Verification System - Nordsonemanuals.nordson.com/adhesives/English_Manuals/321226.pdf · G-NETt...

G-NETtVerification System

Customer Product ManualPart 321 226D

NORDSON CORPORATION D Duluth, Georgiawww.nordson.com

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

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

E 2005 Nordson CorporationAll rights reserved

321 226DIssued 5/05

Manual 56-G-NET-MA-01

CAUTION: If this equipment is used with other Nordson equipment, refer to the manualsprovided with that equipment for instructions and the safety precautions you should take.

Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General information aboutNordson can be found on the Internet using the following address: http://www.nordson.com.

Address all correspondence to:

Nordson CorporationAttn: Customer Service11475 Lakefield DriveDuluth, GA 30097

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2001. No part of this documentmay be photocopied, reproduced, or translated to another language without the prior written consent of Nordson Corporation.

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

Trademarks

AccuJet, AeroCharge, AquaGuard, Asymtek, Automove, Autotech, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, CleanSleeve, CleanSpray, Control Coat,Coolwave, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, Durafiber, Durasystem, Easy Coat, Easymove Plus, Econo-Coat, EFD, ETI, Excel 2000, FlexiCoat,Flexi-Spray, Flex-O-Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Heli-flow, Helix, Horizon, Hot Shot, Isocoil, Isocore, Iso-Flo, JR, KB30, Kinetix, Little Squirt,Magnastatic, MEG, Meltex, Microcoat, Micromark, MicroSet, Millennium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson, OmniScan, OptiMix, Package ofValues, PatternView, PermaFlo, Plasmod, PluraFoam, Porous Coat, PowderGrid, Powderware, Prism, ProBlue, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, RBX, Rhino,Saturn, SC5, S. design stylized, Seal Sentry, Select Charge, Select Coat, Select Cure, Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, Spraymelt,Spray Squirt, Super Squirt, Sure Coat, Tela-Therm, Tracking Plus, Trends, Tribomatic, Ultrasaver, UniScan, UpTime, Veritec, VersaBlue, Versa-Coat, Versa-Screen,

Versa-Spray, Walcom, Watermark, and When you expect more.are registered trademarks of Nordson Corporation.

AeroDeck,AeroWash,Apogee,ATS,Auto-Flo,AutoScan,BetterBook,CanNeck,Chameleon,CheckMate,ColorMax,ControlledFiberization,Control Weave,CPX,DryCure, DuraBlue, Dura-Coat, DuraPail, Dura-Screen, Easy Clean, Eclipse, EcoDry, e.DOT, E-Nordson, Equi=Bead, ESP,

e Stylized, Fillmaster, Fill Sentry, Gluie, HDLV, iControl, iFlow, Ink-Dot, iON, Iso-Flex, iTrend, iTRAX, KVLP, Lacquer Cure, March, Maxima, MicroFin, MicroMax,Minimeter, Multifil, OptiStroke, Origin, PatternPro, PluraMix, Powder Pilot, Powercure, Primarc, Printplus, Process Sentry, Pulse Spray, PurTech, Ready Coat, RoyalBlue, Scoreguard, Select Series, Sensomatic, Shaftshield, SheetAire, Spectral, Spectronic, Speedking, Spray Works, Summit, SureBead, Sure Brand, Sure Clean,

Sure-Max,Swirl Coat,Tempus,ThruWave,Trade Plus,Trak,TrueBlue,Ultrasmart,Universal,Vantage,Viper,Vista,WebCure,and2 Rings (Design)are trademarksofNordson Corporation.

Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes,could lead to violation of the owners’ rights.

Table of Contents 1


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Table of ContentsSystem Overview 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Standard Components 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Console 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G-SITE Network Interface 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glue Sensors 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Triggers 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Encoder 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transformer 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Cables 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Components 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Batch Kicker and Batch Trigger 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . .

Marking System 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ejection System 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Feed-count Sensor 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Horn 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning Light Tower 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting Components 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Double-sheet Detector 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bar Code Scanner 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cello Presence Detector 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cello Position Detector 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Printer 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SystemOverview

Table of Contents2


321 226DIssued 5/05


System Capabilities 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applications 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Features 1-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section Overview 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Getting Started 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the Parts Inventory 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Locate the Glue Sensors 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Locate the Zone Triggers 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Locate Other System Components 2-6. . . . . . . . . . . . . . . . . . . . . . . .

Equipment Installation 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install the Required System Components 2-8. . . . . . . . . . . . . . . . . .

Install the Equipment for Rejecting or Marking Products 2-12. . . . .

Install Optional Equipment and Accessories 2-14. . . . . . . . . . . . . . .

Electrical Installation 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connect the Cables for All Required Components 2-16. . . . . . . . . .

Connect the Cables for the Air-Operated Equipment 2-17. . . . . . .

Connect All Other Cables 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatic Connections 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connect All Air Lines 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Setup Overview 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup Keys 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Report Menu 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glue Detection Zone Screens 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counter Menu 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tracking and Machine Constants Menu 3-7. . . . . . . . . . . . . . . . . . . .

Equipment Adjustment Procedures 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glue Sensors 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Zone Trigger 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Feed Sensor 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Batch or Pre-eject Sensor 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

All Other System Components 3-14. . . . . . . . . . . . . . . . . . . . . . . . . .

SystemOverview (contd)

Installation

Setup

Table of Contents 3


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System Setup Procedures 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Set the System Clock 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Select a Different Language 3-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Set Up the Encoder 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjust the Timing of the Batch Kicker 3-18. . . . . . . . . . . . . . . . . . . . .

Adjust the Timing of the Reject or Marking Equipment 3-19. . . . . .

Teach the Tracking Distances for the System 3-21. . . . . . . . . . . . . .

Assign the Glue Sensors to Detection Zones 3-22. . . . . . . . . . . . . .

Teach the System a Good Pattern Set 3-23. . . . . . . . . . . . . . . . . . . .

Set Pattern Error Tolerances 3-24. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Set Up the Bead-length Detection Feature 3-27. . . . . . . . . . . . . . . .

Make a Zone Active or Inactive for Ejection or Marking 3-29. . . . .

Management of Settings 3-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Zero All Settings 3-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Record the System Settings 3-30. . . . . . . . . . . . . . . . . . . . . . . . . . . .


Basic Operation 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Panel 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Procedures 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start the System After It Has Been Turned Off 4-6. . . . . . . . . . . . . .

Teach the System a Good Pattern Set 4-8. . . . . . . . . . . . . . . . . . . . .

Enable or Disable the Outputs 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . .

Enter the Standby Mode 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Track a Job 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clear a Pattern Error 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Restart the System After a Machine Stop 4-16. . . . . . . . . . . . . . . . .

Change Products 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shut Down the System 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation

Table of Contents4


321 226DIssued 5/05


Monitoring Procedures 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Monitor Pattern Placement 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Error Messages 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Monitor Panel Lights 4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Monitor the Warning Light Tower 4-23. . . . . . . . . . . . . . . . . . . . . . . . .

Monitor Counts 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reset Counts 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Job Reporting 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Record Key Production Data 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Print a Production Report 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Precautions 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagrams 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before Troubleshooting 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two Basic System Problems 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Tools 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Console Lights and Screen Display 5-5. . . . . . . . . . . . . . . . . . . . . . .

Counter Menu 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Error Messages 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four Key Questions 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Tables 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Using the Illustrated Parts List 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Components 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cables 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting Components 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessories 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Components 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cables 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Operation (contd)

Troubleshooting

Parts

Table of Contents 5


321 226DIssued 5/05


Optional Detection Equipment 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Cables 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Reject, Marking, and Batch Control Equipment 6-9. . . . . . . . . . . . . . . . . . .


Cables 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting Components 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare Parts 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sensor 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Unit 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transformer 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Unit 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G-SITE Interface 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Continuous Web Gluing A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Application Overview A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup Procedures A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Enter Initial Settings A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Set the Product Count for Tracking A-4. . . . . . . . . . . . . . . . . . . . . . . .

Set Up the Bead-length Detection Feature A-4. . . . . . . . . . . . . . . . .

G-NET Envelope System B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Overview B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Photo Eye in Detection Zone One B-3. . . . . . . . . . . . . . . . . . .

Install the Case Packer Signal Cable B-3. . . . . . . . . . . . . . . . . . . . . .

Technical Data

Appendix A

Appendix B

Table of Contents6


321 226DIssued 5/05


Setup B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjust the Sensors and Triggers B-4. . . . . . . . . . . . . . . . . . . . . . . . . .

Enter the Report Menu Settings B-5. . . . . . . . . . . . . . . . . . . . . . . . . .

Enter the Glue Detection Screen Settings B-6. . . . . . . . . . . . . . . . . .

Enter the Counter Menu Settings B-7. . . . . . . . . . . . . . . . . . . . . . . . .

Enter the Settings for Tracking and Machine Constants Menu B-8

Set the Start of the Reject Mark B-9. . . . . . . . . . . . . . . . . . . . . . . . . .

Set the End of the Reject Mark B-10. . . . . . . . . . . . . . . . . . . . . . . . . .

Test the System B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Set Up Tracking for the Case Packer B-12. . . . . . . . . . . . . . . . . . . . .

Operation B-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Activate the Test Function B-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clear a Pattern Error B-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting B-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts B-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting Components for W + D 102 Machines B-14. . . . . . . . . . .

Mounting Components for W + D 202 Machines:Version 1 B-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Technical Data B-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index I-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B (contd)

Index

1-1System Overview


321 226DIssued 5/05


Section 1System OverviewSystem Overview 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Standard Components 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Console 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-SITE Network Interface 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Glue Sensors 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Triggers 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Encoder 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transformer 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting Cables 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Components 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Batch Kicker and Batch Trigger 1-8. . . . . . . . . . . . . . . . . . . . . . . . .Marking System 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ejection System 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Feed-count Sensor 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Remote Horn 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Warning Light Tower 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mounting Components 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Double-sheet Detector 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bar Code Scanner 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cello Presence Detector 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cello Position Detector 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Printer 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Capabilities 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Applications 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Features 1-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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System Overview

This section is divided into four main parts:

S Product DescriptionS System ComponentsS System CapabilitiesS Specifications

The Veritec G-NET verification system detects missing or defective cold glue(liquid adhesive) patterns in up to four different detection zones. The systemcan be equipped with as many as eight glue sensors. Each sensor can beassigned to one of the four zones. The system activates a fault output anytimeit detects a defective or missing bead. It activates a machine stop if a clusterof pattern errors or a misfeed occurs. The system can be equipped with adouble-sheet detector, which can be used to stop the machine.

Using input from an encoder, a G-NET verification system can monitor gluepatterns in both constant speed and variable speed applications. In addition tothree cold glue sensors—one for extruded patterns, one for wheel generatedpatterns, and one for dot patterns—the G-NET system can be equipped withbar-code sensors, cello detectors, and other monitoring devices. Nordson alsooffers ejectors, pushers, kickers, and marking systems for use with the G-NETverification system. The system is ideal for carton folder gluers, envelopeproduction, and other paper converting applications.

A G-NET system with typical components is shown on the following page on acarton folder-gluer machine.

System Overview

ProductDescription

1-3System Overview


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5601110

Catch Basket

Ejector

Pusher

WarningLight

ZoneTrigger

CelloDetector

Double SheetDetector

Feed Sensor

Bar CodeScanner

GlueSensor

G-NETConsole

G-SITEInterface

Carton FolderGlue Machine

Typical G-NET Components on a Carton Folder Gluer

S G-NET consoleS G-SITE network interfaceS glue sensorS zone trigger (a photosensor)S encoderS transformerS connecting cables

StandardComponents

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The G-NET console houses the system’s control panel, a microprocessor, anda DC power supply. The control panel contains 12 function keys, indicatorlights for monitoring system operation, and a large LCD display. Using thedisplay and the function keys, program the system to detect a wide variety ofpattern errors in up to four different zones and to reject or mark the defectiveproducts. The display provides a real-time view of the pattern being applied inany of the four zones. When any pattern error occurs, the display freezes tocapture the fault on the screen.

The console can be mounted on a special adjustable arm or attached directlyto the machine or other mounting surface.

5601007

Console

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321 226DIssued 5/05


Each G-NET verification system includes at least one network interface,referred to as the G-SITE. All inputs (sensors, triggers, and other detectiondevices) and all outputs (alarms, kickers, and reject equipment) are connectedto the G-SITE with quick-disconnect cables. Having a central location for allelectrical connections simplifies installation and troubleshooting.

In some installations a second G-SITE is used to prevent long cable runs.

5601046

G-SITE NetworkInterface

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A G-NET system can be equipped with as many as eight glue sensors. Usingfiber-optic technology, the optical sensors analyze the product’s surface for thepresence or absence of cold glue. Each sensor consists of three parts: a lensunit, an amplifier unit, and the cable that connects the lens to the amplifier. Aseparate cable is used to connect each amplifier to the G-SITE.

Three types of glue sensors are available:

Sensor Type Detects

GD-100 extruded beads

GD-100W wheel-applied glue patterns

GD-100X1 dot patterns

If a sensor lens must be mounted with the lens directed upward, an air purgesystem is installed to prevent dust and other contaminants from covering thelens.

5601107

Amplifier

Lens

Cable

Glue Sensors

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G-NET systems require one trigger for each detection zone, with a maximumof four zones. The trigger signals the controller to start tracking the position ofeach product when the leading edge (or some other selected edge) of theproduct passes the photosensor.

Two different triggers are available for the G-NET system:

S standardS high-speed fiber-optic

The standard trigger is housed in a single enclosure and has a response timeof 300 microseconds. The fiber-optic trigger has a response time that can beset to either 50 or 500 microseconds. Both are diffuse-mode photosensors.

For most applications, the standard zone trigger works well. The fiber-optictrigger is intended for use in applications where a faster response time isrequired or where mounting space is limited.

5601111

StandardZone Trigger

Fiber-OpticZone Trigger

Triggers

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An encoder with a friction wheel is used to track the position of products asthey move through the machine. Two types of encoders are available: onethat generates 333 pulses per revolution and one that generates 500 pulsesper revolution.

If the system is equipped with a pattern control, a linking cable is available thatallows the signal to be shared with the existing pattern control encoder. Thisarrangement requires keeping the pattern control turned on anytime theG-NET detection system is operating.

Each G-NET system requires a transformer to convert the power supplied tothe system to a 24 VAC output. Two versions of the transformer are available:one for use with a 120 VAC, 1∅, 50/60 Hz power supply and one for use with a240 VAC, 1∅, 50/60 Hz power supply.

All system components in a G-NET system are connected with quick-connectcables to simplify installation and troubleshooting. Most cables are available ina variety of lengths to fit different customer requirements. A complete list ofcables is in the Parts section.

S batch kicker and batch triggerS marking systemS ejection systemS pusherS feed sensorS remote hornS warning light towerS mounting componentsS double-sheet detectorS bar-code scanner systemS cello presence detector or cello position detectorS catch basketS printerS air purge kitS connecting cables for optional components

A pneumatically operated batch kicker is available for use with the G-NETsystem. With a batch kicker and batch trigger installed, the G-NET systemautomatically separates each batch according to the programmed batch size.

Encoder

Transformer

Connecting Cables

OptionalComponents

Batch Kicker andBatch Trigger

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Instead of using an ejector to reject the defective products the G-NET systemfinds, a marking system can be used to spray the products with UV ink.Defective products can be identified quickly when they pass beneath a UV lightand then pulled from the line.

The main components of the marking system are a pressurized ink supplyreservoir, a spray gun, and a solenoid valve that actuates the gun upon asignal from the G-NET system. The system also includes a pressure regulator,a gauge, and a shutoff valve.

Nordson offers a pneumatically actuated rotary ejector for use with the G-NETverification system. The ejector automatically rejects products with patternerrors, bar-code errors, and other defects. A pre-eject sensor, a catch basket,and, if needed, a pusher can be ordered to complete the reject system.

The ejector is available in three versions:

S a 115 VAC power supply (1 ∅, 60 Hz)S a 208--230 VAC power supply (1 ∅, 60 Hz)S a 220 VAC power supply (1 ∅, 50 Hz)

It is designed to be mounted on either side of the machine.

5601102

The feed-count sensor allows the G-NET system to track the number ofproducts fed into the production machine. The count can be reset at theG-NET console.

The remote horn notifies personnel who are away from the console that analarm has sounded. The horn sounds anytime the internal horn in the consolesounds, but at a higher decibel level.

Marking System

Ejection System

Feed-count Sensor

Remote Horn

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321 226DIssued 5/05


The warning light tower allows an operator to see from a distance that theG-NET system has detected a defective product. The red light turns onwhenever a pattern error or an alarm condition occurs.

The tower can be ordered with either a 1.5 m (5 ft) or a 4.5 m (15 ft) cable thatconnects to the G-SITE network interface.

5601070

Red = Error or Alarm Condition

Green = Normal Operation

A complete selection of custom-engineered clamps, brackets, rods, and bars isavailable for mounting the sensors, triggers, and other components of theG-NET system. By choosing the right mounting components, the parts of theG-NET system can be quickly mounted in the desired locations. The mountingcomponents are designed so it is easy to adjust or move the sensors ortriggers.

The double-sheet detector detects double-fed sheets.

The bar-code scanner detects bar codes that are defective, incorrect, ormissing.

The cello presence detector detects missing cellophane windows.

Warning Light Tower

MountingComponents

Double-sheet Detector

Bar Code Scanner

Cello PresenceDetector

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321 226DIssued 5/05


The cello position detector detects missing and out-of-position cellophanewindows.

A printer with a protective enclosure can be used with the G-NET verificationsystem to compile and print a production report at the end of a job. The dataprovided can improve quality and track production costs.

This part of the section explains the applications for which a G-NET systemcan be used and the features it provides.

Application Description

Inspect almost any type of gluepattern

Detects errors in extruded patternsand in wheel-generated patterns.The patterns can consist of multiplebeads, dots, stitches, or a singlebead. Detecting errors inedge-to-edge patterns andmonitoring continuous gluingoperations are also possible.

Detect different types of patternerrors

Reports a pattern error wheneverany pattern is missing or out ofposition or whenever it has gaps thatare equal to or larger than the settolerance.

Detect errors in different glue types Works with all types of cold glues.

Detect errors on a variety of productsurfaces

Works on most product surfaces.

Operate on constant-speed andvariable-speed lines

Uses input from an encoder to trackline position and can be used in bothfixed-speed and variable-speedapplications of up to 700 m/min(2300 ft/min).

Detect errors on different products Monitors a variety of differentproducts. A product can be up to1000 mm (39.4 in.) in length.

Cello PositionDetector

Printer

SystemCapabilities

Applications

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321 226DIssued 5/05


The following table explains some of the features of the G-NET glue detectionsystem.

Feature Description

Adjustable toleranceper zone

Sets the deviation from a good pattern for eachzone. Adjust tolerances online during a productionrun.

Reject disablefunction

Stops the rejection of faulty products by pressing akey on the operator panel. Select individual zonesfor rejection and have the system ignore errors inother zones.

Teach mode Captures pattern lengths and locations, eliminatingthe need for lengthy setup measurements orcalculations. Captures tracking distancesautomatically.

Fault count feature Tracks the number of faults that have occurred ineach detection zone, making it easy to findrecurring problems

Machine stopcapabilities

Stops the line for major problems such as a doublefeed, an overlapped product, or a cluster of patternerrors

Real-time display ofpatterns

Displays the actual pattern in any detection zone forcomparison to the reference pattern

Minimum speedcutout

Stops the reporting of pattern errors anytime theline speed falls below a preset value

Spare input forrejecting defectiveproducts (force 1)

Rejects a product when input from some monitoringdevice, such as a bar code scanner, detects a fault

Spare input forstopping machine(force 2)

Stops the machine when input from somemonitoring device, such as a double-feed detector,finds a serious problem

Local languagecapability

Selects any one of 11 different languages for thedisplay: English, German, Dutch, French, Spanish,Italian, Portuguese, Swedish, Norwegian, Finnish,or Danish. International symbols are used on theoperator panel.

Reporting function Prints a job report that provides key production datafor productivity and cost analysis

Features

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321 226DIssued 5/05


Section 2Installation

Section Overview 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Getting Started 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Check the Parts Inventory 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Locate the Glue Sensors 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Locate the Zone Triggers 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Locate Other System Components 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Installation 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Install the Required System Components 2-8. . . . . . . . . . . . . . . . . . . . . . . . . .Install the Equipment for Rejecting orMarking Products 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Install Optional Equipment and Accessories 2-14. . . . . . . . . . . . . . . . . . . . . .

Electrical Installation 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connect the Cables for All Required Components 2-16. . . . . . . . . . . . . . . . .Connect the Cables for theAir-Operated Equipment 2-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connect All Other Cables 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatic Connections 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connect All Air Lines 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Installation

This section is divided into four parts:

S Getting StartedS Equipment MountingS Electrical InstallationS Pneumatic Connections

This part of Section 2 contains:

S Check the Parts InventoryS Locate the Glue SensorsS Locate the Zone TriggersS Locate Other System Components

Section Overview

Getting Started

2-3Installation


321 226DIssued 5/05


5601072

A

1 32

B

C4

5

6

D

7E8

F

G

H

PatternControl

Pattern ControlTrigger

GlueGun

Components of a G-NET Verification System with Two Detection Zones

Standard Components Optional Components

1. Transformer2. G-NET console3. Horn on console4. G-SITE network interface5. Glue sensor6. Zone trigger7. Product8. Encoder

A. PrinterB. Remote warning lightC. Remote hornD. Feed sensorE. EjectorF. Batch kickerG. Batch sensorH. Pre-eject sensor

Installation2-4


321 226DIssued 5/05


1. These core components are required for any G-NET system:

S G-NET consoleS G-SITE network interfaceS glue sensorS zone trigger (a photosensor)S encoderS transformerS connecting cables

NOTE: If the production machine is long, the G-NET system may requirea second G-SITE network interface (and another main wiring harness) toavoid the use of long sensor cables.

2. These optional components may also be included:

S batch kicker and batch triggerS marking systemS ejection systemS pusherS feed sensorS remote hornS warning light towerS mounting componentsS double-sheet detectorS bar-code scanner systemS cello presence detectoror cello position detectorS catch basketS printerS air purge kitS connecting cables

3. Inspect the equipment for any damage that may have occurred duringshipping. Report any problems to your Nordson representative.

Check the PartsInventory

2-5Installation


321 226DIssued 5/05


Consider these guidelines in choosing a location for each glue sensor.

Location Factor Guideline

Distance of lenshousing from productsurface

Mount the lens unit so that the end of the lenshousing is 29 mm (1.13 in.) from the productsurface on which the glue will be applied.

