Concert Series Basic Standalone Temperature Controlleremanuals.nordson.com/adhesives/English_Manuals/1123727.pdf · 2014-09-26 · Concert™ Series Basic Standalone Temperature Controller

Concert™ Series Basic Standalone

Temperature Controller

Customer Product ManualPart 1123727_01

Issued 06/14

NORDSON CORPORATION DULUTH, GEORGIA USAwww.nordson.com

This document contains important safety informationBe sure to read and follow all safety information in thisdocument and any other related documentation.

Part 1123727_01 � 06/2014 Nordson CorporationAll rights reserved

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

Address all correspondence to:

Nordson CorporationAttn: Customer Service11475 Lakefield Drive

Duluth, GA 30097

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2013.No�part�of�this�document may be photocopied, reproduced, or translated to another language without the prior written

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

Trademarks

AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, Bowtie, Build‐A‐Part, CanWorks, Century, CF, CleanSleeve,CleanSpray, ColorMax, Color‐on‐Demand, Control�Coat, Coolwave, Cross‐Cut, cScan+, Dage, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber,

DuraPail, Dura‐Screen, Durasystem, Easy�Coat, Easymove Plus, Ecodry, Econo‐Coat, e.DOT, EFD, Emerald, Encore, ESP, e stylized, ETI‐stylized,Excel 2000, Fibrijet, Fillmaster, FlexiCoat, Flex‐O‐Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Fulfill, GreenUV, HDLV, Heli‐flow, Horizon, Hot Shot,iControl, iDry, iFlow, Isocoil, Isocore, Iso‐Flo, iTRAX, Kinetix, LEAN�CELL, Little�Squirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, Microcoat,

Micromark, Micromedics, MicroSet, Millennium, MiniBlue, Mini Squirt, Mountaingate, NexJet, Nordson, Optimum, Package of Values, Pattern View,PermaFlo, PicoDot, Porous�Coat, PowderGrid, Powderware, Precisecoat, PRIMARC, Printplus, Prism, ProBlue, Prodigy, Pro‐Flo, ProLink, Pro‐Meter,

Pro‐Stream, RBX, Rhino, Saturn, Saturn with rings, Scoreguard, Seal Sentry, Select�Charge, Select�Coat, Select Cure, Signature, Slautterback, Smart‐Coat,Solder Plus, Spectrum, Speed‐Coat, SureBead, Sure Coat, Sure‐Max, Sure Wrap, Tracking�Plus, TRAK, Trends, Tribomatic, TrueBlue, TrueCoat,

Tubesetter, Ultra, UpTime, u‐TAH, Value Plastics, Vantage, VersaBlue, Versa‐Coat, VersaDrum, VersaPail, Versa‐Screen, Versa‐Spray, VP Quick Fit, Watermark, and When you expect more. are registered trademarks of Nordson Corporation.

Accubar, Active Nozzle, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AltaSlot, Alta Spray, Artiste, ATS, Auto‐Flo, AutoScan, Axiom, Best Choice, Blue Series, Bravura, CanPro, Champion, Check Mate, ClassicBlue, Classic IX, Clean�Coat, Cobalt, Controlled Fiberization, Control�Weave,

ContourCoat, CPX, cSelect, Cyclo‐Kinetic, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, e.dot+,E‐Nordson, Equalizer, EquiBead, FillEasy, Fill�Sentry, Flow Coat, Fluxplus, Get Green With Blue, G‐Net, G‐Site, IntelliJet, iON, Iso‐Flex, iTrend,

Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros, MiniEdge, Minimeter, Multifill, MultiScan, Myritex, Nano, NexJet, OmniScan, OptiMix, OptiStroke,Partnership+Plus, PatternJet, PatternPro, PCI, PharmaLok, Pinnacle, Plasmod, Powder�Pilot, Powder Port, Powercure, Process Sentry, Pulse Spray,

PURBlue, PURJet, Ready Coat, RediCoat, RollVIA, Royal Blue, Select�Series, Sensomatic, Shaftshield, SheetAire, Smart, Smartfil, SolidBlue, Spectral,SpeedKing, Spray Works, StediFlo, StediTherm, Summit, SureFoam, Sure�Mix, SureSeal, Swirl�Coat, TAH, ThruWave, Trade�Plus, Trilogy, Ultra FoamMix,UltraMax, Ultrasaver, Ultrasmart, Universal, ValueMate, Versa, Vista, Web Cure, YESTECH, and 2�Rings (Design) are�trademarks of Nordson�Corporation.

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

Table of Contents i

Part 1123727_01� 06/2014 Nordson Corporation

Table of Contents

Safety 1‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Alert Symbols 1‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Responsibilities of the Equipment Owner 1‐2. . . . . . . . . . . . . . . . . . . . . . .

Safety Information 1‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instructions, Requirements, and Standards 1‐2. . . . . . . . . . . . . . . . . .User Qualifications 1‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applicable Industry Safety Practices 1‐3. . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use of the Equipment 1‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instructions and Safety Messages 1‐4. . . . . . . . . . . . . . . . . . . . . . . . . .Installation Practices 1‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Practices 1‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance and Repair Practices 1‐5. . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Safety Information 1‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Equipment Shutdown 1‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving System Hydraulic Pressure 1‐6. . . . . . . . . . . . . . . . . . . . .De‐energizing the System 1‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disabling the Applicators 1‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Safety Warnings and Cautions 1‐7. . . . . . . . . . . . . . . . . . . . . .Other Safety Precautions 1‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .First Aid 1‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Label and Tag 1‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 2‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Overview 2‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configurations 2‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use 2‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Limitations of Use 2‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Product Description 2‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

External Components 2‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Internal Components 2‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature Controller Identification 2‐6. . . . . . . . . . . . . . . . . . . . . . . .

Installation 3‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ElectroMagnetic Compliance Information 3‐1. . . . . . . . . . . . . . . . . . . . . .Experience of Installation Personnel 3‐1. . . . . . . . . . . . . . . . . . . . . . . . . . .CustomerSupplied Installation Components 3‐1. . . . . . . . . . . . . . . . . . .Installation Considerations 3‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unpacking the Temperature Controller 3‐2. . . . . . . . . . . . . . . . . . . . . .Mounting Guidelines 3‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Positioning and Mounting the Temperature Controller 3‐2. . . . . . . . .Temperature Controller Dimensions 3‐3. . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsii

Part 1123727_01 � 06/2014 Nordson Corporation

Electrical Connections 3‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Making External Connections 3‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hose/Applicator Connections 3‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Information 3‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Making Internal Board Connections 3‐8. . . . . . . . . . . . . . . . . . . . . . . . .Before System Setup 3‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 4‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Start the Controller for the First Time 4‐1. . . . . . . . . . . . . . . . . . . . . . . . . .About the Home Screen 4‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Navigating the Home Screen 4‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monitoring the Controller Status 4‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Screen Saver 4‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Status Indicator Table 4‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Master Controls 4‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .What you can do from Master Controls 4‐7. . . . . . . . . . . . . . . . . . . .Master Controls Setup 4‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Understanding the Zones 4‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configuration 5‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Configure the Zones 5‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Enabling and Disabling the Zones 5‐2. . . . . . . . . . . . . . . . . . . . . . . . . .Modifying Zone Setpoint Temperatures 5‐3. . . . . . . . . . . . . . . . . . . . .Modifying Zone Names 5‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Modifying Zone PID Types 5‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configure the Master Controls 5‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Configuring the Settings 5‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Access Temperature Settings 5‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . .Configure Input Settings 5‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Configure Output Settings 5‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configuring System Settings 5‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Formats and Units 5‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Date and Time 5‐16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Service Intervals 5‐17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scheduled Events 5‐18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Password Protection 5‐22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Display Settings 5‐24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Administration Settings 5‐26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 6‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preventive Maintenance 6‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 7‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety 7‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Touch Screen Alerts and Faults 7‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Zone Alerts/Faults 7‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Alerts 7‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Faults 7‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents iii


Repair 8‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace the Control Panel Board 8‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace the Main Board 8‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace the Expansion Board 8‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts 9‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Boards 9‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ship with Kits 9‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A

Technical Data A‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications A‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General A‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Conditions A‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical A‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Default User Settings and Ranges A‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Settings A‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temperature Settings A‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Input/Output Settings A‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Schematic A‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B

Upgrade Software and Firmware B‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . .Upgrade to Latest Software B‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Revert to a Previous Software Version B‐4. . . . . . . . . . . . . . . . . . . . . . . . .

Information about Recipes B‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsiv


Safety 1-1

� 06/2014 Nordson Corporation Issued 10-11

Section 1Safety

Read this section before using the equipment. This section containsrecommendations and practices applicable to the safe installation, operation,and maintenance (hereafter referred to as “use”) of the product described inthis document (hereafter referred to as “equipment”). Additional safetyinformation, in the form of task‐specific safety alert messages, appears asappropriate throughout this document.

WARNING! Failure to follow the safety messages, recommendations, andhazard avoidance procedures provided in this document can result inpersonal injury, including death, or damage to equipment or property.

Safety Alert SymbolsThe following safety alert symbol and signal words are used throughout thisdocument to alert the reader to personal safety hazards or to identifyconditions that may result in damage to equipment or property. Comply withall safety information that follows the signal word.

WARNING! Indicates a potentially hazardous situation that, if not avoided,can result in serious personal injury, including death.

CAUTION! Indicates a potentially hazardous situation that, if not avoided,can result in minor or moderate personal injury.

CAUTION! (Used without the safety alert symbol) Indicates a potentiallyhazardous situation that, if not avoided, can result in damage to equipment orproperty.

Safety1-2

� 06/2014 Nordson CorporationIssued 10−11

Responsibilities of the Equipment Owner Equipment owners are responsible for managing safety information, ensuringthat all instructions and regulatory requirements for use of the equipment aremet, and for qualifying all potential users.

Safety Information � Research and evaluate safety information from all applicable sources,

including the owner‐specific safety policy, best industry practices,governing regulations, material manufacturer's product information, andthis document.

� Make safety information available to equipment users in accordance with

governing regulations. Contact the authority having jurisdiction forinformation.

� Maintain safety information, including the safety labels affixed to the

equipment, in readable condition.

Instructions, Requirements, and Standards � Ensure that the equipment is used in accordance with the information

provided in this document, governing codes and regulations, and bestindustry practices.

� If applicable, receive approval from your facility's engineering or safety

department, or other similar function within your organization, beforeinstalling or operating the equipment for the first time.

� Provide appropriate emergency and first aid equipment.

� Conduct safety inspections to ensure required practices are being

followed.

� Re‐evaluate safety practices and procedures whenever changes are

made to the process or equipment.

