through 6. Wires Ll and L2 are connected at the top of the circuit breaker, wires 9 and 10 at the bottom. The higher numbered wire of each pair goes toward the outside of the cabinet.

MAINFRAME BOARD REPLACEMENT


A 5

A ‘s

The input terminal block and the terminals on the main circuit breaker behind the front panel remain energized even when the PC-10 is turned OFF at the main circuit breaker. Disconnect and lock out external power to the unit before removing the cabinet cover or opening the electrical access panel at the rear of the cabinet. Failure to observe this precaution could result in fatal personal injury.


2. Remove all modules from the card cage and set them aside.

3. Loosen the two captive screws at each side of the cabinet cover and lift the cover off the unit.

4. Remove the four screws from the bottom of the rear panel and lower the panel to gain access to the rear of the Mainframe Board.

5. Disconnect all cables from the connectors on the Mainframe Board and separate the rear panel from the unit.

6. Remove eight self-tapping screws from the Mainframe Board and separate the Mainframe Board from the Card Cage.

7. Reinstall the Mainframe Board by reversing Steps 1 through 6. The cable connections to the back of the Mainframe Board are shown in Figure 26.

POWER TRANSISTOR AND ZENER DIODE REPLACEMENT

The transistor for each Driver Module is located directly behind the module it serves. The zener diode is mounted on the heat sink behind slots No. 3 and 4.

/SSUED 10/82 LITHO U.S.A.


All Rights Reserved

0 Nordson PackagIng and Assembly Dwlslon

Atlanta, Georgia TECHNICAL PUB1 ICATION 5 7 - 17 - 6 5/G 6


The input terminal block and the terminals on the main circuit breaker behind the front panel remain energized even when the PC-10 is turned OFF at the main circuit breaker. Disconnect and lock out external Dower to the

2.

3.

4.

Loosen the two captive screws at each side of the cabinet cover and remove the cover from the unit.

Remove the four screws holding the transistor or diode heat sink in place on the rear panel and remove the heat sink.

Remove the two screws securing the transistor/diode (13, Figure 32/14, Figure 31) and remove it from its socket.

0 Be careful not to damage the insulating material on the mounting bracket when removing or installing the transistor/diode. The insulation is essential to its proper operation.

5. Reinstall the transistor/diode by reversing Steps 1 through 4.

unit before removing the cabinet cover or opening the electrical access panel at the rear of the cabinet. Failure to observe this precaution could result in fatal personal injury.

lSSUE0 10/82 LITHO U.S.A.


57-17-68 0 Nordson Packa.qqlng and Assemblv Dwlslon

Atlanta, Georgia

c-

r- 2 +a

-I On When Pushbutton Engaged

A0

61

Vl

Light Source

Receiver

Light Source and Receiver 2

Break-Light

Make-Light

Extrusion (TEST)

Delay

Duration

Pushbutton Engaged

Pushbutton Disengaged

Off When Pushbutton Disenqayed

Timer/Gear-To-Line Module 1

Driver Module 1

Encoder Signal

Run-Up Control Signal

Figure 25 - Symbol Key, PC-10 Cabinet and Module Faceplates

/SSUED lo/82 I ITun II c A

SUPERSEDES @ NORDSON C9RPORATION 1982 All Rlcjhts Reserve<1



, Jll

J12

J20 3 0 0

a

296025 MAIN FRAME BOARD 0 0

1 2

J16 J17 J18 J19

J15 J14

6.3VAC LIGHT SOURCE VOLTAGE

3m J21 i--r 1234

3 3 ,

PA 173 v

Cabling Chart

MAIN FRAME DESCRIPTION RECEPTACLE NO.

