Nordson Sure Coat Manual Download Page 29

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Installation

A 3-1

Part 331235C

2003 Nordson Corporation

Part A: System Overview

Section A 3

Installation

WARNING:

Allow only qualified personnel to perform the following tasks.

Follow the safety instructions in this document and all other related

documentation.

Introduction

This section explains general installation procedures for the Sure Coat

modular gun control system. Installation procedures for optional

components are explained in their individual parts of this manual.

NOTE:

If you order any of the optional upgrade kits for the modular gun

control system, installation and operation instructions will be shipped with

the kit.

NOTE:

Refer to the powder application equipment manuals for additional

installation instructions.

Mounting

NOTE:

The modular gun control system is mounted on top of a varying

number of metal bases. The number of the bases is dependant upon the

number of pneumatic modules used in the system. The bases raise the

modular gun control system so that the central control unit will be at eye

level.
1. The modular gun control system is shipped bolted upright to a wooden

pallet. Unbolt the modular gun control system from the pallet.

2. Find a clean, flat floor surface to install the modular gun control system.

The area should be near the powder spray booth main electrical panel

and air supply.

3. Bolt the modular gun control system to the floor or booth operator

platform using suitable, customer-supplied hardware.

Summary of Contents for Sure Coat

Page 1: ...HERST OHIO USA For parts and technical support call the Industrial Coating Systems Customer Support Center at 800 433 9319 or contact your local Nordson representative This document is subject to chan...

Page 2: ...Attn Customer Service 555 Jackson Street Amherst OH 44001 Notice This is a Nordson Corporation publication which is protected by copyright Original copyright date 2000 No part of this document may be...

Page 3: ...ed were installed when the system was manufactured Use the following chart to record the components contained in your system If you upgrade your system at a later date be sure to update the informatio...

Page 4: ...mentation if you misplace any parts of your manual NOTE Parts A and B apply to all configurations of the system If you order part A you will automatically receive parts A and B a three ring binder and...

Page 5: ...ion Section A4 Operation Section A5 Troubleshooting Section A6 Parts Section A7 Part B Pneumatic Modules Description Section B1 Operation Section B2 Repair Section B3 Parts Section B4 Part C Interface...

Page 6: ...Table of Contents ii Part 331235C E 2003 Nordson Corporation Part A System Overview...

Page 7: ...ed 4 03 NORDSON CORPORATION AMHERST OHIO USA For parts and technical support call the Industrial Coating Systems Customer Support Center at 800 433 9319 or contact your local Nordson representative Th...

Page 8: ...Attn Customer Service 555 Jackson Street Amherst OH 44001 Notice This is a Nordson Corporation publication which is protected by copyright Original copyright date 2000 No part of this document may be...

Page 9: ...8 Pneumatic Modules A 2 8 Main Control Cabinet A 2 8 Front View A 2 8 Back View A 2 10 Optional Equipment A 2 12 Gun Purge Module A 2 12 Automated Triggering Controls A 2 12 Interface Cards A 2 12 Spe...

Page 10: ...or Codes A 6 4 Clearing Error Codes A 6 5 Alarm Override A 6 5 Gun Driver Cards A 6 6 Switches A 6 6 LEDs A 6 6 Electrical Schematics A 6 8 Central Control Unit A 6 8 Solenoid and Gun Control Panels A...

Page 11: ...afety rules and 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 th...

Page 12: ...protection devices 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 m...

Page 13: ...pray area must be grounded S 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...

Page 14: ...Safety A 1 4 Part 331235C E 2003 Nordson Corporation Part A System Overview...

Page 15: ...information Table A 2 1 System Components Item Component Description 1 Application Triggering Controller Optional Automates triggering for all guns in the system Refer to Optional Equipment in this s...

Page 16: ...d monitoring functions for all automatic powder spray guns connected to the Sure Coat modular gun control system The control status information and parameters are adjusted and viewed from the front pa...

Page 17: ...is controlled by each individual gun panel 3 Gun Display LED Indicates which gun is currently being viewed on the display Indicates which gun s set points may be adjusted 4 Gun Select Key Selects an i...

Page 18: ...ected gun Pressing the button continuously causes the set point value to decrease until the minimum value is reached 17 Gun Type LEDs Indicates the type of gun IPS or Tribomatic connected to the syste...

Page 19: ...ctual parameter information Additional information that may be shown is gun on hours total hours error codes kV set point A set point and actual A value The display is blank when no appropriate value...