Safety 1-3


User Qualifications

Equipment owners are responsible for ensuring that users:

� receive safety training appropriate to their job function as directed by

governing regulations and best industry practices

� are familiar with the equipment owner's safety and accident

prevention policies and procedures

� receive equipment‐ and task‐specific training from another qualified

individual

NOTE: Nordson can provide equipment‐specific installation,operation, and maintenance training. Contact your Nordsonrepresentative for information

� possess industry‐ and trade‐specific skills and a level of experience

appropriate to their job function

� are physically capable of performing their job function and are not

under the influence of any substance that degrades their mentalcapacity or physical capabilities

Applicable Industry Safety Practices The following safety practices apply to the use of the equipment in themanner described in this document. The information provided here is notmeant to include all possible safety practices, but represents the best safetypractices for equipment of similar hazard potential used in similar industries.

Intended Use of the Equipment � Use the equipment only for the purposes described and within the limits

specified in this document.

� Do not modify the equipment.

� Do not use incompatible materials or unapproved auxiliary devices.

Contact your Nordson representative if you have any questions onmaterial compatibility or the use of non‐standard auxiliary devices.

Safety1-4


Instructions and Safety Messages � Read and follow the instructions provided in this document and other

referenced documents.

� Familiarize yourself with the location and meaning of the safety warning

labels and tags affixed to the equipment. Refer to Safety Labels and Tagsat the end of this section.

� If you are unsure of how to use the equipment, contact your Nordson

representative for assistance.

Installation Practices � Install the equipment in accordance with the instructions provided in this

document and in the documentation provided with auxiliary devices.

� Ensure that the equipment is rated for the environment in which it will be

used. This equipment has not been certified for compliance with theATEX directive nor as nonincendive and should not be installed inpotentially explosive environments.

� Ensure that the processing characteristics of the material will not create a

hazardous environment. Refer to the Material Safety Data Sheet (MSDS)for the material.

� If the required installation configuration does not match the installation

instructions, contact your Nordson representative for assistance.

� Position the equipment for safe operation. Observe the requirements for

clearance between the equipment and other objects.

� Install lockable power disconnects to isolate the equipment and all

independently powered auxiliary devices from their power sources.

� Properly ground all equipment. Contact your local building code

enforcement agency for specific requirements.

� Ensure that fuses of the correct type and rating are installed in fused

equipment.

� Contact the authority having jurisdiction to determine the requirement for

installation permits or inspections.

Operating Practices � Familiarize yourself with the location and operation of all safety devices

and indicators.

� Confirm that the equipment, including all safety devices (guards,

interlocks, etc.), is in good working order and that the requiredenvironmental conditions exist.

� Use the personal protective equipment (PPE) specified for each task.

Refer to Equipment Safety Information or the material manufacturer'sinstructions and MSDS for PPE requirements.

� Do not use equipment that is malfunctioning or shows signs of a potential

malfunction.

Safety 1-5


Maintenance and Repair Practices � Allow only personnel with appropriate training and experience to operate

or service the equipment.

� Perform scheduled maintenance activities at the intervals described in

this document.

� Relieve system hydraulic and pneumatic pressure before servicing the

equipment.

� De‐energize the equipment and all auxiliary devices before servicing the

equipment.

� Use only new Nordson‐authorized refurbished or replacement parts.

� Read and comply with the manufacturer's instructions and the MSDS

supplied with equipment cleaning compounds.

NOTE: MSDSs for cleaning compounds that are sold by Nordson areavailable at www.nordson.com or by calling your Nordson representative.

� Confirm the correct operation of all safety devices before placing the

equipment back into operation.

� Dispose of waste cleaning compounds and residual process materials

according to governing regulations. Refer to the applicable MSDS orcontact the authority having jurisdiction for information.

� Keep equipment safety warning labels clean. Replace worn or damaged

labels.

Equipment Safety Information This equipment safety information is applicable to the following types ofNordson equipment:

� hot melt and cold adhesive application equipment and all related

accessories

� pattern controllers, timers, detection and verification systems, and all

other optional process control devices

Safety1-6


Equipment Shutdown

To safely complete many of the procedures described in this document, theequipment must first be shut down. The level of shut down required varies bythe type of equipment in use and the procedure being completed. If required, shut down instructions are specified at the start of the procedure.The levels of shut down are:

Relieving System Hydraulic Pressure

Completely relieve system hydraulic pressure before breaking any hydraulicconnection or seal. Refer to the melter‐specific product manual forinstructions on relieving system hydraulic pressure.

De‐energizing the System

Isolate the system (melter, hoses, applicators, and optional devices) from allpower sources before accessing any unprotected high‐voltage wiring orconnection point.

1.. Turn off the equipment and all auxiliary devices connected to theequipment (system).

2.. To prevent the equipment from being accidentally energized, lock andtag the disconnect switch(es) or circuit breaker(s) that provide inputelectrical power to the equipment and optional devices.

NOTE: Government regulations and industry standards dictate specificrequirements for the isolation of hazardous energy sources. Refer to theappropriate regulation or standard.

Disabling the Applicators

NOTE: Adhesive dispensing applicators are referred to as “guns” in someprevious publications.

All electrical or mechanical devices that provide an activation signal to theapplicators, applicator solenoid valve(s), or the melter pump must bedisabled before work can be performed on or around an applicator that isconnected to a pressurized system.

1.. Turn off or disconnect the applicator triggering device (pattern controller,timer, PLC, etc.).

2.. Disconnect the input signal wiring to the applicator solenoid valve(s).

3.. Reduce the air pressure to the applicator solenoid valve(s) to zero; thenrelieve the residual air pressure between the regulator and the applicator.

Safety 1-7


General Safety Warnings and Cautions

Table 1‐1 contains the general safety warnings and cautions that apply toNordson hot melt and cold adhesive equipment. Review the table andcarefully read all of the warnings or cautions that apply to the type ofequipment described in this manual.

Equipment types are designated in Table 1‐1 as follows:

HM = Hot melt (melters, hoses, applicators, etc.)

PC = Process control

CA = Cold adhesive (dispensing pumps, pressurized container, andapplicators)

Table 1‐1 General Safety Warnings and Cautions

EquipmentType Warning or Caution

HM

WARNING! Hazardous vapors! Before processing any polyurethanereactive (PUR) hot melt or solvent‐based material through a compatibleNordson melter, read and comply with the material's MSDS. Ensurethat the material's processing temperature and flashpoints will not beexceeded and that all requirements for safe handling, ventilation, firstaid, and personal protective equipment are met. Failure to comply withMSDS requirements can cause personal injury, including death.

HM

WARNING! Reactive material! Never clean any aluminum componentor flush Nordson equipment with halogenated hydrocarbon fluids.Nordson melters and applicators contain aluminum components thatmay react violently with halogenated hydrocarbons. The use ofhalogenated hydrocarbon compounds in Nordson equipment cancause personal injury, including death.

HM, CAWARNING! System pressurized! Relieve system hydraulic pressurebefore breaking any hydraulic connection or seal. Failure to relieve thesystem hydraulic pressure can result in the uncontrolled release of hotmelt or cold adhesive, causing personal injury.

Continued...

Safety1-8


Table 1‐1 General Safety Warnings and Cautions (contd)

EquipmentType Warning or Caution

HMWARNING! Molten material! Wear eye or face protection, clothing thatprotects exposed skin, and heat‐protective gloves when servicingequipment that contains molten hot melt. Even when solidified, hot meltcan still cause burns. Failure to wear appropriate personal protectiveequipment can result in personal injury.

HM, PC

WARNING! Equipment starts automatically! Remote triggering devicesare used to control automatic hot melt applicators. Before working onor near an operating applicator, disable the applicator's triggeringdevice and remove the air supply to the applicator's solenoid valve(s).Failure to disable the applicator's triggering device and remove thesupply of air to the solenoid valve(s) can result in personal injury.

HM, CA, PC

WARNING! Risk of electrocution! Even when switched off andelectrically isolated at the disconnect switch or circuit breaker, theequipment may still be connected to energized auxiliary devices.De‐energize and electrically isolate all auxiliary devices beforeservicing the equipment. Failure to properly isolate electrical power toauxiliary equipment before servicing the equipment can result inpersonal injury, including death.

HM, CA, PC

WARNING! Risk of fire or explosion! Nordson adhesive equipment isnot rated for use in explosive environments and has not been cerfifiedfor the ATEX directive or as nonincendive. In addition, this equipmentshould not be used with solvent‐based adhesives that can create anexplosive atmosphere when processed. Refer to the MSDS for theadhesive to determine its processing characteristics and limitations.The use of incompatible solvent‐based adhesives or the improperprocessing of solvent‐based adhesives can result in personal injury,including death.

HM, CA, PCWARNING! Allow only personnel with appropriate training andexperience to operate or service the equipment. The use of untrainedor inexperienced personnel to operate or service the equipment canresult in injury, including death, to themselves and others and candamage to the equipment.

Safety 1-9


Warning or CautionEquipment

Type

HMCAUTION! Hot surfaces! Avoid contact with the hot metal surfaces ofapplicators, hoses, and certain components of the melter. If contactcan not be avoided, wear heat‐protective gloves and clothing whenworking around heated equipment. Failure to avoid contact with hotmetal surfaces can result in personal injury.

HM

CAUTION! Some Nordson melters are specifically designed toprocess polyurethane reactive (PUR) hot melt. Attempting to processPUR in equipment not specifically designed for this purpose candamage the equipment and cause premature reaction of the hot melt. Ifyou are unsure of the equipment's ability to process PUR, contact yourNordson representative for assistance.

HM, CA

CAUTION! Before using any cleaning or flushing compound on or inthe equipment, read and comply with the manufacturer's instructionsand the MSDS supplied with the compound. Some cleaningcompounds can react unpredictably with hot melt or cold adhesive,resulting in damage to the equipment.

HM

CAUTION! Nordson hot melt equipment is factory tested with NordsonType R fluid that contains polyester adipate plasticizer. Certain hot meltmaterials can react with Type R fluid and form a solid gum that canclog the equipment. Before using the equipment, confirm that the hotmelt is compatible with Type R fluid.

Safety1-10


Other Safety Precautions � Do not use an open flame to heat hot melt system components.

� Check high pressure hoses daily for signs of excessive wear, damage, or

leaks.

� Never point a dispensing handgun at yourself or others.

� Suspend dispensing handguns by their proper suspension point.

First Aid

If molten hot melt comes in contact with your skin:

1.. Do NOT attempt to remove the molten hot melt from your skin.

2.. Immediately soak the affected area in clean, cold water until the hot melthas cooled.

3.. Do NOT attempt to remove the solidified hot melt from your skin.

4.. In case of severe burns, treat for shock.