Power Supply Low Voltage Connector P2 Jll

Power Supply High Voltage Connector Pl ---- --~ -__-__.-___--

Light Source & Receiver No. 1

521

J15

Zener Diode -- -.-I.--- --

OPTIONAL EQUIPMENT -- e-e-.-- .--_-~

Gun Connector and Transistor No. 1 ----.---.-- ~- _---._

Gun Connector and Transistor No. 2

320

J16

517

Gun Connector and Transistor No. 3 518

Gun Connector and Transistor No. 4 J19

Encoder Connector 512

Run-Up Connector 513

Light Source & Receiver No. 2 514

Figure 26 - Mainframe Board and Cabling Chart, PC-10 Pattern Control

lSSUED 10/82 LITHO U.S.A.




SECTION VI ILLUSTRATED PARTS LIST

COLUMN IDENTIFICATION

The Item No, column indicates the number assigned to the part in the associated figure. shown.

A dash is used for parts that are not

The Part No. column indicates the Nordson part number for the part. A dash signifies that the item is a nonsaleable part or a nonsaleable subassembly of a saleable assembly.

The Description column gives the name of the part together with its dimensions and other physical properties, where appropriate.

The Req'd column indicates the quantity required per unit or assembly. When the item is listed for reference only or the quantity is not applicable, the term Weft' or a dash, respectively, appears in the column.

/SSUED lo/82 LITHO U.S.A.


@3 Packaging and Assembly Division Atlanta, Georgia

PARTS LIST

7ECHNICAL PUBLICA77ON 57-17-75

Item No. Part No. Description Req'd

1 296 000

296 026 296 065 296 051 296 069 296 055 296 063 296 096

-

8 9

9

9

9

10

-

10

11 12

13

14

296 105 296 101 296 073 296 085

296 086

296 088 296 080*

296 153*

296 151*

296 081

296 082 296 084 296 047

296 091 296 090

296 171

296 092

296 162 296 160 00 Encoder, 200 PPR

PC-10 Pattern Control 0 Enclosure, PC-lo, w/power

Module (Figures 29 and 30) 00 Module, Power Supply o Module, Sensor, PC-10 o Module, Timer, PC-10 0 Module, Gear-To-Line, PC-10 0 Module, Stitcher, PC-10 o Module, Driver, 3OV, PC-10 o Module, Driver, 30V

w/Compensation, PC-10 0 Module, RunUp Control 0 Module, Counter o Module, Blank 0 Panel, Blank, Encoder and

Run-Up, w/Gasket 00 Panel, Blank, Encoder and

Run-Up 00 Gasket, Panel 0 Panel, Receptacle, Encoder

and Run-Up 0 Panel, Receptacle, Light

Source 2 0 Panel, Receptacle, Encoder

Run-Up, and Light Source 2 o Panel, Blank, Transistor,

w/Gasket 00 Panel, Blank, Transistor 00 Gasket, Panel 0 Heat Sink Assembly, Transistor

(Figure 32) 0 Light Source w/20 ft Cable o Receiver, Phototransistor,

w/20 ft Cable 0 Cable, Alternate Trigger,

10 ft 0 Cable, Interconnection,

Gun, 20 fit 0 Encoder, 200 PPR, w/Cable

Ref 1

1 1

ISSUED 2 / 9 5 SUPERSEDES 3 / 8 4 ONORDSON CORPORATION 1984

All Rights Reserved


Atlanta, Georgia TECHNICAL PUBl/CATION

PARTS LIST (Continued)


296 089 O" Cable, Encodler, 10 ft 1 296 163 O Encoder, 500 PPR, w/Cable 296 161 O" Encoder, 500 PPR 1 296 089 O" Cable, Encoder, 10 ft 1 296 205 O Extension Cable, Encoder, 15 ft

15 296 144 O Friction Wheel, 0.50 m circum. - 16 273 289 O Expander, Four Solenoid

296 170 O Cable, Run-Up Control, 10 ft 1

(4.6 m)

* See 59-25.


