Process Sentry PLC Controller - Nordson

Process Sentry� PLC Controller

Customer Product ManualPart 1615366-01

Issued 01/19

NORDSON CORPORATION • AMHERST, OHIO • USA

For parts and technical support, call the Industrial CoatingSystems Customer Support Center at (800) 433-9319 or

contact your local Nordson representative.

This document is subject to change without notice.Check http://emanuals.nordson.com for the latest version.

Part 1615366-01 � 2018 Nordson Corporation

tents

Table of ContentsSafety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Qualified Personnel 1. . . . . . . . . . . . . . . . . . . . . . . . .Intended Use 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Regulations and Approvals 1. . . . . . . . . . . . . . . . . .Personal Safety 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-Pressure Fluids 2. . . . . . . . . . . . . . . . . . . . .Fire Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Halogenated Hydrocarbon Solvent Hazards 4.Action in the Event of a Malfunction 5. . . . . . . . . . .Disposal 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Theory of Operation 8. . . . . . . . . . . . . . . . . . . . . . . . .Alarms 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Security 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Guidelines 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operator Interface, Screens and Setup 10. . . . . . . .

User Login 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Test Points 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Status 18. . . . . . . . . . . . . . . . . . . . . . . . . . .Program Screen 20. . . . . . . . . . . . . . . . . . . . . . . . .Heating Screen (If equipped) 44. . . . . . . . . . . . . .Temperature Control Unit (TCU) (If equipped) 52Pumps Screen 54. . . . . . . . . . . . . . . . . . . . . . . . . .Diagnosis Screen 55. . . . . . . . . . . . . . . . . . . . . . . .Fault Reset 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Statistics Screen 58. . . . . . . . . . . . . . . . . . . . . . . . .Manual Operations 59. . . . . . . . . . . . . . . . . . . . . . .Data Log 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Product Manuals 62. . . . . . . . . . . . . . . . . . . . . . . . .Back 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Optional Controller Configurations 64. . . . . . . . . . . .

Part ID Setup Screen 65. . . . . . . . . . . . . . . . . . . . . . . .Limits 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Segment Volumes 68. . . . . . . . . . . . . . . . . . . . . . . .

Pre−Pressure Setup 69. . . . . . . . . . . . . . . . . . . . . . . . .Pro-Meter S PLC Dispenser 70. . . . . . . . . . . . . . . . . .

Installation 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Robot Interface/Communication Ethernet 71. . . . . .

Repair 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Parts 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PS PLC Controllers 74. . . . . . . . . . . . . . . . . . . . . . . . .Ordering Parts 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contact UsNordson Corporation welcomes requests for information, comments, andinquiries about its products. General information about Nordson can befound on the Internet using the following address:http://www.nordson.com.Address all correspondence to:

Nordson CorporationAttn: Customer Service555 Jackson StreetAmherst, OH 44001

NoticeThis is a Nordson Corporation publication which is protected by copyright.Original copyright date 2019. No part of this document may bephotocopied, reproduced, or translated to another language without theprior written consent of Nordson Corporation. The information containedin this publication is subject to change without notice.

Trademarks

Pro-Meter, Nordson, and the Nordson logo are registered trademarks ofNordson Corporation.

Process Sentry is a trademark of the Nordson Corporation.

Pro−Meter is a registered trademark of the Nordson Corporation.

All other trademarks are the property of their respective owners.

Change Record i

Part 1615366-01� 2018 Nordson Corporation

Change RecordRevision Date Change

01 01/19 Initial Release.

Change Recordii


Process Sentry� PLC Controller 1


Process Sentry� PLC Controller

Safety Read and follow these safety instructions. Task- and equipment-specificwarnings, cautions, and instructions are included in equipmentdocumentation where appropriate.

Make sure all equipment documentation, including these instructions, isaccessible to persons operating or servicing equipment.

Qualified Personnel Equipment owners are responsible for making sure that Nordson equipmentis installed, operated, and serviced by qualified personnel. Qualifiedpersonnel are those employees or contractors who are trained to safelyperform their assigned tasks. They are familiar with all relevant safety rulesand regulations and are physically capable of performing their assignedtasks.