5.. Seek expert medical attention immediately. Give the MSDS for the hotmelt to the medical personnel providing treatment.

Safety 1-11


Safety Label and Tag Figure 1‐1 illustrates the location of the product safety labels and tags affixedto the equipment. Table 1‐2 provides an illustration of the hazardidentification symbols that appear on each safety label and tag, the meaningof the symbol, or the exact wording of any safety message.

Figure 1‐1 Safety label and tag location

Table 1‐2 Safety Label and Tag description

Item Description

1.

WARNING! Hazardous voltage.

Disconnect all power supply

connections before servicing.

Safety1-12


Description 2-1


Section 2

Description

System Overview This manual describes the installation, operation, and setup of the basicstandalone Concert Series Temperature Controller.

The temperature controller is used in a material delivery system to controland/or monitor adhesive consumption and addon weights by providinginline measurement and reporting of adhesiveperpiece data for betterprocess control. The temperature controller includes the followingcapabilities:

‐ Monitor and control temperatures within the heated hoses and

applicators.

‐ Preset control parameters, warnings, and alarms to stop the line if

dispensing deviates beyond upper or lower dispensing limits.

See Figure 2‐1 for an overview of how the temperature controller isintegrated in a typical adhesive delivery system.

Description2-2


System Overview (contd)

2

3

6

7

4

5

1

Figure 2‐1 Temperature controller in a typical adhesive delivery system

1. Melter

2. Controller

3. TruFlow meter

4. TruFlow transmitter

5. Hose from melter to the TruFlowmeter

6. Hose from TruFlow meter to theapplicator

7. Applicator

Description 2-3


Configurations

Two different configurations are available:

‐ Temperature controller with 100 Ohmplatinum RTD

‐ Temperature controller with 120 Ohmnickel RTD

NOTE: The information in this manual is standard except where noted.

Intended Use

The temperature controller is specifically designed for use:

‐ With compatible equipment manufactured by Nordson Corporation

‐ In non‐explosive environments

The temperature controller is intended to be incorporated into machinery orassemblies by an integrator. The equipment must not be placed into use in amember state of the European Union until the parent machinery orassemblies have been declared by the integrator to be in conformity with theapplicable directives of the European Commission.

Limitations of Use

Use the temperature controller only for the purpose for which it is designed.Do not use the controller:

‐ With any material that creates a health or safety hazard when heated

‐ In environments that require the system to be cleaned using a water

wash or spray

Description2-4


Product Description

The temperature controller is used in conjunction with Nordson hot meltmelter, hose, and applicator to create a material application system as shownin Figure 2‐1.

External Components

1

OR

4

5

6

2

3

Figure 2‐2 External components of the temperature controller

1. Left panel connectors

2. Temperature controller front view

3. Touch screen panel

4. Right panel (power switch, safetylabel, and unit identification plate)

5. Base panel specific to platinumRTD

6. Base panel specific to nickel RTD

Description 2-5


Internal Components

1

6

7

8

5

42

3

Figure 2‐3 Internal boards of the temperature controller

1. Control panel board

2. HOST connector

3. AC power

4. Expansion board

5. Main board

6. Configurable I/O connector

7. Hose/applicator connector (basepanel with nickel RTD shown here)

8. Power supply board

Description2-6


Temperature Controller Identification

You will need the model and part number of the temperature controller whenrequesting service or ordering spare parts and optional equipment. Themodel and part number are indicated on the equipment identification plate.

Figure 2‐4 Location of the equipment identification plate

Installation 3-1


Section 3

Installation

WARNING! Allow only qualified personnel to perform the following tasks.Follow the safety instructions in this document and all other relateddocumentation.

Installation involves positioning the temperature controller in the desiredlocation and making the electrical connections.

For installation details on the melters, hoses, applicators, and otherequipment refer to the equipment‐specific documentation.

ElectroMagnetic Compliance Information This system is classified as Class A, Group 1 under the European standardfor limits and methods of measurement, EN 55011.

Experience of Installation Personnel The instructions provided in this section are intended to be used bypersonnel who have experience in the following subjects:

‐ Hot melt application processes

‐ Industrial power and control wiring

‐ Industrial mechanical installation practices

‐ Basic process control and instrumentation

CustomerSupplied Installation Components In addition to the components provided by Nordson Corporation, installingthe temperature controller requires the following customersuppliedcomponent:

‐ appropriate guarding and signage as required to prevent personal

injury during operation and service activities

Installation3-2


Installation Considerations

Unpacking the Temperature Controller 1. Carefully unpack the temperature controller. Exercise care to prevent

equipment damage during unpacking.

2. Inspect for any damage that may have occurred during shipping. Reportany damage to your Nordson representative.

Mounting Guidelines � Position the temperature controller as close as possible to the parent

machine or production line.

� Make sure that the mounting location provides sufficient clearance

around the sides, base, and rear for easy access to the connectors.

NOTE: For unhindered air flow, the recommended minimum clearanceat the top and base of the unit is 50 mm (1.96 in.).

� Mount the temperature controller vertically on the wall or post to provide

maximum cooling by convection across the heatsink fins.

� Mount the temperature controller on a rigid support (e.g. wall or post) to

prevent external vibration.

Positioning and Mounting the Temperature Controller

Equipment and production line configuration may dictate a variation in themounting options described in this section. Regardless of the mountingmethod used, refer to Mounting Guidelines.

The available temperature controller configurations are as follows:

‐ Temperature control with 100 Ohmplatinum RTD

‐ Temperature control with 120 Ohmnickel RTD

Installation 3-3


Temperature Controller Dimensions

469 mm

(18.49 in.)

445.5 mm

(17.50 in.)

419.9 mm

(16.53 in.)

355.6 mm

(14.00 in.)

381 mm

(15 in.)

7.9 mm

(0.31 in.)199.4 mm

(7.85 in.)

45.3 mm

(1.78 in.)

144.2 mm

(5.68 in.)

Figure 3‐1 Dimensions of temperature control with platinum RTD

401.1 mm

(15.79 in.)

456 mm

(17.95 in.)

444.5 mm

(17.50 in.)

419.9 mm

(16.53 in.)

355.6 mm

(14 in.)

381 mm

(15 in.)

7.9 mm

(0.31 in.)

144.2 mm

(5.68 in.)

45.3 mm

(1.78 in.)199.4 mm

(7.85 in.)

Figure 3‐2 Dimensions of temperature control with nickel RTD

Installation3-4


Electrical Connections

WARNING! Operate only at the operating voltage shown on the ID plate.

Making External Connections

Use the following connectors for external connections:

� AC power connector.

Make sure that the power cable includes a ground connection.

� Hose/applicator connectors (Temp 1A/B, Temp 2A/B, and Temp 3A/B)

Refer to Hose/Applicator Connections.

Installation 3-5


Hose/Applicator Connections

Use these connectors to connect to external hose/applicator devices.

Controller Base Panel with Platinum RTD

Hose/Applicator Connector Connects to…

1 2313

1000 W1000 W

1000 W

1000 W

1000 W1800 W

2800 W 1200 W

2000 W

1200 W

Special2

OR

Controller Base Panel with Nickel RTD

Hose/Applicator Connector Connects to…

1 23 13

1000 W1000 W

1000 W

1000 W

1000 W1800 W

2800 W 1200 W

2000 W

1200 W

Special2

Installation3-6


Electrical Information

Table 3‐3 Electrical Service Information

Use Electrical ConnectorTerminals..

Use Voltage Plug..

If the Electrical Service Type is..L1 L2 L3 N

400/230 VAC 3‐phase (4‐wire service, including aneutral) See note.

3/N/PE AC400/230V 227569

Red/Yellow

230 VAC 1‐phase(2‐wire service, including aneutral) See note.

1/N/PE AC200–240V 232617

Blue/Yellow

200 to 240 VAC 3‐phase(3‐wire service without aneutral)

3/PE AC200–240V 227568

Red/Green

200 to 240 VAC 1‐phase(2‐wire service without aneutral)

1/PE AC200–240V 227567

Blue/Green

NOTE: The 400/230 VAC 3‐phase service (4‐wire service including neutral) includes the 415/240 VAC 3‐phase(4‐wire service, including neutral) voltage. The 230 VAC 1‐phase service (2‐wire service, including a neutral)includes the 240 VAC 1‐phase (2‐wire service, including a neutral) voltage.

Connect a Voltage Plug to the Controller

1. Refer to Table 3‐3 to determine the part number of thevoltage plug that matches the required electrical service.

NOTE: Each voltage plug is color‐coded and is labeled with its partnumber and service type.

See Figure 3‐3.

2. Insert the correct voltage plug into receptacle J1 on the expansion board.Ensure that the plug snaps into place. If the plug contains a neutral lead,connect the neutral lead to receptacle J2 on the main board.

3. When the electrical service is completely installed and inspected inaccordance with local electrical codes and standards, close the electricalenclosure door and switch the local power disconnect switch on.

If the electrical service was configured correctly, the melter control panelwill display dashes.

Installation 3-7


J1

J1

J2

P/N 227568

3/PE AC

200-240V

P/N 227567

1/PE AC

200-240V

P/N 227569

3/N/PE AC

400-240V

1/N/PE AC200-240V

P/N 232617

Figure 3‐3 Connecting a voltage plug

Installation3-8


Making Internal Board Connections

Refer to Table 3‐1 for internal connector pin‐out details.

For the location of the internal boards, refer to Figure 2‐3 in Description.

23

1 ad

eb

c

L1L2

L3N

Figure 3‐4 Location of internal connectors

1. AC power 2. Configurable I/O 3. Host

Installation 3-9


Table 3‐1 Internal Connector pin‐out details

Connector Connects to…

1. AC POWER XT1 on the Expansion board. Connect the wires as follows:

a. Ground (green)

NOTE: Ground is located above the power supply board.

b. L1

c. L2

d. L3

e. Neutral (only present in 400/230V WYE power)

2. Configurable I/O XT7 on the Expansion board

Pin‐out information

Pin Signal

1 STD, OUTPUT 1

2 STD, OUTPUT 1

3 STD, OUTPUT 2

4 STD, OUTPUT 2

5 STD, OUTPUT 3

6 STD, OUTPUT 3

7 STD, INPUT 4

8 STD, INPUT 1

9 STD, INPUT 1

10 STD, INPUT 2

11 STD, INPUT 2

12 STD, INPUT 3

13 STD, INPUT 3

14 STD, INPUT 4

NOTE: Configurable I/O provides the user with four configurable inputs andthree configurable outputs. The inputs are activated by applying a constant 10-30 VDC signal voltage, which is supplied by the customer's control equipment.

Inputs and outputs are not polarity sensitive.

3. HOST JP5, Fieldbus (Anybus) card located on the control panel board.

NOTE: Use the HOST connector only when you need to make an Ethernet,ControlNet, DeviceNet, or Profibus connection.