SUPERSEDES LO/82 @ NORDSON CORPORATION 1984

All Rlghts Reserved

Packagmg and Assembly Dwwon

pdsy Atlanta, Georgia TECHNICAL PUELICATION 5 7-1 7 - 7 7

Figure 29 - Enclosure, PC-lo, with Power Module, Side View

PARTS LIST


296 000 Enclosure, PC-lo1 w/Power Ref Module, Side View

1 296 048 O Cover, Unit, w/Gasket 1 296 049 O" Cover, Unit 1 296 079 O" Gasket, Neoprene, 0.12 x 1.87 ft

2 982 111 3 983 146 4 983 508 5 296 134

296 165 6 296 009

982 056 7 296 008

296 010 8

296 013

0.38 in. O" Screw, Captive, M4 x 8.4 mm O" Lockwasher, Internal, M4, ZN O" Washer, Retainer, No. 8-32 O Cover, Switch and Light O Gasket, Cover, Switch O Breaker, Circuit, 2 Pole,

250 VAC, 2A O Screw, Flat Head, M3 x 6 mm, ZN O Lamp w/Speed Nut O Decal, Power O Latch O Plunger, Spring O Bracket, Lock

4 4 4 1 1 1

2 1 1 1 1 1

982 099 O Screw, Pan Head, M3.5 x 6 mm, ZN 2

ISSUED 3/84 SUPERSEDES lo/82 @ NORDSON CORPORATION 1984


57-17-78 PackagIng and Assembly Divwon

Atlanta, Georgia TECHNICAl PUBLICATION

PARTS LIST (Continued)


983 413

985 108 9 296 133

10 296 017 296 016

296 137 983 413

984 714 296 019 982 155

296 164

296 007

O Lockwasher, Internal Thread, M3.5, ZN

O Rivet, Pop, 0.125 in. dia O Door O Window, Door O Gasket, Window, 0.06 x

0.81 in. O Clamp, Window O Lockwasher, Internal Thread,

M3.5, ZN O Nut, Hex, M3.5, ZN O Hinge, Door o Screwp Flat Head, M4 x

13 mm, ZN O Gasket, Doo:r O Tag, Card F:rame O Tag, Caution, Circuit Board O Key, Tool Head

2

2 1 1

3.25 ft

8 8

8 1 6

lSSUE0 3/84 SUPEWSE5ES lo/82 @ NORDSON CORPORATION 1984


0 Nordson PackagIng and Assembly Divwon

Atlanta, Georgia TECHNlCAl PUBLICATION 5 7 - 1 7 - 79

Figure 30 - Enclosure, PC-lo, with Power Module, Top View

PARTS LIST

Item NO . Part No. Description Req'd

5 296 022 6 296 c24

7 8 9

10 11 12 13

296 000

296 001 296 003 982 112 296 020 296 025 981 734

983 401 984 706 296 026 982 094 984 526 933 005 273 144 296 169 296 168

Enclosure, PC-lo, w/Power Module, Top View

O Base O Pad, Mounting O Screw, Pan Head, M6 x 16 mm * Frame, Card O Circuit Board, Mainframe * Screw, Hex Head, Self-Tapping

6-20 x 0.375 in. O Guide, Card O Rod, Threaded, M5 x 139.7 mm,

ZN O Lockwasher, Split, M5, ZN O Nut, Hex, M5, ZN O Module, Power Supply O Screw, Pan Head, M5 x 6 mm, ZN O Nut, Hex, % NPT O Connector, Cord O Panel, Assembly, Access O" Panel, Access, w/Caution Note O" Gasket, Access Panel

Ref

20 4

ISSUED 3/84 SUPERSEDES lo/82 @ NORDSON CORPORATION 1984


0 Nordson PackagIng and Assembly Dlvwon Atlanta, Georgia TECHNICAL PUB1 ICATION 5 7 - 1-i’ - 8 1

Figure 31 - Zener Heat Sink Assembly, PC-10

PARTS LIST


1 2 3 4 t.