Distance from amplifierunit to lens unit

Mount the lens close enough so the fiber-opticcable can reach the amplifier. The GD-100sensors have a 457 mm (18 in.) cable. TheGD100W fiber-optic cable is 813 mm (32 in.)long.

Fiber optic cable routing Avoid excessive bending of the fiber-optic lenscable. The inside bend radius should be greaterthan 25 mm (1 in.) inch.

Distance of glue sensorfrom glue gun

Locate the sensor downstream from the point ofglue application. Place sensors as close topossible to the glue guns.

Protection of cables Locate the sensor amplifier unit so that thecables connected to it are protected from anymoving machine parts and from the passingproducts.

Sufficient space formounting

See the following figure.

5601030A

27 mm(1.06 in.)

193 mm(7.60 in.)

63 mm(2.48 in.)

16 mm(0.62 in. diameter)

67 mm(2.64 in.)

28 mm(1.13 in.)

GD-100 Glue Sensor Dimensions

Locate the GlueSensors

Installation2-6


321 226DIssued 5/05


Consider these guidelines in choosing a location for each zone trigger in thesystem.

Location Factor Guideline

Distance of lens fromproduct surface

(standard trigger) Position the trigger lens 15--18mm (0.6--0.7 in.) from the product surface.

(fiber-optic trigger) Position the fiber-optic cable11--15 mm (0.4--0.6 in.) from the product surface.

Location in relation tozone glue sensor (orsensors)

Make sure that the trigger will be activated by theproduct edge before any glue pattern reachesthe glue sensor monitoring the pattern.

Fiber optic cable routing Avoid excessive bending of the fiber-optic lenscable. The inside bend radius should be greaterthan 25 mm (1 in.).

Protection of cables Select a location that protects cables from anymoving machine parts and from the passingproducts.

Protection from dustand water

Select a location that meets IP67 requirements.

Component Guideline

G-NET Console Locate at eye level for optimum viewing.

Locate as near as possible to the trombone section oncarton folder gluer machines.

Mount on a stand or base for reduced vibration,especially at high line speeds.

G-SITE networkinterface

Locate where all the connecting cables can reach fromthe components to the G-SITE.

Locate as close as possible to the console.

Locate where the G-SITE is free from vibration.

Protect the G-SITE from personnel moving about andfrom moving equipment or other objects.

Encoder Locate on a belt moving at the same speed that theproducts move through the detection zones.

Locate where easily accessible.

Ejector Locate on the side of the machine opposite the operatorto protect the operator from ejected products.

Ensure that other personnel in the area will not be in thepath of ejected products.

Locate the ZoneTriggers

Locate Other SystemComponents

2-7Installation


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Component Guideline

Pusher Mount on the opposite side of the machine from theejector.

Pre-eject sensor (standard sensor) Position the pre-eject sensor lens40--100 mm (1.6--3.9 in.) from the product surface.

(fiber-optic sensor) Position the fiber-optic cable11--15 mm (0.4--0.6 in.) from the product surface.

Batch sensor (standard sensor) Position the batch sensor lens 40--100mm (1.6--3.9 in.) from the product surface.


Feed sensor (standard sensor) Position the lens 51--254 mm(2--10 in.) from the product surface.


Bar codescanner

Locate the scanner after the glue flap pre-break sectionof the folder gluer. However, it can be located elsewhereif the bar code is scanned on the printed section of theproduct.

Avoid scanning over glue assist cuts in the glue flap andplace the laser scanner at an angle to avoid reflectionfrom the carton surface.

Refer to the Accubar product manual for otherrecommendations.

Double-sheetdetector

Locate close to the feed section of the machine.

Remote horn Mount the horn near the feed section of the machine sothat the feed operator is notified when a fault is detectedor the machine is stopped.

Air regulator Mount the air regulator (or regulators) in a convenientplace for making pressure adjustments.

Installation2-8


321 226DIssued 5/05


This part of the section contains three procedures:

S Install the Required System ComponentsS Install the Equipment for Rejecting or Marking ProductsS Install Optional Equipment and Accessories

Prior to mounting the required system components, review the previousguidelines for locating the components.

1. Install the adjustable arm for mounting the console and other systemcomponents as follows:

Type of Base Instructions

Floor stand Level the floor stand and secure it to the floor usingthe four holes for UNC 3/8-16 screws. Mount theadjustable arm on the stand.

Leveling base Mount the adjustable arm on the stand and mount thestand on the leveling base. Then level the base in thedesired location.

Mounting clamp Mount the adjustable arm on the machine or anothersecure structure using the mounting clamp.

Portable cart(not shown)

Remove the leveling pads from the base and installthe supplied casters.

5601033A

Floor Mounting Leveling Base Clamp Mounting

Different Ways to Mount the Adjustable Arm for the G-NET System

EquipmentInstallation

Install the RequiredSystem Components

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321 226DIssued 5/05


2. Install the G-NET console on the adjustable arm or on some other securestructure.

3. Install the G-SITE network interface. If the adjustable arm and the straightG-SITE mounting bracket were ordered, mount the G-SITE to theadjustable arm. If the inclined G-SITE mounting bracket was ordered, useit to mount the G-SITE to the machine frame or some other securestructure.

4. Install the transformer either on the adjustable arm or in anotherconvenient location.

5. If using a separate encoder for the G-NET system, install it so that theencoder wheel makes good contact with a transport roller or belt on themachine. Select a location where the speed of the wheel equals the speedof the products during the detection process. The following illustrationshows how to install the 500 ppr encoder.

NOTE: With the 500 ppr encoder, using a gear or a belt to drive theencoder is also an option. Choose a gear ratio that results in 500 mm ofproduct travel for each revolution of the encoder. Ensure that themaximum axial and radial shaft loading do not exceed 5 kg (11 lb).

NOTE: The encoder wheel can be mounted so it rotates in either aclockwise or counterclockwise direction. It will work correctly mountedeither way.

5601035A

Mounting

Clamping

Rod

500 ppr Encoder

Encoder Shaft

Spring Holder

Friction

Encoder

Mounting Rod

Bracket

Block

Wheel

Bracket

(alternate to mounting bracket)

Installation of 500 ppr Encoder

Installation2-10


321 226DIssued 5/05


6. Install all glue sensors and any cello detectors using either the Nordsonbracket components or other mounting devices. Make sure that the end ofthe lens housing of each glue sensor is 29 mm (1.13 in.) from the productsurface.

5601068

Lens Housing

Product Surface 29 mm(1.13 in.)

Glue Pattern

Recommended Distance from Sensor Lens Housing to Product Surface

7. Make sure that the lens of the glue sensor is centered over the glue patternas shown in the figure above.

Install the RequiredSystem Components(contd)

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321 226DIssued 5/05


8. Install the zone triggers, using the mounting hardware shipped with thetriggers or the Nordson mounting components. Make sure that eachtrigger will be activated before any glue pattern reaches the glue sensorthat monitors the pattern. The following figures show the correct andincorrect ways to position a trigger in relation to a glue sensor:

5601079

Glue Sensor

Zone Trigger

Glue Bead

Direction of Travel

Correct Location of Glue Sensor

5601080

Glue Sensor

Zone Trigger

Glue Bead

Direction of Travel

Incorrect Location of Glue Sensor

Installation2-12


321 226DIssued 5/05


Use this procedure to install an ejector, pusher, marker, and related optionalequipment.

1. Install the ejector and the ejector starter box. Refer to the manual(part 331 179A) shipped with the ejector for mounting instructions.

2. Install the pusher and the pusher stop plate.

3. Install the marking system. Refer to the instructions shipped with themarking system.

4. Turn the pre-eject sensor so that it is correctly oriented to the direction ofproduct travel as shown below:

5601040

Target Target

Directionof travel

IncorrectCorrect Position

Target

Directionof travel

Directionof travel

PositionCorrectPosition

5. Install the pre-eject sensor upstream from the device that is actuated forrejection or marking: either the pusher, the ejector, or the marking system.To determine how far upstream:

a. Place the product in the ejector, pusher, or marker where the productwill first be grabbed, pushed, or marked.

b. Back the product up approximately 127 mm (5 in.) and place thepre-eject sensor at the leading edge of the product. The following figureshows this procedure for a system with an ejector.

Install the Equipmentfor Rejecting orMarking Products

2-13Installation


321 226DIssued 5/05


5601078

A B

Grab Point

Product

Locaton of

127 mm(5.0 in.)

Pre-eject Sensor

How to Locate the Pre-eject Sensor

6. If using an ejector, place the catch basket where it will catch the rejectedproducts.

7. Add oil to any lubricators that are not full.

NOTE: If using a marking system, refer to the manual for instructions onmounting the air regulators.

Installation2-14


321 226DIssued 5/05


Use this procedure to mount all remaining equipment in the G-NET systemexcept the connecting cables.

1. Install the feed sensor downstream of the feeder.

2. Install the detection device that will be connected to the force-2 input(typically a double-sheet detector).

3. Install the Accubar control unit, laser scanner, and the scanning-systemtrigger. Refer to the manual supplied with this equipment for mountinginstructions. If using another type of scanner, refer to the instructionsshipped with the equipment.

4. Install the batch kicker and then mount the batch sensor immediatelyupstream of the kicker.

5. Install the stop plate for the kicker opposite the kicker.

6. Install the printer in its mounting case. Mount the case on the adjustablearm for the console or in some other suitable location.

5601022

G-NET Console

G-SITE

PrinterCase

NetworkInterface

7. Mount the remote light tower. It can be mounted on the adjustable arm oron some other suitable surface.

8. Mount the remote horn in the selected location.

This part of the section contains these procedures:

S Connect the Cables for All Required ComponentsS Connect the Cables for the Air-Operated EquipmentS Connect All Other Cables

Refer to the following figure, which shows all of the possible cable connectionsfor a G-NET system.

Install OptionalEquipment andAccessories

ElectricalInstallation

2-15Installation


321 226DIssued 5/05


Cable Connections for G-NET System

5601061

fiber optic lens glue sensor 1

(typical sensor)

glue sensor 1

glue sensor 2

glue sensor 3

glue sensor 4

glue sensor 5

glue sensor 6

glue sensor 7

glue sensor 8

trigger zone 1

trigger zone 2

trigger zone 3

trigger zone 4

feed sensor

force 1 sensor

force 2 sensor

batch sensor

encoder

alarm light

alarm horn

batch kicker

pre-eject sensor

eject confirm (not used)

ejector valve

machine control

site-link input 1

site-link input 2

24 VAC in

24 VAC out

site-link output 1

site-link output 2

G-SITEINTERFACE

SECONDG-SITE (if used)

zone 1 trigger

(typical trigger)

feed sensor

BAR CODE SCANNER

photoeye

laser

power

machine stop

bad code output

force 2 sensor

batch sensor

encoder

pre-eject sensor

m/c sensors

glue sensors

24 VAC out

24 VAC in

printer

RS--232

scanner trigger

bar code scanner

power

transformer

printer

remote warning

remote horn

pusher, ejector,

kicker solenoid

ejector

light tower

or marker solenoidvalve

ejector motor box

productionmachine

power

power

power

G-NET CONSOLE

Installation2-16


321 226DIssued 5/05


Connect To Instructions for Connecting

G-SITE G-NET console Use the 3-connector harness (1.8m/6 ft, 4.6 m/15 ft, 6.1 m/20 ft,or 7.6 m/25 ft) to connect the console to the G-SITE.

Connect one end of the 25-pin cable to the connector labeled site-linkinput 1 on the G-SITE interface and the other end to the connector labeledm/c sensors on the console.

Connect one end of the 37-pin cable to the connector labeled site-linkinput 2 on the G-SITE interface and the other end to the connector labeledglue sensors on the console.

Connect one end of the power cable to the connector labeled 24 VAC in onthe G-SITE interface and the other end to the connector labeled 24 VAC outon the console.

NOTE: If using the adjustable arm, route the cables inside the metal tubingof the arm.

120 VAC or220 VACTransformer

G-NET consoleand powersource

Connect one of the two transformer cables to the connector on the back ofthe console labeled 24 VAC in. Plug the other cable into a 120 VAC or 220VAC receptacle (depending upon the voltage rating of the transformerordered). A 15 amp service is required.

NOTE: Do not connect the transformer to the G-SITE. Doing so causes theloss of fuse protection and prevents the sensors being turned on and offwith the power switch on the console.

Glue sensor orCello-presencedetector orCello-positiondetector

G-SITE Connect one end of the sensor cable (3.1 m/10 ft or 6.1 m/20 ft) to theamplifier box for the glue sensor. Connect the other end of the cable to theconnector labeled glue sensor x on the G-SITE interface.

NOTE: Instead of a sensor cable, you may have received a two-cableharness that contains one sensor cable and one zone trigger cable.

Zone trigger G-SITE Connect one end of the trigger extension cable (3.1 m/10 ft or 6.1 m/20 ft)to the trigger cable (if an extension cable is needed). Connect the other endof the extension cable to the connector labeled trigger zone x on theG-SITE interface.

Encoder G-SITE Connect one end of the encoder cable (6.1 m/20 ft or 7.6 m/25 ft) to theencoder and the other end to the connector labeled encoder on the G-SITEinterface. Or, if you are using the encoder for an existing pattern control,connect one end of the special linking cable (4.6 m/15 ftor 7.6 m/25 ft) to the pattern control and the other end to the connectorlabeled encoder on the G-SITE interface.

Connect the Cablesfor All RequiredComponents

2-17Installation


321 226DIssued 5/05


Use the following procedure to connect the cables for all air-operatedcomponents. The cables for reject or marking equipment and for a kicker areoptional and may not be part of every system.


Reject device(ejector, pusher,or marker) andPre-eject sensor

G-SITE Use two of the four cables in the four-cable wiring harness cable(3.1 m/10 ft, 6.1 m/20 ft, or 9.1 m/30 ft) to connect the reject device that isactuated (ejector or pusher) and the pre-eject sensor to the G-SITE:

S Connect one end of a pneumatic cable to the solenoid on the rejectdevice and the other end to the connector labeled ejector valve on theG-SITE interface.

S Connect one end of a sensor cable (the one that is paired with thepneumatic cable just connected) to the cable on the pre-eject sensorand the other end to the connector labeled pre-eject sensor on theG-SITE interface.

NOTE: The other two cables in the harness are for the kicker and batchsensor (if installed).

Ejector starterbox

Machine Refer to the manual shipped with the ejector for instructions on connectingpower to the starter box. The ejector should be wired so that it turns on andoff with the production machine.

Batch kickerandBatch sensor

G-SITE Use two of the four cables in the four-cable wiring harness(3.1 m/10 ft, 6.1 m/20 ft, or 9.1 m/30 ft) to connect the kicker and the batchsensor to the G-SITE:

S Connect one end of the unused pneumatic cable to the solenoid on thekicker and the other end to the connector labeled batch kicker on theG-SITE interface.

S Connect one end of the unused sensor cable to the cable on the batchsensor and the other end to the connector labeled batch sensor on theG-SITE interface.

NOTE: The other two cables in the harness are for the reject deviceand pre-eject sensor (if installed).

Connect the Cablesfor the Air-OperatedEquipment

Installation2-18


321 226DIssued 5/05


1. Make all remaining cable connections.


Feed sensor G-SITE If an extension cable is needed, connect one end of the sensor extensioncable (3.1 m/10 ft or 6.1 m/20 ft) to the trigger cable. Connect the other endof the extension cable to the connector labeled feed sensor on the G-SITEinterface.

Accubar unit/Laser scanner

G-SITE/Accubar

Connect one end of the cable (9.2 m/30 ft) to the connector labeled badcode output on the Accubar control unit and the other end to the connectorlabeled force 1 sensor on the G-SITE interface. Refer to the Accubarmanual for instructions on connecting the remaining Accubar cables.

Force 2 input G-SITE If an extension cable is needed, connect one end of the extension cable(3.1 m/10 ft or 6.1 m/20 ft) to the double-feed detector connector and theother end of the cable to the connector labeled force 2 sensor on theG-SITE interface.

NOTE: If connecting some other device to the force 2 input, use acustom-made cable.

Remote horn G-SITE Connect the horn cable (7.6 m/25 ft) to the connector labeled alarm horn onthe G-SITE interface.

Remote lighttower

G-SITE Connect the light tower cable (1.5 m/5 ft or 4.6 m/15 ft) to the connectorlabeled alarm light on the G-SITE interface.

Printer G-NET console Connect one end of the printer cable to the printer and the other end to theconnector labeled printer on the back of the console. Connect the printerpower cable (with the attached power supply) to either a 120V or 240Voutlet, depending upon the type of printer ordered.

Machine stopcable

G-SITE Connect one end of the cable to the connector labeled machine control onthe G-SITE interface. Connect the wires on the other end of the cable to themachine controls as shown in the following figure. If using the stackercontrol feature of the G-NET system, make the required wiring connectionsas shown in the same figure.

Connect All OtherCables

2-19Installation


321 226DIssued 5/05


5601144A

5

3

7

2

6

1

4

RED

BLK

GRN

ORG

MACHINE STOPRELAY

PACKER TRACKINGRELAY

LUMBERG KV71G-SITE MACHINE CONTROL

CONNECTOR

=

=

=

=

Wiring Diagram for Machine Control Cable Connections

2. Where possible, tie cables together using wire ties and ensure that allcables are embedded in conduits or raceways along the machine. Alsoensure that cables are protected from any moving or rotating parts of themachine or from moving products.

3. Label all trigger and sensor cables and other components usingappropriate names or numbers.

Installation2-20


321 226DIssued 5/05


Use this procedure to connect the air lines to pneumatic components that areinstalled in the G-NET system:

S ejectorS pusherS kickerS air purge system

(used only when a GD100W sensor lens is mounted facing up)

NOTE: If the G-NET system is equipped with a marking system, refer toinstructions in the marking system product manual to install the air lines.

1. Route an air line from the plant’s air supply to all filter/regulators in thesystem. The line should be capable of supplying 5.5--7.0 Bar (80--100 psi)air to the regulator(s).

5601042

Solenoid Valvefor Batch Kicker

Batch Kicker

Pusher or Ejector

Solenoid Valvefor Pusher orEjector

From PlantAir Supply

Shutoff Valve (not supplied)

Filter/Regulator/Lubricator

Air Stream for Keeping SensorLens Clean (optional)

2. Route an air line from the regulator(s) to each pneumatic device in thesystem.

NOTE: All devices in the system except the air purge for the GD-100Wsensor lens require lubricated air. The air for the air purge system must beclean and unlubricated.

3. Turn on the air supply and adjust the air pressures.

Device Bar psi

Ejector 2.8 60

Air Purge Sensor 1.4--5.5 20--80

Kicker 4.8--5.5 70--80

NOTE: These pressures are recommended starting points and can befine-tuned during setup procedures.

PneumaticConnections

Connect All Air Lines

3-1Setup


321 226DIssued 5/05


Section 3Setup

Section Overview 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setup Overview 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setup Keys 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Report Menu 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Glue Detection Zone Screens 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Counter Menu 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tracking and Machine Constants Menu 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Adjustment Procedures 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Glue Sensors 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Zone Trigger 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Feed Sensor 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Batch or Pre-eject Sensor 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .All Other System Components 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Setup Procedures 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Set the System Clock 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Select a Different Language 3-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Set Up the Encoder 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjust the Timing of the Batch Kicker 3-18. . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjust the Timing of the Reject orMarking Equipment 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Teach the Tracking Distances for the System 3-21. . . . . . . . . . . . . . . . . . . . .Assign the Glue Sensors to Detection Zones 3-22. . . . . . . . . . . . . . . . . . . . .Teach the System a Good Pattern Set 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . .Set Pattern Error Tolerances 3-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Set Up the Bead-length Detection Feature 3-27. . . . . . . . . . . . . . . . . . . . . . .Make a Zone Active or Inactive forEjection or Marking 3-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Management of Settings 3-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Zero All Settings 3-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Record the System Settings 3-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup3-2


321 226DIssued 5/05


SetupThis section explains how to set up the G-NET verification system prior tooperation. It is divided into:

S Setup OverviewS Equipment Adjustment ProceduresS System Setup ProceduresS Record of Settings

Software revision 1.28c is documented.

This part of Section 3 explains the:

S Setup KeysS Report MenuS Glue Detection Zone ScreensS Counter MenuS Tracking and Machine Constants Menu

SectionOverview

Setup Overview

3-3Setup


321 226DIssued 5/05


5601032A

Zeros counts,

Sets values or

Selects menus

Selects

Places the

Teaches the systempatterns or trackingdistances

system instandby mode

and zone screens

toggles betweensettings

clears errors,re-activatesfrozen screens

settings

Setup Keys

Setup3-4


321 226DIssued 5/05


5601047

Report Menu

Setting Explanation

Date and Time Displays the current date and time for keeping recordsand generating reports.

MACHINE # Identifies the machine or line used for a production runwith a number of up to six digits

JOB # Identifies the job with a number of up to six digits

ORDER # Identifies the customer order with a number of up to sixdigits

SHIFT # Identifies the production shift with a number of up to twodigits

JOB STATUS Displays status setting used in generating reports whenthe G-NET system is equipped with a printer. At thebeginning of a job, change the job status to RUNNING.At the end of a job, change the job status to SETUP.Press the print key to generate a report that providesproduction data, including start time, end time, productiontime, and downtime.

LANGUAGE Identifies which of 11 different languages is used todisplay text

softwareversion

Shows the current software version

Report Menu

3-5Setup


321 226DIssued 5/05


5601031A

Glue Detection Zone Screens

Setting Explanation

GLUE DETECTIONZONE: X

X = 1,2,3,or4

Shows which of the four glue detection zones iscurrently displayed

ACTIVE or STANDBYorTEACH

Determines which mode a detection zone iscurrently in: STANDBY, TEACH, or ACTIVE

TOLERANCE Determines the amount of deviation (mm) from thereference pattern that the system will permit. Thesystem reports any error equal to or greater thanthis amount. A different tolerance can be set foreach detection zone.

ACTIVE SENSORS Settings that determine which sensors are currentlyactive in the zone being displayed. If a sensor isactive in the displayed zone, its number appears. Ifit is not, a dash appears.

bead length Shows the total length (mm) of the current patternmonitored by sensor 1 in zone 1. The length isdefined as the total millimeters of glue detected bysensor 1 from the beginning to the end of theproduct.

min Determines the minimum total length (mm) of gluethat the system will accept from the start to the endof the product

max Determines the maximum total length (mm) of gluethat the system will accept from the start to the endof the product

Glue Detection ZoneScreens

Setup3-6


321 226DIssued 5/05


5601048

Counter Menu

Setting Explanation

BATCH COUNT Displays the current product count detected by the batchsensor

BATCH PRESET Determines which product in a series of products a batchkicker will kick

KICK TIME Determines the kick duration (ms) for the batch kicker

FEED COUNT Displays the total number of products detected by thefeed sensor since the count was last reset to zero

DELIVERY COUNT Displays the total number of products detected by thebatch sensor since the count was last reset to zero. Thefeed count minus delivery count equals the number ofrejected products.

