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Powder Pilot

™ HD

P/N 7192721_02

Page | 4

Table of Contents

.................................................................................................................................................. 5

Introduction

................................................................................................................................... 5

Qualified Personnel

...................................................................................................................... 5

Intended Use

.................................................................................................................................. 5

Regulations and Approvals

.......................................................................................................... 5

Personal Safety

............................................................................................................................. 6

Fire Safety

...................................................................................................................................... 6

Grounding

........................................................................................................................................... 7

PE (Protective Earth) Grounding ............................................................................................................. 8

Electrostatic Grounding ............................................................................................................................ 8

Disposal ................................................................................................................................................. 11

Description

....................................................................................................................................... 12

Product Information ................................................................................................................................ 12

Console dimensions ............................................................................................................................... 13

Specifications ......................................................................................................................................... 13

Booth Operation ................................................................................................................................. 14

Start-up sequence: ................................................................................................................................. 14

BOOTH CONTROL SCREEN

................................................................................................................ 15

Screen elements .................................................................................................................................... 17

GUNS TRIGGERED STATUS SCREEN

................................................................................................ 21

GUN SET POINT STATUS SCREEN

..................................................................................................... 22

GUN FEEDBACK SCREEN

................................................................................................................... 23

GUN SPRAY CONTROL

........................................................................................................................ 24

Group set point adjust

............................................................................................................................ 26

GUN CONFIGURATION

........................................................................................................................ 27

BOOTH CONFIGURATION

................................................................................................................... 29

PUMP CONTROLLER CONFIGURATION

............................................................................................ 31

PURGE TIMING CONFIGURATION

...................................................................................................... 33

Spectrum

CONTROL SECTION

......................................................................................................... 34

Spectrum

MANUAL CONTROL SECTION

......................................................................................... 36

Spectrum

CONFIGURATION SECTION 1

.......................................................................................... 37

Spectrum

CONFIGURATION SECTION 2

.......................................................................................... 38

COLOUR CHANGE OPERATION

.......................................................................................................... 39

Troubleshooting

............................................................................................................................... 45

Repair

................................................................................................................................................ 45

Customer Specific Information

...................................................................................................... 47

Parts

.................................................................................................................................................. 48

Console Parts

......................................................................................................................................... 48

Summary of Contents for PowderPilot HD

Page 1: ...PowderPilot HD PowderPilot HD Controls Manual P No 7192721_02 Issued 09 2017 NORDSON Deutschland GmbH ERKRATH GERMANY...

Page 2: ...Powder Pilot HD P N 7192721_02 Page 2...

Page 3: ...Powder Pilot HD P N 7192721_02 Page 3...

Page 4: ...rt up sequence 14 BOOTH CONTROL SCREEN 15 Screen elements 17 GUNS TRIGGERED STATUS SCREEN 21 GUN SET POINT STATUS SCREEN 22 GUN FEEDBACK SCREEN 23 GUN SPRAY CONTROL 24 Group set point adjust 26 GUN CO...

Page 5: ...d regulations and are physically capable of performing their assigned tasks Intended Use Use of Nordson equipment in ways other than those described in the documentation supplied with the equipment ma...

Page 6: ...s To prevent injury be aware of less obvious dangers in the workplace that often cannot be completely eliminated such as hot surfaces sharp edges energized electrical circuits and moving parts that ca...

Page 7: ...d There is a possible ignition potential from the charged human body Personnel standing on a painted surface such as an operator platform or wearing non conductive shoes are not grounded Personnel mus...

Page 8: ...ground wires do not protect against electrostatic discharge Electrostatic Grounding Electrostatic grounding protects electronic equipment from damage caused by electrostatic discharges ESD Some electr...

Page 9: ...lding ground back to the controller through a ground braid and back to the spray gun through the gun driver board The current attracted to the booth is returned through the booth ground to the control...

Page 10: ...and Equipment Always use the special flat braided copper ESD ground cables furnished with all Nordson spray gun controllers to ground them The ESD ground cables should always be attached to the welded...

Page 11: ...Identify the reason for the malfunction and correct it before restarting the equipment Disposal Dispose of equipment and materials used in operation and servicing according to local codes Safety Label...