i 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21

296 046 Heat Sink Assembly, Zener Ref 296 138 O Panel, Zener 1 296 088 O Gasket, Panel 1 296 123 O Heat Sink, Zener 1 296 132 O Gasket, Heat Sink 1

O Cable, Zener Connector 1 O Cable, Light and Receiver 1

939 110 O Strap, Cable 2 O Bracket, Security, 3 Pole 2

982 086 O Screw, Pan Head!, M3 x 8 mm 4 983 400 O Lockwasher, Split, M3 5 984 700 O Nut, Hex, M3 5 982 056 O Screw, Flat Head, M3 x 6 mm 4 296 121 O Diode, Zener 1 981 035 O Screw, Pan Head, 6-32 x 0.62 in. 2 296 119 O Insulator, Transistor 1

O Socket, Transistor 1 982 113 O Screw, Flat Head, M3 x 16 mm 1 296 131 O Clamp, Cable, 0.25 in. dia 1 982 063 O Screw, Pan Head, M4 x 16 mm 1 983 403 O Lockwasher, Split, M4 1 984 715 O Nut, Hex, M4 1



All Rights Reserved

57-17-82 0 Nordson Packaging and Assembly Dwislon


4 3

Figure 32 - Transistor Heat Sink Assembly, PC-10

PARTS LIST


1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20

296 047 296 115 296 084 296 113 296 116

939 110 939 554 982 086 983 400 984 700 982 056 296 118 981 035 296 119

982 113 296 131 982 069 983 403 984 217

Heat Sink Assembly, Transistor Ref O Panel, Mounting, Transistor 1 O Gasket, Mounting Panel 1 O Heat Sink, Transistor 1 O Gasket, Heat Sink, Transistor 1 O Harness, Wire, Transistor 1 O Strap, Cable 3 O Bracket, Security 1 O Screw, Pan Head, M3 x 8 mm 2

O Lockwasher, Split, M3 3 O Nut, Hex, M3 3 O Screw, Flat Head, M3 x 6 mm 4 O Transistor, Power 1 O ScrmJ, Pan Head, 6-32 x 0.63 in. 2 O Insulator, Transistor 1 O Socket, Transistor 1 O Screw, Flat Head, M3 x 16 mm 1 O Clamp, Cable, 0.25 in. dia 1 O Screw, Pan Head, M4 x 16 mm 1 O Lockwasher, Split, M4 1 O Nut, Hex, M4 1

ISSUED 3/84 SUPERSEDES lo/82 Q NORDSON CORPORATION 1984

1 Irun I I c A All Rights Reserved


Atlanta. Georgia TECHNICAL PllBLICATlDN 5.7 - 1 7 -83 184

RECOMMENDED SPARE PARTS

PART NO. DESCRIPTION QTY

296 008 296 009 296 065* 296 051* 296 069* 296 055* 296 063* 296 096* 296 118 296 121 296 095 296 094 296 090 296 091 937 121

Lamp w/Speed Nut Breaker, Circuit, 2 Pole, 250 VAC, 2A Module, Sensor, PC-10 Module, Timer, PC-10 Module, Gear-To-Line, PC-10 Module, Stitcher, PC-10 Module, Driver, 3OV, PC-10 Module, Driver, 3OV, w/Compensation Transistor, Power Diode, Zener Connector, Male, 3 Pole Connector, Male, 2 Pole Receiver, Phototransistor, w/20 ft Cable Light Source w/20 ft Cable Lamp I Photocell Light Source

1 1

*For all applications, Nordson recommends purchase of at least one additional Timer or Gear-To-Line Module and an additional Driver Module of the appropriate type. Purchase a spare Stitcher Module only if a Stitcher Module is in use and a spare Sensor Module only if dual trigger capability is required for application.