STACKERCONTROL

Determines the maximum spacing between products(mm) before the systems stops the stacking conveyor.

GLUE DETECTIONREJECT COUNTS

(ZONES 1-4)

Displays the number of faults that have occurred in eachzone since the counts were last reset to zero

FORCE 1 Displays the number of force 1 errors that have occurredsince the count was last reset to zero

FORCE 2 Displays the number of force 2 errors that have occurredsince the count was last reset to zero

WORK RATE Displays the current production rate in 1000 units perhour based upon the count of the batch sensor

MACH. SPEED Displays the current machine speed (m/min) based uponinput from the encoder

Counter Menu

3-7Setup


321 226DIssued 5/05


5601074

Tracking and Machine Constants Menu

Setting Explanation

LOW SPEED CUTOUT Determines the speed below which the systemstops reporting pattern errors, force 1 errors, andforce 2 errors

ACTIVE ZONES Determines which detection zones are active orinactive for ejection or marking

EJECTOR COMP Determines compensation for the response timeof an ejector, pusher, or marker so it actuates atthe proper time

REJECT MARK Determines the length of line travel (mm) that therejecting device or marker is actuated

ENCODER TYPE Determines the number of mm that the systemuses for tracking each time it receives one pulsefrom the encoder

MACHINE STOP PRESET Determines the number of faulty products thatcan be in the machine at any one time before amachine stop occurs

OVERLAP DETECT PRESET Allows the zone 1 trigger to detect misfeedproblems (such as overlapped products orproducts with open flaps) and stop the machine ifthe alarm feature is turned on

TRACK ZONE X

X = 1, 2, 3, or 4

Shows the distance from each zone trigger to thepre-eject sensor

TRACK FORCE1 Shows the distance from the force 1 trigger tothe pre-eject sensor when teaching trackingdistances

Tracking and MachineConstants Menu

Setup3-8


321 226DIssued 5/05


This part of Section 3 includes instructions on adjusting:

S Glue SensorsS Zone TriggerS Feed SensorS Batch or Pre-eject SensorS All Other System Components

Use this procedure to adjust the sensitivity of the glue detection sensors. Thesensors are factory adjusted and should not require adjusting before they areplaced in operation.

1. To determine whether a sensor is working correctly, slowly jog the line orpush a product with glue on it past the sensor. The green glue light shouldturn on (without flickering) when the glue is opposite the lens and turn offwhen the bare paper surface is opposite the lens. Repeat this processusing a product with no glue on it and verify that the green light does notturn on.

2. If the sensor is working correctly, it requires no adjustment. If it is not, goto the next step of this procedure.

WARNING: Avoid looking directly into the light or shining thelight into the eyes of others. Looking directly at the light cancause an eye injury.

3. Remove the sensor lens from its mounting and point the lens off in thedistance so it is not focused on any close object.

4. Remove the protective brass screws that cover the adjustment screws.

5. Turn the zero adjustment screw counterclockwise until the red low lightturns off.

5601084

Low Light

High Light

Zero Adjust-mentscrew

Out-putLight

SensitivityAdjustmentScrew

EquipmentAdjustmentProcedures

Glue Sensors

3-9Setup


321 226DIssued 5/05


6. Slowly turn the zero adjustment screw clockwise until the red low light turnson.

7. Continue turning the screw clockwise an additional 1/4 to 1/2 turn.

8. Place the sensor lens back in its mounting bracket on the line.

9. Put a product on the line and focus the sensor light where glue will beapplied. Verify that the distance from the end of the lens housing to theproduct surface is 29 mm (1.13 in.).

5601068

Lens Housing

Product Surface 29 mm(1.13 in.)

NOTE: When the lens is properly focused, small dark spots (the receptors)appear in the sharp circle of light on the surface of the product.

10. Turn the sensitivity adjustment screw clockwise until the green glue lightturns on.

11. Slowly turn the sensitivity adjustment screw counterclockwise until thegreen glue light turns off.

12. Continue turning the screw counterclockwise an additional 1/4 to 1/2 turn.

13. Replace the covers on the adjustment screws.

Setup3-10


321 226DIssued 5/05


Determine which type of zone trigger is used in your G-NET system and followthe appropriate procedure to adjust the trigger sensitivity: Adjust the StandardZone Trigger or Adjust the Fiber-optic Zone Trigger. Both types of triggers areshown below.

5601111

StandardZone Trigger

Fiber-OpticZone Trigger

Adjust the Standard Zone Trigger

1. Remove the cover from the back of the trigger housing.

5601098

Sensitivity Adjustment Screw

Alignment/Output Indicator

Light/Dark Mode Selector

2. Decide whether to use the light-operate or the dark-operate setting.The light-operate mode is for light-colored or reflective products.The dark-operate mode is for dark-colored or non-reflective products.

3. To set the light/dark mode switch:

S (For light-on operation) Ensure that the mode selector switch is turnedfully clockwise.

S (For dark-on operation) Ensure that the mode selector switch is turnedfully counterclockwise.

Zone Trigger

3-11Setup


321 226DIssued 5/05


4. With the production line stopped, place the product on the line opposite thetrigger and verify that the red output light is flashing rapidly. If it is not,adjust the distance of the lens from the product surface until the light isflashing rapidly, keeping within the recommended distance of 15—18(0.6—0.7 in.).

5. Turn the sensitivity adjustment screw until the red output light is turning onand off at the fastest rate.

NOTE: Turning the screw clockwise increases sensitivity. Turning itcounterclockwise decreases sensitivity.

6. Run the line at jog speed and verify that the red output light turns on withthe leading edge of the product (or some other edge used to activate thetrigger) and turns off with the trailing edge of the product (or some otheredge used to deactivate the trigger).

7. Run the line at normal operating speed and verify that the trigger is workingcorrectly.

8. Replace the cover on the back of the trigger housing.

Adjust the Fiber-optic Zone Trigger

1. Decide whether to use the 50 μs (0.05 ms) response mode or the 500 μs(0.5 ms) response mode. For most applications, the 50 μs mode is best.

2. Check the current setting of the response time selector switch. Turn theswitch to the desired setting.

5601083


Signal Strength Display

Response Time Selector

Output Indicator

Power-on Indicator

(50 μs mode only)

Setup3-12


321 226DIssued 5/05


Adjust the Fiber-optic Zone Trigger (contd)

3. Run the production line at the normal operating speed.

4. Turn the sensitivity adjustment screw until the yellow output light is turningon and off with each product.

NOTE: Turning the screw clockwise increases sensitivity. Turning itcounterclockwise decreases sensitivity.

Use this procedure to adjust the standard feed sensor. If the G-NET system isequipped with a fiber-optic feed sensor, refer to Adjust the Fiber-optic ZoneTrigger in this section for instructions.

1. Set the MODE switch to L for light-on operation or to D for dark-onoperation. The light-on mode is for light-colored or reflective products.The dark-on mode is for dark-colored or non-reflective products.

5601100

Red Light Green Light

Light/DarkMode Selector

SensitivityAdjustmentScrew

2. With no target in front of the sensor, either:

S (For light-on operation) Turn the sensitivity adjustment screw clockwiseuntil the red light turns on or the screw stops turning (whichever occursfirst). Note the position of the screw.

S (For dark-on operation) Turn the sensitivity adjustment screw clockwiseuntil the red light turns off or the screw stops turning (whichever occursfirst). Note the position of the screw.

3. With the target in front of the sensor, turn the sensitivity adjustment screwcounterclockwise until the green light turns off. Note the position of thescrew.

Feed Sensor

3-13Setup


321 226DIssued 5/05


4. Turn the sensitivity adjustment screw midway between the positionsdetermined in steps 2 and 3.

5. With the line running at jog speed or at a low speed, make sure that the redlight turns on with the leading edge of each product and turns off with thetrailing edge of each product. It should turn on and off only once perproduct.

6. Run the line at normal operating speed and verify that the sensor isworking properly. To check the sensor, reset the feed count to zero, feed aknown number of products into the system, and verify that the feed countequals this number of products. Refer to Reset Counts in Operation.

Use this procedure to adjust the standard batch or pre-eject sensor. If theG-NET system is equipped with a fiber-optic batch sensor or a fiber-opticpre-eject sensor, refer to Adjust the Fiber-optic Zone Trigger in this section forinstructions.

1. With no target in front of the sensor, turn the sensitivity adjustment screwclockwise until the red light turns on or the screw stops turning (whicheveroccurs first). Note the position of the screw.

5601099

Output Indicator


2. With the target in front of the sensor, turn the sensitivity adjustment screwcounterclockwise until the red light turns off. Note the position of thescrew.

3. Turn the sensitivity adjustment screw midway between the positionsdetermined in steps 1 and 2.

4. With the line running at jog speed or at a low speed, make sure that the redlight turns on with the leading edge of each product and turns off with thetrailing edge of each product. It should turn on and off only once perproduct.

Batch or Pre-ejectSensor

Setup3-14


321 226DIssued 5/05


5. Run the line at normal operating speed and verify that the sensor isworking properly. To check the batch sensor, reset the batch count to zero,send a known number of products past the batch sensor, and verify thatthe batch count equals this number of products. Refer to Reset Counts inOperation. Check the pre-eject sensor later when making adjustments tothe ejection or marking system.

Ensure that all the necessary adjustments have been made to the remainingcomponents in the system except the timing adjustments for the pneumaticallyoperated equipment (such as an ejector or pusher). The timing of allequipment will be adjusted in procedures performed later in this section.

Component Adjustments

Double-sheetdetector

Use the micrometer adjustment screw to set the distancebetween the anvil and the wheel to the thickness of asingle flap. The light on the sensor should turn on whentwo layers of carton are placed between the wheel andthe anvil and remain off when only one layer is present.If necessary, adjust the position of the sensor to achievethis result.

Cello positiondetector

Locate the sensor approximate 20 mm (0.8 in.) above theproduct surface and in a path where it will detectcellophane with paper below and will not detect anywindows. Place the selector switch in the TEACHposition, place paper only below the sensor head, andpress the TEACH button. The light turns red. Now placecellophane (with paper underneath) below the sensorand press the TEACH button. The light turns green.Place the selector switch in the OFF position. Test theoperation of the sensor with good and defective productsand make sure that the sensor output is active at thecorrect times.

NOTE: If the indicator light starts flashing during thesetup procedure, readjust the position of the sensor andrepeat the procedure.

Bar codescanner andtrigger

Ensure that the laser scanner is at a slight angle to theproduct. Verify that there is no double triggering fromwindows, cut-outs, or print variations on the product. Foradditional adjustments and setup procedures, refer tomanual shipped with this equipment.

Pusher Adjust the air pressure setting and the height of thepusher.

Ejector Adjust the height of the rotating disk, the gap, and the airpressure setting. Refer to manual shipped with thisequipment for instructions.

Marker Refer to the product manual shipped with this equipment.

Kicker Adjust the height of the kicker so it strikes midwaybetween the top and the bottom of the product.

Othercomponents

Adjust any other components in the system that need tobe adjusted.

Batch or Pre-ejectSensor (contd)

All OtherSystem Components

3-15Setup


321 226DIssued 5/05


The following procedures are used in setting up the G-NET system:

S Set the System ClockS Select a Different LanguageS Set Up the EncoderS Adjust the Timing of the Batch KickerS Adjust the Timing of the Reject or Marking EquipmentS Teach the Tracking Distances for the SystemS Assign the Glue Sensors to Detection ZonesS Teach the System a Good Pattern SetS Set Pattern Error TolerancesS Set Up the Bead-length Detection FeatureS Make a Zone Active or Inactive for Ejection or Marking

1. Press select until the Report Menu appears on the display.

2. Note the date and time shown on the display and determine if the settingsneed to be changed.

5601076

THURSDAY 04/27/00 15:12

Day of Week Month Day of Month Year Hour Minute

3. To change a setting, press setup until the desired time or date setting ishighlighted.

4. Press inc or dec until the correct time or date setting is shown.

5. Repeat steps 3 and 4 for each time/date setting that needs to be changed.

System SetupProcedures

Set the System Clock

Setup3-16


321 226DIssued 5/05


Use this procedure to change the language used on the display.

1. Press select until the Report Menu appears on the display.

2. Press setup until the LANGUAGE setting is highlighted.

3. Press inc or dec until the LANGUAGE option changes to the desiredselection.

Desired Selection Text Displayed

English ENGLISH

German Deutsch

Dutch Nederlands

French Francais

Spanish Espanol

Italian Italiano

Portuguese Portuguese

Swedish Svenska

Norwegian Norwegian

Finnish Finnish

Danish Danish

4. Press select until another menu or screen appears on the display. All textnow appears in the selected language.

Select a DifferentLanguage

3-17Setup


321 226DIssued 5/05


Set up the encoder and verify that it is sending signals to the controller.Complete this procedure before starting any of the remaining procedures inthis section.

1. Press select until the TRACKING AND MACHINE CONSTANTS MENU appears onthe display.

2. Press setup until the ENCODER TYPE setting is highlighted.

3. Press inc or dec to change the setting to 1 mm.

4. Spin the encoder wheel and verify that the green encoder light on theconsole turns on. If it does not, check for a loose connection and ensurethat the friction wheel is turning properly and making good contact with thebelt of the machine.

5. Record the encoder type setting in the table provided at the end of thissection.

Set Up the Encoder

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321 226DIssued 5/05


Adjust the batch kicker (if installed) so it kicks in the center of the product.There is no compensation setting for the kicker, so the timing is adjusted bymoving the batch sensor either closer to or further from the kicker until itproduces the best result at normal operating speed. You can also adjust theamount of time that the kicker is actuated.

1. Press select until the COUNTER MENU appears on the display.

2. Press setup until the BATCH PRESET setting is highlighted.

3. Press inc or dec until the batch preset is the number that will be used forsetup. For example, if the batch preset is 5, the display shows:

BATCH PRESET: 0 0 0 5

4. Start the production line and run it at jog speed.

5. Note where the kicker strikes the product.

S If the kicker strikes too early, move the batch sensor closer to thekicker.

S If the kicker strikes too late, move the batch sensor farther from thekicker.

6. Repeat step 5 with the line running at normal operating speed.

7. Press setup until the KICK TIME setting is highlighted.

8. Set inc or dec until the kick time is 40--60 ms. For example, if the kick timeis 50 ms, the display would show:

KICK TIME: 0 0 5 0 ms

9. Run the line at jog speed and note how long the kicker stays engaged.

S If the kicker is engaged too long, reduce the kick time.S If the kicker is not engaged long enough, increase the kick time.


11. Run the line at normal operating speed. If the strikes the product with toomuch or too little force, adjust the kicker air pressure accordingly.

12. Press setup until the BATCH PRESET setting is highlighted.

13. Press inc or dec until the batch preset setting is the size of the batch. Forexample, if the batch preset is 100, the display shows:

BATCH PRESET: 0 1 0 0

14. Record the batch preset and kick time settings in the table provided at theend of this section.

Adjust the Timing ofthe Batch Kicker

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321 226DIssued 5/05


This procedure applies to systems equipped with a pusher, with an ejector,with both a pusher and an ejector, or with a marking system. It ensures thatthe device is actuated at the right point on the product.

1. If the system is equipped with an ejector, ensure that the catch basket iscorrectly positioned to catch rejected products.

2. Press reject on/off and reject test so all products will be rejected ormarked. The lights on the keys turn on.

3. Run the production line at jog speed and note where the reject devicegrabs the product or the marker begins its mark.

S If the device pushes, grabs, or marks too early, move the pre-ejectsensor closer to the device.

S If the device pushes, grabs, or marks too late, move the pre-ejectsensor farther from the device.


Pre-eject Sensor

Ejector

Product Being Conveyor

5601075

Ejected

Moving the Pre-eject Sensor to Find the Best Position for Ejection

5. Stop the production line.


7. Press setup until the EJECTOR COMP setting is highlighted.

8. Press inc or dec until the desired ejector compensation setting (multipliedby 10) is shown. For example, if the Nordson ejector is used, therecommended compensation is 20 ms. Enter 200 and the display wouldshow:

EJECTOR COMP: 0 2 0 0 msec/10

Adjust the Timing ofthe Reject or MarkingEquipment

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321 226DIssued 5/05


9. Run the production line at jog speed and note where the reject devicegrabs the product or the marker starts marking.

S If the ejector or pusher grabs too early or the mark starts too early,decrease the compensation setting.

S If the ejector or pusher grabs too late or the mark starts too late,increase the compensation setting.


11. Press setup until the REJECT MARK setting is highlighted.

12. Press inc or dec until the desired reject mark length (mm) is shown.

NOTE: If you are setting up a pusher or an ejector instead of a markingsystem, this setting determines the length of line travel (mm) that the rejectdevice will be activated. For the standard ejector or pusher, 25--40 mm is agood starting point for this setting.

13. Send a product through the marker with the line running at the normaloperating speed. Note how long the reject device or marking device is on.

S If the reject device is on too briefly or the mark is too short, increase thelength of line travel.

S If the reject device is on too long or the mark is too long, decrease thelength of line travel.

Repeat as necessary.

14. Press reject test to turn the reject test off. The light on the key turns off.

15. Record the ejector compensation and the reject mark settings in the tableprovided at the end of this section.

Adjust the Timing ofthe Reject or MarkingEquipment (contd)

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321 226DIssued 5/05


When performing the teach procedure, the system automatically captures the:

S distance from each zone trigger to the pre-eject sensorS distance from the trigger for the force 1 detection device (usually a bar

code scanner) to the pre-eject sensorS overlap preset detect setting, which is the product length that the zone1

trigger senses, plus 10 mm

1. Run the production line until it is clear of all products.

2. If a bar code scanner is installed, cover the laser beam.


4. Press teach. The system enters the teach tracking mode.

5. Start the production line and run products through the machine. Thesystem uses the first product to determine the tracking distances. Forexample, if the system has two detection zones, zones 1 and 2, and thetracking distances for these zones are 690 mm and 1320 mm respectively,the display would show:

TRACK ZONE 1: 0690 mm and TRACK ZONE 2: 1320 mm

6. Check the distance shown for the OVERLAP DETECT PRESET. Subtract 10mm from this distance, and the result should be within a few millimeters ofthe actual product length.

NOTE: If the overlap preset detect is half or double the product length, theencoder type may have been entered incorrectly and need to bere-entered. If the distance shown for the detect setting is incorrect in someother way, troubleshoot the encoder installation and check for loose cablesor wheel slippage. Also, make sure the zone 1 trigger is working properlywith no double triggering.

7. Check the other tracking distances to verify that they are correct.

8. Record the tracking distances for each active zone, for the force 1detection device (if installed), and for the overlap detect preset in the tableprovided at the end of this section.

Teach the TrackingDistances for theSystem

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321 226DIssued 5/05


Assign each sensor in the system to one of four possible detection zones.Each sensor must be dedicated to a single zone.

1. Press select until the desired GLUE DETECTION ZONE screen appears on thedisplay.

2. Look at the ACTIVE SENSORS settings. If a sensor is assigned to the zone,the sensor number is displayed. If the sensor is not assigned to the zone,a dash is displayed in place of the sensor number. For example, if sensor3 is assigned to the zone, the display would show:

ACTIVE SENSORS: - - 3 - - - - -

3. Decide which sensor (or sensors) are to be assigned to the zone (orreassigned to another zone). If using the bead-length error reportingfeature, sensor 1 must be assigned to detection zone 1.

4. Press setup until the number of the desired sensor (or the dash where thesensor number would be) is highlighted.

5. Press inc. If the sensor was not assigned to this zone, the dash changesto the number of the sensor, showing that it is now assigned to the zone. Ifthe sensor was assigned to the zone before, the number of the sensorchanges to a dash and the sensor can now be reassigned to another zoneor left unassigned.

For example, if sensor 3 was assigned to the zone before and then sensor5 is assigned to the zone, the display would now show:

ACTIVE SENSORS: - - 3 - 5 - - -

NOTE: If assigning a sensor to a zone but the dash does not change tothe sensor number, the sensor is assigned to another zone. To reassign asensor, first de-activate it in the zone in which it is currently assigned. Thenassign it to any of the three other detection zones.

6. Record the zone to which each sensor is assigned in the table provided atthe end of this section.

Assign the GlueSensors to DetectionZones

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Prior to teaching the system a good pattern set, each sensor must be assignedto the correct detection zone. See the previous procedure, Assign Sensors toDetection Zones.

1. Start the production line and run it with products at the normal operatingspeed. Let the speed stabilize.

2. Press select until the desired GLUE DETECTION ZONE screen appears on thedisplay. If zone 1 is the first zone, it is usually best to teach zone 1 first.

3. Check the pattern shown on the display (the thin line). Make sure it meetsthe following requirements for accuracy and stability:

S It is in the desired position. Use the product ruler to determine this.S The ends of the pattern are stable, with only slight movement, if any.S There is a steady line where glue should appear, indicating that the pattern

is not frequently breaking up.

4. Press teach. The screen text changes from STANDBY to TEACH (briefly) toACTIVE. The system samples the next five products and overlays all fivepatterns to create the reference pattern, which it displays in a bold line (orlines, if there is more than one bead in the pattern). The reference patternis a composite pattern, showing glue anywhere there is glue on any of thefive products.

NOTE: If the system remains in the teach mode when the teach key ispressed, either the zone trigger is not sensing the products or five productshave not yet passed the trigger.

5601064

Product 1

Product 2

Product 3

Product 4

Product 5

Reference

Pattern

Pattern

Pattern

Pattern

Pattern

Pattern

Example 1: How the System Determines the ReferencePattern from Five Products

Teach the System aGood Pattern Set

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5601071

Product 1

Product 2

Product 3

Product 4

Product 5

Reference

Pattern

Pattern

Pattern

Pattern

Pattern

Pattern


5. Inspect the reference pattern. Make sure that the pattern captured is thedesired pattern or very close to it. If the pattern is not correct, repeat steps3 and 4 until the system has a good reference pattern.

NOTE: If part or all of the pattern is not visible on the screen, press theincrease key to advance the product ruler or the decrease key to move theruler back so the pattern (or the rest of the pattern) is visible.

6. Repeat for each zone activated.

7. Record the start and stop points for the reference pattern in each zone inthe table provided at the end of this section.

Define how much deviation is allowed from the reference pattern for each zoneand how many pattern errors can be present in the system at any one timebefore the machine stop is activated. Before starting this procedure, teach thesystem a good set of reference patterns for the product.