Page 20: ...Panel Components Item Component Description 1 Ground Stud Grounds the central control unit enclosure 2 AC IN Cable Feed Through Connects main ac power to the central control unit 3 AC OUT Knockout Su...

Page 21: ...nd current to coat parts effectively Mode 3 Deep Cavity This mode is for coating inside boxes or other deep cavities This mode uses fixed low voltage and current to coat front edges and high voltage a...

Page 22: ...me each gun has been triggered This timer cannot be reset The total spray timer can be viewed by pressing the Nordson key and going into the diagnostics mode Time is shown as HRS x 10 The numeral 1 ap...

Page 23: ...part of the manual for a description of the three modes of operation 2 Gun Driver Cards Slots 1 8 Allow the modular gun control system to interface with the individual guns and pneumatic modules Each...

Page 24: ...on A 2 10 Part 331235C E 2003 Nordson Corporation Part A System Overview Back View See Figure A 2 6 and refer to Table A 2 6 1400862A 6 1 10 7 3 2 9 8 5 4 Figure A 2 6 Main Control Cabinet Components...

Page 25: ...ing controller 4 Network Cable Feed Through Connects the network interface cable to the main control cabinet from the central control unit 5 Purge Manifold Optional Sends pilot air signal to activate...

Page 26: ...r a purge timer interface card for triggering guns in groups or discrete I O interface card for triggering guns individually Interface Cards Interface Card Description Purge Timer The purge timer inte...

Page 27: ...egory III Pneumatic Operating Air Pressures Minimum input air pressure 5 6 bar 80 psi Maximum input air pressure 7 bar 100 psi Typical Air Pressures Flow rate air 2 bar 30 psi Atomizing air 1 bar 15 p...

Page 28: ...1235C E 2003 Nordson Corporation Part A System Overview Symbols See Figure A 2 7 1400863A FLOW RATE AIR ATOMIZING AIR GUN AIR ELECTROSTATICS GROUND GUN PURGE DIAGNOSTICS MODE SYSTEM PURGE ERROR GUN TR...

Page 29: ...ed with the kit NOTE Refer to the powder application equipment manuals for additional installation instructions Mounting NOTE The modular gun control system is mounted on top of a varying number of me...

Page 30: ...Refer to Table A 3 1 Connect the leads to the booth s main electrical panel using the information listed in Table A 3 1 6 Connect the the gun cables to the cable receptacles on the gun receptacle pan...

Page 31: ...Remove screws securing the main I O panel 5 to the rear of the main control cabinet 2 Carefully remove the main I O panel from the main control cabinet 3 See Figure A 3 1 Locate the main terminal blo...

Page 32: ...ibomatic Not Required 1 Versa Spray guns can only use the gun air connection if the gun is equipped with a diffuser Refer to your Versa Spray gun manual for more information about the gun diffuser 1 S...

Page 33: ...nnections 1 Gun air connector 2 Atomizing air connector 3 Flow rate air connector 4 Gun receptacle panel 5 Main I O panel 6 Main electrical line 7 Ground stud 8 Flexible air hose 9 Ball valve 10 Main...

Page 34: ...Installation A 3 6 Part 331235C E 2003 Nordson Corporation Part A System Overview...

Page 35: ...also perform these procedures to change your system to fit changing application requirements Restoring Factory Default Settings If you are not satisfied with the settings that you have set up for your...

Page 36: ...play 8 press the PGM key 16 CHOOSE CONFIG scrolls across the display and LEDs blink on the keys that correspond to the configurable options 3 Refer to Table A 4 2 for a list of the system s configurab...

Page 37: ...M key Gun Mapping See Figure A 4 1 The central control unit gun panels 1 are factory configured in one of the following ways S Horizontal numbering Left column controls odd numbered guns right column...

Page 38: ...t key The gun select LED lights to indicate the gun s new location 6 Repeat steps 4 and 5 to assign as many guns as necessary NOTE If you have an odd number of guns in your system one location must be...

Page 39: ...ation mode press the corresponding configurable option key Configurable option keys are indicated by blinking LEDs 4 To exit the configuration mode press the Nordson key 15 Select Charge AFC Enable Di...

Page 40: ...pressure settings 1 Enter the configuration mode Refer to Entering Configuration Mode for instructions 2 See Figure A 4 1 Press the ALL key 10 DENY CHANGE scrolls across then either 0 or 1 appears th...