SUPERSEDES H/82 @ NORDSON CORPORATION 1984

All Rights Reserved

INSTRUCTION SHE'ET FOR GEAR-TO-LINE MODULE WITH MEMORY CAPABILITY (P/N 101 395)

(USED WITH PC-10 PATTERN CONTROLLERS) PUBLICATION NO. 108 426A

NOTE: These instructions should be used in place of - the instructions on page 57-17-38 of the PC-10 manual. The instructions on page 57-17-38 are for Gear-To-Line Modules without memory and do not apply to Gear-To-Line Modules with memory.

Description The Gear-To-Line Module with memory capability is used in the PC-10 Pattern Control in place of the standard Gear-To-Line Module, which has no memory capability. Its purpose is to eliminate packaging line rejects caused by emergency stops. If power to the PC-10 is removed during the de1a.y cycle, the Gear-To-Line Module "remembers" wher'e it stopped and completes the interrupted cycle upon startup. The duration cycle that follows (in which .adhesive is deposited on the substrate) will place the bead in the correct position.

If power to the PC-10 is removed during the duration cycle, the PC-10 will slhut off the gun immediately, minimizing adhesive loss and damage to the package, and reset the module's counter. Upon startup the PC-10 will not begin a new delay-duration sequence until the trigger is activated.

Figure 1 - Location Of Programming Switches On New G-T-L Board

57-22mIssued 11/88QNordson Corporation 1988

2

New Board Layout

How The Programming Switches Function

Instructions For Proper Handling Of Boards

Programming The Switches During Initial Setup Of The PC-lo.

The board layout of G-T-L Modules with memory is different than that found on standard G-T-L Modules. On the new module there is just one board instead of two, and the location and the number of programming switches are different. The new board layout is shown in Figure 1.

Switch Sl is the memory on/off switch, and Switch S2 is the TACH switch. Switch S3 is a 6-position dip switch (see Figure 1), where the first four positions on the switch (1, 2, 3, and 4) are used to set on-board compensation and the last two positions (5 and 6) determine whether the G-T-L Module is activated by Trigger 1, Trigger 2, or both.

Digital logic circuit boards are highly sensitive to static electricity, high temperature, and foreign sub- stances. To avoid damage to the boards, always observe the following precautions when handling, storing, or transporting modules:

1. Turn the power OFF at the main circuit breaker on the front panel before inserting or removing modules.

2. Use the handle at the top of the module faceplate when removing the modules from the cabinet and when carrying them from place to place. If it is necessary to handle the printed circuit boards, do so by the edges only. Do nlot place fingers on the surface of the board, as skin oils affect the components and can degrade the performance of the board.

3. Do not place modules on hot surfaces, near heavy electrical equipment or strong magnetic fields, or on ungrounded surfaces of any kind.

4. To avoid damage to the boards from static electricity, all personnel should ground themselves while handling the modules.

5. All digital circuit boards must be stored and trans- ported in the special, conductive plastic bags provided in the shipping carton. Never place the modules in conventional plastic bags or trays. For shipping, use the foam packing materials provided with the unit.

Use the following procedures and Figure 1 to program the switches during initial setup of the PC-lo. These instructions take the place of the ones on page 57-17-38 of the PC-10 manual.

1. Set Sl to the ON position (to the right).

57-22mIssued 11/88WNordson Corporation 1988

3

Programming The Switches During Initial Setup Of The PC-10 (Cont'd)

Changing On-Board Compensation

2. Set S2 to the TACH position (to the right)

3. Set S3 as follows:

positions 1, 2, and 3 are OFF position 4 is ON position 5 (trigger 2) is OFF position 6 (trigger 1) is ON

NOTE: If the response time of the gun is known to be more than 20 ms (an integral slot nozzle, for example), or if the viscosity of the adhesive is extremely high, set switch 4 to the OFF position.