1. If the reject function is on, press reject on/off. The light on the rejecton/off key turns off.

2. If the reject test is on, press reject test. The light on the reject test keyturns off.


Teach the System aGood Pattern Set (contd)

Set Pattern ErrorTolerances

3-25Setup


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4. Press setup until the TOLERANCE setting is highlighted.

5. Press inc to set the tolerance to some high setting, such as 50 mm, duringthe first part of this procedure. For example, if the tolerance is 50 mm, thescreen would show:

TOLERANCE: 50

6. If you are setting up zone 1, make sure that the max setting is 9999 and themin setting is 0 0 0 0 (off).

7. Isolate the pattern-error reporting to a single glue sensor in a single zoneby de-activating all sensors but one in the displayed zone and deactivatingall other sensors in all other zones. Refer to Assign the Glue Sensors toDetection Zones in this section.

NOTE: Instead of isolating individual sensors as described above, it is alsopossible to enter the STANDBY mode now, teach one zone at a time and setits tolerance. Then reenter STANDBY after setting the tolerance in eachzone. This procedure will isolate the error reporting to a single zone (butnot to a single sensor). At the end of this procedure, re-teach a goodreference pattern in all zones activated.


9. Start the line with products on it. Because of the high tolerance setting, noerrors should occur unless the patterns are very defective. If the system isfinding pattern errors, refer to Troubleshooting.

10. Press setup until the TOLERANCE setting is highlighted.

11. Press dec until the tolerance is lowered to the setting at which an errorshould be reported. For example, if the tolerance is 10 mm, the system willfind all patterns in this zone that deviate from the reference pattern by 10mm or more and report a pattern error.

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321 226DIssued 5/05


12. If the system is not reporting pattern errors, continue to step 13. If thesystem is reporting pattern errors, one of two possible problems isoccurring:

Problem Solution

The tolerance setting istoo low.

Increase the tolerance setting and press clear tounfreeze the screen. Run the line again to see ifpattern errors occur. When the problem isresolved, continue to the next step.

Some error hasoccurred during setup,causing the system todetect errors wherenone exist.

Refer to The System Detects Pattern ErrorsWhen None Exist in, Troubleshooting. When theproblem is resolved, continue to the next step.

13. If additional sensors are used in this zone, continue to step 14. If not, go tostep 17.

14. Turn off the sensor that was just tested and turn on the next sensor to betested. Refer to Assign the Glue Sensors to Detection Zones in thissection.

15. Run the line with products on it and verify that the zone tolerance settingworks for this sensor.

16. Repeat steps 13--16 for any additional sensors in the same detection zone.

NOTE: If using a G-NET detection system for the first time, try to operatewith the system finding errors in just one zone before setting up otherzones. Become familiar with the way the system operates before goinginto full operation. Add other zones one at a time.

17. Activate all of the glue sensors in the system, assigning each one to theappropriate zone. Refer to Assign the Glue Sensors to Detection Zones inthis section.


19. Press setup until the MACHINE STOP PRESET setting is highlighted.

Set Pattern ErrorTolerances (contd)

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321 226DIssued 5/05


20. Press inc or dec to change the setting to the desired value. The settingshould equal the total number of faulty products in the system (at any onetime) that will cause an alarm (and therefore a machine stop). Forexample, if the machine stop preset is 4 and four products currently in thesystem have pattern errors, the system will generate an alarm and themachine will stop.

21. Record the tolerances for each detection zone and the machine stoppreset in the table provided at the end of this section.

Use this procedure to set up the bead-length error reporting feature. Thisfeature is available only on sensor 1 in detection zone 1.

1. Press select until GLUE DETECTION ZONE 1 appears on the display.

2. Press setup until max is highlighted.

NOTE: Set the maximum value first. If the minimum value is set first, thesystem will detect errors on every product until the maximum value is set.

5601031A

Set Up the Bead-lengthDetection Feature

Setup3-28


321 226DIssued 5/05


3. Press inc or dec until the maximum length is set to the maximum totallength of glue allowed in all of the beads monitored by sensor 1.

4. Run the production line with products on it.

5. Determine whether the system is detecting bead-length errors. When abead-length error occurs, the screen freezes to capture the error, and thebead length displayed exceeds the maximum setting. The pattern errorlight for sensor 1 turns on.

6. If the system is correctly distinguishing between good patterns andpatterns that are too long, continue to step 7. If the system is not workingcorrectly, press clear and repeat steps 2--5, setting the maximum beadlength to a higher or lower value.

7. Press setup until min is highlighted.

8. Press inc or dec until the minimum length is set to the minimum totallength of glue allowed in all of the beads monitored by sensor 1.

9. Run the production line with products on it.

10. Determine whether the system is detecting bead-length errors. When abead-length error occurs, the screen freezes to capture the error and thebead length displayed is lower than the minimum setting. The pattern errorlight for sensor 1 also turns on.

11. If the system is correctly distinguishing between good patterns andpatterns that are too short, continue to step 12. If the system is notworking correctly, press clear and repeat steps 7--10, setting the minimumbead length to a higher or lower value.

12. Record the maximum and minimum bead length settings in the tableprovided at the end of this section.

Set Up theBead-lengthDetection Feature(contd)

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321 226DIssued 5/05


Occasionally the system may report errors in a zone but the glue patternseems to be good. If this happens, make the zone inactive for rejection ormarking until the cause of the problem is found.


2. Check the ACTIVE ZONES settings to see which zones are active. If a zoneis active, a number (1, 2, 3, 4) is displayed. If it is inactive, adash ( -- ) is displayed in place of a number. For example, if zones 1 and 2are active for ejection or marking, the display would show:

ACTIVE ZONES: 1 2 - -

3. Press setup until the desired zone is highlighted.

4. Press inc. If the zone was active, it becomes inactive and the number onthe display changes to a dash. If the zone was inactive, it becomes activeand the dash on the display changes to the number of the zone. Forexample, if zones 1 and 2 were active and zone 3 was activated, thedisplay would show:

ACTIVE ZONES: 1 2 3 -

This part of Section 3 includes:

S Zero All SettingsS Record the System Settings

Use this procedure to change all of the current settings to zero, off, or inactive.Perform this procedure if moving the G-NET system to a new machine.

1. Turn the system off at the switch on the back of the console.

2. Hold the alarm reset key while turning the system back on. All fields willbe reset to the zero values or off settings except the clock settings. Theclock settings will not change.

Make a Zone Active orInactive for Ejection orMarking

Management ofSettings

Zero All Settings

Setup3-30


321 226DIssued 5/05


ProductDescription

Zone Settings Zone 1 Zone 2 Zone 3 Zone 4

Tolerance

Active Sensors

Maximum BeadLength

Minimum BeadLength

System CounterSettings

Batch Preset

Kick Time

Stacker Control

System TrackingSettings

EjectorCompensation

Reject Mark

Encoder Type

Machine StopPreset

Overlap DetectPreset

Track Force 1(automatically set)

Tracking SettingsPer Zone

Zone 1 Zone 2 Zone 3 Zone 4

Tracking Distance(automatically set)

Record the SystemSettings

3-31Setup


321 226DIssued 5/05


Line Speed

Other Settings

Reference Pattern Zone 1 Zone 2 Zone 3 Zone 4

Start Stop Start Stop Start Stop Start Stop




Setup3-32


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4-1Operation


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Section 4Operation

Section Overview 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Basic Operation 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operator Panel 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Procedures 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Start the System After It Has Been Turned Off 4-6. . . . . . . . . . . . . . . . . . . . . .Teach the System a Good Pattern Set 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Enable or Disable the Outputs 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Enter the Standby Mode 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Track a Job 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clear a Pattern Error 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Restart the System After a Machine Stop 4-16. . . . . . . . . . . . . . . . . . . . . . . .Change Products 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shut Down the System 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Monitoring Procedures 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monitor Pattern Placement 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Check Error Messages 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monitor Panel Lights 4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monitor the Warning Light Tower 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monitor Counts 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reset Counts 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Job Reporting 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Record Key Production Data 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Print a Production Report 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation4-2


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OperationThis section explains how the G-NET glue detection system works and givesprocedures for operating and monitoring the system. It is divided into fourparts:

S Basic OperationS Operator Panel OverviewS Operating ProceduresS Monitoring ProceduresS Job Reporting

The G-NET verification system monitors the production line for glue patternerrors and pushes, marks or ejects faulty products. The system can beequipped with up to eight sensors to monitor patterns in as many as fourdifferent detection zones.

The system can perform other verification tasks as well:

S It can push, reject, or mark products that have faulty bar codes, cellophanewindows, or other defects. When a bar code error is found, it is referred toas a force-1 error because the bar code scanner is connected to theG-NET system at the force 1 input.

S It can stop the machine when a serious operational problem occurs, suchas a misfeed or a doublefeed, or when a cluster of faulty products is found.When a doublefeed error is found, it is referred to as a force 2 errorbecause the doublefeed detector is connected to the G-NET system at theforce 2 input.

Prior to operating the G-NET system, define a set of good reference patternsfor the system. Then, for each detection zone, set the amount of deviation (thetolerance) allowed from each reference pattern.

SectionOverview

Basic Operation

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321 226DIssued 5/05


As products pass under the system’s glue sensors, the controller comparesthe current patterns to the reference patterns. The system registers an erroranytime the current pattern deviates from the reference pattern by more thanthe set tolerance. For example, if the tolerance is set at 10 mm, the systemwill detect an error if the pattern:

S extends 10 mm or more past either end of the reference patternS falls 10 mm or more short of either end of the reference patternS has a gap of 10 mm or more where the reference pattern does not

5601063

Reference

Good

Pattern

Good

Pattern

Good

Pattern

Pattern

with Error

Pattern

with Error

Pattern

Tolerance = X

X

X X

X

Examples of Good Patterns and Patterns With Errors

When an error is detected, the system:

S sounds a horn at the console

S turns on a pattern error light that shows which sensor detected the fault

S displays a message showing the zone in which the pattern error occurred

S rejects, pushes, or marks the product (if an ejector, pusher or marker isinstalled and the reject function is turned on)

S sounds a remote horn (if installed)

S turns on a red light on a remote warning light tower (if installed)

The system can also perform these actions for faulty or missing bar codes andfor missing or out-of-position cellophane windows.

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5601058

8

7

6

5

1

3

4

2

Controls and Indicators on the Operator Panel

Item Explanation

1select

Advance to the next menu or screen.

2incdec

Increase or decrease the value of settings or enable or disablesettings. A new setting becomes active immediately.

3clear

Reset counters to zero, clear error messages, and re-activatefrozen screens.

4display

View any of the three menus or any of the four zone screens.

5print

Print a report.

6setup

Advance to the next setting or field on any menu or screen.

7stand by

Suspend the detection of pattern errors in all zones.

8teach

Capture the desired pattern from the next five productspassing through a zone when a zone screen is displayed orcapture tracking distances when a product passes through thesystem while the tracking menu is displayed.

Operator Panel

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5601096

8

1

2 3

5

6

7

4

Controls and Indicators on the Operator Panel

ItemNumber

Explanation

1rejecton/off

Enables or disables the reject capability of the pusher, ejector,or marker.The light on the key turns on when the rejection capability isenabled.

2reject test

Operates a pusher, ejector or marker during testing.The light on the key turns on when the test function is enabled.

3alarmon/off

Enables or disables the alarm (machine-stop) capabilityThe light on the key turns on when the alarm capability isenabled.

4alarmreset

Resets the alarm (machine-stop) contacts.The light on the key turns on when the alarm needs to bereset.

5encoderlight

Turns on whenever the controller is receiving pulses from theencoder

6glue

sensorlight

Turns on when a sensor is currently detecting adhesive

7pattern

error light

Turns on when a sensor detects a pattern error

8zonetriggerlight

Turns on when a trigger is currently sensing a passing product

Operation4-6


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This part of Section 4 includes:

S Start the System After It Has Been Turned OffS Teach the System a Good Pattern SetS Enable or Disable the OutputsS Enter the Standby ModeS Track and Print a JobS Clear a Pattern ErrorS Restart the System After a Machine StopS Change ProductsS Shut Down the System

This procedure assumes that the same product is running that was runningwhen the system was turned off. If changing products, refer to ChangeProducts in this section.

1. Turn the system on using the power switch on the back of the console.The system turns on in the STANDBY mode with the Report Menu displayed.

NOTE: The system loads the settings that were active when the systemwas turned off.

5601029A

Console

PowerSwitch

on/off

Power Switch on Back of Console

OperatingProcedures

Start the SystemAfter It Has BeenTurned Off

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2. If using a link cable to share the input of the encoder for the pattern controlsystem, ensure that the pattern control system is on.

NOTE: If using the pattern controller encoder signal, make sure thepattern controller is always on when operating the G-NET system. If it isnot on, the G-NET system receives no encoder input and cannot detectand report pattern errors.

3. Check the information on the Report Menu. If any information needs to bechanged, change it now. If starting a new production run, refer to Start orEnd a Job in this section.


5. Reset any counts necessary. Refer to Reset Counts in this section.

6. If any of the following equipment must be started independently, start itnow:

S printerS bar code scannerS ejector

NOTE: The ejector on/off switch is normally left in the on position so thatthe ejector will start when the machine is started.

7. If the air to the system is off, turn it on now. Check the air pressures andadjust them as needed.

8. Start the production line and teach the system a good pattern for eachdetection zone used. Refer to the next procedure, Teach the System aGood Pattern Set.

9. Press reject on/off to enable the reject function.

10. Press alarm on/off to enable the alarm (machine-stop) function.

11. Begin production.

Operation4-8


321 226DIssued 5/05


Teach a good pattern set for each active detection zone.

1. If the production line is not running, start it now. Run it with products on itat the normal operating speed. Let the speed stabilize.

2. Press select until the desired GLUE DETECTION ZONE appears on thedisplay. If zone 1 is the first zone, teach zone 1 first.

3. Check the pattern as shown on the display (the thin line). Make sure itmeets the criteria for accuracy and stability:

S The pattern is in the desired position on the product (as indicated bythe product ruler).

S The ends are of the pattern are stable, with only slight movement, ifany.

S There is a continuous, steady line for each bead, indicating that thepattern is not frequently breaking up.

5601024A

Product Ruler

Old Reference PatternActual Pattern Detected (thin line)

Zone Number

Zone StatusTolerance Seting(in millimeters)

(in millimeters)

(thick line)

Key Information on Detection Zone Screens

Teach the System aGood Pattern Set

4-9Operation


321 226DIssued 5/05


4. If the entire pattern is not visible on the screen, press inc to advance theproduct ruler toward the trailing edge or dec to move the ruler back towardthe leading edge.

NOTE: Make sure that no setting is highlighted on the screen whenpressing the increase or decrease key. If a setting is highlighted, press thesetup key until no setting is highlighted. If you press the increase ordecrease key with a setting highlighted, you will change the setting insteadof scrolling the product ruler.

5. When the pattern shown is accurate and stable, press teach. The screentext changes from STANDBY to TEACH (briefly) and then to ACTIVE.

NOTE: If the system remains in the TEACH mode when the teach key ispressed, either the zone trigger is not sensing the products or five productshave not yet passed the trigger.

NOTE: When the teach key is pressed, the system samples the next fiveproducts and overlays all five patterns to create the reference pattern,which it displays in a bold line (or lines, if there is more than one bead inthe pattern). In other words, the reference pattern will show glue anywherethere was glue on any of the five products.

5601064

Product 1

Product 2

Product 3

Product 4

Product 5

Reference

Pattern

Pattern

Pattern

Pattern

Pattern

Pattern


5601071

Product 1

Product 2

Product 3

Product 4

Product 5

Reference

Pattern

Pattern

Pattern

Pattern

Pattern

Pattern


Operation4-10


321 226DIssued 5/05


6. Inspect the reference pattern that the system captures. Make sure that thepattern captured is the pattern needed for the product. If the pattern is notgood, repeat steps 3--5 until the system has been taught a good pattern.

Use this procedure to enable or disable the reject function and the machinestop contacts.

1. Find the desired system action for the reject function in the following table.Then determine the status of the key lights (on or off) that will achieve thedesired result.

How the Reject On/Off and Reject Test Keys Work

Desired SystemAction

Status of Key LightsAction

Reject On/Off Reject Test On/Off

Do not reject/mark anyproducts, even if theyhave pattern errors

Off Off

Reject/mark productswith errors

On Off

Reject/mark allproducts

On On

2. Check the light on the reject on/off key on the console. If necessary,press reject on/off to turn the light on the reject on/off key on or off.

3. Check the light on the reject test key on the console. If necessary, pressreject test to turn the light on the reject test key on or off.

4. Find the desired system action for the alarm (machine stop) function in thefollowing table. Then determine the status of the key lights that will achievethe desired result.

Teach the Systema Good Pattern Set(contd)

Enable or Disable theOutputs

4-11Operation


321 226DIssued 5/05


How the Alarm and Alarm Reset Keys Work

Desired SystemAction

Status of Key LightsAction

Alarm On/Off Alarm Reset

Do not stop themachine when analarm condition occurs.

Off Off

Stop the machine whenan alarm conditionoccurs.

On Off

An alarm has causedthe system to stop themachine and turn onthe alarm reset light.When alarm reset ispressed, the alarmcontacts change stateand the machine canbe started.

On On

An alarm has causedthe system to stop themachine and turn onthe alarm reset light.When alarm reset ispressed, the alarmcontacts change stateand the machine canbe started. To enablethe alarm again, pressalarm on/off.

Off On

5. Check the light on the alarm on/off key on the console. If necessary,press the alarm on/off key to enable the alarm.

6. Check the light on the alarm reset key on the console. If necessary, pressalarm reset to reset the alarm.

NOTE: Each time the system stops the machine, press the alarm resetkey to reset the machine stop contacts. If the light on the alarm reset keyremains on, the machine cannot start.

Operation4-12


321 226DIssued 5/05


When the system is in STANDBY, the system stops finding and reporting patternerrors. It continues to sense and display patterns, which can be monitored onthe zone screens. It also continues to report force 1 errors and force 2 errors.

1. Press stand by. All zones enter the STANDBY mode. The word STANDBY isdisplayed on the zone screen. The system stops reporting pattern errors,but all other detection continues: force 1, force 2, and misfeed reporting.The reference patterns remain on the detection zone screens until a newpattern is taught to the system.

5601073

stand by

Placing the System in the Standby Mode

2. When reactivating the outputs, teach the system a good pattern in everydetection zone that is being used. For example, if all four zones are usedfor detection, teach the system a new reference pattern in all four zones.Refer to Teach the System a Good Pattern Set in this section.

Enter the StandbyMode

4-13Operation


321 226DIssued 5/05


Use this procedure to track an individual job and print a report. This procedureassumes that patterns are being applied to the same product that ran in theprevious job. If changing products, refer to Change Products in this section.

1. Before starting the production run, press select until the Report Menuappears on the display.

2. Determine which report settings need to be changed, if any.

S MACHINE #S JOB #S ORDER #S SHIFT #

3. Press setup until the report setting to be changed is highlighted.

4. Press inc or dec until the desired value is displayed.

5. Check the JOB STATUS on the Report Menu. If the status is SETUP, continueto the next step. If the status is RUNNING, press setup until RUNNING ishighlighted on the display. Press inc. The status changes to SETUP.

NOTE: If the status was RUNNING prior to step 5, the last production jobwas not ended properly.

6. Press select until the COUNTER MENU appears on the screen.

7. Check the counts and, if they have not been zeroed, zero them now. Referto Reset Counts in this section.

8. Press select until the report menu appears on the display.

9. Press setup until SETUP is highlighted.

10. Press inc. The job status changes to RUNNING. The system captures thecurrent time and date to use as the job start time in any printed reports.The system also tracks the production rate, the line speed, and downtime.

11. Press select to scroll through the detection zone screens and ensure thatthe status of each zone being used is ACTIVE. If the status of any zonebeing used is STANDBY, refer to Teach the System a Good Pattern Set andactivate the appropriate zone(s).

Track a Job

Operation4-14


321 226DIssued 5/05


12. Start the production run.

13. When the production run has finished, press select until the report menuappears on the display.

14. Press setup until RUNNING is highlighted.

15. Press inc or dec. The job status changes to SETUP. The system capturesthe current time and date to use as the job finish time in any printedreports.

16. Press print. For an explanation of the report printed, refer to Print aProduction Report in this section.

17. Zero the counts for the next job. Refer to Reset Counts in this section.

Anytime the system finds a pattern that deviates from the reference pattern byan amount that is equal to or greater than the set tolerance, it records a patternerror. Then:

S The alarm horn in the console sounds a short beep.

S An error message identifying the faulted zone is displayed at the bottom ofthe screen.

S The red pattern error light for the sensor that detected the fault turns onand remains on until the error is cleared.

S The system freezes the screen for the detection zone in which the erroroccurred.

S The fault count for the zone is increased by one.

S The remote horn (if installed) sounds a short beep.

S The red light on the remote warning light tower (if installed) turns on.

The system continues to operate and detect pattern errors in all zones and, ifthe zones are active and rejection is enabled, the system will eject any faultyproducts. Also, the system continues to display the patterns in non-faultedzones, and if a pattern error occurs in another zone, it will freeze the screen onthe pattern error in this zone too.

Track a Job (contd)

Clear a Pattern Error

4-15Operation


321 226DIssued 5/05


To clear one or more pattern errors:

1. Determine the screen, or screens, that are frozen by either:

a. Reading the error message displayed. However, if another systemerror has occurred since the zone was frozen (such as a misfeed oranother pattern error), the error message for the most recent error willoverwrite any previous error messages.

b. Observing which red pattern error light has turned on. The zone thatcontains this sensor will be frozen. However, if more than one patternerror has occurred, more than one sensor light will turn on and morethan one zone screen may be frozen.

c. Scrolling through all of the detection zone screens to see whichscreen(s) are frozen.

2. Press select until a frozen GLUE DETECTION ZONE appears on the display or,if more than one screen is frozen, until one of the frozen screens appearson the display.

3. Inspect the faulty pattern to see what kind of error occurred. Determinewhere the error occurred and which sensor detected it.

NOTE: If the error is not visible, advance the product ruler (using the inckey) until the part of the pattern containing the error is visible. Each timethe inc key is pressed, the ruler advances by 100 mm. If all patternsappear to be good and the error is on sensor 1, check the bead length. Ifthe bead length is less than the minimum setting or greater than themaximum setting, the system will report a pattern error in zone 1 and turnon the sensor 1 error light.

NOTE: If the error is in detection zone 1, the BEAD LENGTH is also frozen.