Intended Use Use of Nordson equipment in ways other than those described in thedocumentation supplied with the equipment may result in injury to personsor damage to property.

Some examples of unintended use of equipment include

� using incompatible materials

� making unauthorized modifications

� removing or bypassing safety guards or interlocks

� using incompatible or damaged parts

� using unapproved auxiliary equipment

� operating equipment in excess of maximum ratings

Regulations and Approvals Make sure all equipment is rated and approved for the environment in whichit is used. Any approvals obtained for Nordson equipment will be voided ifinstructions for installation, operation, and service are not followed.

Process Sentry� PLC Controller2


Personal Safety To prevent injury follow, these instructions.

� Do not operate or service equipment unless you are qualified.

� Do not operate equipment unless safety guards, doors, or covers areintact and automatic interlocks are operating properly. Do not bypass ordisarm any safety devices.

� Keep clear of moving equipment. Before adjusting or servicing movingequipment, shut off the power supply and wait until the equipmentcomes to a complete stop. Lock out power and secure the equipment toprevent unexpected movement.

� Relieve (bleed off) hydraulic and pneumatic pressure before adjusting orservicing pressurized systems or components. Disconnect, lock out,and tag switches before servicing electrical equipment.

� While operating manual spray guns, make sure you are grounded.Wear electrically conductive gloves or a grounding strap connected tothe gun handle or other true earth ground. Do not wear or carry metallicobjects such as jewelry or tools.

� If you receive even a slight electrical shock, shut down all electrical orelectrostatic equipment immediately. Do not restart the equipment untilthe problem has been identified and corrected.

� Obtain and read Safety Data Sheets (SDS) for all materials used.Follow the manufacturer’s instructions for safe handling and use ofmaterials, and use recommended personal protection devices.

� Make sure the spray area is adequately ventilated.

� To prevent injury, be aware of less-obvious dangers in the workplacethat often cannot be completely eliminated, such as hot surfaces, sharpedges, energized electrical circuits, and moving parts that cannot beenclosed or otherwise guarded for practical reasons.

High-Pressure Fluids High-pressure fluids, unless they are safely contained, are extremelyhazardous. Always relieve fluid pressure before adjusting or servicing highpressure equipment. A jet of high-pressure fluid can cut like a knife andcause serious bodily injury, amputation, or death. Fluids penetrating theskin can also cause toxic poisoning.

If you suffer a fluid injection injury, seek medical care immediately. Ifpossible, provide a copy of the SDS for the injected fluid to the health careprovider.

The National Spray Equipment Manufacturers Association has created awallet card that you should carry when you are operating high-pressurespray equipment. These cards are supplied with your equipment. Thefollowing is the text of this card:



WARNING: Any injury caused by high pressure liquid can be serious. Ifyou are injured or even suspect an injury:

� Go to an emergency room immediately.

� Tell the doctor that you suspect an injection injury.

� Show them this card

� Tell them what kind of material you were spraying

MEDICAL ALERT—AIRLESS SPRAY WOUNDS: NOTE TO PHYSICIAN

Injection in the skin is a serious traumatic injury. It is important to treat theinjury surgically as soon as possible. Do not delay treatment to researchtoxicity. Toxicity is a concern with some exotic coatings injected directly intothe bloodstream.

Consultation with a plastic surgeon or a reconstructive hand surgeon maybe advisable.

The seriousness of the wound depends on where the injury is on the body,whether the substance hit something on its way in and deflected causingmore damage, and many other variables including skin microflora residingin the paint or gun which are blasted into the wound. If the injected paintcontains acrylic latex and titanium dioxide that damage the tissue’sresistance to infection, bacterial growth will flourish. The treatment thatdoctors recommend for an injection injury to the hand includes immediatedecompression of the closed vascular compartments of the hand to releasethe underlying tissue distended by the injected paint, judicious wounddebridement, and immediate antibiotic treatment.

Fire Safety To avoid a fire or explosion, follow these instructions.

� Ground all conductive equipment. Use only grounded air and fluidhoses. Check equipment and workpiece grounding devices regularly.Resistance to ground must not exceed one megohm.

� Shut down all equipment immediately if you notice static sparking orarcing. Do not restart the equipment until the cause has been identifiedand corrected.