Installation3-10


Before System Setup


Before setting up the system make sure of the following:

� All required internal/external connections have been completed.

� Temperature controller is connected to a melter or parent machine.

� Temperature controller is connected to the TruFlow meter and

transmitter.

� Hoses and applicators are connected.

� Temperature controller power cable must include a ground connection.

� Temperature controller power switch is turned on.

Operation 4-1


Section 4

Operation


Start the Controller for the First Time If the controller was not configured for you from the factory, the followingConfiguration Wizard screen appears.

Next

Welcome

Use the Configuration Wizard to set up the following information:

* Date/Time Format and Temperature Units

* Current Date and Time

Click Next to Continue.

Figure 4‐1 Configuration Wizard

Operation4-2


Start the Controller for the First Time (contd)

If the controller was configured for you from the factory, the following Home Screen appears.

Zone 3B

175�C

MasterControls

Zone 1A

175�C

Zone 1B

175�C

Zone 2A

175�C

Zone 3A

175�C

Zone 2B

175�C

Heaters: On Recipes

Nothing Loaded Ready \ OK

System Status:

Password: Disabled

Set Point: 180� C Set Point: 180� C Set Point: 180� C Set Point: 180� C

Set Point: 180� C Set Point: 180� C

Figure 4‐2 Home Screen

Operation 4-3


About the Home Screen The Home Screen allows you to navigate the graphical user interface tosetup, operate, and maintain the controller.

The controller is shipped from the factory with most software settingspre-configured and ready to use. However, there are some settings that youmust configure and fine tune to best fit your manufacturing process.

Navigating the Home Screen

The following components on the Home Screen allow you to navigatethrough the various screens for setup and operation.

Refer to Table 4‐1 for the Home Screen button functionalities.

Heaters: On

Password: Disabled

Recipes

Nothing Loaded

Zone 3B

175�C

Ready \ OK

System Status:

MasterControls

Zone 3A

175�C

Zone 1B

175�C

Zone 1A

175�C

Zone 2B

175�C

Zone 2A

175�C

2

3

1



Figure 4‐3 Home Screen navigating buttons

1. Zone buttons 2. Monitor buttons 3. Navigation button

Operation4-4


Navigating the Home Screen (contd)

Table 4‐1 Home Screen button functionalities

Item Section Functions

1 Zones � Enable/disable

� Create or modify zone name

� Define individual set point temperatures

� Modify default channel associations

� View state and status for each zone

2 Monitor � View controller status

� View state of the master heater control, and whether or not

password protection is enabled

� View and manage recipes

3 Navigation � Access the Master Control display

Operation 4-5


Monitoring the Controller Status

The following figure shows the location that allows you to view the controllerstatus.

Heaters: On Recipes


System Status:

Password: Disabled

1 2

Figure 4‐4 Location of the Status Indicator buttons

1. Status Indicator button 2. Recipes button

1. Touch the Status Indicator button to view the event log, like an alert, fault,or service reminder. Refer to Status Indicator Table for the differentsystem statuses and their explanation.

2. Touch the Recipes button to load, view, or delete a recipe. Refer toManaging Recipes in the Configuration section for more information.

Screen Saver

The screen saver appears after 5 minutes (the default) of no user interactionwith the touch screen. The Home Screen re-appears when you touchanywhere on the screen saver.

System Status: Ready / OK

Figure 4‐5 The Screen Saver

Operation4-6


Status Indicator Table

The following table details the controller status messages.

Button Color Heaters Description

System Status Ready/OK

Dark green On All available and enabled zones are attheir set points and/or have a status ofReady/OK.

System StatusReady/Service

Dark Green On Same as Ready/OK, but a componentrequires regular scheduled servicing.

System Status Heaters Off

Light Green Off Zones at set point temperatures, butthe master Heater control is Off.

NOTE: This could be the result of azone fault.

System Status Alert

Yellow On The controller continues to work, butsome functions may not be available.The controller requires servicing.

Zone Alert: Zone 1A

Yellow On The system has detected a zone alertcondition. The controller continues tooperate normally, but some functionsmay not be available. The controllerrequires servicing.

NOTE: You have 2 minutes from thetime the system detects an RTD and/oran over/under temperature alert beforeit is upgraded to a Fault condition.

System Status Fault

Red Off A system fault condition has beendetected. The controller has stoppedworking.

Zone Fault Zone 1A

Red Off The system has detected a zone faultcondition. The controller has stoppedworking.

System Status Heating

Orange On The system is in the process of heatingall available and enabled zones to theirset point temperatures.

System StatusStandby Mode

Blue On The system has been manually orautomatically placed into Standbymode.

Operation 4-7


Using the Master Controls

Use the Master Controls display to switch on/off the primary controls of thecontroller, including the heater and scheduler as well as to manually placethe controller into standby mode.

From the Home Screen, touch Master

Controls to access the Master Controlsdisplay.

Standby

Settings System

Master Controls

Heater Control

Heaters: Off

Scheduler

Scheduler: Off

Standby

Done

Standby: Off

Figure 4‐6 The Master Controls display screen

What you can do from Master Controls

Switch on/off the following master control buttons:

� Heater Control

� Standby

� Scheduler

Operation4-8


What you can do from Master Controls (contd)

Settings

Modify the default settings.

Settings Functions

Temperature � Global Set Point

� Temperature Limits

� Standby

Inputs � Configure standard inputs

Outputs � Configure standard outputs

System

Modify the default system settings.

Settings Functions

Formats/Units � Time

� Date

� Temperature

� Pressure

Date/Time Current date and time

Service Interval Set Service schedules

Scheduler Define daily heat and standby events

Password � Create/Modify (codes)

� Timeout

� Set Security Level

Display � Brightness/Contrast

� Screen Saver Delay

� Calibrate Screen

� Wipe Display

Administration � System Reset

� Display/Save Diagnostics

� Reset Password

� Recipes

� RTD Options

� Lockout Communications

� Firmware version information

� Heaters On hours

Language Select languages from the available list

Operation 4-9


Master Controls Setup


The controller is shipped from the factory with preconfigured system settingsand ready to use. However, there are some settings that you must configureand finetune to best fit your manufacturing process.

1. From the Home Screen, touch Master

Controls to access the MasterControls display. See Figure 4‐6.

2. Touch the color coded button to switch On or Off the following:

Master Control Function

Heater Control Manually switch the heaters On/Off. By default, themaster heater control is Off.

NOTE: The master heater control automaticallyswitches off when the controller is in a Fault condition.

Standby Manually switch the controller in or out of standbymode.

Scheduler Manually switch the scheduler option On/Off.

NOTE: Refer to Scheduled Events in theConfiguration section for more information.

3. Touch the color coded button to enable or disable the zone. Touch Done.

What the Button Colors Indicate

The following table details what the Heater Control, Standby, and Schedulerbuttons indicate.

Button Color Description

Green On

White Off

Operation4-10


Understanding the Zones

Use the Zone display screen to re‐configure the zone settings to best fit yourmanufacturing requirements.

Type Default Name Notes

ExternalZones

Zone (# + letter)for example Zone 1A

� External zones include hoses, applicators and optional air

heaters.

� Default name consists of the word Zone, and its corresponding

channel number. Typically, these are pairs, where the letter Arepresents a hose and the letter B represents the applicator. Youcan change these default channel associations.

� At least one zone is required for normal operation.

Touch any of the Zone buttons, highlighted in the following figure, to accessthe Zone display screen.

Zone 3B

175�C

MasterControls

Zone 1A

175�C

Zone 1B

175�C

Zone 2A

175�C

Zone 3A

175�C

Zone 2B

175�C

Heaters: On Recipes


System Status:

Password: Disabled



Figure 4‐7 The Zone buttons

Operation 4-11


About Zone States and Statuses

Figure 4‐8 details what an enabled zone displays. Refer to Tables 4‐2 and4‐3 for a detailed list and explanation of each zone state and status.

3

1

Zone 1A

175� C

Set Point: 180 �C

2

Figure 4‐8 Zone button details

1. Name of zone 2. Set point 3. Real‐timetemperature

Table 4‐2 Zone State and Status Color Reference

Zone States

Button Color State Notes

Zone 1A

175�C

White Disabled The zone is available, but disabled.

Gray Unavailable The system cannot detect the zone.

Operation4-12


Understanding the Zones (contd)

Table 4‐3 Zone State and Status Color Reference

Zone Status

Button Color Status Notes

Zone 1A

180� C

Set Point: 180� C

Dark green Ready/OK The zone is enabled and has reached its set pointtemperature.

Zone 1A

145� C

Set Point: 180� C

Light green Waiting forReady

� The zone is enabled and is in the process of heating to

its set point temperature.

� A zone is in an alert or fault condition.

� The system itself is in an alert or fault condition.

Zone 1A

180� C

Set Point: 180� C

Blue Standby The system is in Standby mode.

Zone 1A

Alert

Yellow Alert The zone is enabled, but the system has detected an alertcondition. Touch the Status Indicator button to viewsystem message.

NOTE: In an alert condition, the master Heater controlremains On.

You have two minutes from the time the systemdetects an RTD or an over/under temperaturecondition before the alert condition is upgraded to afault condition.

Zone 1A

Fault

Red Fault The zone is enabled, but the system has detected a faultcondition. Touch the Status Indicator button to viewsystem message.

NOTE: In a fault condition, the master Heater controlis switched Off.

NOTES:

� You can modify zones at any time.

� Changes to set point temperatures and PID Type take effect when the

zone is enabled and when the controller itself is in a Ready/OK state.

� Changes to the zone name and enabling/disabling take effect when you

touch Done.

� The default name is displayed unless you modify it.

� The state of a zone is independent of the overall status of the controller.

Configuration 5-1

Part 1123727_01E 06/2014 Nordson Corporation

Section 5Configuration


Configure the ZonesConfiguring zones includes the following tasks:S Enabling and disabling external zonesS Defining individual setpoint temperaturesS Creating or modifying external zone namesS Modifying default channel PID typesRefer to Understanding the Zones in Operation for more information.

Configuration5-2


Enabling and Disabling the Zones

Use the Zone screen to enable or disable a specific zone.

Heaters: On Recipes


System Status:

Password:Disabled

MasterControls

Zone 3B

175�C

Zone 1A

175�C

Zone 1B

175�C

Zone 2A

175�C

Zone 3A

175�C

Zone 2B

175�C

Zone 1ADone

Zone 1A

Zone State:Enabled

Adjust Set Point

Create/Modify Name

Zone 1A

Change PID Type

Hose175�C


Zone 1A

Zone State: Enabled

2

1

3

Figure 5‐1 Zone button details

1. Name of zone

2. Color coded Enable/Disable button

3. Current zone state

Configuration 5-3


1. From the Home Screen, touch

ZONE 1A

175�C

.