4. Press clear. The screen is unfrozen and resumes showing real-timepatterns. The error message is cleared, and all of the red pattern-errorlights that were on (including those for other zones) turn off. If the systemhas a remote warning light tower, its green light turns on.

NOTE: Always check all zone screens anytime the pattern-error sensorlights for more than one detection zone turn on.

Operation4-16


321 226DIssued 5/05


The machine can be stopped in one of four ways if the alarm (machine-stop)function is turned on:

S The detection device connected to the force 2 input (such as adouble-sheet detector) finds an error.

S The trigger for zone 1 detects an overlapped product.

S The number of faulty products currently in the system is equal to or greaterthan the machine stop preset.

S The system is finding more defective products than it can reject.

When one of these problems occurs, the system:

S stops the machineS sounds the hornS turns on the red light on the warning towerS displays an error messageS increases the error count

In addition, the light on the alarm reset key turns on, indicating that the alarmkey must be pressed to reset the machine-stop contacts.

1. Solve the problem that caused the machine stop. If a misfeed ordoublefeed has occurred, solve the problem on the production line.

2. Press clear. The error message is removed from the display. If thesystem has a remote warning light tower, the green light turns on.

3. Press alarm reset. The red light on the alarm reset key turns off and themachine stop contacts change state.

4. Start the production line.

NOTE: The production line will not start without resetting the alarm.

NOTE: Any products being tracked for ejection when a machine stopoccurs are ejected when the machine restarts.

Restart the SystemAfter a Machine Stop

4-17Operation


321 226DIssued 5/05


Use the following table as a checklist of possible tasks for a productchangeover.

Production Change Task

New product is a different size or shape orhas a different glue pattern

Change the position of one ormore glue sensors

Position of the sensor changes. May alsobe required if a different adhesive is used.

Adjust the sensitivity of oneor more glue sensors

New product is a different size or shape orhas different features, such as a window

Change the position of one ormore zone triggers

Position of the trigger changes Adjust the sensitivity of oneor more zone triggers

Batch size changes Change the batch preset

Product size changes significantly Adjust the timing of the batchkicker

Product size changes significantly Adjust kick time

Product length changes significantly Adjust the position of thepre-eject sensor

Position of the pre-eject sensor changes orif the position of any zone trigger changes.

Adjust the timing of the rejector marking function

Product length changes significantly Change the length of thereject mark

Product length changes significantly or theline speed changes significantly

Change the machine stoppreset

Zone trigger (or force 1 trigger) has beenmoved or if the pre-eject sensor has beenmoved. Also required if the product lengthchanges.

Teach the line trackingdistances

Patterns require a different detectionscheme

Assign sensors to detectionzones

Any change Teach the system a goodpattern set

Pattern changes or quality controlspecifications change

Change pattern tolerances

Different detection zones are used for thenew product

Make a zone active orinactive for ejection

Any change Track and print

Any change Reset counts

Any change Activate the outputs

Change Products

Operation4-18


321 226DIssued 5/05


If running the same product in the next production run, leave the system on.Anytime the system is turned off and then turned back on, it turns on in theSTANDBY mode and the system must be taught a good pattern in each zoneactivated.

1. Stop the production line.

2. Turn the G-NET system off using the power switch on the back of theconsole.

3. Turn off the power to any equipment that has an independent on/off switch(such as a printer or a bar code scanner).

4. Turn off the air supply to any equipment in the system that requires air tooperate (such as an ejector, a pusher, a kicker, or an air purge system).

This part of Section 4 includes procedures for monitoring the operation of theG-NET verification system:

S Monitor Pattern PlacementS Check Error MessagesS Monitor Panel LightsS Monitor CountsS Reset Counts

Use this procedure to monitor the pattern being generated in any detectionzone.


2. Observe the actual pattern. If part or all of the entire pattern is not visible,Press inc. The screen scrolls to the right, showing patterns toward thetrailing edge of the product.

NOTE: Each time the inc key is pressed, the product ruler advances 100mm toward the trailing edge. Each time the dec key is pressed, theproduct ruler moves 100 mm toward the leading edge. The zero point onthe ruler is the product edge that activates the zone trigger.

Shut Down theSystem

MonitoringProcedures

Monitor PatternPlacement

4-19Operation


321 226DIssued 5/05


5601059

Actual Pattern Reference Pattern

Advancing the Product Ruler to Inspect the Entire Pattern

NOTE: If any field on the screen is highlighted, pressing the inc or dec keyhas no effect on the product ruler (but will change the value of thehighlighted field).

3. Compare the screen display of the glue beads (indicated by thin lines) tothe reference pattern (indicated by one or more bold lines). From thescreen, determine the consistency of the the patterns. Check if the patternerrors are large enough to be approaching the pattern-error tolerance(shown on the screen) for the pattern. Observe whether a pattern hasshifted and make the necessary corrections at the pattern controller.

Operation4-20


321 226DIssued 5/05


5601069

Tolerance Setting

Reference BeadDetected Bead

Example of a Good Bead when the Tolerance Is 10 mm

4. Compare the screen display of the glue beads (indicated by thin lines) tothe actual glue bead lengths on the product. Use the product ruler todetermine the length of each bead in millimeters and ensure that the lengthis either correct or within the set tolerances. If there is a large deviation ineither length or position of the actual and detected beads, refer toTroubleshooting.

Monitor PatternPlacement (contd)

4-21Operation


321 226DIssued 5/05


When an error occurs, an error message immediately appears at the bottom ofthe display, no matter which menu or screen is currently displayed. If anothererror occurs before the first error is cleared, the second message overwritesthe first one. In this case, observe the pattern error lights to determine whichsensors have detected pattern errors since the system was last cleared.

For an explanation of each error message, refer to Get Help from ErrorMessages in Troubleshooting.

5601055

Error

Error

Message

Count

Typical Error Message

Check ErrorMessages

Operation4-22


321 226DIssued 5/05


5601066

1

2 3 4

5

6

7

8

Item Number Operation Indicator

1zone 1

Turns on when the trigger for the designated zone (1--4)senses a passing product

2reject on/off

Turns on when the reject/marking function is enabled

3reject test

Turns on when the reject test is enabled

4alarm on/off

Turns on when the alarm (machine stop) function isactivated

5alarm reset

Turns on when the alarm contacts change state andneed to be reset

6encoder light

Turns on when the encoder is sending pulses to thecontroller

7pattern error

light

Turns on whenever a pattern error occurs in thepattern(s) monitored by the designated sensor (1--8).The light remains on until the error is cleared.

8glue sensor

light

Turns on when the designated glue sensor (1--8) isdetecting glue

Monitor Panel Lights

4-23Operation


321 226DIssued 5/05


The red light on the tower turns on when there is faulty product in the systemor an alarm condition occurs. It turns green when cleared (unless a count fieldwas highlighted, in which case pressing clear resets the count).

5601070

Red = Error or Alarm Condition

Green = Normal Operation

Use this procedure to monitor system counts.


2. Observe the fault counts:

S pattern error count (for any detection zone)S force 1 input count (for the force 1 monitoring device)S force 2 input count (for the force 2 monitoring device)

Each counter shows the fault count since the counter was last reset.

5601060

Monitor the WarningLight Tower

Monitor Counts

Operation4-24


321 226DIssued 5/05


Use this procedure to reset any fault counts to zero.


2. Press setup until the desired count is highlighted.

S BATCH COUNTS FEED COUNTS DELIVERY COUNTS ZONE X COUNTS FORCE 1 COUNTS FORCE 2 COUNT

3. To reset the count, press clear. The count changes to zero.

NOTE: The batch count can be reset to a number other than zero. To do this,highlight the count. Use the inc or dec key to set the desired value.

NOTE: If there is an error message displayed when clear is pressed, thesystem will also clear the error message.

5601067

Reset Counts

4-25Operation


321 226DIssued 5/05


This part of Section 4 includes two procedures:

S Record Key Production DataS Print a Production Report

Use this table to record production data from the report and counter menus.Some of the data, such as the start time, must be recorded at the start of a job.Counts are typically zeroed at the start of a job and recorded at the end.

Job Number Job Notes:

Machine Number

Order Number

Date

Start Time End Time

Feed Count

Delivery Count

Reject Calculation

Zone Fault Counts Zone 1 Zone 1 Zone 3 Zone 4

Force Counts Force 1 Force 2

Machine Speed

Work Rate

Use this procedure to create a production report if a printer is connected to thesystem.

1. At the end of the job, press select until the report menu appears on thescreen.

2. Press setup until RUNNING is highlighted.

3. Press inc. The job status changes to SETUP.

4. Press print. The system prints a production report. The following tableexplains each item in the report.

Job Reporting

Record KeyProduction Data

Print a ProductionReport

Operation4-26


321 226DIssued 5/05


G-NET Production Report

Item in Report Explanation

Machine number Shows the MACHINE# entry obtained from the reportmenu

Job number Shows the JOB# entry obtained from the report menu

Order number Shows the ORDER# entry obtained from the report menu

Job started Shows the job start time (when the job status waschanged form SETUP to RUNNING)

Job finished Shows the job end time (when the job status waschanged from RUNNING to SETUP)

Downtime Shows the total amount of time that the work rate fellto zero during the production run. The work rate fallsto zero anytime the batch sensor detects no productsfor more than one minute.

Machine status Shows whether the current job status is RUNNING orSETUP

Feed count Shows counts since last cleared

Delivery count Shows counts since last cleared

Batch size Obtained from the BATCH PRESET setting in the CounterMenu

Cartons/hour Shows the products/hour for the last hour of operation

Line speed(meters/minute)

Shows the line speed for the last hour of operation

Glue errors inzone 1--4

Shows counts since last cleared

Errors in force 1inputs


Errors in force 2inputs


Ejector status Shows the current status of the ejector status: ENABLEDor DISABLED

NOTE: Some of these items are explained more fully in Brief Explanationsof Menus and Screens in Setup.

4-27Operation


321 226DIssued 5/05


5601062

VeriTec G--NET Production Report

FRIDAY 07 JUNE 2000 15:33

Printout for Shift Number 1

MACHINE #: 000096 JOB #: 211821 ORDER #: 191819

JOB STARTED

JOB FINISHED

DOWN TIME

MACHINE STATUS

FEED COUNT

DELIVERY COUNT

BATCH SIZE

CARTONS/HOUR

LINE SPEED mpm

GLUE ERROR ZONE1

GLUE ERROR ZONE3

ERROR @FORCE1 IN

EJECTOR STATUS

: 00:15

: SETUP

: 016740

: 016651

: 0040

: 20,150

: 186.2

: 000018

: 000051

: 000018

: ENABLED

Reject Statistics

GLUE ERROR ZONE2

GLUE ERROR ZONE4

ERROR @FORCE2 IN

: 000008

: 000012

: 000005

Comments:_______________________________________ Team Operator: ________________________________________

: FRIDAY 07 JUL 2000 07:30

: FRIDAY 07 JUL 2000 11:30

Operation4-28


321 226DIssued 5/05


Troubleshooting 5-1


321 226DIssued 5/05


Section 5Troubleshooting

Safety Precautions 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagrams 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before Troubleshooting 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Two Basic System Problems 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Diagnostic Tools 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Console Lights and Screen Display 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Counter Menu 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Error Messages 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Four Key Questions 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Tables 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Does Not Detect Pattern Errors in All Zones 5-12. . . . . . . . . . . . . . .System Does Not Detect Pattern Errors inOne or More Individual Zones 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Detects Pattern Errors When None Exist 5-13. . . . . . . . . . . . . . . . . .One or More Glue Patterns Are Missing 5-14. . . . . . . . . . . . . . . . . . . . . . . . . .Screen Does Not Display Entire Pattern 5-15. . . . . . . . . . . . . . . . . . . . . . . . .System Does Not Eject or Push Defective Products 5-15. . . . . . . . . . . . . . .System Always Ejects or Pushes the Wrong Product 5-16. . . . . . . . . . . . . .System Intermittently Ejects or Pushes the Wrong Product 5-16. . . . . . . . .Ejection System Is Not Smooth/Timing Is Off 5-17. . . . . . . . . . . . . . . . . . . . .System Is Ejecting All Products 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Machine Stop Function Is Not Working Properly 5-18. . . . . . . . . . . . . . . . . . .

Troubleshooting5-2


321 226DIssued 5/05


Troubleshooting

WARNING: Allow only qualified personnel to perform thefollowing tasks. Follow the safety instructions in this documentand all other related documentation.

WARNING: If this equipment is used with other Nordson orVeriTec equipment, refer to the manuals provided with thatequipment for instructions and applicable safety precautions.Failure to observe this warning may result in personal injury ordeath.

5601042

Solenoid Valvefor Batch Kicker

Batch Kicker

Pusher or Ejector

Solenoid Valvefor Pusher orEjector

From PlantAir Supply

Shutoff Valve (not supplied)

Filter/Regulator/Libricator

Air Stream for Keeping SensorLens Clean (optional)

Pneumatic Diagram

SafetyPrecautions

Diagrams

Troubleshooting 5-3


321 226DIssued 5/05


Diagram of System Connections

5601061

fiber optic lens glue sensor 1

(typical sensor)

glue sensor 1

glue sensor 2

glue sensor 3

glue sensor 4

glue sensor 5

glue sensor 6

glue sensor 7

glue sensor 8

trigger zone 1

trigger zone 2

trigger zone 3

trigger zone 4

feed sensor

force 1 sensor

force 2 sensor

batch sensor

encoder

alarm light

alarm horn

batch kicker

pre-eject sensor

eject confirm (not used)

ejector valve

machine control

site-link input 1

site-link input 2

24 VAC in

24 VAC out

site-link output 1

site-link output 2

G-SITEINTERFACE

SECONDG-SITE (if used)

zone 1 trigger

(typical trigger)

feed sensor

BAR CODE SCANNER

photoeye

laser

power

machine stop

bad code output

force 2 sensor

batch sensor

encoder

pre-eject sensor

m/c sensors

glue sensors

24 VAC out

24 VAC in

printer

RS--232

scanner trigger

bar code scanner

power

transformer

printer

remote warning

remote horn

pusher, ejector,

kicker solenoid

ejector

light tower

or marker solenoidvalve

ejector motor box

productionmachine

power

power

power

G-NET CONSOLE

Troubleshooting5-4


321 226DIssued 5/05


This part of the troubleshooting section offers ways to solve system problemsquickly. It includes the following five areas of troubleshooting help:

S Basic System ProblemsS Diagnostic ToolsS Counter MenuS Error MessagesS Four Key Questions

Up to 90% of all problems that occur in a G-NET system are one of two types.

S The system does not detect pattern errorsS The system detects pattern errors when none exists

The G-NET system’s three diagnostic tools can help troubleshoot:

S Console Lights and Screen DisplayS Real Time Display of PatternsS Screen Captures of Pattern Errors

5601056

1

2

3 4

6

5

7

8

9

10

Console Lights and Screen Display

BeforeTroubleshooting

Two Basic SystemProblems

Diagnostic Tools

Troubleshooting 5-5


321 226DIssued 5/05


Item No. Description How to Use in Troubleshooting

1 Actual Pattern(thin line)

Provides a real-time display (mm) of each pattern in the selectedzone, allowing comparison to the reference pattern shown above ina thicker line.

NOTE: If all patterns in a zone are not visible on the screen, usethe inc and dec keys to scroll the screen back and forth along thelength of the product.

2 Reference Pattern(thick line)

Displays the pattern or patterns that were taught to the system forthe displayed zone. Use the reference patterns to make sure thatthe system was taught good patterns before putting the system intooperation. The system compares each pattern to the referencepattern in determining which ones are good and bad.

3 Zone tolerance setting Shows the amount of allowable deviation from any reference patternin this zone before the system will report an error

4 Zone status Shows whether the detection zone is in STANDBY or ACTIVEmode. If a zone is in STANDBY, the system will not report patternerrors in this zone.

5 Active sensors Shows the glue sensors that are active in the zone being displayedon the screen

6 Error message Shows the most recent error that occurred since the system waslast cleared or turned on. If the error is a pattern error or a beadlength error, the screen also freezes to capture this error.

7 Error count Shows the number of pattern errors that have occurred in thefaulted zone (the one for which there is an error message) since thesystem was last cleared or turned on. Error counts for all zones inthe Counter Menu are displayed.

8 Glue sensor light Turns on when the glue sensor is sensing glue. If this light is notturning on and off when glue is passing by the sensor, the sensor isnot sensing the glue.

9 Pattern error lights Turns on (and remains on) when the glue sensor finds a patternerror (or, in the case of zone 1, a bead length error). One of theselights will turn on for each sensor that has detected at least onepattern error since the system was last cleared or turned on. Youcan therefore see how many sensors (if any) have detected errors.

10 Zone trigger light Shows when the trigger is sensing the product. The light turns onas the leading (or activating) edge passes and off as the trailing (orde-activating) edge passes. If this light is not turning on as productspass by the trigger, the trigger is not sensing the product. The lightshould turn on and off once for each product. To see this clearly,the machine may need to be slowed to jog speed.

Console Lights andScreen Display

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Real-Time Display of Patterns

The display shows the actual patterns that the glue sensors are monitoring.Each pattern is displayed in a thin line just below the reference pattern, whichis shown in a thick line. This close placement allows comparison between thetwo patterns by:

S ensuring that the reference patterns taught to the system are goodS checking for consistent pattern placement by the pattern controllerS checking for pattern shifts, especially as the line speed changesS finding problems with glue guns, such as clogged nozzles

5601057

Product Ruler

Reference PatternActual Pattern Detected (thin line)

Zone Number

Zone StatusTolerance Setting (mm)

(in millimeters)

(thick line)

Key Information on Detection Zone Screens

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Screen Captures of Pattern Errors

When the system detects a pattern error, it freezes the zone screen in whichthe error occurred. Examine the error by displaying the appropriate zonescreen (if it is not already displayed) and finding the faulty pattern. Scroll theproduct ruler, if necessary, (using the inc or dec key) to view the error. Eachtime the inc key is pressed, the screen advances 100 mm toward the trailingedge of the product. Pressing the dec key scrolls the screen in the otherdirection.

The following figure shows information displayed when viewing a faultypattern. For additional information about screen captures, refer to Clear aPattern Error in Operation.

5601059

Actual Pattern Reference Pattern

Pattern Error Captured on Frozen Screen

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The Counter Menu shows how many errors have occurred in each zone sincethe counts were last cleared. Using this menu, determine whether a problemis occurring in all zones or in just one or two zones.

5601060

Display of Error Counts in Counter Menu

The following table explains all of the possible error messages and describeswhat action (if any) the system takes.

NOTE: When an error occurs, an error message immediately appears at thebottom of the display, no matter which menu or screen is currently displayed.If another error occurs before clearing this message, the system will overwritethe message for the first error with an error message for the most recent error.To obtain information about previous errors, use the pattern error lights and thescreen captures of pattern errors. This information is retained until it iscleared.

NOTE: When the machine stop preset is reached, the error messagedisplayed will show only the last error in the series of errors that caused themachine stop to occur. For example, if the machine stop preset is set to 4 andthere are three pattern errors in zone 1 and then one error in zone 2, themessage displayed will be ERROR: GLUE ZONE 2.

Counter Menu

Error Messages

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Error Message Explanation Note

ERROR GLUE ZONE X

(X = 1, 2, 3, or 4)

A sensor in the zone identified has detected a pattern error and, ifthe reject function is enabled, the system is tracking the product formarking or ejection. The message also shows the current errorcount for the zone.

A

ERROR: FORCE1 INPUT The monitoring device connected to the force 1 input has detected afaulty product, and the system is tracking the product for marking orejection. The message also shows the current number of force 1errors.

B

ERROR: FORCE2 INPUT The monitoring device connected to the force 2 input has detected afault, and the system shuts down the machine. The message alsoshows the current number of force 2 errors.

C

ERROR: MISFEED The zone 1 trigger has detected a product that is longer thanallowed by the overlap detect preset, and the system shuts downthe machine.

C

EJECTOR TRACKING ERROR The processor is overloaded. There may be more faulty products inthe system than is allowed by the machine stop preset for totalerrors. The system continues to operate but may not be ejectingproperly.

C

ERROR@: PRINTER Communication has stopped between the system controller and theprinter. The printer is not connected, not plugged in, busy, out ofpaper, or jammed.

NOTE A: To unfreeze the screen in the faulted zone, refer to Clear a Pattern Error.

B: Press clear to remove a force 1 error message.

C: To resume operation, refer to Start the System After a Machine Stop.

Error Messages(contd)

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What Type of Problem Is Occurring?

Problem Recommended Place to Start Troubleshooting

System is reportingerrors when the patternsseem to be good.

Troubleshooting: System Detects Pattern Errors When None Exist

System is not reportingerrors when patternsare missing or out ofposition.

Troubleshooting: System Does Not Detect Pattern Errors in All Zones or System DoesNot Detect Pattern Errors in One or More Individual Zones

Some other kind of erroris occurring.

If the problem relates to the ejection function or the machine-stop function, see one ofthe two tables, System Does Not Eject or Push Defective Products or theMachine-Stop Function Is Not Working Properly. If the problem relates to the bar codescanner or the marking system, refer to the troubleshooting sections of the manualsshipped with that equipment.

When Did the Problem Start Occurring?

Problem Began After Recommended Place to Start Troubleshooting

Teaching patterns Display each zone screen and ensure that the reference pattern shown is good. Also,verify that the pattern tolerance settings are not too large or too small.

Adjustments to theparent machine

If the adjustment has changed the position of one or more glue patterns, re-teach thepatterns to the system. If the position of any zone trigger or sensor was changed(intentionally or accidentally), ensure it is still sensing properly. Re-teach patterns andtracking distances.

Product changeover Make sure that all the necessary adjustments to the system that are required by thenew product have been made. Make sure that the zone triggers are not beingactivated by cutouts, windows, or reflective areas on the product. For a checklist ofsettings that may need to be changed (and procedures that may need to beperformed), refer to Change Products in the Operation section.

Line speed change If the system starts reporting errors after a significant change in line speed, the locationof the patterns may be shifting (usually toward the trailing edge) on the product. Setthe proper compensation on the pattern controller or re-teach the pattern.

Change to a patterncontroller setting

If the position of a pattern has changed, re-teach the pattern in the zone that has therevised pattern so the system learns the new pattern. Always re-teach the pattern inany zone where a change to the pattern has occurred.

Turning on the system Each active zone must be re-taught the correct pattern at startup.

Package redesign(example: a change incolor)

The sensitivity of zone triggers and glue sensors may need to be readjusted after theprint on a package changes.

There was no oneoccasion for the start.The problem occursintermittently.

Refer toWhere Is the Problem Occurring?

Four Key Questions

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Where Is the Problem Occurring?