Page 41: ...nuals for additional operation instructions before operating the modular gun control system Interface and Conveyor Interlock Signals The following paragraphs explain how the system operates depending...

Page 42: ...connected to an application triggering controller or remote PLC the guns turn on or off at different times depending on the status of the conveyor and trigger signals Refer to Table A 5 3 Table A 5 3...

Page 43: ...the on position There is one switch on the back of the main control cabinet and one on the back of the central control unit Make sure that all the icons on the display light NOTE The system performs a...

Page 44: ...desired spray pattern by adjusting the flow rate and atomizing air pressures 4 Record the A output with no parts in front of the gun 5 Monitor the A output daily under the same conditions A significa...

Page 45: ...ng initial adjustments to the guns NOTE Figure A 5 3 shows the typical display when the gun is triggered Refer to the Description section in this part of the manual for more information about the disp...

Page 46: ...a pre programmed group of guns S ALL Key 9 Triggers all guns in the system 5 Adjust the set points as necessary Refer to Set Point Adjustments in this section for more information NOTE Obtaining a hi...

Page 47: ...Range 0 then 25 95 kV 0 then 33 100 kV On Adjust the desired AFC set point by using the keys The factory set starting point is 30 A If the set point is changed the controller remembers the new set po...

Page 48: ...ormation 2 AFC set point adjustment can be enabled or disabled by reconfiguring the system Refer to Select Charge Enable Disable in the Configuration section for more information Mode Application Desc...

Page 49: ...T ALL mode 5 Press the ALL key 9 to test the spray patterns Setting Up Groups of Guns The central control unit can be programmed to trigger an operator specified group of guns at the same time The cen...

Page 50: ...type etc STD and Nordson while the system is powering up Shutdown 1 Stop triggering all guns in the system NOTE If the control system is wired to the booth electrical panel you may leave the control s...

Page 51: ...trode assembly or multiplier is shorted or failed Refer to the Troubleshooting section for more information WARNING Check all ground connections thoroughly Ungrounded equipment and parts may accumulat...

Page 52: ...Operation A 5 12 Part 331235C E 2003 Nordson Corporation Part A System Overview...

Page 53: ...gun is not triggered is a warning to the operator that voltage may be present at the gun because of faulty hardware Failure to observe this warning may result in an electrical shock Icon Icon Status G...

Page 54: ...ts in an automatic exit from this mode and a return to the previous operating mode NOTE Do not power off the system unless instructed Error codes are erased when the system is powered off WARNING Do n...

Page 55: ...e number 2 is displayed in the upper left corner e All segments and icons light on the LCD display f The controller type is displayed for example SC3 g The software version is displayed for example 3...

Page 56: ...ck the multiplier cable and electrode assembly for loose connections If the connections are secure check the multiplier with a ohmmeter as described in the gun manual If the multiplier reading is acce...

Page 57: ...en wiring can be found replace the power supply 29 Gun mapping error Reconfigure gun numbering on the central control unit 30 Incompatible module Incorrect software version Install new gun driver soft...

Page 58: ...r card Flashing once for approximately two seconds Power up reset when no node applications Wait for the gun driver card to initialize If it does not initialize replace the card Repeated short on puls...

Page 59: ...dson Corporation Part A System Overview 1400872A 6 7 8 5 2 1 3 4 Figure A 6 3 Gun Driver Card Switches and LEDs 1 SW1 2 SW2 3 Red alarm LED 4 Yellow service LED 5 Green status LED 6 Green power LED 7...

Page 60: ...E COAT MGC SYS MAIN CABINET TERMINAL BLOCK NET AC IN TERMINAL BLOCK AC OUT POWER SUPPLY 24VDC 5VDC 12VDC SUPRESSOR FILTER SWITCH CENTRAL CONTROL KEYPAD MODULE 24 14 23 13 SK1 1 N 3 L SK2 1 2 3 4 5 6 B...

Page 61: ...GUN DRIVER GUNS 1 2 TO J1 GUN CONTROL PANEL REAR VIEW STANDARD DOUBLE MODULES DOUBLE F1 F2 MODULES or DUAL GUN DRIVER GUNS 3 4 TO J2 DUAL GUN DRIVER GUNS 5 6 TO J3 DUAL GUN DRIVER GUNS 7 8 TO J4 DUAL...