� Do not smoke, weld, grind, or use open flames where flammablematerials are being used or stored.

� Do not heat materials to temperatures above those recommended bythe manufacturer. Make sure heat monitoring and limiting devices areworking properly.



Fire Safety (contd)

� Provide adequate ventilation to prevent dangerous concentrations ofvolatile particles or vapors. Refer to local codes or your material SDSfor guidance.

� Do not disconnect live electrical circuits when working with flammablematerials. Shut off power at a disconnect switch first to preventsparking.

� Know where emergency stop buttons, shutoff valves, and fireextinguishers are located. If a fire starts in a spray booth, immediatelyshut off the spray system and exhaust fans.

� Shut off electrostatic power and ground the charging system beforeadjusting, cleaning, or repairing electrostatic equipment.

� Clean, maintain, test, and repair equipment according to the instructionsin your equipment documentation.

� Use only replacement parts that are designed for use with originalequipment. Contact your Nordson representative for parts informationand advice.

Halogenated Hydrocarbon Solvent Hazards Do not use halogenated hydrocarbon solvents in a pressurized system thatcontains aluminum components. Under pressure, these solvents can reactwith aluminum and explode, causing injury, death, or property damage.Halogenated hydrocarbon solvents contain one or more of the followingelements:

Element Symbol Prefix

Fluorine F “Fluoro-”

Chlorine Cl “Chloro-”

Bromine Br “Bromo-”

Iodine I “Iodo-”

Check your material SDS or contact your material supplier for moreinformation. If you must use halogenated hydrocarbon solvents, contactyour Nordson representative for information about compatible Nordsoncomponents.



Action in the Event of a Malfunction If a system or any equipment in a system malfunctions, shut off the systemimmediately and perform the following steps:

� Disconnect and lock out system electrical power. Close hydraulic andpneumatic shutoff valves and relieve pressures.

� Identify the reason for the malfunction and correct it before restarting thesystem.

Disposal Dispose of equipment and materials used in operation and servicingaccording to local codes.



Description See Figure 1 and refer to Table 1.

The Process Sentry (PS) PLC controller uses signals from a robot or cellcontroller to control the material dispensing process. A constant bead sizecan be maintained by adjusting the material dispensing rate for changes inrobot speed.

The controller can be configured with various options for dispensers andsystem interfaces. The PS PLC controller also:

� displays recover procedures if faults are detected,

� communicates faults to the robot controller,

� stores SPC and fault data, and

� controls material temperature of four independent zones (integratedtemperature control unit (TCU) model only).

Table 1 Major Components

Item Description

1

Alarm Tower: Alerts the operator that a fault condition exists within the system

� RED — Major Fault, Immediate Action

� AMBER — Minor Fault

� GREEN — Ready

2 Display Screen (Available in 10− or 15−in.)

3 Start Button

4 Stop Button

5 Programming Port

6 TCU (if equipped)



1

3

4

5

6

2

1

2

3

4

5

PS PLC without TCU

PS PLC with TCU

Figure 1 Process Sentry PLC Controller



SpecificationsItem Description

1615339 480 VAC, 3 phase, 60 HZ, 7 full−load amperes (FLA)

1615340 480 VAC, 3 phase, 60 HZ, 7 FLA

1615341 120 VAC, 1 phase, 60 HZ, 15 FLA

1615342 120 VAC, 1 phase, 60 HZ, 15 FLA

1615343 480 VAC, 3 phase, 60 HZ, 7 FLA

1615344 480 VAC, 3 phase, 60 HZ, 7 FLA

1615345 480 VAC, 3 phase, 60 HZ, 11 FLA

1615346 480 VAC, 3 phase, 60 HZ, 11 FLA

1615347 480 VAC, 3 phase, 60 HZ, 8 FLA

1615348 480 VAC, 3 phase, 60 HZ, 8 FLA

1615349 120 VAC, 1 phase, 60 HZ, 25 FLA

1615350 120 VAC, 1 phase, 60 HZ, 25 FLA

1615351 480 VAC, 3 phase, 60 HZ, 8 FLA

1615352 480 VAC, 3 phase, 60 HZ, 8 FLA

1615353 480 VAC, 3 phase, 60 HZ, 8 FLA

Theory of OperationThe robot sends a flow rate command that is proportional to the speed ofthe robot. This voltage can be a 16-bit word in the case of an Ethernet I/Osystem. The voltage controls the speed of the servomotor, which in turncontrols the material flow rate, allowing the dispensed bead to remainconstant through corners. The material dispensing rates can be changed.