Possible Answers Recommended Place to Start Troubleshooting

In the patterns of onezone only

Ensure that the zone trigger is transitioning only once for each product. Check thetolerance set for the zone and ensure that the correct glue sensors are activated for thezone.

In the pattern (orpatterns) monitored byone glue sensor only

Compare the actual pattern with the reference pattern on the zone to which the sensoris assigned. Ensure that the tolerance is not set too low for the zone. Also, if theproblem occurs only with sensor 1 in zone 1, make sure that the bead length settingsare correct for the pattern.

On different sensors indifferent zones

Check for carton flutter if the problem seems random. Also, verify that each gluesensor is assigned to the correct zone. If no problem is found, refer to the appropriatetroubleshooting table.

On all sensors in allzones

Ensure that the reference patterns shown on the zone screens are good. If they arenot, repeat the teach procedure. If they are, check the encoder type setting andencoder operation.

How Often Does the Problem Occur?

Possible Answers Recommended Place to Start Troubleshooting

Seldom If the problem occurs infrequently, some adjustment in the system may be on theborderline between a correct and incorrect setting. Check the sensitivity settings of thezone triggers or the glue sensors. Carton flutter may be occurring only under certainconditions.

Intermittently Look at frozen screens if the system is reporting errors when none seem to exist.Observe the zone counts to see if there is any consistency to where the problemoccurs. Then use the tables in this section to help isolate the problem further. Also,carton flutter may be occurring only under certain conditions.

Always Look for a major problem such as failure to activate the zones or failure to assign gluesensors to the correct zones. Ensure the reference patterns are correct for the productthat is running. Check that all cables are connected at the correct positions on theG-SITE and that the encoder is working properly.

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The tables in this section help isolate and solve problems with the G-NETsystem.

System Does Not Detect Pattern Errors in All Zones

Possible Cause Recommended Action

The encoder signal is not reaching theG-NET console.

Check the encoder light on the console panel. If it is not on whenthe machine is running, the system is not receiving pulse signalsfrom the encoder. Ensure the encoder cable is connected both tothe encoder and to the G-SITE. Ensure that the encoder wheel ismaking good contact with the belt. If using a linking cable to sharethe signal from the pattern-controller encoder, ensure that thepattern controller is turned on.

The system is in the STANDBY mode. Activate the zones anytime the system has either been placed in theSTANDBY mode or turned on after a shutdown. Refer to Teach theSystem a Good Pattern Set in the Setup section.

The line speed has dropped below thesetting for LOW SPEED CUTOUT.

Anytime the line speed drops below the low-speed-cutout setting,the system stops reporting pattern errors. Lower this setting or set itto zero to disable the function.

The reject function is turned off. If the horn is beeping but the system is not rejecting or markingproducts, the system is detecting pattern errors but the settings arenot correct to cause ejection or marking. If the light on the rejectkey is off, press the key to turn on the reject function.

The detection zones are not active forrejection or marking.

If the horn is beeping but the system is not rejecting or markingproducts, the system is detecting pattern errors but the settings arenot activating ejection or marking. To determine if zones are activeor to activate them, refer to Make a Zone Active or Inactive forRejection in the Setup section.

System Does Not Detect Pattern Errors in One or More Individual Zones


The zone trigger has been knocked out ofposition, so that it no longer sees theproduct.

Check the alignment of the trigger and adjust if needed. Anytime atrigger is moved, re-teach tracking distances and patterns to thesystem. Refer to Teach the Tracking Distances for The System andTeach the System a Good Pattern Set in the Setup section.

The trigger cable is loose or disconnectedat the G-SITE or the trigger connector.

Plug the cable back into the appropriate connector on the G-SITEinterface.

The sensitivity of the trigger is not properlyset.

Refer to Equipment Adjustment Procedures in the Setup section.

The lens of the trigger is dirty or blocked bysome object.

Ensure that the lens is clean and that nothing is blocking the view ofthe lens.

The trigger or trigger cable is defective. Replace the trigger and/or the cable.

The zone is in STANDBY mode. To activate, refer to Teach the System a Good Pattern Set in theSetup section.

TroubleshootingTables



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System Detects Pattern Errors When None Exist


Reference patterns are incorrect. Re-teach the patterns to the system. See Teach the System a GoodPattern Set in Setup.

The trigger or sensor position haschanged.

Return the glue sensor to the desired position. Perform the teachprocedure again.

Skewing Assign each glue sensor to an individual detection zone.

The tolerance setting is less than 5 mm. Increase the tolerance so that the system does not detect patternerrors when minor fluctuations occur.

The encoder wheel is slipping or skippingon belt.

Make sure that the wheel is making good contact with the belt andrunning smoothly.

Encoder type not set correctly. The encoder type should be set to 1 mm for almost all systems.The only exception is when the encoder has the label VT602 orLA602. The encoder type setting for this encoder is 2 mm.

Encoder is installed on the wrong belt. Ensure that the encoder wheel is installed on a belt that runs thesame speed as the belt that conveys the product through thedetection zones.

Carton flutter is causing pattern movement. Stabilize the carton so that the distance form the glue sensor to theglue pattern remains the same from one product to the next.

The wrong type of zone trigger is used. If a high-speed machine with a wide range of line speeds is used,not all zone triggers will respond fast enough. Try switching to thefiber optic high speed trigger and use the fast setting to eliminatecompensation errors.

The detected bead length (the length of allbeads detected by sensor 1) does not fallwith the minimum and maximum settingsfor zone 1.

The overall bead length is not within the specifications set for thesystem. If the pattern is acceptable, adjust the minimum ormaximum setting, or both settings. Refer to Set Pattern ErrorTolerances in the Setup section.

Pattern is drifting when line speedchanges.

The problem is occurring in the pattern controller, not the G-NETsystem. Either increase the G-NET tolerance to allow for some driftor better adjust the compensation of the pattern controller. Ifadjusting the pattern controller compensation, re-teach the systemthe pattern after adjusting the pattern controller.

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One or More Glue Patterns Are Missing


The sensitivity of the sensor is not properlyadjusted.

If the sensor is not properly adjusted, it may fail to detect somepatterns or all patterns it inspects. Refer to Equipment AdjustmentProcedures in the Setup section.

One of the zone triggers is activating morethan once per product (double-triggering).

Reposition or readjust the trigger so that it activates only once perproduct. Double-triggering restarts the inspection process before itis completed, causing the system to find errors where none exist.

The glue gun has been knocked out ofposition, and the glue pattern is outside thefield of view of the glue sensor.

Check the gun alignment to ensure that the glue pattern passesthrough the center of the glue sensor’s light circle.

The height of the product surface haschanged or varies from one product to thenext (carton flutter).

For proper adjustment, the lens housing should be approximately29 mm (1.13 in.) from the product. If necessary, use brackets toprevent vertical movement of the surface on which the glue isapplied.

The lens of the sensor is dirty or blockedby some object.

Make sure that the lens is clean and that nothing is blocking theview of the lens.

The sensor has been deactivated orassigned to the wrong zone.

Ensure that the sensor is active and assigned to the correct zone.Refer to Assign Sensors to Detection Zones in the Setup section.

The glue sensor cable has been pluggedinto the wrong connector on the G-SITEinterface.

Ensure that the sensor cable is plugged into the correct connector.

The fiber-optic cable is loose or notconnected.

Ensure the fiber optic cable is secure and that light is coming fromthe lens.

The sensor cable is disconnected from theG-SITE.

Check for a loose or disconnected cable. Secure or plug the cableback into the appropriate connector on the G-SITE interface.

The glue sensor has been knocked out ofposition, so that it no longer sees the gluepatterns.

Check the alignment of the glue sensor so that the pattern passesthrough the center of the light circle. Readjust the sensitivity afterrealigning the sensor. Refer to Adjust the Sensitivity of the GlueSensors in Setup.

The sensor or the sensor cable isdefective.

Replace the sensor and/or the cable.



321 226DIssued 5/05


Screen Does Not Display Entire Pattern


Detection zone is not activated for asufficient length of time to permit completeinspection of the pattern by the gluesensor.

Make sure the trigger keeps the inspection cycle active during theentire time the pattern is being monitored by the glue sensor. Checkthe output light on the trigger while jogging the product past the gluesensor.

The pattern is too long to be shown on onescreen.

Press the increase or decrease key while no settings on the zonescreen are highlighted to scroll the screen.

System Does Not Eject or Push Defective Products


The reject function is turned off. Press the reject on/off button. The light on the button should turnon.

None of the zones have been activated forrejection.

Refer to Make a Zone Active or Inactive for Rejection in the Setupsection.

The actuator cable (for the pusher or theejector) is disconnect from the G-SITE orthe solenoid valve.

Ensure that the cable is securely connected at the G-SITE and atthe solenoid valve.

The air to the ejector (or pusher) solenoidis turned off or not set high enough.

Ensure that the air pressure is sufficient to operate the actuator ofthe ejector or pusher.

The pre-eject sensor is not sensing theproduct.

Ensure that the cable between the G-SITE and the sensor isconnected, that the sensor lens is clean and not blocked by someobject, and that the output light on the sensor is turning on asproduct pass the sensor. Refer to Equipment AdjustmentProcedures in the Setup section. If adjusting the sensitivity does notsolve the problem, replace the pre-eject sensor.

The ejector motor is not turning. Ensure that the ejector motor is turning. If it is not, troubleshoot thecause of the problem.

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System Always Ejects or Pushes the wrong Product


The procedure for teaching the trackingdistances was not correctly performed.

Make sure that the machine is clear of all products. Then pressteach and run product through the system. Refer to Teach theTracking Distances for The System in the Setup section.

The ejection process needs fine tuning. If the product being ejected is the product just before or just after theone that is supposed to be ejected, the system is only slightly out ofadjustment. Refer to Adjust the Timing of the Reject or MarkingEquipment in the Setup section.

System Intermittently Ejects or Pushes the Wrong Product


The position of the pre-eject sensor needsa minor adjustment.

A pre-eject sensor that is near (but not in) the correct position cancause intermittent rejection of the wrong product. Refer to Adjustthe Timing of the Reject or Marking Equipment in Setup.

The ejector or pusher compensation is notcorrectly set, causing the problem to occuronly at fast line speeds.

Adjust the compensation setting (EJECTOR COMP). Refer to Adjust theTiming of the Reject or Marking Equipment in Setup.

One or more zones has not been activatedfor rejection.

Refer to Make a Zone Active or Inactive for Rejection in Setup.

A zone trigger has been knocked out of itsoriginal position.

If the position of a zone trigger changes enough, the system willeject the wrong product when errors are found in this detectionzone. The trigger must be returned to its original position or the newtracking distance must be taught to the system. Refer to Teach theTracking Distances for Your System in Setup.

An ejector tracking error has occurred. If the message EJECTOR TRACKING ERROR appears on the display, thesystem cannot eject all of the faulty products it is finding. It will ejectas many products as possible and ignore the rest until the processorcan again handle the number of errors occurring in the system.

NOTE: If the alarm function is turned on, a large number of faultyproducts that equals or exceeds the machine stop preset will stopthe machine.



321 226DIssued 5/05


Ejection Process Is Not Smooth/Timing Is Off


The pre-eject sensor has been knocked outof position, changing its original positionslightly.

Check the alignment of the sensor. Perform the timing procedureagain to find the best location for the sensor. Refer to Adjust theTiming of the Reject or Marking Equipment in Setup.

The timing of the eject process is slightly off. If the system is ejecting the right product but the ejection is notsmooth, fine-tune the timing of the ejector or pusher. Refer toAdjust the Timing of the Reject or Marking Equipment in Setup.

The height or tension of the ejector grabwheel is not set correctly.

Refer to the ejector product manual for the wheel adjustmentprocedure.

The ejector is not grabbing the product at theright point.

If the system has a pusher, it may be pushing the product too faror not far enough. Try adjusting the position of the kick plate. Ifthis does not work, refer to the ejector manual.

System Is Ejecting All Products


The reject test is turned on. If the light on the reject test key is on, push the key to turn the testoff.

Solenoid valve for the pusher or ejector isstuck in the open position.

Check for proper operation of the solenoid valve.

The G-NET system is finding errors in allproducts.

If the horn is beeping at each product, the system is finding errors inall products. The problem is not in the ejection system but in thepattern-error detection process. Refer to Determine Why theSystem Is Detecting Errors When None Exist.

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Machine Stop Function Is Not Working Properly

Possible Cause Explanation

A misfeed error occurred. Anytime the product length exceeds the setting for OVERLAP DETECT PRESET, thesystem will detect a misfeed error. If the system stops the machine when thereare minor variations in product length, add 10 mm to this setting to preventfrequent machine stoppages.

A force-2 error occurred. The force-2 monitoring device connected to the system has detected an error. Allforce-2 errors stop the machine if the alarm function is turned on.

Check the cable between the force 2 monitoring device and the G-SITE. If noproblem is found, adjust, repair, or replace the force-2 monitoring device.

Too many defective productsare in the machine at onetime.

Anytime the number of products with pattern errors between zone 1 and thepre-eject sensor reaches the number set for the MACHINE STOP PRESET, the systemwill stop the machine.

NOTE: If the machine stops, turn the alarm off, clear out the machine, and thenenable the alarm again. Otherwise one more defective product will stop themachine again.

NOTE: When this occurs, the display will show one of the following errormessages: EJECTOR TRACKING ERROR or ERROR: GLUE ZONE X, where X is the zonein which the last error occurred.

The machine-stop contactshave not been reset

Press the alarm re-set key to re-set the contacts.

The alarm (line-stop function)is off.

Turn the alarm on.

The machine-stop cable hasbecome disconnected.

Reconnect the cable.

Overlap preset is incorrect. Check the setting for OVERLAP PRESET DETECT. It should be slightly longer than thelength of the product. If it is not, perform the procedure Teach the TrackingDistances for The System again. Refer to Setup.

The machine stop preset wasreached.

Check the setting for the MACHINE STOP PRESET. The system should stop themachine only when the number of defective products between the zone triggersand the reject equipment equals or exceeds this setting. If the system is notstopping the machine in this situation, contact your Nordson representative.

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Section 6Parts

Section Overview 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using the Illustrated Parts List 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Components 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cables 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mounting Components 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessories 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Components 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cables 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mounting Components 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Detection Equipment 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Components 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cables 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mounting Components 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reject, Marking, and Batch Control Equipment 6-10. . . . . . . . . . . . . . . . . . .System Components 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cables 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mounting Components 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare Parts 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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321 226DIssued 5/05


PartsThis section includes parts lists for:

S Standard ComponentsS Optional Detection EquipmentS Reject/Marking and Batch Control EquipmentS Accessories

After finding the correct part number or numbers, contact your Nordson orVeritec representative.

SectionOverview

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321 226DIssued 5/05


Numbers in the Item column correspond to numbers that identify parts inillustrations following each parts list. The code NS (not shown) indicates that alisted part is not illustrated. A dash (—) is used when the part number appliesto all parts in the illustration.

The number in the Part column is the Nordson Corporation part number. Aseries of dashes in this column (- - - - - -) means the part cannot be orderedseparately.

The Description column gives the part name, as well as its dimensions andother characteristics when appropriate. Indentions show the relationshipsbetween assemblies, subassemblies, and parts.

Item Part Description Quantity Note

— 000 0000 Assembly 1

1 000 000 S Subassembly 2 A

2 000 000 S S Part 1

S If you order the assembly, items 1 and 2 will be included.S If you order item 1, item 2 will be included.S If you order item 2, you will receive item 2 only.

The number in the Quantity column is the quantity required per unit, assembly,or subassembly. The code AR (As Required) is used if the part number is abulk item ordered in quantities or if the quantity per assembly depends on theproduct version or model.

Letters in the Note column refer to notes at the end of each parts list. Notescontain important information about usage and ordering. Special attentionshould be given to notes.

Using the IllustratedParts List

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321 226DIssued 5/05


5601039

12 3 4

5

6

10 7

8

9

Item Part Description Note

1 727 097 Transformer, 120 VAC (includes bracket)

1 727 098 Transformer, 220 VAC (includes bracket)

2 727 095 Console, G-NET, standard

2 738 467 Console, G-NET, envelope-system, standard

4 727 096 Interface, network, G-SITE

7 738 243 Sensor, glue, GD-100, 16 mm lens, 32 in. long

7 738 051 Sensor, glue, GD-100, 16 mm lens, 18 in. long

7 738 272 LAD Sensor, glue, (for wheel-generated patterns)

7 727 540 Sensor, glue, GD-100X1 (for dot patterns)

7 727 659 Hot melt HD100, pkg.

8 727 141 Trigger, zone, standard

8 313 785 Trigger, zone, fiber-optic

9 727 133 Encoder, 333 pulse (includes bracket and wheel) A

9 311 433 Encoder, 500 pulse (bracket and wheel not included) A

NS 311 454 Wheel, encoder, 500 pulse

NOTE A: Not required if a Pafra, WM 408, or WM500 pattern control system is used. Refer to the cables partslist for a splitter cable that allows sharing of the pattern-control encoder signal.

NS: Not Shown

Standard Components

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321 226DIssued 5/05


Item Part Description Note

3 738 615 Harness, wiring, main, 1.83 m (6 ft)





5 727 121 Cable, extension, trigger, standard, 3.0 m (10 ft)



5 374 871 Cable, interconnect, trigger, fiber-optic, 4.0 m (13 ft)

NS 372 501 Cable, extension, trigger, fiber-optic, 5.0 m (16 ft)

6 727 142 Cable, sensor, 3.0 m (10 ft)

6 727 143 Cable, sensor, 6.1 m (20 ft)

NS 727 139 Harness, combination trigger/sensor, 3.0 m (10 ft) A

NS 727 140 Harness, combination trigger/sensor, 6.1 m (20 ft) A

10 727 191 Cable, encoder, 333 pulse, 6.1 m (20 ft)

10 727 192 Cable, encoder, 333 pulse, 7.6 m (25 ft)

10 727 108 Cable, link, encoder, (Veritec) 4.6 m (15 ft)

10 727 942 Cable, link, encoder, (LA4400/G--Site) 4.6 m (15 ft)

10 374 863 Cable, encoder, 500 pulse, 2.0 m (6.6 ft)

10 372 500 Cable, extension, encoder, 500 pulse, 5.0 m (16 ft)

NS 727 108 Cable, splitter, encoder, Veritec/Pafra, 4.6 m (15 ft) B

NS 727 110 Cable, splitter, encoder, Veritec/Pafra, 7.6 m (25 ft) B

NS 371 537 Cable, splitter, encoder, WM 408/WM 500, 0.2 m (0.5 ft) B

NOTE A: Includes one of item 5 and one of item 6

B For using the pattern control encoder instead of having a separate G-NET system encoder

NS: Not Shown

Cables

Parts6-6


321 226DIssued 5/05


Part Description Note

G-NET Console and G-SITE Mounting Components

727 099 Arm, adjustable (for mounting G-NET console)

727 101 Base, leveling (for mounting adjustable arm to floor-supported base) A

727 100 Base, machine (for mounting adjustable arm to machine)

727 106 Bracket, straight (for mounting G-SITE to adjustable arm)

727 107 Bracket, inclined (for mounting G-SITE to machine)

738 554 Kit, Mtg. Gun/Sensor Bracket 5/8 in.

738 559 Kit, Mtg. Gun/Sensor Bracket 1 in.

738 560 Kit, Mtg. Gun/Sensor Bracket 30 mm

Glue Sensor Mounting Components

727 167 Bar, drop, standard (for GD-100 and GD-100X1)

727 166 Bar, drop, Post-machine (for GD-100 and GD-100X1)

727 161 Bracket, square bar,3/4 in. (for GD-100 and GD-100X1)

727 162 Bracket, square bar, 1 in. (for GD-100 and GD-100X1)

727 163 Bracket, square bar, 30 mm (for GD-100 and GD-100X1)

727 164 Bracket, square bar, 33 mm (for GD-100 and GD-100X1)

727 165 Bracket, round bar, 5/8 in. (for GD-100 and GD-100X1)

727 168 Mounting, Post-Arrow 20, 30, and 40 (for GD-100W)

727 169 Mounting, International-Speed King (for GD-100W)

727 170 Mounting, Bobst-Media, Domino, Alpina (for GD-100W)

727 171 Mounting, International-Royal and Speed Queen (for GD-100W)

727 172 Mounting, Jagenberg F. G. (for GD-100W)

738 317 Mounting, Signature F. G. (for GD-100W)

Zone Trigger Mounting Components

727 160 Bar, drop, standard trigger

727 159 Bar, drop, standard trigger (Post machine only)

727 161 Bracket, square bar, 3/4 in., standard trigger

727 162 Bracket, square bar, 1 in., standard trigger

727 163 Bracket, square bar, 30 mm, standard trigger

727 164 Bracket, square bar, 33 mm , standard trigger

727 165 Bracket, round bar, 5/8 in., standard trigger

375 249 Bracket, mounting, fiber-optics trigger

313 370 Bracket, encoder, 500 pulse

NOTE A: When requested, base includes casters for making a portable cart.

Mounting Components

Parts 6-7


321 226DIssued 5/05



727 111 Horn, remote (includes attached 7.6 m/25 ft cable)

727 124 Tower, warning light (includes attached 1.5 m/5 ft cable)

727 452 Cable, extension, warning light 3.7 m (12 ft)

727 149 Printer (includes mounting case and power cord)

727 621 Cable, printer (7 ft)

727 622 Cable, printer 4.6 m (15 ft)

727 113 Sensor, feed, standard

313 785 Trigger, bar code system, fiber-optic

738 377 Assembly, feed trigger, Post Arrow

738 378 Assembly, feed trigger, International

738 092 Assembly, feed trigger, Bobst

738 423 Assembly, feed trigger, Jagenberg

738 094 Assembly, feed trigger, Signature

738 090 Assembly, feed trigger, Other


727 121 Cable, extension, feed sensor, standard, 3.0 m (10 ft)



374 871 Cable, interconnect, feed sensor, fiber-optic, 4.0 m (13 ft)

372 501 Cable, extension, feed sensor, fiber-optic, 5.0 m (16 ft)


727 160 Bar, drop, feed sensor, standard

727 159 Bar, drop, feed sensor, Post machine

727 161 Bracket, square bar, 3/4 in.

727 162 Bracket, square bar, 1 in.

727 163 Bracket, square bar, 30 mm


727 165 Bracket, round bar, 5/8 in.