To change on-broard compensation, use the instructions on page 57-17-41F of the PC-10 manual. Positions 1, 2, 3, and 4 on S3 have the same function as positions 1, 2, 3, and 4 shown on this page. The only difference is that the S3 on G-T-L Modules with memory use ON/OFF as designations instead of OPEN/CLOSED. (ON is equivalent to CLOSED and OFF is equivalent to OPEN)

Settings For Dual Using the following instructions, you can program the Trigger Applications G-T-L Module to respond to trigger 1, trigger 2, or

both:

Trigger 1 alone: position 6 ON, position 5 OFF Trigger 2 alone: position 5 ON, position 6 OFF Triggers 1 & 2: position 5 ON, position 6 ON

57-22mIssued 11/88@Nordson Corporation 1988

LED Photoelectric Sensor Kits

PC-10 Pattern Control

Part 104 508A

NORDSON CORPORATION. AMHERST, OHIO l USA

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

Address all correspondence to

Nordson Corporation 11475 Lakefield Drive

Duluth, GA 30136

Notice

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

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

Trademarks

AquaGuard, Blue Box, Control Coat, Equi=Bead, Flofvlelt, FoamMelt, FoamMix, Helix, Hot Shot, Hot Stitch, 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 Flberfzatfon, Easy-Screen, Fibermelt, Flo-Tracker, PrintGuard, and Package of Values are trademarks of Nordson Corporation.

Manual 59-35 104 508A Issued 5184

Q 1984 Nordson Corporatim All Rghts Reserved

0 Notdson Packaging and Assembly Division Atlanta. Georggla TECHAllCAl PUBLICATION 59-35-l

INSTALLATION AND SETUP PROCEDURES LED PHOTOELECTRIC SENSOR KITS

PC-10 PATTERN CONTROL (P/Ns 296 201, 296 202, 296 203, and 296 204)

Description

,

With the four optional sensor kits listed above, Nordson provides an alternative to through-beam detection with conventional incandescent photoelectric sensors. All four kits utilize a modulated- beam LED light source combined with a receiver in a single unit. Two of the kits are designed for detecting interruption of a beam transmitted between the unit and a reflector; the other two are designed for proximity (diffuse reflectivity) detection of the substrate. Both the retroreflective and the proximity sensors are available in rectangular and tubular housings.

Figure 1 - Rectangular and Tubular Housings for Sensor Kits

The primary advantages of LED detection systems over incandescent systems are these:

1. LED detectors are unaffected by sunlight and incandescent lighting because they utilize the near-infrared region of of the light spectrum.

ISSUED 5 / 8 4 LITHO U.S.A.


All Rights Resewed

Packaging and Assembly Division Atlanta. Georgia TECHNICAL PUB1 ICATlON 59-35-2 0 Nordson

2. LED detection systems are much less vulnerable to shock and vibration than incandescent detection systems because they use solid-state componentry and do not require bulbs with filaments.

3. LED systems provide long-range cost benefits over incandescent units because of reduced down time, longer service life, and increased performance.

The optional sensors also differ from conventional through-beam sensors in another important way: they combine the light source and the receiver in the same housing. This feature provides two additional advantages:

1. Installation and alignment are much easier with only one unit.

2. Having the light source and the receiver in the same housing also means that the unit can be located on the safest side of the conveyor line, away from traffic,

Although through-beam detection is still the preferred system where the light beam must travel over long distances or where the environment is dusty, steamy, or otherwise "dirty," proximity and retro-reflective detection systems are best for many standard applications.

Selection Criteria

The decision whether to use a proximity sensor or a retro-reflective sensor will depend on several factors, such as the reflectivity of the substrate and the distance of the substrate from the trigger. With proximity detection, a reflector is not required, so installation is easier and misalignment cannot occur; however, the range of proximity sensors is much less than that of retroreflective sensors, especially when the reflectivity of the substrate is low. Generally speaking, proximity sensors are less precise than retro- reflective sensors. In difficult applications, however, neither retro-reflective detectors nor proximity detectors may be suitable. When the sensing distance is great or the environment is "dirty," through-beam detection is the preferred method.