2. Touch the color coded button to enable or disable the zone. Touch Done.

Button Color Description

Green On

White Off

Modifying Zone Setpoint Temperatures

Use the numeric keypad to assign setpoint temperatures.

Zone 1ADone

Zone 1A

Zone State:Enabled

Adjust Set Point

Create/Modify Name

Zone 1A

Change PID Type

Hose175�C Done

Cancel7 8 9

4 5 6

1 2 3

0

Zone 1A - Set Point

400

�F

Home


ZONE 1A

175�C

Set Point: 180� C

.

2. Touch Adjust Set Point and enter the temperature.

3. Touch Done.

Configuration5-4


Modifying Zone Names

Use the following screen to assign unique names for each of the zones.

Zone 1ADone

Zone 1A

Zone State:Enabled

Adjust Set Point

Create/Modify Name

Zone 1A

Change PID Type

Hose175�C

Done

Cancel

Q

Zone 1A

W E R T Y U I O P

A S D F G H J K L

Z X C V B N M

Zone 1AHome

123…


ZONE 1A

175�C

Set Point: 180� C

.

2. Touch Create/Modify Name and enter the name you want for this zone.The name can be up to 15 characters long. Spaces, dashes, underscoreand numbers count as a single character.

3. Do the following to continue:

� Touch to switch between upper and lower letters.

� Touch 123 …

to include numeric and extended special

characters.

� Touch to delete.

� Touch to add space.

4. Touch Done when finished.

Configuration 5-5


Modifying Zone PID Types

PID is an acronym for Proportional, Integral, Derivative, which is a continuousfeedback loop that ensures the desired amount of adhesive. The systemtakes appropriate corrective action when there is a deviation from either theflow rate or pressure set point. These deviations could be caused byanything from a slight change in line speed, ambient temperature or due to ablockage in a filter or applicator.

PID loops can be tuned manually or automatically using various techniques.Tuning techniques that compute PID constants only get you close to theoptimal system response. Manual adjustments are typically required forfine-tuning the system response.

Term Description

P Controls how fast the system responds to changes.

I Controls the offset error between the setpoint and the actual.

D Used to optimize the system response - but only if thefeedback signal is stable.

Note: Always leave the Derivative constant set to zero unlessthe feedback signal is very stable and noise free; otherwise,you may experience unstable system response.

Although default PID values are provided, they should be used as a startingpoint from which you can fine-tune to best suit your manufacturing process.

By default, the system assigns PID types as follows:

� Zones ending with the letter A with a Hose

� Zones ending with the letter B with a Standard Applicator.

NOTE: PID types optimize the performance of the device.

Configuration5-6


Modifying Zone PID Types (contd)

Zone 1A Done

Zone 1A

Zone State:Enabled

Adjust Set Point

Create/Modify Name

Zone 1A

Change PID Type

Hose175�C

Hose

Large Gun

Standard Gun

Air Heaters

MiniBlue

External Zone 1A Done

Home


ZONE 1A

175�C

Set Point: 180� C

.

2. Touch Change PID Type and select the appropriate button for theselected zone.

3. Touch Done.

Configuration 5-7


Configure the Master Controls


Configuring the Settings

The Settings screen provides access to the following operational settingsthat are frequently changed:

� Temperature

� Input

� Output

Access Temperature Settings

The following sections detail:

� Defining a global setpoint temperature

� Defining temperature limits

� Defining standby settings


Controls .

2. Touch Settings.

Settings System

Heater Control

Heaters: On

Scheduler

Scheduler: Off

Master Controls Done

Standby

Standby: Off Done

Home

Settings

Temperature

Input

Output

Configuration5-8


Defining a Global Set Point Temperature

Use global setpoint temperature to configure all zones with a uniform setpointtemperature.

Default Minimum Maximum

175°C (350°F) 40 °C (104 °F) 204 °C (400 °F)

NOTE: Defining a global setpoint temperature enables previously disabledzones.

DoneTemperature

Global Set Point

Temperature Limits

Standby Temp

Home

Manual

Done

Cancel�F 7 8 9

4 5 6

1 2 3

0

Global Set Point Temperature

50 Home

1. On the Settings screen touch Temperature.

2. Touch Global Set Point and enter the global setpoint temperature youwant for all available zones.

3. Touch Done.

Configuration 5-9


Defining Temperature Limits

Use Temperature Limits to define the number of degrees a zone canincrease or decrease from its assigned setpoint temperature before atemperature alert/fault occurs.

Setting Default Minimum Maximum

Over Temperature 15°C (59°F)

5°C (41°F) 60°C (140°F)Under Temperature 25°C (77°F)

NOTE: The system displays an Alert message if either an over or undertemperature event occurs to any zone.

NOTE: The zone itself changes to yellow

Zone 1A

Alert. If you do not

resolve the over/under alert condition within two minutes of it being detected,the Alert changes to a Fault condition, causing the Heater Controls toautomatically switch Off.

DoneTemperature

Global Set Point

Temperature Limits

Standby Temp

Home

Done

Cancel�F 7 8 9

4 5 6

1 2 3

0

Temperature Limits

25

Over Temperature

Under Temperature�F

50

Home


2. Touch Temperature Limits and enter over and under temperaturethresholds you want to enforce.

3. Touch Done.

Configuration5-10


Defining Standby Temperature Settings

Define the temperature degree (from the setpoint temperature) of all enabledzones that you want to decrease while in standby mode.

DoneTemperature

Global Set Point

Temperature Limits

Standby Temp

Home

Done

Cancel�F 7 8 9

4 5 6

1 2 3

0

Standby Temp

100 Home


2. Touch Standby Temp.

Default is 50�C (100�F)

Minimum temp is 5�C (41�F)

Maximum temp is 43�C (110�F)

3. Touch Done.

Configuration 5-11


Configure Input Settings

The controller is equipped with four standard user‐configurable inputs.

NOTE: Adhesive dispensing applicators are referred to as guns in someinstances.

Done

Home

Settings

Temperature

Input

Output

Output 2

Output 3

Input 1

Input 2

Input 3

Input 4

Status

Disabled

Disabled

Disabled

Disabled

Input Done

Home

1. On the Settings screen, touch Input.

2. Touch the lnput button that you want to modify.

3. Touch to select from the default settings. Refer to the Default InputSettings for more information.

4. Touch Done.

Default Input Settings

By default, all four inputs are pre-configured for you. The following tabledetails the defaults and available input options.

Input # Default Available Options

Input 1 Standby � Disabled

� Standby

� Heater Control

� Hose/Gun 1

� Hose/Gun 2

� Hose/Gun 3

Input 2 Heater Control

Input 3 Hose/Gun1

Input 4 Hose/Gun 2

Configuration5-12


Configure Output Settings

The controller is equipped with three standard user‐configurable outputs.

Done

Home

Settings

Temperature

Input

Output

Output 1

Output 2

Output 3Output

Output 1

Output 2

Output 3

System Ready

System Ready

Alert

Done

Home

Status Invert

1. On the Settings screen, touch Output.

2. Touch the Output button that you want to modify.

NOTE: Select Invert when the parent machine is not readily able to usethe default output logic.

3. Touch to select from the default settings. Refer to the Default OutputSettings for more information.

4. Touch Done.

Configuration 5-13


Default Output Settings

By default, all three outputs are pre-configured for you. The following tabledetails the defaults and available output options.

Output # Default Available Options

Output 1 System Ready � Disabled

� System Ready (see

Note A)

� Fault (see Note C)

� Alert (see Notes B

and C)

� Service Reminder

Output 2 Fault

Output 3 Alert

NOTE A: When this control option condition occurs, contacts close.Contacts are normally open when power is off.

B: Alert provides an output signal when a warning condition orpotential fault is detected. The alert output signal is active(open‐contact) during the alert period. If the alert condition isnot corrected, a fault output signal is generated. When the faultoutput signal is active (open‐contact), the alert output signalbecomes inactive (close‐contact).

C: When this control option condition occurs, contacts open.Contacts are normally open when power is off.

Configuration5-14


Configuring System Settings

The following sections detail the following:

� Formats and units

� Date and time

� Service intervals

� System schedules

� System passwords

� Display options

� Administrative tasks

� Language


Controls .

2. Touch System.

Settings System

Heater Control

Heaters: On

Scheduler

Scheduler: Off


Standby

Standby: Off

System Done

Formats/Units

Date/Time

Service Interval

Scheduler

Password

Display

Administration

03/20/2012 4:40 PM

500

Home

Language

Configuration 5-15


Formats and Units

The following table details the default selection for each system-wideformat/unit, as well as its available options.

Item Default Available Options

Date Format mm/dd/yy � yy/mm/dd

� dd/mm/yy

� mm/dd/yy

Time Format 12 � 12

� 24

TemperatureFormat

°C � °C

� °F

Pressure Format PSI � kPa

� Bar

� PSI

NOTE: Pressure units apply only if you have the Flow and Pressure OptionBoard installed.

System Done

Formats/Units

Date/Time

Service Interval

Scheduler

Password

Display

Administration

03/20/2012 4:40 PM

500

Home

Formats/Units DoneDate

Time

Temperature

Pressure

yy/mm/dd dd/mm/yy mm/dd/yy

12 24

�C �F

kPa Bar PSI

Home

1. On the System screen, touch Formats/Units.

2. Touch the selection you want to use for each format/unit.

3. Touch Done.

Configuration5-16


Date and Time

The date and time you define here is used by the system for all time and daterelated functions, such as the Event Log and Service Intervals.

System Done

Formats/Units

Date/Time

Service Interval

Scheduler

Password

Display

Administration

03/20/2012 4:40 PM

500

Home

English

Date/Time SettingsDate

Done

Time

Day of the Week:

Cancel

Home

PM

7 8 9

4 5 6

1 2 3

0

03/20/2012

4:40 PM

Tuesday

1. On the System screen touch Date/Time.

2. Enter the current date and time.

3. Touch Done.

Configuration 5-17


Service Intervals

Service interval refers to the number of hours the heaters have been on.

Default Minimum Maximum

500 hours 0 hour 8760 hours

System Done

Formats/Units

Date/Time

Service Interval

Scheduler

Password

Display

Administration

03/20/2012 4:40 PM

500

Home

Done

CancelHours 7 8 9

4 5 6

1 2 3

0

Service Interval

500 Home

Clear Service Reminder

1. On the System screen, touch Service Interval.

2. Enter the number of heater on hours after which you want the system todisplay a service reminder message.

3. Touch Done.

Resetting Service Interval Messages

When the heaters have been on for more than the defined (default 500)hours, a pop-up message appears and the system status indicatesReady/Service.