375 249 Bracket, mounting, sensor, fiber-optics

Accessories

System Components

Cables

Mounting Components

Parts6-8


321 226DIssued 5/05



727 120 Sensor, cello presence

727 138 Sensor, cello position

738 606 Sensor, G--NET security tag

727 646 Console, bar code, LA5100, Accubar (includes power cable)

727 265 Scanner, laser, bar code system

738 180 Scanner, laser, bar code system LA5100 (USA codes)

738 442 Trigger, bar code system, standard

313 785 Trigger, bar code system, fiber-optic

727 123 Detector, double-sheet


727 142 Cable, cello presence or position, 3.0 m (10 ft)

727 143 Cable, cello presence or position, 6.1 m (20 ft)

727 248 Cable, laser scanner, LA5100 3.7 m (12 ft)

727 248 Cable, laser scanner, LA5100 7.4 m (24 ft)

727 463 Cable, extension, bar code trigger, standard, 3.0 m (10 ft), Lgk

727 464 Cable, extension, bar code trigger, standard, 6.1 m (20 ft) Lgk

374 871 Cable, interconnect, bar code trigger, fiber-optic, 4.0 m (13 ft)

372 501 Cable, extension, bar code trigger, fiber-optic, 5.0 m (16 ft)

727 129 Cable, linking, G-NET (force 1 error), 9.1 m (30 ft) A

727 657 Cable, linking, G-NET (force 1 error), 15.2 m (50 ft) A

727 109 Cable, machine-stop, G-NET (force 2 alarm)

727 278 Cable, machine-stop, bar code system B

727 647 Cable, machine-stop, standalone 3.7 m (12 ft)

NOTE A: Typically used for the bar code system

B Used to stop the machine or the feed section when a bad bar code is detected

OptionalDetectionEquipment

System Components

Cables

Parts 6-9


321 226DIssued 5/05



Mounting Components for Bar Code Scanning System

727 173 Clamp, pole supported (for mounting Accubar console) A

727 174 Bracket, pole supported (for mounting Accubar console) A

727 268 Bracket, laser scanner, top mounting

727 269 Bracket, laser scanner, side mounting

738 320 Bracket, laser scanner, signature

375 190 Mounting assembly, laser scanner, Diana and Domino 145

727 161 Bracket, square bar, 3/4 in. (for mounting standard bar code trigger)

727 162 Bracket, square bar, 1 in. (for mounting standard bar code trigger)

727 163 Bracket, square bar, 30 mm (for mounting standard bar code trigger)

727 164 Bracket, square bar, 33 mm (for mounting standard bar code trigger)

727 165 Bracket, round bar, 5/8 in. (for mounting standard bar code trigger)

375 249 Bracket, mounting (for mounting fiber-optic bar code trigger)

727 160 Drop bar, 400 mm/15/7 in. (for mounting fiber-optic bar code trigger)

Mounting Components for Double-sheet Detector

727 161 Bracket, square bar, 3/4 in.

727 162 Bracket, square bar, 1 in.



727 165 Bracket, round bar, 5/8 in

NOTE A: Use either the clamp or the bracket to mount the console.

Mounting Components

Parts6-10


321 226DIssued 5/05



738 562 Ejection system, 115 V, single phase, 60 Hz

337 491 Ejection system, 230 V, 3-phase, 60 Hz

377 490 Ejection system, 460 V, 3-phase, 50/60 Hz

727 119 Pusher (includes air regulator and air hose)

326 663 Marking system

727 112 Sensor, pre-eject, standard A

313 785 Sensor, pre-eject, fiber-optics A

737 136 Basket, catch (for ejected products)

727 088 Kicker, batch (includes air regulator and air hose)

727 112 Sensor, batch

NOTE A: Also used for marking systems


727 116 Harness, wiring, air-operated equipment, 3.0 m (10 ft) A



375 226 Cable, marking gun, 10 m/33 ft (European systems only)

374 871 Cable, interconnect, pre-eject sensor, fiber-optic, 4.0 m (13 ft)

372 501 Cable, extension, pre-eject sensor, fiber-optic, 5.0 m (16 ft)

NOTE A: Includes two sets of paired cables: one pair for the pre-eject sensor and the reject device (ejector,marker, or pusher) and another pair for the batch sensor and batch kicker

Reject, Marking,and BatchControlEquipment

System Components

Cables

Parts 6-11


321 226DIssued 5/05



Mounting Components for Ejector

727 181 Mounting, Post-Arrow 20, 30, and 40

727 182 Mounting, International-Speed King

727 183 Mounting, Bobst-Media, Domino, Alpha

727 184 Mounting, International-Royal and Speed Queen

727 185 Mounting, Jagenberg F. G.

738 278 Mounting, Signature F. G.

Mounting Components for Pusher or Kicker






Mounting Components for Batch or Pre-eject Sensor






Cross Bar Assembly

727 010 Cross Bar Assembly, Universal

727 007 Cross Bar Assembly, Jagenberg Series 1

738 263 Cross Bar Assembly, Jagenberg Series 3

727 359 Cross Bar Assembly, Signature (AIM)

727 006 Cross Bar Assembly, International Royal, Speed Queen

727 005 Cross Bar Assembly, International EG1100

738 261 Cross Bar Assembly, International Right Angle

738 260 Cross Bar Assembly, International 6FX

727 008 Cross Bar Assembly, Sugano

727 009 Cross Bar Assembly, Vega

738 264 Cross Bar Assembly, Omega (Can--AM)

Mounting Components

Parts6-12


321 226DIssued 5/05



- - - - - - Trigger, zone A

- - - - - - Sensor, glue B

738 524 GD100, Xtracto 100 tool with lamp

NOTE A: Order part 727 141 for the standard zone trigger. Order part 313 785 for the fiber-optic zone trigger.

B If the plant has several G-NET detection systems or if any loss of production time is unacceptable,having a spare glue sensor is recommended. Order either the GD-100 for standard patterns(part 727 134), the GD-100W for wheel-generated patterns (part 727 135), or the GD-100X1 for dotpatterns (part 727 540).

Spare Parts

Technical Data 7-1


321 226DIssued 5/05


Section 7Technical Data

Specifications 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sensor 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Unit 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transformer 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Unit 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-SITE Interface 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data7-2


321 226DIssued 5/05


Technical Data

Item Specification Note

Maximum number of detectionzones

4

Maximum number of glue sensors 8 A

Spare inputs for user-selecteddetection devices

Force 1 (provides reject or marking capability)

Force 2 (provides machine-stop capability)

Output capabilities Fault notification (one for horn, one for light tower)

Spiked 12 VDC output (used for product rejection ormarking)

Set of dry contacts (used to stop parent machine)

Spiked 12 VDC output (used for product kicker)

Maximum zone length 1000 mm (39.4 in.)

Maximum line speed 700 m/min (2300 ft/min) B

NOTE A: Other detection devices (such as cello detectors) can also be used.

B: Based upon the use of an encoder with 1 mm/pulse resolution.

Specifications

System

Technical Data 7-3


321 226DIssued 5/05



Sensor types For extruded beads (GD-100)

For wheel-applied patterns (GD-100W)

For dot patterns (GD-100X1)

Response time 100 μsec

Minimum detectable bead size 1 mm (0.04 in.) when extruded or deposited by wheel;0.5 mm (0.02 in.) when applied in dot pattern

Distance from lens housing toproduct surface

29 mm (1.13 in.) A

Service life of light source 50,000 hours minimum

NOTE A: When the lens housing is positioned according to this specification, the lens itself is 32 mm (1.25 in.)from the product surface.


Type Programmable controller with distance-based line tracking(using input from an encoder)

Display Monochrome graphic LCD that provides real-time display ofpatterns

RS-232 capability Port for future use

Mounting On stand or adjustable arm


Input (two versions) 120 VAC, 1∅, 50/60 Hz

220 VAC, 1∅, 50/60 Hz

Output 24 VAC

Amperage rating 0.25 KVA

Sensor

Control Unit

Transformer

Technical Data7-4


321 226DIssued 5/05


Dimensions

5601045

360 mm(14.17 in.)

310 mm(12.20 in.)

190 mm(7.48 in.)

Control Unit

5601043

80 mm(3.14 in.)

305 mm(12.00 in.)

255 mm(10.03 in.)

G-SITE Interface

Appendix A A-1


321 226DIssued 5/05


Appendix AContinuous Web Gluing A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Application Overview A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup Procedures A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Enter Initial Settings A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Set the Product Count for Tracking A-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Set Up the Bead-length Detection Feature A-4. . . . . . . . . . . . . . . . . . . . . . . .

Appendix BA-2


321 226DIssued 5/05


Appendix

This appendix explains how to set up a G-NET system to monitor a continuousweb gluing operation.

A Veritec G-NET system can be used to perform three different tasks incontinuous web gluing:

S to verify that a sufficient amount of glue is being applied to the product

S to verify that no glue (or that a minimum amount of glue) is being applied tothe product

S to verify that the amount of glue being applied to the product falls betweenthe minimum and maximum limits that have been set

To perform these tasks, the system divides the continuous web into discretesegments of uniform length, which are referred to as product segments. Thesystem inspects each product segment and, when a defective segment isfound, tracks it so it can be marked.

A special encoder is used for continuous gluing applications. A small hole isdrilled in the outside perimeter of the encoder wheel, and the zone trigger (aphotosensor) is mounted so that it activates each time it “sees” the hole in thewheel. When the trigger activates, the system begins the inspection processfor a new segment and continues inspecting for one revolution of the encoderwheel. Then the trigger “sees” the hole in the wheel again, and the systemstarts monitoring the next segment of the web.

Because the circumference of the wheel is 333 mm, each segment of the webis 333 mm long. The length of the product segment that is inspected is slightlyshorter since a small part of the wheel (about 6 mm) is occupied by the hole.

ContinuousWeb Gluing

Application Overview

Appendix A A-3


321 226DIssued 5/05


This part of the appendix includes:

S Enter Initial SettingsS Set the Product Count for TrackingS Set Up the Bead-length Detection Feature

Use the following table to enter the correct initial settings for continuous gluingapplications.

Setting Menu or Screen Correct Setting

ENCODER TYPE TRACKING AND MACHINECONSTANTS MENU

1 mm

LOW SPEED CUTOUT TRACKING AND MACHINECONSTANTS MENU

The line speed (m/min) below which theG-NET system stops reporting patternerrors

OVERLAP PRESET DETECT TRACKING AND MACHINECONSTANTS MENU

340 mm

MACHINE STOP PRESET TRACKING AND MACHINECONSTANTS MENU

The number of defective products betweenthe encoder and the marking or identifyingpoint that cause a machine stop. To turnthis feature off, enter 0.

ACTIVE ZONES TRACKING AND MACHINECONSTANTS MENU

1

ACTIVE SENSORS GLUE DETECTION ZONE 1 1

NOTE: Verify that all other sensors in allother zones are off, which is indicated bydashes.

TOLERANCE GLUE DETECTION ZONE 1 99

SetupProcedures

Enter Initial Settings

Appendix BA-4


321 226DIssued 5/05


Use this procedure to provide the information the system requires to trackdefective products from the detection zone to the point where the product ismarked. Do not use the procedure described in Setup for teaching trackingdistances automatically. That procedure, Teach the Tracking Distances for theSystem, does not apply to continuous gluing operations.

1. Determine the product count as follows:

a. Measure the distance (mm) from the trigger lens to the point where theproduct segment is marked.

b. Divide the distance by 333 and round off the result to the nearest wholenumber to obtain the number of product segments. For example, if thedistance is 5100 mm, divide 5100 by 333 to obtain 15.31, which roundsoff to 15 products.


3. Press setup until the value for TRACK ZONE 1 is highlighted.

NOTE: If the machine is running, turn it off prior to completing thisprocedure. If the machine continues to run, the product count will beincorrect.

4. Press inc or dec to change the count shown to the value calculated instep 1.

5. Press clear to reset the memory and enter the new value for the productcount.

This feature is available only on sensor 1 in detection zone 1.

1. Press select until GLUE DETECTION ZONE 1 appears on the display.

2. If the zone is in the ACTIVE mode, press stand by. The text on the screenchanges from ACTIVE to STANDBY.

3. Set the maximum and minimum settings in one of three ways:

Set the Product Countfor Tracking

Set Up theBead-length

Detection Feature

Appendix A A-5


321 226DIssued 5/05


Objective Instructions

To verify that a sufficientamount of glue is beingapplied to the product.

a. Press setup until the max setting ishighlighted.

b. Press inc or dec until 0340 appears on thedisplay.

c. Press setup to highlight the min setting.

d. Press inc or dec until the minimum totallength of glue (mm) appears on the display.

NOTE: See how much glue is actually beingapplied to the product by observing thereal-time bead length reading. Then set theminimum slightly lower than that amount.

To verify that no glue (orthat a minimum amountof glue) is being appliedto the product.

a. Press setup until the max setting ishighlighted.

b. Press inc or dec until the maximum totallength of glue (mm) appears on the display. Ifno glue can be applied, enter 0001.

c. Press setup to highlight the min setting.

d. Press inc or dec until 0000 appears on thedisplay.

To verify that theamount of glue beingapplied to the productfalls between theminimum and maximumlimits that have beenset.

a. Observe the bead length reading as the lineruns, noting the amount of normal variationthat occurs.

b. Press setup until the max setting ishighlighted.

c. Press inc or dec until the maximum is slightlygreater than the highest normal bead lengthreadings observed in step a.

d. Press setup to highlight the min setting.

e. Press inc or dec until the minimum is setslightly lower than the lowest normal beadlength readings observed in step a.

Set Up theBead-length

Detection Feature(contd)

Appendix BA-6


321 226DIssued 5/05


4. Run the production line with product on it.

5. Press teach. The text on the display changes from STANDBY to ACTIVE.

6. If the G-NET system is working correctly, it will detect pattern errors onlywhen the bead length falls outside of the set limits. When an defectiveproduct segment is found, the screen freezes to capture the error and thebead length displayed either exceeds the maximum setting or is less thanthe minimum setting. The pattern error light for sensor 1 turns on. Pressclear to resume the detection process.

7. If the system is working correctly, go to step 8. If the system is not workingas desired, repeat steps 2--6, adjusting the maximum or minimum valuesuntil the system is working as desired.

8. Record the maximum and minimum bead length settings:

S maximum length = _____________ mm

S minimum length = ______________ mm

Appendix B B-1


321 226DIssued 5/05


Appendix BG-NET Envelope System B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Overview B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Install the Photo Eye in Detection Zone One B-2. . . . . . . . . . . . . . . . . . . . . . .Install the Case Packer Signal Cable B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjust the Sensors and Triggers B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Enter the Report Menu Settings B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Enter the Glue Detection Screen Settings B-4. . . . . . . . . . . . . . . . . . . . . . . . .Enter the Counter Menu Settings B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Enter the Settings for Tracking and Machine Constants Menu B-4. . . . . . . .Set the Start of the Reject Mark B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Set the End of the Reject Mark B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Test the System B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Set Up Tracking for the Case Packer B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Activate the Reject Test Function B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clear a Pattern Error B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mounting Components for W + D 102 Machines B-4. . . . . . . . . . . . . . . . . . .Mounting Components for W + D 202 Machines: Version 1 B-4. . . . . . . . . .Mounting Components for W + D 202 Machines: Version 2 B-4. . . . . . . . . .Mounting Components for W + D 202 Machines: Version 3 B-4. . . . . . . . . .

Technical Data B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix BB-2


321 226DIssued 5/05


Appendix

This appendix explains how to install, set up, and operate a G-NET verificationsystem that is specifically designed for envelope production. When theinstructions for this special G-NET system are the same as those for thestandard G-NET system, the appendix refers to the appropriate instructions inthis manual. When the instructions for the G-NET envelope system differ fromthe standard instructions, the appendix explains the differences and describesthe specific procedure that should be used.

The major divisions of this appendix are:

S System OverviewS InstallationS SetupS OperationS TroubleshootingS PartsS Technical Data

This appendix documents software version 1.4a.

The G-NET system for envelope production is the same as the standardG-NET system with two exceptions. The exceptions are explained in thefollowing table.

G-NET System Differences Explanation

Method of tracking productsfor marking

Instead of tracking products by the distance traveled from the zone trigger to themarking or ejection point, a G-NET system for envelope production tracks by thenumber of products between the zone trigger and the marking point. As a result,a G-NET envelope system requires manual setup of the tracking function. Astandard G-NET system captures tracking data automatically.

Method of clearing patternerrors

If an error is not manually cleared within 30 seconds, a G-NET envelope systemautomatically clears it. Standard G-NET systems do not have this automaticclearing function.

G-NETEnvelopeSystem

SystemOverview

Appendix B B-3


321 226DIssued 5/05


To install the G-NET envelope system:

S Install the G-NET envelope system like the standard G-NET system.Refer to the instructions in Installation, Section 2.

S Install a trigger (photo eye) in detection zone 1. Refer to Install PhotoEye in Detection Zone One in this appendix.

S If the G-NET envelope system includes a case packer:

- Install the case packer signal cable. Refer to Install the CasePacker Signal Cable in this appendix.

- Change the case packer tracking count to detect cases containingdefective envelopes. Refer to the Set up Tracking for the CasePacker in the Setup part of this appendix.

Install a photo eye (trigger device) in detection zone 1, even if zone 1 is notused for detection.

NOTE: If a trigger is not installed in zone 1, the system’s automatic trackingfunction will not work.

Follow this procedure to send a signal to the case packer when one or moredefective envelopes are entering the packer. The packer is programmedthrough a PLC to leave any case containing defective envelopes open.

NOTE: This procedure applies only to G-NET systems that use a case packerto pack the envelopes.

1. If a machine-stop cable is not connected to the back on the G-SITEinterface of the G-NET system, connect one now. The cable plugs into theconnector labeled machine control on the G-SITE interface.

NOTE: To order a machine-stop cable, refer to Optional Equipment inParts, Section 6.

Installation

Install Photo Eye inDetection Zone One

Install the Case PackerSignal Cable

Appendix BB-4


321 226DIssued 5/05


2. Connect the wires for the case packer relay to the PLC that operates thepacker. Refer to the following wiring diagram for the machine-stop cable.

5601144A

5

3

7

2

6

1

4

RED

BLK

GRN

ORG

MACHINE STOPRELAY

PACKER TRACKINGRELAY

LUMBERG KV71G-SITE MACHINE CONTROL

CONNECTOR

=

=

=

=

3. Program the PLC so that it leaves a case open when the case packer relaysignal is received.

The setup of a G-NET system for envelope production differs in some areasfrom the standard setup procedures. To set up a G-NET system to monitorenvelope production, complete the following procedures:

S Adjust the Sensors and TriggersS Enter the Report Menu SettingsS Enter the Glue Detection Screen SettingsS Enter the Counter Menu SettingsS Enter the Settings for the Tracking and Machine Constants MenuS Set the Start of the Reject MarkS Set the End of the Reject MarkS Test the System

Refer to Equipment Adjustment Procedures in Setup, Section 3.

Install the Case PackerSignal Cable (contd)

Setup

Adjust the Sensorsand Triggers

Appendix B B-5


321 226DIssued 5/05


Use the instructions in the following table to enter the settings on the ReportMenu screen.

Setting Instructions

Date and Time Enter the current date and time.

MACHINE # Enter a machine number of up to six digits.

JOB # Enter a job number of up to six digits.

ORDER # Enter an order number of up to six digits.

SHIFT # Enter a shift number of up to two digits.

JOB STATUS Skip this setting. If the system has a printer, this is changed before operation.

LANGUAGE If desired, change the language of the text. Choose from 11 different languages.

5601047A

************************************************ ************************************************

Enter the Report MenuSettings

Appendix BB-6


321 226DIssued 5/05


Use the instructions in the following table to enter the settings on the GlueDetection Zone screen.


GLUE DETECTION ZONE X(X =1, 2, 3, or 4)

A read-only field that shows which one of the four glue detection zones iscurrently being displayed

ACTIVE or STANDBY A read-only field that shows which mode a detection zone is currently in:STANDBY, TEACH, or ACTIVE.

TOLERANCE Set the tolerance at approximately 10 mm for the glue sensors assigned todetection zone 1. If the system is equipped with a cello detector in detectionzone 2, set the tolerance in this zone at approximately 15 mm.

ACTIVE SENSORS Assign the glue sensors (usually sensors 1 and 2) to zone 1. If there is a cellodetector (usually sensor 3), assign it to zone 2. NOTE: If the sensor you aretrying to assign to a zone is currently assigned to another zone, you must firstun-assign it (make it inactive) in the zone to which it is assigned.

bead length A read-only field that is not used in envelope production

min If the value shown is not zero, change it to 0000 to turn the bead-length featureoff.

max If the value shown is not zero, change it to 9999 to turn the bead-length featureoff.

5601031A

Taughtbead

Actualbead

Enter the GlueDetection Screen

Settings

Appendix B B-7


321 226DIssued 5/05


Use the instructions in the following table to enter the settings on the CounterMenu screen.


BATCH COUNT A read-only field that shows the current product count detected by the batch sensorif a batch sensor is installed. The counter automatically resets to zero each time thebatch preset count is reached. The count can also be set to zero manually.

BATCH PRESET Not used in envelope systems

KICK TIME Not used in envelope systems

FEED COUNT A read-only field that shows the total number of products that have been detected bythe feed sensor since the count was last reset to zero. The count is available onlywhen a feed sensor is installed.

DELIVERY COUNT A read-only field that shows the total number of products that have been detected bythe batch sensor since the count was last reset to zero. Available only if a batchsensor is installed

STACKER CONTROL Not used in envelope systems

GLUE DETECTION REJECTCOUNTS

(zones 1-4)

A read-only field showing the number of faults that have occurred in each zone sincethe count was last reset to zero

FORCE 1 Count Not used in envelope systems

FORCE 2 Count Not used in envelope systems

WORK RATE A read-only field that shows the current production rate in 1000 units per hour basedupon the count of the batch sensor. Available only if a batch sensor is installed

MACH. SPEED A read-only field that shows the current machine speed in meters/minute basedupon input from the encoder

5601048

Enter the CounterMenu Settings

Appendix BB-8


321 226DIssued 5/05


Use the instructions in the following table to enter the settings on the Trackingand Machine Constants Menu screen.


LOW SPEED CUTOUT Set the speed below which you want the system to stop reporting pattern errors.

ACTIVE ZONES Activate the appropriate detection zones for marking or ejection. For example, ifthe glue sensors are assigned to zone 1 and a cello detector is assigned to zone2, make zones 1 and 2 active so that marking or ejection will occur when errorsare detected in these zones.

EJECTOR COMP Not used in envelope systems

REJECT MARK Skip this setting. It will be entered in a later procedure.

ENCODER TYPE Set this value to 1 mm.

MACHINE STOP PRESET Enter the number of faulty products that will be allowed in the machine at anyone time before a machine stop occurs. For example, if the alarm feature isturned on and the machine stop preset is set to 4, the system stops the machineanytime four products between zone 1 and the pre-eject sensor have patternerrors. The error message will show the last pattern fault before the machinestopped.