Page 62: ...LUE BROWN BLUE GRN YEL GRN YEL SK1 POWER SUPPLY 24V 250W SK 7 SK5 SK4 SK3 MAIN OUTPUT RED BLACK GRN YEL P S CHASSIS BLACK P3 P4 P1 P2 1 J1 J2 J3 J4 J5 J6 J7 J8 J9 J10 1 1 1 SURE COAT BACKPLANE 308183...

Page 63: ...B C D E F G H PE GRN YEL L1 L2 L1 L2 L1 L2 L1 L2 BROWN BLUE FILTER GRN YEL BROWN BLUE BROWN BLUE SWITCH 24 14 23 13 CABINET GROUND GRN YEL GRN YEL 20K RED ORANGE YELLOW YELLOW CONDUIT WIRE TERMINAL BL...

Page 64: ...Troubleshooting A 6 12 Part 331235C E 2003 Nordson Corporation Part A System Overview...

Page 65: ...part cannot be ordered separately The Description column gives the part name as well as its dimensions and other characteristics when appropriate Indentions show the relationships between assemblies s...

Page 66: ...REW machine M pan recessed M4 x 8 2 6 BASE 8 in AR 7 BASE 5 in AR 8 982470 SCREW hex cap M6 x 45 mm black AR 9 983409 WASHER lock M split M6 AR 10 303147 PANEL front base 4 5 in AR 11 303148 PANEL fro...

Page 67: ...Parts A 7 3 Part 331235C E 2003 Nordson Corporation Part A System Overview 1400855A 13 3 3 2 1 4 5 1 6 7 12 8 9 11 10 14 Figure A 7 1 System Components and Hardware Front View...

Page 68: ...6 AR 9 983080 WASHER flat e 0 500 x 1 125 x 0 083 in AR 10 983180 WASHER lock e split 1 2 in AR 11 984170 NUT hex regular 1 2 13 AR 12 981602 SCREW hex 1 2 13 x 2 5 in cap 4 13 981604 SCREW hex 1 2 13...

Page 69: ...A 7 5 Part 331235C E 2003 Nordson Corporation Part A System Overview 1400874A 1 3 4 1 4 9 13 14 16 17 19 20 22 2 5 6 7 5 2 8 10 11 12 10 11 15 18 18 21 Figure A 7 2 System Components and Hardware Back...

Page 70: ...zinc 1 4 1007124 S SCREW thumb round head metric M6 1 5 1007120 S HANDLE flush mount pull snap in 1 6 1007123 S WIRE ground assembly 18 0 in 1 7 984702 S NUT hex M5 brass 1 8 983401 S WASHER lock m sp...

Page 71: ...Parts A 7 7 Part 331235C E 2003 Nordson Corporation Part A System Overview 1400856A 15 2 3 4 5 6 7 8 9 10 11 6 16 13 12 14 1 Figure A 7 3 Sheet Metal Covers...

Page 72: ...5067 SUPPRESSOR ferrite 7 mm dia 1 13 305938 SWITCH keylock 3 position rotary 1 B 13 1000594 SWITCH keylock 3 position 1 C NS 1000595 CONTACT BLOCK 1 NO and 1 NC contact 1 C 14 240674 TAG ground 5 15...

Page 73: ...Parts A 7 9 Part 331235C E 2003 Nordson Corporation Part A System Overview 1400875A 10 DETAIL A 13 12 9 8 5 2 1 1 3 6 4 7 DETAIL A 14 17 18 16 11 15 Figure A 7 4 Main Control Cabinet Front View...

Page 74: ...it 2 9 334700 MANIFOLD purge gun 1 10 334799 SCREW pan recessed M5 x 10 with integral lock washer bezel 34 11 PANEL gun control 1 A 12 PANEL I O main controller 1 B 13 PANEL solenoid 1 C 14 933005 CON...

Page 75: ...Parts A 7 11 Part 331235C E 2003 Nordson Corporation Part A System Overview 1400876A 11 13 12 6 9 15 7 8 10 10 3 4 5 1 2 6 7 8 7 8 14 Figure A 7 5 Main Control Cabinet Back View...

Page 76: ...021 S WASHER flat e 0 203 x 0 406 x 0 040 in brass 1 8 983401 S WASHER lock M split M5 1 9 984702 S NUT hex M5 brass 1 10 334800 S PLUG 1 2 in pipe 1 in hex AR NS 334783 ADAPTER gun cable Versa Spray...