Page 12: ...ator and the machine In addition the control panel is fitted with an Emergency Stop push button a Reset push button and a klaxon unit The 15 touch sensitive screen is used for all interactions between...

Page 13: ...HD including booth control section PowderPilot HD without booth control section Specifications Electrical supply 400 VAC 50Hz 3PH Rated power 31 kVA Panel environmental rating IP54 The cabinet must be...

Page 14: ...er up the control panel via the isolator located on the front of the panel door 3 Power up the after filter control panel via the isolator located on the front of the panel door 4 Ensure the emergency...

Page 15: ...the park position Note The extract fan will run on for 30 seconds after the booth is stopped to remove any remaining air borne powder from the booth B park This button stops the oscillators and mover...

Page 16: ...curs with the system will enable an audible Klaxon alarm to attract the operators attention to the fault Pressing this key silences the alarm The yellow light within the light stack will continue to i...

Page 17: ...f away from the product regardless of the product size There is one entry for the mover on the left side of the booth and one for the mover on the right side 5 conveyor status speed This displays the...

Page 18: ...n these codes The fault codes indicated are explained as follows KV card faults Pump card faults E1 uA has not reached alarm set point This is used with Tribo guns where a low charge uA value is set f...

Page 19: ...is and only moves in and out between the ultimate limits by the operator pressing either key D1 to move in or E1 to move out of the booth CAUTION The operator has total responsibility for the operatio...

Page 20: ...Starts or stops the Oscillator Oscillator set up window Oscillator stroke in mm Distance from 1st gun on oscillator to the part recognition array Distance of last gun on oscillator to the part recogn...

Page 21: ...n the system will display the guns triggered status page as shown below A exit screen 1 2 1 gun 1 triggered The green background denotes that this gun is triggered 2 gun 8 not triggered The red backgr...

Page 22: ...cks This button displays the actual gun feedback screen as described separately 1 gun 1 powder set point This bar displays the current powder set point value applied to gun 1 Its units are displayed a...

Page 23: ...rently by gun 7 Its units are displayed in Standard Cubic Meters per hour SCMH 2 gun 1 pattern air feedback This bar displays the actual pattern air value being generated currently by gun 7 Its units...

Page 24: ...f four guns for set point adjustment C group set point adjust touching this button brings up a screen which allows the user to load set point to various groups of guns as described later on D next gun...

Page 25: ...the assist air compensation value 5 Gun trigger control This button determines whether the gun will fire or not If a red cross is displayed the gun will never fire If a green tick is displayed the gu...

Page 26: ...of guns to be selected 3 last gun the number of the last gun in a series of guns to be selected A all set points touching this symbol will download all set points to the selected guns B KV set point...

Page 27: ...keypad will appear to adjust it 2 before spray This value shows how many millimetres before the product arrives at the gun it will fire Touch the value and a keypad will appear to adjust it 3 gun par...

Page 28: ...is number can be reset by touching the display and entering zero into the keypad that will appear 8 fast pump mode selection touching this symbol will toggle the pump mode between fast and normal pinc...

Page 29: ...er of seconds during which a pulse is not received from the encoder that the conveyor is classed as stopped by the plc 3 Firmware version of the KV cards this shows the firmware of KV cards at the tim...

Page 30: ...Booth start to arrays This is the distance in millimetres from the beam arrays to the entrance of the booth 19 Pump card calibration this symbol is used to bring up the pump card calibration window as...

Page 31: ...e appropriate guns Exit screen Write screen 1 2 3 4 5 1 pump calibration value A enter the calibration value A written on the label sticking at the manifold for gun 1 2 pump calibration value B calibr...

Page 32: ...he actual group of guns is selected by using the pull down menu here 2 send values to pump controllers calibration values are sent to all 4 pump controllers selected on this page controllers Note chan...

Page 33: ...e number of pulses for cleaning the gun here 2 soft purge time guns specify the time for soft gun purging here in seconds 3 hopper pulses specify the number of pulses for cleaning hopper here 4 soft p...