There are two ways to reset the service interval value.

� From the Service Reminder pop-up message

� From the Service Interval screen

Configuration5-18


Scheduled Events

Use the Scheduler to set up the system to automatically switch the heatersOn or Off and to automatically enter and exit the standby mode at specifiedtimes.

Heaters On

Enter Standby - break

Heaters Off

Exit Standby

Enter Standby - shift change

Exit Standby

NOTE: About scheduling events:

� Define up to 12 events per day.

� Each day can have its own unique schedule.

� Copy and paste schedules to other days of the week.

� Scheduled events cannot cross over to the next day.

Creating a Schedule of events is a 3-step process

Step 1: Access the Scheduler and verify that the system date, time and dayof week are correct.

Step 2: Define the first work day of the week that you want to startscheduling events.

Step 3: Switch On the Scheduler control.

Configuration 5-19


Step 1: Access the Scheduler and verify that the system date, time and dayof week are correct

System Done

Formats/Units

Date/Time

Service Interval

Scheduler

Password

Display

Administration

03/20/2012 4:40 PM

500

Home

Display

Administration

Language

English

Scheduler

Sun Mon ThuTue FriWed Sat

Current Date/Time Settings:

Tuesday 03/20/2013 9:56 AM

Cancel

Home

Select day to edit:

Change Date/Time

1. On the System screen, touch Scheduler.

2. To schedule events, touch Change Date/Time

to set the date, time, andday of the week.

It is recommended that you start with the first working day of the week, forexample Monday, and work forward. You can only copy/paste schedulesfrom one day to the next, not backwards.

NOTE: To make corrections, do the following:

� If the date and time need to be revised, touch Change Date/Time

and enter the correct information.

� If the settings of a day need to be revised, touch the appropriate day

of the week button and enter the correct information.

Configuration5-20


Scheduled Events (contd)

Step 2: Define the first work day of the week that you want to startscheduling event

Scheduler: Monday

Add Heat Event

Turn Heaters On:

Done

Cancel

Turn Heaters Off:

6:30

18:00

Home

1. Do the following to continue:

Touch Description

Add Heat Event

Enter the time when you want the heaters to switch On and Off.

Typically, you would have only one heat event per day.

Add Standby Event

Enter the time when you want the system to enter, then exit StandbyMode.

You can include multiple Standby events to include lunch breaks, shiftchanges and so on.

To remove the event.

Configuration 5-21


2. Do you want to copy this exact schedule to the other days of the week?

If…. Then

Yes

a Touch to copy the schedule into memory.

b Touch Next Day.

c Touch to paste the schedule to the day you want.

d Repeat steps b and c until you are done. Proceed to Step 3.

No a Touch Next Day to configure a different schedule.

b Touch Done. Proceed to Step 3.

Step 3: Switch On the Master Scheduler

Zone 3B

175�C

MasterControls

Zone 1A

175�C

Zone 1B

175�C

Zone 2A

175�C

Zone 3A

175�C

Zone 2B

175�C

Heaters: On Recipes


System Status:

Password: Disabled Settings System

Scheduler

Scheduler: Off


Standby

Standby: Off


Heater Control

Heaters: On

1. On the System screen, touch Scheduler to switch On.

2. Touch Done.

Configuration5-22


Password Protection

By default, password protection is disabled.

The following are default password level numeric codes:

Level # Default Code Notes

1 1000 � Cannot start with the number 0 (zero).

� Can be one up to five numbers long.

� The largest 5 digit number is 65535.

� Each level must have a unique numeric code.

2 2000

3 3000

System Done

Formats/Units

Date/Time

Service Interval

Scheduler

Password

Display

Administration

03/20/2012 4:40 PM

500

Home

Done

Help

Password

Create/Modify

Timeout

Set Security Level

5 mins.

Home

1. On the System screen, touch Password.

2. Do the following to continue. When finished, touch Done.

Touch Description

Create/Modify Modify the default numeric password code for eachlevel.

Timeout The amount of time (the default is 1 minute) theselected password protection becomes active afterno user interaction with the touchscreen.

Set Security Level Refer to Table 5‐1 for an explanation of eachsecurity level.

Configuration 5-23


The following table indicates the different security levels:

� High Security includes levels 1, 2 and 3

� Medium Security includes levels 2 and 3

� Low Security includes only level 3

Table 5‐1 Security Level Details

Security Level Functions Enabled High Medium Low

Level 1 (high) Temperature set point

Level 2(medium)

Under-temperature/over-temperature warnings/faults

Level 3 (low) Application names (temperature channels)

Switch between °C, °F

Switch between bar, psi, kPa (only if you have the Flowand Pressure Option Board installed)

Temperature channel settings (PID control mode)

Maximum temperature set point

Assign standard I/O inputs for application groups

Seven-day clock settings: (delete/edit schedule, copyschedule)

Restore default settings

Customer setup (recipes / application names)

Service interval

Password setup

Configuration5-24


Display Settings

The following table details what you can define, along with the default andavailable options.

Setting Default Minimum Maximum

Brightness/Contrast 75% | 75% 30% 100%

Screen Saver Delay 5 minutes 1 minutes 120 minutes

Calibrate Screen -- -- --

Wipe Display 30 seconds -- --

System Done

Formats/Units

Date/Time

Service Interval

Scheduler

Password

Display

Administration

03/20/2012 4:40 PM

500

Home

DoneDisplay

Brightness/Contrast

Screen Saver Delay

Calibrate Screen

Wipe Display

Home

75% | 75%

5 min

Configuration 5-25


1. On the System screen, touch Display.

2. Do the following to continue.

Touch Description

Brightness/Contrast Enhance the visibility and readability of thetouchscreen displays.

Screen Saver Delay The amount of time (default 5 minutes) of no userinteraction with the touchscreen before the screensaver appears.

The screen saver only displays the controller statusand its corresponding color. To extend the lifespanof the touchscreen itself, the brightness andcontrast are reduced from its current settings to30%

Touch anywhere on the screen to access the HomeScreen.

Calibrate Screen Allows you to improve the accuracy of yourinteraction with the touchscreen.

Touch the + symbol to calibrate the touchscreen.

Wipe Display Locks the screen for 30 seconds, allowing you toclear dust from the touchscreen without touching abutton and accidentally changing a setting.

3. Touch Done.

Configuration5-26


Administration Settings

The following sections detail the following:

� Reset system defaults

� Display and save diagnostics

� Reset password level codes

� Manage recipes

� Change RTD types

� Lock out controller communication

� View firmware version information

� View heaters On hours

System Done

Formats/Units

Date/Time

Service Interval

Scheduler

Password

Display

Administration

03/20/2012 4:40 PM

500

Home

AdministrationDone

System Reset

Display/Save Diagnostics

Reset Password

Recipes

RTD Options

Lockout Communications

Hours Heaters On 0Firmware Version: 2.661

Off

Home

On the System screen, touch Administration.

Refer to the following sections for more information.

Configuration 5-27


Resetting System Defaults

Use System Reset to revert all user definable software settings back tofactory defaults.

NOTES:

� Use a recipe to restore controller settings.

� Recipes and event log information are stored on the Customer SD

card.

AdministrationDone

System Reset


Reset Password

Recipes

RTD Options



Off

Home

Motor Board 1 Firmware Version: 44

System Reset Done

Home

Reset Alarm - Level 1

Parameters only

Parameters and custom names

Reset System- Level 2

Are you sure you want to revert back to factory settings?

Yes No

Confirm

CAUTION! There are two SD cards installed in the control panel board. Youcan remove or access only the Customer SD card for upgrading to the latestsoftware. Do not remove the Internal SD Card, doing so may disrupt thecontroller operation. For more information refer to Appendix B, UpgradeSoftware and Firmware in Appendix B.

Configuration5-28


Resetting System Defaults (contd)

1. On the Administration screen, touch System Reset.

2. Decide what you want to do next.

Touch Description

Reset Alarm - Level 1Parameters only

A Confirm pop-up message appears:

� Touch Yes or No.

If Yes, then the system reverts to thefactory default settings.

If No, then the system retains thecurrent settings.

� Touch Done.

Reset System - Level 2Parameters andcustomer names

A Confirm pop-up message appears:

� Touch Yes or No.

If Yes, then the system reverts to thefactory default settings and names.

If No, then the system retains thecurrent settings.

� Touch Done.

Configuration 5-29


Viewing Event Logs - Save Diagnostics

Use the event log to view a list of up to 200 of the most recent fault, alert, andparameter change events. You can save those events from memory to theCustomer SD card. The default file name is EventLog.csv.

Additionally, a Diagnosticsfile.xml, file is also written to the Customer SDcard. This file contains detailed controller information. The informationcontained in both files can help Nordson technical support troubleshoot yourissue. For the location and additional information refer to Appendix B,Upgrade Software and Firmware.

NOTES:

� The system writes the entire event log to the Customer SD card,

regardless of what level of detail you selected.

� The event log can display up to 200 events, after which the oldest

event is overwritten with new events.

� You cannot clear nor change the name of either file.

Recipes

RTD Options


Hours Heaters On

10.0797 770 hours

Display/Save Diagnostics Next

BackComplete EventLog

Faults Only

Warnings Only

Parameter/Set PointChanges

Display/Save DiagnosticsBack

05/04/12 11:52:20 Event Ready enterDone

Save File

Source: System Status: OK

Zone/Parameter: 0 Zone/Sub-code: 0

05/04/12 11:50:50 Event Ready enter



05/04/12 11:40:03 Event Zone control off

Source: HMI Status: OK


05/04/12 11:34:29 Event Ready enter



Old value: 1 New value: 0

Home

Home

Configuration5-30


Viewing Event Logs - Save Diagnostics (contd)

1. On the Administration screen, touch Display/Save Diagnostics andselect from the list of event log you want to view.

2. Touch Next to view the details of the most recent event log.

3. Decide what you want to do next.

Touch Description

Back Select a different event log option to view.

Done Exit the event log to go to the Administrationscreen.

Save File Save both the event log and the diagnostic file tothe Customer SD card. For the location andadditional information refer to Appendix B,Upgrade Software and Firmware.

Touch this button only one-time. Depending onthe number of events in the log, this can take afew minutes.

When done, the Attention message appears,indicating The diagnostics file was saved to theSD Card.

The default names are:

EventLog.csv

Diagnosticsfile.xml

Home Exit the event log to go to the Home Screen.

4. Touch Done.

Configuration 5-31


Resetting Password Level Codes

Use Reset Password to revert all 3 levels of password codes back to theirdefault codes.

The following are the default password level numeric codes:

Level # Default Code Notes

1 1000 � Cannot start with the number 0 (zero).

� Can be one up to five numbers long.

� The largest 5 digit number is 65535.