Page 77: ...solenoid connector 1 2 334773 S RECEPTACLE 4 position solenoid AR 3 334753 S GASKET panel solenoid 1 4 240674 S TAG ground 1 5 983021 S WASHER flat e 0 203 x 0 406 x 0 040 in brass 1 6 983401 S WASHER...

Page 78: ...W with fan 1 7 S BRACKET power supply 24 V 1 8 981039 S SCREW pan 6 32 x 0 312 in slotted 2 9 983102 S WASHER lock split 6 zinc 2 10 334780 S HARNESS power ac 1 11 334817 S POWER SUPPLY 60 W with cove...

Page 79: ...Parts A 7 15 Part 331235C E 2003 Nordson Corporation Part A System Overview 1400879A 1 2 3 4 5 6 DETAIL A 10 11 14 15 17 18 21 16 12 13 19 20 DETAIL A 6 8 9 7 Figure A 7 8 Sub Panel Assembly...

Page 80: ...lane 1 3 982824 SCREW pan recessed M3 x 8 with integral lock washer bezel zinc 8 4 334801 GUIDE printed circuit board 7 in 20 NS 308178 PCA Sure Coat dual gun driver AR A NS PCA interface 1 B NOTE A E...

Page 81: ...Parts A 7 17 Part 331235C E 2003 Nordson Corporation Part A System Overview 1400880A 1 2 2 3 4 Figure A 7 9 Card Frame...

Page 82: ...ule 40 1 2 10 in long 1 9 901151 S VALVE ball 1 2 NPT 1 10 972620 S CONNECTOR male 37 1 1 16 12 x 1 2 in brass 1 11 S GASKET bulk 0 25 x 0 50 in with PSA AR 12 163435 S CLAMP 0 75 in conduit one hole...

Page 83: ...Parts A 7 19 Part 331235C E 2003 Nordson Corporation Part A System Overview 1400881A 2 1 3 4 5 7 9 10 6 12 11 13 14 15 16 17 15 16 17 8 DETAIL A DETAIL A 18 19 20 21 20 Figure A 7 10 Pneumatic Section...

Page 84: ...M5 brass 1 7 240674 S TAG ground 1 8 143010 S FITTING carflex liqtite 1 2 in 1 9 143009 S CONDUIT carflex liqtite 1 2 in 20 ft 1 10 931221 S TUBING heat shrink 0 046 in ID 0 187 ft long 1 11 320586 S...

Page 85: ...331235C E 2003 Nordson Corporation Part A System Overview 1400857A 7 4 12 10 11 15 17 18 19 3 2 5 6 16 1 9 8 14 13 V D E R C P P 1 5 2 L1 L1 L1 L1 L2 L2 L2 L2 E G F H L1 L1 20 21 Figure A 7 11 Main I...

Page 86: ...EL rear central control unit Sure Coat 1 3 982825 S SCREW pan recessed M4 x 12 with integral lock washer bezel 20 4 240674 S TAG ground 2 5 982437 S SCREW pan M5 x 10 brass 1 6 983401 S WASHER lock M...

Page 87: ...Parts A 7 23 Part 331235C E 2003 Nordson Corporation Part A System Overview 1400882A 4 8 6 7 9 4 2 10 3 1 5 6 7 11 3 Figure A 7 12 Central Control Unit Assembly...

Page 88: ...12 983403 S WASHER lock M split M4 steel zinc 2 13 984715 S NUT hex M4 steel zinc 2 14 S FILTER line RFI power 1 15 982824 S SCREW pan recessed M3 x 8 with integral lock washer bezel 4 16 288803 S POW...

Page 89: ...t 331235C E 2003 Nordson Corporation Part A System Overview 1400854A AC OUT AC IN O I NET 24 1 6 7 8 12 14 15 16 1 19 22 28 18 2 3 17 2 3 4 5 9 10 11 13 25 26 27 23 21 20 Figure A 7 13 Central Control...

Page 90: ...odule purge manifold purge timer interface card and instructions Part Description Note 1040836 KIT Sure Coat gun purge upgrade Application Triggering Controllers NOTE To integrate these controllers in...

Page 91: ...tially Explosive Atmospheres Directive STANDARDS USED FOR COMPLIANCE EN292 EN50081 EN50177 EN50014 EN50082 IEC417L EN50020 EN55011 FM7260 EN50050 EN60204 PRINCIPLES This product has been manufactured...

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