The sensors with rectangular housings have essentially the same specifications as those with tubular housings. The choice between the two housings will be determined primarily by the desired method of mounting and the available space.

ISSUED 5184 LITHO U.S.A.


All Rights Reserved

@3 Atlanta, Georgia Packaging and Assembly Division

TECHNICAL PUBLICATION 5 g- 3 5 - 3

PARTS LISTS

296 201 Photosensor Kit, Retro-Reflective, Ref Tubular

296 194 O Photosensor 1 296 095 O Connector, Male, 3-Pole 1 296 190 O Bracket, Mounting, Photosensor 1 296 192 O Target, 4Oxmn Diameter 1

296 202 Photosensor Kit, Proximity, Ref Tubular

296 193 O Photosensor 1 296 095 O Connector, Male, 3-Pole 1 296 190 O Bracket, Mounting, Photosensor 1

296 203 Photosensor Kit, Retro-Reflective, Ref Rectangular

296 196 O Photosensor 1 296 095 O Connector, Male, 3-Pole 1

296 204 Photosensor Kit, Proximity, Ref Rectangular

296 195 O Photosensor 1 296 095 O Connector, Male, 3-Pole 1

296 205 Cable, Extension, 15 Ft 1

Specifications*

Maximum Operating Distance (see note) 296 201 42 in. (1067 mm) 296 202 3.1 in. (80 mm) 296 203 39 in. (1 m) 206 204 8 in. (200 mm)

NOTE: In proximity detection the maximum operating distance depends upon the reflectivity of the substrate. Specifications are based on matte white paper. With less reflective surfaces, the maximum operating distance could be considerably less than that given in the specifications. See Figure 2 for a comparison of various surfaces.

* Due to possible technological and/or quality improvements, equipment specifications are subject to change without notice.

ISSUED 5 / 8 4 SUPERSEDES LITHO U.S.A.


All Rights Reserved



Response Time 296 201 296 202 296 203 296 203

Maximum Switching Rate

5 ms 5 ms 3 ms 3 ms

- 296 201 296 202 296 203 296 204

Power Requirements 296 201 296 202 296 203 296 204

Temperature Range 296 201 296 202 296 203 296 204

Cable Length 296 201 296 202 296 203 296 204

Enclosure Rating 296 201 296 202 296 203 296 204

output 296 201 296 202 296 203 296 204

200 operations/set 200 operations/set 333 operations/set 333 operations/set

10 to 30 vdc (&lo%), 50 mA 10 to 30 Vdc (+lO%), 50 mA 12 to 24 vdc (HO%), 35 mA 12 to 24 vdc (flO%O, 40 mA

32OF to 122'F (OOC to 50°C) 32OF to 122OF (OOC to 50°C) 14OF to 140'F (-10°C to 60°C) 14OF to 140'F (-10°C to 6OOC)

6% ft (2 m) 6% ft (2 m) 6 ft (1.8 m) 6 ft (1.8 m)

NEMA 1, 2, 3R, 3S, 4X, 13 and IP65 NEMA 1, 2, 3R, 3S, 4X, 13 and IP65 NEMA 3, 4, 6, 12, 13 and IP66 NEMA 3, 4, 6, 12, 13 and IP66

NPN Transistor: 100 mA sink NPN Transistor; 100 mA sink NPN Transistor; 80 mA sink NPN Transistor; 80 mA sink

Material Correction Factor White Paper 1.0 Bright Metal 1.2-1.6 Black Aluminum 1.1-1.8 White Cotton 0.6 Raw Wood 0.4 Glossy Black Cardboard 0.3 Dull Black Cardboard 0.1

Figure 2 - Effect of Target Material on Maximum Sensing Distance in Proximity Detection

lSSUED 5104 LITHO U.S.A.