� Each level must have a unique numeric code.

2 2000

3 3000

AdministrationDone

System Reset


Reset Password

Recipes

RTD Options



Off

Home

Confirm

Are you sure you want to reset all passwords tofactory default?

Yes No

1. On the Administration screen, touch Reset Password. A pop-upmessage appears.

2. Touch Yes to revert all three password level codes to their default values.

3. Touch Done.

Configuration5-32


Managing Recipes

Use recipes to save production settings, such as zones settings, as well asother controller settings including scheduled events, and security settings, toa file that you can use, modify and delete.

NOTES:

� Recipes are stored on the Customer SD Card. For the location and

additional information refer to Appendix B, Upgrade Software andFirmware.

� Refer to Table 5‐2 for more information about what is saved to a

recipe.

� The controller retains the settings of the previously loaded recipe,

even if you delete or decide not to make use of a recipe.

Configuration 5-33


Access the Recipes Screen

You can access the Recipes screen by doing one of the following:

a. From the Home Screen, touch Recipes.

NOTE: The Recipes button displays the name of the currently loadedrecipe, otherwise displays:

Recipes

Nothing Loaded

Heaters: On Recipes


System Status:

Password: Disabled

RecipesNothing Loaded

OR

b. From the Master Controls, touch System, Administration, and thenRecipes.

AdministrationDone

System Reset


Reset Password

Recipes

RTD Options



Off

Home


Recipes Next

Cancel

Load or Deletea Recipe

Do not use a Recipe

Save Recipe

Home

Configuration5-34


Access the Recipes Screen (contd)

1. On the Administration screen, touch Recipes.

2. Decide what you want to do and touch Next to continue.

Touch Task Description

Load or Delete aRecipe

Load a recipe

Select an existing recipe you want use.

Touch Load. In the Confirm pop‐up message box, you needto confirm Yes or No.

Delete a recipe

Select an existing recipe you no longer want to use.

Touch Delete. In the Confirm pop‐up message box, youneed to confirm Yes or No.

NOTE: The controller retains the settings of the previouslyloaded recipe.

Do not use aRecipe

Unload and/or notmake use of anyrecipe

Unloads the currently loaded recipe.

Select this option when troubleshooting or performingmaintenance on the controller.

NOTE: The controller retains the settings of the previouslyloaded recipe.

Save Recipe

Create a newrecipe

Do the following:

1 Configure and test controller settings until it meets yourmanufacturing requirements.

2 Access the Recipes screen, touch Save Recipe andenter an easily identifiable recipe name.

NOTES:

� To update the settings of the recipe, enter the exact

same recipe name.

� The system unloads the currently loaded recipe, then

saves the new settings and automatically loads it.

Modify an existingrecipe

Configuration 5-35


What's Being Saved in a Recipe

The following highlights what a recipe is saving to a file.

Table 5‐2 Recipe Details

General Information Administration Information

� Software Version

� Language

� Date, Time, Temp and Pressure format

� Under and Over Temperature threshold values

� Configuration settings for standard and expanded

Inputs and Outputs

� Service Alerts (enabled or disabled)

� Service Interval value

� RTD Type value

� Scheduler (enabled or disabled)

Settings and events for each day of the week

� Selected password level

� Numeric password code for each password

level

� Password Timeout value

Temperature Information Zone Information

� Standby Temperature

� Standby (enabled or disabled)

� Zone (enabled or disabled)

� Default and user-defined names

� Setpoint values

� PID values

Configuration5-36


Changing RTD Types

The RTD type is preset when the temperature controller is shipped from thefactory:

If your temperature controller is configured with 120 Ohmnickel RTD, thedefault setting is NI120.

If your temperature controller is configured with 100 Ohmplatinum RTD,the default setting is PT100.

AdministrationDone

System Reset


Reset Password

Recipes

RTD Options



Off

Home


RTD Options

NI120

PT100

Home

Done

Configuration 5-37


Locking Out Communications

Use this feature to prevent remote access to the controller while you aretroubleshooting or performing maintenance on the controller.

AdministrationDone

System Reset


Reset Password

Recipes

RTD Options



Off

Home

1. On the Administration screen, touch Lockout Communication totoggle On or Off.

2. Touch Done.

Viewing Firmware Version and Heater On Hours

Access the Administration screen to view:

� Firmware Version

� Hours Heaters On

AdministrationDone

System Reset


Reset Password

Recipes

RTD Options



Off

Home

1. On the Administration screen, review the Firmware Version and/orHours Heaters On hours for information.

2. Touch Done.

Configuration5-38


Language

Use this screen to select from the following languages.

System Done

Formats/Units

Date/Time

Service Interval

Scheduler

Password

Display

Administration

03/20/2012 4:40 PM

500

Home

LanguageDone

Home

Language

1. On the System screen, touch Language.

2. Touch the language selection.

3. Touch Done.

Maintenance 6-1


Section 6

Maintenance

WARNING! Allow only personnel with appropriate training and experience tooperate or service the equipment. The use of untrained or inexperiencedpersonnel to operate or service the equipment can result in injury, includingdeath, to themselves and others, and damage to the equipment.

Preventive Maintenance

Table 6‐1 provides recommended maintenance activities and a schedule forperforming those activities. Base how often you perform maintenance onyour operating conditions.

Table 6‐1 Recommended Maintenance

Activity Interval Procedure

Inspect forexternal damage

Daily When damaged parts pose a risk to the operational safetyof the unit and/or safety of personnel, switch off thesystem and have the damaged parts replaced by qualifiedpersonnel. Use only original Nordson spare parts.

Clean the exterior Daily Remove dust, flakes, etc. with a vacuum cleaner or a softcloth.

Do not damage or remove warning labels. Replace anydamaged or removed warning labels.

For information on relieving pressure refer to the appropriate melter manual.

Maintenance6-2


Troubleshooting 7-1


Section 7

Troubleshooting


WARNING! Observe all safety instructions and regulations concerningenergized unit components (active parts). Failure to observe may result in anelectric shock.

This section contains troubleshooting procedures. These procedures coveronly the most common problems that you may encounter. If you cannotsolve the problem with the information given here, contact your local Nordsonrepresentative for help.

Safety� Before breaking any hydraulic connection, always relieve system

pressure. Refer to the melter manual for detailed instructions.

� Refer to the safety information provided with optional equipment.

Troubleshooting7-2


Touch Screen Alerts and Faults The controller diagnoses many alert and fault conditions that may occurduring operation. An “alert” condition is a situation in which a potentialproblem may be occurring with the controller. The controller will operateunder an “alert” condition unless the problem goes unresolved, at which pointthe controller will go into a “fault” condition, during which it will shut down untilthe problem is resolved.

All the tables in this section use the Cause and Corrective Action columnsto help resolve the alert or fault condition.

Zone Alerts/Faults

Screen Message Cause Corrective Action(s)

Temperature for[ZoneName] hasdropped belowdefined setpointthreshold

The actual temperature of the componenthas dropped below the set temperature limit

Check for conditions that may cause a dropin ambient temperature or replace thecomponent.

Check fuses for affected zone.

Temperature for[ZoneName] hasrisen above definedsetpoint threshold

The actual temperature of the componenthas risen above the set temperature limit

Check for conditions that may cause anincrease in ambient temperature or replacethe component.

Check control circuit board for affected zone.

Short RTD on[ZoneName]

The RTD for the component indicated hasfailed or the component was disconnectedfrom the melter

Check the connections, or replace the RTD.

Open RTD on[ZoneName]

Troubleshooting 7-3


System Alerts


FieldbusCommunicationsFailure

Fieldbus card failure Visually check the wiring connections fordamage. If necessary replace the Fieldbuscard.

Failed motor controlboard

Communication failure between control panelboard and the motor control board

Visually check the wiring connections fordamage. If necessary replace motor controlboard or control panel board.

NVRAM test failureInternal RAM failure Visually check the wiring connections for

damage. If necessary replace control panelboard.

Analog-to-DigitalFailure

RTD analog‐to‐digital converter failed Visually check the wiring connections fordamage. If necessary replace the main boardor control panel board.

Troubleshooting7-4


System Faults


Brownout

Plant power dipped and came back up Typically nothing to address, unless thesystem does not operate properly, or variousmessages appear.

Stop/Start the controller.

Analog-to-DigitalFailure Calibration

Failed hose or applicator

RTD analog‐to‐digital converter could not becalibrated (grounded RTD in system)

Replace hose or applicator.

NOTE: Set setpoint to zero to avoid fault.

Replace Main Board or ribbon cable, orcontrol panel board.

Expansion BoardConnection Failure

Communication failure between expansionboard and main board

Visually check the ribbon cable connectionsbetween the expansion board and the mainboard.

Expansion BoardFailure

Visually check the wiring connections fordamage. If necessary replace the expansionboard.

User Interface Failedto Load

Visually check the wiring connections fordamage. If necessary do the following:

� Reload SD card information.

� Replace SD card.

� Replace control panel board.

Main Board FailureVisually check the wiring connections fordamage. If necessary replace the mainboard.

RAM FailureVisually check the wiring connections fordamage. If necessary replace the controlpanel board.

Motor ThermostatFailure

Faulty jumper connection Check jumpers and connections at motorcontrol board.

Runaway fault on[ZoneName]

Temperature continues to rise beyond setpoint.

Visually check the wiring connections fordamage. If necessary replace the mainboard.

Repair 8-1


Section 8

Repair


WARNING! Risk of electrocution! Turning the power switch off does notremove high‐voltage power from the controller. Before opening the enclosuredoor, make sure that the local power disconnect switch is in the off positionand locked. Failure to properly disconnect power can result in personalinjury, including death.

WARNING! The internal boards contain energized electrical componentswith potentials that can cause death, serious injury, or equipment damage.Allow only qualified personnel to perform the following procedures.

Repair8-2


Replace the Control Panel Board

CAUTION! Before removing the new board assembly from its anti‐static bag,ground yourself by touching any bare metal part of the equipment chassis orany grounded structure. Failure to properly ground yourself can causeelectrostatic discharge, resulting in damage to the board.

1. Disconnect and lock out power to the controller.

2. Open the controller door and locate the control panel board.

3. Disconnect the ribbon cables and other cables from the control panelboard.

Figure 8‐1 Removing the control panel board

4. Remove and retain the four nuts that secure the control panel board andthen remove the assembly.

Repair 8-3


5. Install the new control panel board and secure with the four nuts removedin step 4.

NOTE: To insert and secure the nuts easily, you may need to remove theCustomer SD card from the new control panel board. If you do so, makesure to reinstall the Customer SD card once the new control panel boardis installed.