The Bead Size feature controls the percentage of the robot analog signal tothe servomotor. It also eliminates the need to change the robot programdue to changes in the material dispensing rates. Increasing the bead sizevalue increases the rate dispensing material. Decreasing the bead sizevalue decreases the rate of dispensing material.

NOTE: A different bead size can be entered for each Part ID. A Globalbead size can be entered if the bead size applies to all Part IDs.

AlarmsThe PS PLC controller alerts the operator when a fault occurs by lighting thealarm tower. The status screen will also flash the graphic of the faultedsystem component, allowing the user to quickly access help information forthe fault by simply selecting the flashing icon. The fault help screenprovides a description of the fault, the corrective action needed, and how tocontact Nordson for assistance. A fault log screen displays a list of the mostrecent faults.



SecurityFeatures and changeable settings are locked to prevent accidental changesin process. User name and passwords, and/or USB flash drives, areneeded to make changes.

Installation

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

WARNING: The PS PLC contains electrical connections that can be fatal.Disconnect and lock out electrical power before making connections.

Read and understand this entire section before performing actions. Contacta Nordson representative regarding these procedures if necessary.

NOTE: Refer to the Optional Controller Configurations section foradditional data that is applicable to this controller configuration.

1. Unpack the PS PLC controller and inspect it for dents, scratches,corrosion, or other physical damage. If there is any visible damage, calla local Nordson representative immediately.

2. Install the PS PLC controller as close to the robot controller as possible.

GuidelinesRefer to the following guidelines:

� Hard wire the controller to a dedicated power supply to provide safeoperation and reduce interference from electrical noise.

� Install all electrical connections to local code.

� Install a locking disconnect switch or breaker in the service line ahead ofany electrical equipment.

� Electrical, fluid, and air connections are dependent upon applicationrequirements. Use the System Layout and Interconnect drawingsprovided with the system documentation for all connections.

� Make sure there is enough slack in all hose and cable routings to allowfor proper system operation.

NOTE: Most of the critical setup parameters that are described in thissection are configured prior to shipment. The information onenabling/disabling pump and TCU is provided for reference and shouldnot be needed during a typical installation.



Operator Interface, Screens and Setup Use this section to configure the main menu screens. Use the touchscreento navigate between the menu screens.

See Figure 2 and refer to Table 2.

NOTE: Refer to the Optional Controller Configurations section foradditional data that is applicable to this and other controllerconfigurations.

Select the screen to choose one of the main menus.

Table 2 System Status Screen

Item Description Function

1 User Login Login and/or change users

2 Test Points Menus used to verify that the robot signals are beingsent and received by the controller. Green is active,gray is inactive

3 System Status Appears as the default screen; displays the systemconfiguration

4 Program Screen Menus used to set up and configure systemparameters and access control screens for thepumps, temperature controls, etc

5 Heating Screen/TCU Screen Menus allow user to set up heating and/or coolingoptions (if equipped)

6 Pumps Screen Menus to set up and configure pump settings

7 Diagnosis Screen Shows fault information, buttons to view fault logs,fault status and allows faults to be reset

8 Fault Reset Resets all faults

9 Statistics Screen Shows usage statistics since last performedmaintenance

10 Manual Operations Menus allow user to perform different manualoperations

11 Data Log Provides log of operation tasks

12 Product Manuals Allows access to online versions of the Operator’sManuals

13 Back Moves the system back one page

14 Stop Purging Stops a system purge

15 Start Purging Starts a system purge



1 2 3

4 5 6 7 8 9 10 11 12

14 15

13

Figure 2 System Status Screen



User LoginSee Figure 3.

Use the User Login to:

� Login/Logout

� Check Security Level

� Check current or last user

Figure 3 User Login Screen



Test PointsRefer to Table 3 and see Figures 4−9.

These screens are used to verify the state of I/O signals to and from therobot and peripheral devices (pump stand, TCU). The screen displaysdepend on the system configuration.