All Rights Reserved

@g Atlanta. Georgia Packaging and Assembly Division

TECHNICAL PUBlICATlON 59-35-s

Installation

1.

2.

3.

4.

5.

6.

Ensure that the PC-10 is turned off at the main circuit breaker on the front panel.

Remove the sensor module from the PC-10 and set the mode switch(es) for the desired mode of operation as follows (see Manual 57-17 for diagram):

(a) For leading-edge detection of substrate, set S2 to the makelight mode position;

(W for trailing-edge detection of substrate, set S2 to the breaklight mode position.

(cl Reinstall sensor module.

Select a suitable location for the trigger point. It should provide a smooth surface for mounting, be away from traffic if possible, and be free of dust and excessive vibration. Position the unit (and the reflector in the case of retro- reflective sensors) to avoid reflections from background surfaces. If some background reflection is unavoidable, attempt to darken it. If the background is reflective, such as a metal surface, ensure that the beam strikes it at an angle in order to avoid reflection directly back into the receiver. In retroflective applications it may also be necessary to ensure that a highly reflective substrate does not cause reflection directly back into the receiver. Positioning the unit so that the beam strikes the substrate at an angle will work here, too.

NOTE: The greater the sensing distance, the more important it is for the environment to be free of dust and vibration.

Mount the photosensor with the mounting bracket provided. Do not tighten the mounting screws securely yet. Leave them loose to allow for a few degrees of pivot in the horizontal and vertical planes during alignment. In installation of retro-reflective kits, the reflector should be mounted at this time also. A mounting bracket is provided for the purpose.

Route the cable from the photosensor to the PC-10 cabinet and connect it to the keyed fitting for the receiver (marked by the symbol Cc ) at the rear of the PC-10 control cabinet. (See Manual 57-17)

To align the photosensor, follow the procedures in step 6a for units with P/N 296 201, those in step 6b for units with P/N 296 202 or 296 203, and those in step 6c for units with P/N 296 204.

(a) Set up the condition in which the sensor should "see" light. In the case of retro-reflective detection, this will mean positioning the substrate



All Rights Reserved

59-35-6, 0 Nordson Packaging and Assembly Division Atlanta, Georgia TECHNICAL PUBLICATION

in front of the photosensor at the desired trigger position. After turning the power on at the PC-10 control panel, swivel the sensor unit in both the horizontal and vertical planes until the beam is sensed, causing the LED indicator on the unit to go off. Now swivel the unit in one plane only. Find the two extreme positions where LED comes on. Position the unit midway between the two positions. Repeat this procedure in the other plane to locate the optimum sensing position.

(b) Set up the condition in which the sensor should "see" light. In the case of proximity detection, this will mean positioning the substrate in front of the photosensor; in the case of retro-reflective detection, it will mean having no object in the line of the beam and the reflector. After turning the power on at the PC-10 control panel, swivel the sensor unit in both the horizontal and vertical plane until the beam is sensed, causing the LED indicator on the unit to come on. Now swivel the unit in one plane only. Find the two extreme positions where LED goes off. Position the unit midway between the two positions. Repeat this procedure in the other plane to locate the optimum sensing position.

(4 Position the substrate in front of the sensor unit. Turn the sensitivity adjustment, which is located near the LED indicator, fully counterclockwise. After turning the power on at the PC-10 control panel, slowly turn the sensitivity clockwise until the LED indicator comes on. Note the position of the setting. Now remove the substrate, which will cause the LED indicator to turn off. Continue turning the sensitivity screw clockwise until background reflections cause the LED to come on again. Reset the sensitivity midway between this setting and the first one.

NOTE: If background reflections are low, it will be possible to reach a full scale setting without the LED coming on. In this case, reset the sensitivity midway between the first setting and full scale (fully clockwise).

7. Tighten all mounting screws. The photosensor is ready for operation.



All Rights Reserved

PC-1 0 Pattern Control - Welcome to Nordson...

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