OVERLAP DETECT PRESET Enter 9999 to disable this setting.

TRACK ZONE X

(X = 1, 2, 3, or 4)

Skip this setting. A setting for one or more zones will be entered in a laterprocedure.

TRACK FORCE 1 Not used in envelope systems

TRK2 PACKER Skip this setting. It will be entered in a later procedure if the system has a casepacker.

5601054A

Enter the Settings forTracking and Machine

Constants Menu

Appendix B B-9


321 226DIssued 5/05


Use the following procedure to set the starting point for marking when theG-NET system detects one or more defective envelopes. The starting point isdetermined by setting the product count used for tracking.

1. Start the production machine and run it at jog speed.

2. Fill the machine with envelopes from the feed section to the markingsystem.

NOTE: Make sure that the machine setup is completed and it is fullyprepared for production at normal operating speed. The machine shouldbe full of envelopes with proper spacing and all adjustments completed.

3. Place a large mark on the envelope that will enter the detection zone firstwhen the machine is started. The leading edge of this envelope should bethe first leading edge that the zone trigger detects.

NOTE: If the envelope machine is a web-type system where the zonetrigger is activated by a machine part, mark the envelope that will beinspected first by the glue sensors when the machine is started.

4. Place a large mark on the first envelope downstream of the marking gun onthe production machine.

5. Have a helper stand where he/she can collect the envelopes as theyemerge from the marking station.

6. Run the machine at jog speed and have the helper remove the first markedenvelope, all envelopes between the two marked envelopes, and the lastmarked envelope.

7. Count the envelopes between the two marked envelopes. Do not includeeither of the marked envelopes in the count.

8. Subtract several envelopes from this count, so that the marking will startbefore the defective envelope. The objective is to mark the defectiveenvelope and some envelopes before and after it. Marking or ejecting allof these envelops provides a safe margin of error during production andensures that the operator removes the defective envelope.

EXAMPLE: If the count between the two marked envelopes is 10, subtracttwo or three and use seven or eight as the product count. If the count islarger, such as 200 envelopes, subtract ten or so envelopes and use acount of approximately 190. You can adjust the count up or down later toachieve the best results.

9. Press select until the TRACKING AND MACHINE CONSTANTS MENUappears on the display.

10. Press setup until the value for TRACK ZONE 1 is highlighted.

11. If the machine is not stopped, stop it now.

NOTE: If the machine is left running when the following steps areperformed, the product count will be incorrect.

Set the Start of theReject Mark

Appendix BB-10


321 226DIssued 5/05


12. Press inc or dec to change the count shown to the adjusted countobtained in step 8.

13. Press clear to reset the memory and enter the new value for the productcount.

14. If the system has one or more additional detection zones besides zone 1,repeat steps 2 through 13 for each additional zone. For example, if zones2 and 3 are used in addition to zone 1, repeat steps 2 through 13 twice toset the product counts for TRACK ZONE 2 and TRACK ZONE 3.

Use the following procedure to set the end of the reject mark by adjusting itslength.

1. With the TRACKING AND MACHINE CONSTANTS MENU displayed,press setup until the REJECT MARK setting is highlighted.

2. Calculate the length of the reject mark that will work for the system:

a. Take the number you subtracted in step 8 of the previous procedure,double it, and then add one. This ensures that the system marks thedefective envelope and an equal number of additional envelopes oneach side of it.

b. Multiply the number calculated in step 2a by the length (in the directionof line travel) of one of the envelope blanks or web sections.

EXAMPLE: If you subtracted four in the Set the Start of the Reject Markprocedure and the envelopes are 200 mm long in the direction of linetravel, multiply nine (4 x 2 + 1) by 200 mm. The result 1800 mm. If youenter this value for the reject mark setting, the system will mark nineenvelopes.

3. Press inc or dec to change the REJECT MARK setting to the valuecalculated in step 2.

Use this procedure to test the setup and operation of the G-NET system.

1. Devise a way to quickly turn each glue gun off, then back on during routineoperation. You can do this one of three ways:

S Use the controls available at the envelope system’s pattern controller.

S Insert a piece of paperboard under the gun nozzle, then quickly removeit.

S Disconnect and quickly reconnect the gun’s power cable.

2. Run the machine at normal operating speed with envelopes in themachine.

3. Press reject on/off. The light on the key turns on.

Set the Start of theReject Mark (contd)

Set the End of theReject Mark

Test the System

Appendix B B-11


321 226DIssued 5/05


4. Press select until the screen for GLUE DETECTION ZONE 1 is displayed.

5. Press teach. The system creates a reference pattern from the next fiveenvelopes that it inspects.

6. Verify that the system is not detecting pattern errors when no errors exist.

S If the system is detecting errors when the patterns are good, increasethe tolerances some to see if the problem is solved.

S If the system is not detecting errors, you may be able to decreasetolerances until the system starts finding errors and then increase thetolerance setting slightly to find the best tolerance setting.

7. Challenge the system by creating some pattern errors in the patternmonitored by glue sensor no. 1. Verify that the system detects theseerrors. If it does not, refer to Troubleshooting, Section 5.

8. Repeat step 7 for any other glue sensors in the system.

9. Verify that the marking system is marking in the correct place. Thedefective envelope should be located approximately in the center of thegroup of marked envelopes.

S If the marking system is marking too early, turn the machine off,increase the product count for the tracking setting (TRACK ZONE 1 orTRACK ZONE 2), and press clear to enter the new value.

S If the marking system is marking too late, turn the machine off,decrease the product count for the tracking zone, and press clear toenter the new value.

S If the marking system is turning off too soon, increase the REJECTMARK length.

S If the marking system is turning off too late, decrease the REJECTMARK length.

10. If the system has one or more additional detection zones besides zone 1,repeat steps four through nine for each additional zone.

Appendix BB-12


321 226DIssued 5/05


Follow this procedure to set up the tracking of defective envelopes to the casepacker. The case packer will leave any case containing defective envelopesopen, so they can be removed and replaced with properly sealed envelopes.

1. With the production machine full of envelopes, count the number ofenvelopes between the marking gun and the case packer.

2. Press select until the TRACKING AND MACHINE CONSTANTS MENUappears on the display.

3. Press setup until the value for TRK2 PACKER is highlighted.

4. If the machine is not stopped, stop it now.

NOTE: If the machine is left running when the following steps areperformed, the product count will be incorrect.

5. Press inc or dec to change the case packer tracking count to the numberof envelopes counted or calculated in step 1.

6. Press clear to reset the memory and enter the new value for the packercount.

7. Start the machine and run it at jog speed.

8. Activate the marking gun (momentarily) so that it marks a single group ofenvelopes.

9. Observe the marked envelopes as they approach the case packer. Whenthe marked envelopes are packed, the case packer should leave the casethat contains them open instead of closing and sealing it.

10. Determine whether further adjustment of the packer count is necessary:

S If the case packer left the correct case open, this procedure iscomplete.

S If the case packer left the wrong case open, repeats steps 3--9 of thisprocedure, adjusting the packer count up or down as needed.

Set Up Tracking forthe Case Packer

Appendix B B-13


321 226DIssued 5/05


G-NET envelope systems operate in the same way as standard G-NETsystems with two exceptions:

S The method used to activate the reject test functionS The method used to clear a pattern error

The following table explains how the reject test function is activated onstandard G-NET systems and on G-NET envelope systems.

Objective Instructions

Activate the reject test functionin a standard G-NET system.

Press reject test. The system will ejector mark all products.

Activate the reject test functionin a G-NET envelope system.

Press reject on/off until the light on thekey turns on; then press reject test.The system will mark all envelopes.

G-NET envelope systems are different from standard G-NET systems in theway pattern errors are cleared. If a pattern error is not manually cleared withinthirty seconds after it occurs, the G-NET envelope system clears itautomatically, without any action on the part of the operator. The followingtable summarizes the two ways to clear an error detected by the G-NETenvelope system.

Ways to Clear an Error Instructions

Manually Before 30 seconds pass,complete the procedure forclearing pattern errors inOperation, Section 4.

Automatically Wait 30 seconds. The systemwill clear the error automatically.

Refer to Troubleshooting, Section 5.

Operation

Activate the RejectTest Function

Clear a Pattern Error

Trouble-shooting

Appendix BB-14


321 226DIssued 5/05


The following parts lists are for mounting components used on either W + D102 or W + D 202 envelope production machines. If the G-NET envelopesystem is used on any other type of machine, contact your Nordsonrepresentative to order mounting components.

NOTE: To order any other parts for the G-NET envelope system, refer toParts, Section 6.

W + D 102 Components


NS 374 843 Mounting, piggyback 1 A

----- 375 386 W + D 102 mounting assembly 1

1 375 378 S Side seam bracket assembly 1 B

2 374 894 S Sensor/guide bracket assembly 2 C

NS 374 655 W + D 102 trigger mounting assembly 1 D

NS 313 370 Bracket, encoder 1 E

NS 373 759 Bracket, trigger (photosensor) 1 E

NOTE A: Used to mount a G-NET console on top of a Walcom WM 408 pattern control

B: Refer toW + D 102 Side Seam Bracket Assembly for the parts of this assembly.

C: Refer toW + D 102 Sensor/Guide Bracket Assembly for the parts of this assembly.

D: Refer toW + D 102 Trigger Mounting Assembly for the parts of this assembly.

E: Required if a Nordson pattern controller is not used

NS: Not Shown

5601037A

1 2 1

Parts

Mounting Componentsfor W + D 102

Machines

Appendix B B-15


321 226DIssued 5/05


W + D 102 Side Seam Bracket Assembly

5601145A

SECTION B--BSECTION A--A

9

2

1

3

87

4

7 6 5 14

19

212

137

11

A

A

B

B

10


----- 375 378 Side seam bracket assembly 1

1 375 379 S C-profile, L = 115 2

2 313 554 S Screw, hex, M6 x 25 mm 2

3 375 380 S Fiber adapter, insert banner 1

4 372 821 S Lever, M6 x 32 mm 1

5 313 612 S Washer, M6 1

6 313 738 S Compression spring 1

7 374 293 S Screw, hex, M6 x 10 mm 3

8 375 381 S Block, fixed 1

9 375 382 S Counter plate 2

10 375 383 S Beam, L = 590 mm 1

11 375 384 S Hinge pin 1

12 375 292 S Compression spring 1

13 311 138 S Washer, M10 1

14 375 385 S Block, hinged 1

Appendix BB-16


321 226DIssued 5/05


W + D 102 Sensor/Guide Bracket Assembly

5601038A

9

8

4

3

1

6 7

5

9

2


----- 374 894 Sensor/guide bracket assembly 1

1 373 724 S Clamping block SQ30 1

2 374 895 S Connection block 1

3 374 896 S Sensor plate 1

4 374 897 S Guide block 1

5 374 898 S Guide plate 1

6 311 058 S Screw, hex, M6 x 30 mm 1

7 313 583 S Hex nut, M6 1

8 313 545 S Screw, hex, M5 x 20 mm 2

9 311 044 S Screw, hex, M5 x16 mm 4

Appendix B B-17


321 226DIssued 5/05


W + D 102 Trigger Mounting Assembly

5601049A

3

52

4

1


----- 374 655 W + D 102 trigger (photosensor) mounting assembly 1

1 374 656 S Support 1

2 374 657 S Support ring 1

3 313 532 S Screw, hex, M4 x 10 mm 3

4 311 032 S Screw, hex, M4 x 8 mm 1

5 313 598 S Washer, M4 3

Appendix BB-18


321 226DIssued 5/05


Use the following parts lists for W + D 202 machines with Nordson gunbrackets and Nordson WM801 guns.

W + D 202 Version 1 Components



NS 375 248 Main mounting assembly, Version 1 1 B

NS 374 834 Tablet sensor mounting, GD-100, left 1 C

NS 374 835 Tablet sensor mounting, GD-100, right 1 C


B: Refer toW + D 202 Version 1 Main Mounting Assembly for the parts of this assembly.

C: Used to provide surface mounting for the GD-100 magnets on open-type machines

NS: Not Shown


Machines: Version 1

Appendix B B-19


321 226DIssued 5/05


W + D 202 Version 1 Main Mounting Assembly

5601050A

1

4

3

5

2

8

7

9

6


----- 375 248 Main mounting assembly, Version 1 1

1 374 839 S Sensor bracket, left 1

2 374 840 S Sensor bracket, right 1

3 375 233 S Photocell bracket assembly 1 A

4 374 842 S Product guide 1

5 313 565 S Screw, M5 x 12 mm 2

6 374 837 S Product guide envelope, right 1

7 374 836 S Product guide envelope, left 1

8 313 543 S Screw, hex, M5 x 10 mm 4

9 313 532 S Screw, hex, M4 x10 mm 4

NOTE A: Refer to theW + D 202 Version 1 Trigger Mounting Assembly for the parts of this assembly.

Appendix BB-20


321 226DIssued 5/05


W + D 202 Version 1 Trigger Mounting Assembly

5601052A

1

8

4

2

5

6

7

3


----- 375 233 Trigger (photosensor) mounting assembly 1

1 375 039 S Bracket 202 1

2 313 298 S Holder, glass fiber 1


4 371 484 S Fiber adapter, insert WLL12 1

5 371 483 S Bracket, fiber adapter 1

6 371 490 S Connecting bolt 1

7 371 491 S Connector 1

8 313 664 S Screw, M6 x 8 mm 1

Appendix B B-21


321 226DIssued 5/05


Use the following parts lists for W + D 202 machines with W + D gun bracketsand Nordson WM801 guns.




NS 375 242 Main mounting assembly, W + D 202, Version 2 1 B






NS: Not Shown


Machines: Version 2

Appendix BB-22


321 226DIssued 5/05



5601051A

1

4 3

5

2

6



1 374 243 S Bracket W + D 202/WM801, left 1

2 374 244 S Bracket W + D 202/WM801, right 1

3 375 233 S Photocell bracket assembly 1 A


5 313 565 S Screw, M5 x 12 mm 2

6 313 556 S Screw, M6 x40 mm 4

NOTE A: Refer toW + D 202 Version 2 Trigger Mounting Assembly for the parts of this assembly.

Appendix B B-23


321 226DIssued 5/05



5601052A

1

8

4

2

5

6

7

3



1 375 039 S Bracket 202 1







8 313 664 S Screw, M6 x 8 mm 1

Appendix BB-24


321 226DIssued 5/05


Use the following parts lists for W + D 202 machines with W + D gun bracketsand Dynatec guns.




NS 375 241 Main mounting assembly, W + D 202, Version 3 1 B



NOTE A: Used to mount a G-NET console on top of a 2005 pattern control



NS: Not Shown


Machines: Version 3

Appendix B B-25


321 226DIssued 5/05



5601053A

1

4

3

5

2

6



1 374 845 S Bracket, Dynatec/Veritec, left 1

2 374 846 S Bracket, Dynatec/Veritec, right 1

3 375 233 S Trigger (photosensor) bracket assembly 1 A


5 313 565 S Screw, M5 x 12 mm 2

6 313 532 S Screw, M4 x 10 mm 8

NOTE A: Refer toW + D 202 Version 3 Trigger Mounting Assembly for the parts of this assembly.

Appendix BB-26


321 226DIssued 5/05



5601052A

1

8

4

2

5

6

7

3



1 375 039 S Bracket 202 1







8 313 664 S Screw, M6 x 8 mm 1

Appendix B B-27


321 226DIssued 5/05


Refer to Technical Data, Section 7.Technical Data

Appendix BB-28


321 226DIssued 5/05


Index I-1


321 226DIssued 5/05


IndexA

Accessories, parts, 6-7

Activating a zone for ejection, 3-29

Active mode, 3-5

Active sensors, 3-5, 5-5

Active zones, 3-7

Actual pattern, 5-5

Adjusting glue sensors, 3-8

Adjusting zone triggers, 3-10

Air lines, instructions for connecting, 2-20

Alarm function, how to enable/disable, 4-10

Alarm on/off, 4-5

Alarm reset, 4-5

Applicationscontinuous gluing, A-2summary of, 1-11

Assigning sensors to zones, 3-22

BBatch control system, description, 1-8

Batch count, 3-6

Batch kicker, how to adjust timing of, 3-18

Batch preset setting, 3-6

Batch Sensor, 3-13

Bead length, 3-5

Bead-length detection, how to set, 3-27

Bead-length feature, setting up for continuous gluing,A-4

CCablesconnecting, 2-16connecting case packer signal cable, B-3

Case packerconnecting signal cable, B-3tracking setup for envelope system, B-12

Changing products, 4-17

clear, 4-4

Clearing error, 4-14

Clock, setup, 3-15

Console, description, 1-4

Continuous web glue detection, A-2

Counter menu screen, 3-6, B-7

DDefective product not ejected, 5-15, 5-16

Delivery count, 3-6

Detection equipment, optional, 1-8

Disable outputs, 4-10

display, 4-4

Display pattern, 5-6

AppendixI-2


321 226DIssued 5/05


EEjectordescription, 1-9how to adjust timing of, 3-19

Ejector comp, 3-7

Enable outputs, 4-10

Encoder, 4-5description, 1-8for continuous gluing, A-2setup, 3-17

Encoder type, 3-7

Ending a job, 4-13

Envelope system, B-2

Error, clear, 4-14

Error count, 5-5

Error message, 5-5, 5-8

Error messages, 4-21

Errors, pattern, 5-7

FFault countshow to monitor, 4-23how to reset, 4-24

Features, description, 1-12

Feed count, 3-6

Feed count sensor, description, 1-9

Force 1, 3-6

Force 2, 3-6

GG-NET control unit, description, 1-4

G-SITE, description, 1-5

Glue Detection Reject Counts, 3-6

Glue detection zone screen, 3-5, B-6

Glue detector, description, 1-6

Glue sensordescription, 1-6specifications, 7-3

Glue sensor light, 4-5, 5-5

Glue sensors, 2-5assigning zones, 3-22dimensions, 2-5location, 2-5

Iinc dec, 4-4

JJob #, 3-4

Job reporting, 4-25

Job status, 3-4

KKey questions, 5-10

Kick time, 3-6

LLanguage, how to select, 3-16

Lights, panel, 4-22

Low speed cutout, 3-7

MMach. speed, 3-6

Machine #, 3-4

Machine stop, causes of, 4-16

Machine stop not working, 5-17

Machine stop preset, 3-7

Marking Equipment, adjust timing, 3-19

Marking system, description, 1-9

max, 3-5

min, 3-5

Monitor counts, 4-23

Monitoring pattern placement, 4-18

Index I-3


321 226DIssued 5/05


OOperation of envelope system, B-13

Operation of system, explanation, 4-2

Operator panel, function of keys and indicators, 4-4

Optional detection equipment, parts, 6-8

Optional equipment, instructions for mounting, 2-14

Order #, 3-4

Outputs, enable and disable, 4-10

Overlap detect preset, 3-7

PPanel indicators, explanation of, 4-22

Panel lights, 4-22

Partsaccessories, 6-7envelope system, B-14optional detection equipment, 6-8reject equipment, 6-10spare parts, 6-11standard components, 6-4

Pattern, teach, 3-23

Pattern displays, 5-6

Pattern error, 4-5effect of on system operation, 4-14

Pattern error lights, 5-5

Pattern error tolerances, 3-24

Pattern errors, 5-7clearing, B-13detected when there are none, 5-13

Pattern errors not detected, 5-12

Pattern errors not detected in 1 zone, 5-12

Pattern missing, 5-14

Pattern placement, how to monitor, 4-18

Photo eye, envelope system installation, B-3

Photosensor, description, 1-7

Pneumatic diagram, 5-2

Pre-eject sensor, 3-13

print, 4-4

Printer, description, 1-11

Printing a report, 4-25

Product count, for continuous gluing, A-4

Production datakeeping records of, 4-25obtaining a report of, 4-25

Pusher, how to adjust timing of, 3-19

RRecording settings, 3-30

Reference pattern, 5-5explanation of, 4-9

Reject equipmentadjust timing, 3-19parts, 6-10

Reject function, how to enable/disable, 4-10

Reject mark, 3-7

reject mark, envelope system, B-9

reject on/off, 4-5

Reject system, instructions for mounting, 2-12

reject test, 4-5

Report menu screen, 3-4, B-5

Reset counts, 4-24

Restarting the system, 4-16

Sselect, 4-4

Sensitivity, how to set, 3-8

Set tolerances, 3-24

Setting the encoder type, 3-17

Setting up the bead-length feature, 3-27

Settings, zero all, 3-29

Setupclock, 3-15encoder, 3-17for continuous gluing applications, A-3procedures, 3-15

setup, 4-4

Shift #, 3-4

Shutting down the system, 4-18

Specifications, system, 7-2

Stacker control, 3-6

stand by, 4-4

AppendixI-4


321 226DIssued 5/05


S (contd)

Standby modeexplanation of, 4-12how to exit, 4-12

Starting a job, 4-13

Starting the system, 4-6

Systemdescription, 1-2specifications, 7-2

System components, 1-3how to adjust, 3-14instructions for mounting, 2-8location of, 2-6

System connections, 5-3

TTeach, pattern, 3-23

teach, 4-4

Teaching a reference pattern, 3-23

Teaching the system a pattern, 4-8

Teaching tracking distances, 3-21

Test function, activating, B-13

Timing, adjust marking equipment, 3-19

Tolerance, 3-5how to set, 3-24

Track a job, 4-13

Track force1, 3-7

Track zone x, 3-7

Tracking, how to teach, 3-21

Tracking and machine constants screen, 3-7, B-8

Tracking, setup for case packer, B-12

Transformer, description, 1-8

Trigger, description, 1-7

Triggersadjusting sensitivity, 3-10location of, 2-6

Troubleshooting, 5-12

WWarning light towerdescription, 1-10how to monitor, 4-23

Work rate, 3-6

Wrong product ejected, 5-16

ZZero all settings, 3-29

Zone status, 5-5

Zone tolerance setting, 5-5

Zone trigger, 3-10

Zone trigger light, 4-5, 5-5

Zones, assigning glue sensors, 3-22

DECLARATION of CONFORMITY(For CE Certified Adhesive/Sealant Application Equipment)

PRODUCT:

VeriTec G-NET Verification System

APPLICABLE DIRECTIVES:

73/23/EEC (Low Voltage Directive)89/336/EEC (Electromagnetic Compatibility Directive)

STANDARDS USED TO VERIFY COMPLIANCE:

EN60950EN61000-6-2EN61000-6-4

PRINCIPLES:

This product has been manufactured according to good engineering practice.

The product specified conforms to the directive and standards described above.

Date: 14 February 2003

Donald J. McLane, Senior Vice President

Nordson Corporation S Duluth, Georgia DOC 020

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