Page 34: ...same functions as on the main screen F Colour change activating this button evokes the Colour change sequence described in the section colour change of this manual J Manual operation this button brin...

Page 35: ...the powder level drops below this an alarm is raised to inform the operator about this issue Hopper empty no level probe actually detects powder This can happen right after a colour change or when the...

Page 36: ...close the damper inside the main extraction duct behind the feed centre Note when this duct is closed the full extraction goes to the purge duct on top of the sieve 4 Recycle HDLV transfer pump on off...

Page 37: ...der when emptying the hopper 2 hopper empty time out Count down time after the low level probe gets free of powder when emptying the hopper After the countdown the OK button will be displayed to move...

Page 38: ...t a virgin powder mix ratio to realise a consistent amount of fines within the powder 5 virgin powder mix ratio The virgin ratio is set and the reclaim rate follows correspondingly e g If a ratio is s...

Page 39: ...n the screen above the operator can choose to carry on colour changing by touching this button or to cancel the procedure and go return to the Spectrum HD screen this button can be used at any time du...

Page 40: ...er The next screen asks the operator to move the powder box underneath the hopper to collect the powder still remaining inside the hopper After a box is placed under the hopper the operator pushes thi...

Page 41: ...mp valve on bottom of the hopper will be opened and powder is released into the box below it As soon as the low level probe is uncovered a timer starts to count down for a time to be set up during con...

Page 42: ...xtraction pipe above the sieve to the cleaning position and move the pump hoses to the extraction sockets He will also need to close the sieve opening with the delivered plugs to avoid powder leaking...

Page 43: ...avoided to open the cyclone hopper or anything else effecting the extraction Otherwise the cleaning result will be compromised The operator needs to start the cleaning of the HDLV transfer pumps by to...

Page 44: ...an be activated or stopped by touching the pump symbols on the right side of the screen This is visualized by the blue arrows again After cleaning the hoses need to be placed back to their operating p...

Page 45: ...e WARNING Hazardous voltages exist within the Spectrum HD console Unless power must be on to test circuits always shut off and lock out power before opening the console to make repairs All repairs sho...

Page 46: ...wear a grounding wrist strap connected to the Spectrum HD enclosure or other ground Handle the cards only by their top and bottom edges See Figure 5 1 Gun control cards 2 are installed in the card ca...

Page 47: ...ge 47 Section 6 Customer Specific Information Wiring electrical diagrams Appendix Please see the separate PDF FILE attached to this manual for more specific information about your individual system Wi...

Page 48: ...B 24 1098442 POWER SUPPLY 24V 250 watt w fan 2 C 2 C NOTE A One card controls the electrostatics for 2 automatic spray guns B Use to prevent fault LED from lighting when odd number of guns are connect...

Page 49: ...position gun 70 in AR A 27A 1023695 SEAL bulkhead 7 8 16 thread AR B 28 984526 NUT lock 1 2 in conduit AR 29 939122 SEAL conduit fitting 1 2 in AR 30 334800 PLUG 1 2 in AR NOTE A One receptacle is req...

Page 50: ...TAL FLOW NET PWR ICONTROL 1 per 16 guns 8 1033831 HARNESS CONTROL UNIT POWER ICONTROL 1 per 16 guns 9 1027138 HARNESS POWER 24V ICONTROL 1 per 16 guns 10 1042647 HARNESS SIGNAL INTERFACE ICONTROL 1 pe...

Page 51: ...Powder Pilot HD P No 7192721_02 Page 51 1 1031501 RECEPTACLE 8 POSITION GUN 70 IN 1 per gun 2 939122 SEAL CONDUIT FITTING 1 2 1 per gun 3 984526 NUT LOCK 1 2 CONDUIT 1 per gun...

Page 52: ...ARNESS POWER 5 12 12V ICONTROL 1 per 16 guns 5 1107144 PCA AUTO DUAL GUN DRIVER ENCORE 1 per 2 guns 12 1098444 GUIDE PCB CARD CONDUCTIVE 7 INCH 20 per 16 guns 13 334755 BRACKET CARDFRAME CTRL CAB 1 pe...

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