6. Align the cable connectors correctly on the control panel board pinterminals.

Figure 8‐2 Location of CustomerSD card on the controlpanel board

7. Re‐connect the ribbon cables and other cables on the new control panelboard.

8. Close the controller door.

9. Restore power and switch on the controller.

For information on upgrading to the latest software, refer to UpgradeSoftware and Firmware in Appendix B.

Repair8-4


Replace the Main Board

CAUTION! Before removing the new board assembly from its anti‐static bag,ground yourself by touching any bare metal part of the equipment chassis orany grounded structure. Failure to properly ground yourself can causeelectrostatic discharge, resulting in damage to the board.

1. Turn off the controller power switch.


3. Open the controller door and locate the main board.

4. Disconnect all cables from the control panel board.

Figure 8‐3 Removing the main board

5. Remove and retain the four M4 nuts that hold the main board, and thenremove the assembly.

6. Install the new main board using the four M4 nuts that were removed instep 5.

7. Reconnect all of the power and control cables to the new main board.



Repair 8-5


Replace the Expansion Board 1. Turn off the controller power switch.


3. Open the controller door and locate the expansion board.

4. Disconnect all cables from the expansion board.

1

2

Figure 8‐4 Removing the expansion board and mounting plate assembly

1. Mounting plate 2. Expansion board

5. Remove and retain the screws that hold the expansion board andmounting plate assembly.

6. Remove the expansion board from the mounting plate. Retain themounting plate and the screws.

7. Install the new expansion board to the mounting plate (removed in step 6)using the screws also removed in step 6.

Repair8-6


Replace the Expansion Board (contd)

8. Install the new expansion board and mounting plate assembly using thescrews that were removed in step 5.

9. Reconnect all the control cables to the new expansion board.



Parts 9-1


Section 9

Parts

Boards

The following boards are used in the controller.

Part Description Quantity

1122064 KIT,SVCE,MAIN,PCA,IP54 1

1025597 PCA,EXPANSION,DURABLUE 1

1121884 SERVICE KIT,LCDW/FRAME,ASSEMBLY,CONCERT

1

1121887 SERVICE KIT, PCA POWER SUPPLY, 24VDC 1

Ship with Kits

The ship with kit contains the following connectors and accessories.

Part Description Quantity

227569 JUMPER3/N/PE,AC 400-230V 1

232617 JUMPER,1/N/PE AC,200-240V 1

227568 JUMPER,3/PE AC,200-240 V 1

227567 JUMPER,200-240V 1PH,3000V 1

Parts9-2


Optional Communication Cards

The following optional communication cards are available.

Part Description

1053287 KIT,CIRCUIT BOARD,PROFIBUS CARD

1053288 KIT,CIRCUIT BOARD,DEVICENET CARD

1053289 KIT,CIRCUIT BOARD,ETHERNET CARD

Technical Data A-1


Appendix A

Technical Data

Specifications

General

Item Specification

Temperature sensor � 100 Ohm Platinum RTD

� 120 Ohm Nickel RTD

Hose/applicator pairs 1 and 2:

� Each zone supports up to 1000 W

� Both zones together support up to 1200 W

� Both pairs together support up to 2000 W

3 (Special):

� One zone supports up to 1000 W and the

other supports up to 1800 W

� Both zones together support up to 2800 W

Input/Output 4 inputs and 3 outputs

Inputs: 10 ‐ 30 VDC, 10 mA, not polarity sensitive

Outputs: Up to 240 VAC, 2A or 30 VDC, 2A

Operating Conditions

Item Specification

Ambient temperaturerange

0-40 �C (32-104 �F)

Enclosure rating IP33

Humidity 5-95% non‐condensing

Technical DataA-2


Electrical

Item Specification

Power 200 - 240 VAC, 1 or 3 ph, 17 ‐ 20A

400/230 VAC, 1 or 3 Y, 20A

Total power limitation 4800W all zones combined

Technical Data A-3


Default User Settings and RangesThe following details default settings and ranges for user definable controller,and temperature settings.

System Settings

Item Default Range/Option

Date Format mm/dd/yy yy/mm/dd

dd/mm/yy

mm/dd/yy

Temperature Format C C

F

Time 12 12

24

Service Interval 500 (hours) Minimum: 0

Maximum: 8760

Scheduler No entries Minimum: 2 events per day

Maximum: 12 events per day

Password Security Level No Password Protection High

Medium

Low

No Password Protection

Password Timeout 1 (minutes) Minimum: 1

Maximum: 60

Password Level Codes Level 1: 1000Minimum: 1

Maximum: 65535Level 2: 2000

Level 3: 3000

Display Brightness/Contrast 75% 30, 60, 75, 100

Screen Saver Delay 5 (minutes) Minimum: 1

Maximum: 120

Lockout Communications Off On

Off

Technical DataA-4


Temperature Settings


Set points External zone: 175°C (350°F) Minimum: 40 °C (104 °F)

Maximum: 204 °C (400 °F)

Global: 175°C (350°F) Minimum: 40 °C (104 °F)

Maximum: 204 °C (400 °F)

Temperature limits Overtemperature: 15°C (25°F) Minimum: 5 °C (41 °F)

Maximum: 60 °C (140 °F)

Undertemperature: 25°C (50°F) Minimum: 5 °C (41 °F)

Maximum: 60 °C (140 °F)

Automatic Standby Disabled Enabled

Disabled

AutoExit Standby Time Disabled Enabled

Disabled

Auto Standby Start Time 0 (minutes) Minimum: 0 minutes

Maximum: 1,440 minutes

Auto Exit Standby Time 0 (minutes) Minimum: 0 minutes

Maximum: 180 minutes

Auto Heaters Off Time 60 (minutes) Minimum: 0 minutes

Maximum: 1,440 minutes

Standby Temperature 50°C (100°F) Minimum: 5 °C (41 °F)

Maximum: 60 °C (140 °F)

Technical Data A-5


Input/Output Settings

NOTE: Adhesive dispensing applicators are referred to as guns in someinstances.


Input 1 Standby � Disabled

� Standby

� Heater Control

� Hose/Applicator 1



Input 2 Heater Control

Input 3 Hose/Gun 1

Input 4 Hose/Gun 2

Output 1 System Ready � Disabled

� System Ready

� Alert

� Fault

� Service Reminder

Output 2 Fault

Output 3 Alert

Technical DataA-6


Schematic

PE

Figure A‐1 Temperature Controller Schematic

Upgrade Software and Firmware B-1


Appendix B

Upgrade Software and Firmware


WARNING! Allow only personnel with appropriate training and experience tooperate or service the equipment. The use of untrained or inexperiencedpersonnel to operate or service the equipment can result in injury, includingdeath, to themselves and others, and damage to the equipment.

WARNING! Risk of electrocution! Disconnect and lock out electrical power tothe equipment. Failure to properly disconnect power can result in personalinjury, including death.

Upgrade to Latest Software Upgrades typically include changes to both the CPU software and MotorControl Board firmware.

WARNING! The internal boards contain energized electrical componentswith potentials that can cause death, serious injury, or equipment damage.Allow only qualified personnel to perform the following procedures.

Upgrade Software and FirmwareB-2


Upgrade to Latest Software (contd)

1

2

Figure B-1 Location of the Customer and Internal SD Cards

1. Customer SD Card 2. Internal SD Card

CAUTION! There are two SD cards installed in the control panel board. Youcan remove or access only the Customer SD card (item 1 in Figure B‐1) forupgrading to the latest software. Do not remove the Internal SD Card (item 2in Figure B‐1), doing so may disrupt the controller operation.


2. Open the controller door and locate the control panel board.

3. Locate the Customer SD card and remove. Refer to Figure B‐1.

4. Using a PC, copy the *.dat file to the root of the SD Card.

NOTE: It is recommended that you copy and rename the *.dat file,appending the current date in case you want to revert back a differentsoftware\firmware version.

NOTE: It is also recommended that you copy the *.dat files to another backstorage media in case the SD card is damaged.

5. Re‐install the Customer SD Card on control panel board.

6. Reconnect power and switch On the controller.

Upgrade Software and Firmware B-3


7. The system automatically detects a new *.dat file and does the following:

� A copy of the current *.dat file is copied into the \backup directory on

the SD Card.

� The CPU board is upgraded first, followed by the Motor Control

board(s).

� The entire upgrade process should take approximately 10 minutes.

When done, the software automatically reboots the melter. Theupgrade is complete.

Starting

Entering Flash

Loader Version: 01.05

Found Upgrade File

Updating Firmware

Percent Complete: 40

Figure B-2 The upgrade process


Upgrade Software and FirmwareB-4


Revert to a Previous Software VersionAs part of the upgrade process, the current *.dat file is automatically copiedinto the \backup directory of the Customer SD Card.

1. Refer to Upgrade to Latest Software, follow steps 1, 2, and 3 to begin theupgrading process.

2. Using your PC, do the following:

� Navigate to the \backup directory and copy the *.dat file you want.

� Navigate to the root of the SD Card and paste the *.dat file.

� If you previously renamed the *.dat file, then you must change it back

to its original name.

3. Refer to Upgrade to Latest Software, follow steps 5, 6 and 7.

Information about Recipes

For more information on recipes, refer to Resetting System Defaults, ViewingEvent Logs, and Managing Recipes in Administrations Settings in theConfiguration section.

Use recipes to save production settings, such as zones settings, as well asother settings including scheduled events and security settings, to a file thatyou can use, modify and delete.

EC Declaration of Conformity

for Adhesive and Sealant Application Equipment conforming to European Council Directives

PRODUCTS:

Concert™ Control System

APPLICABLE DIRECTIVES:

Low Voltage Directive: 2006/95/EC

Electromagnetic Compatibility Directive: 2004/108/EC

STANDARDS USED TO VERIFY COMPLIANCE:

EN 61010‐1 EN 61010‐2‐010

EN 61010‐2‐201

EN 55011 (Class A, Group 1 for industrial environments. Use in

other environments may pose potential difficulty ensuring

electromagnetic compatibility due to conducted as well as

radiated disturbances.)

PRINCIPLES:

This product has been manufactured according to good engineering practice.

The product specified conforms to the directives and standards described above.

Technical File Contact:

Dieter Ziesmer

Nordson Engineering GmbH

Lilienthalstrasse 6

21337 Lueneburg

GERMANYDate: 06/June/2014

Gregory P. Merk, Senior Vice PresidentAdhesives Dispensing Systems

1122124_02

DOC078R2

Nordson Corporation � 28601 Clemens Road ��Westlake, Ohio

Model Number_________________________

Serial Number______________________________________

Year of Manufacture (Last Two Digits) _________________

Documents

Concert Series Basic Standalone Temperature Controlleremanuals.nordson.com/adhesives/English_Manuals/1123727.pdf · 2014-09-26 · Concert™ Series Basic Standalone Temperature Controller