Select buttons on the left to toggle through the available I/O screens.

When an Input/Output is active, the box to the left is green. When theInput/Output is inactive, the box to the left is gray.

Table 3 Test Points Screen

Item Description Setting

1 System I/O Opens system input/output test point screen

2 Pumps I/O Opens pumps test point screen

3 Remote Meter I/O Opens remote meter test point screen

4 All Inputs From Robot Opens inputs from robot test point screen

5 All Outputs To Robot Opens outputs to robot test point screen

6 Vision I/O Opens Vision test point screens. (If equipped)

1

Figure 4 Test Point Screens (1 of 6)



2

Figure 5 Test Point Screen (2 of 6)

3




4


5




6




Servo Status Screen

See Figure 10.

Touch anywhere on the text listing the servo information on the Remote I/Oscreen (see Figure 6) to access the Servo Status screen.

When an Input/Output is active, the box to the left is green. When theInput/Output is inactive, the box to the left is gray.

Press the CLOSE button to close the screen.

Figure 10 Servo Status Screen



System StatusSee Figure 11.

The System Status screen is the default screen displayed at power-up.

This screen shows the layout of major system components includingmaterial supply pumps, the applicator, and the controller itself. Eachcomponent image can flash red when a fault condition occurs involving thatcomponent. When an image or applicator is flashing, selecting the flashingimage or View Faults takes the user to the View Faults screen wheredetailed information on the fault and recovery instruction appears.

The status screen also features indicators for the status of digital inputs andmeter pressure.

NOTE: The actual system configuration may differ from the view onFigure 11.



Figure 11 System Status Screen (4 of 4)



Program Screen Refer to Table 4 and see Figure 12.

Use the Program Screen to configure the system parameters to accesscontrol screens for the pumps and the TCU. The following provide adescription.

NOTE: The display screen will vary depending on the security level,configuration used and the robot interface.

Table 4 Program Screen and Security Level

Description Default Maintenance Supervisor

Clock X X X

Simulation Mode X X X

Lamp Test X X X

Part ID Set−up X X

PM Set−up X X

Pre−Pressure Set−up X X

Delay Timers X X

Signals I/O Trace X X

Fault Set−up X X

Purge X X

Temperature/TCUSet−up X X

Devices Enabled X

Pump Stand Set−up X

Pro−Meter® S Set−up X

Vision Setup X



X.XX

X.XX

XX.XXX

X.XX

Figure 12 Program Screen



Clock

See Figure 13.

The time and date used on the Process Data screen and in the stored SPCand fault logs are based on a clock that runs on the PS PLC controllerboard.

Click/touch the Set button to set the time. The HMI clock will synchronizewith the PLC clock once an hour.



Figure 13 Clock Synchronization Screen



Part ID Setup

See Figure 14 and refer to Table 5.

NOTE: When on the Part ID Setup screen, any part can be brought upby clicking in the Part−ID Setup box and inputting the number. Operatorcan also scroll through the parts by using the arrows to the right of thebox.

NOTE: The amount of available parts and segments available variesaccording to the system configuration. Refer to the Optional ControllerConfigurations section for additional data and screens that areapplicable to the system configurations.

Table 5 Part ID Setup Screen

Item Description Setting 1 Setting 2

1 Part ID Setup Variable Arrows to Scroll

2 Pro−Meter S Prepressurization Setpoint Variable —

3 Target Volume Variable —

4 High Volume Fault (1−99%) Variable —

5 Low Volume Fault (1−99%) Variable —

6 High Instantaneous Pressure Variable

Major

Minor

Disabled

7 Low Instantaneous Pressure Variable

Major

Minor

Disabled

8 Low Average Pressure Delta Variable

Major

Minor

Disabled

9 Teach Pressure AverageLoads current part average pressure

into average pressure First in First Out(FIFO)

10 Dynamic Pre−Pressure —Enabled

Disabled

11 Bead Size (1−100%) Variable —



3

7

8

4

5

6

29

10

11

12

13

14

15

1

Figure 14 Part ID Set−up Screen



Preventative Maintenance Set−up

See Figure 15.

To change the maintenance intervals select the box to the right of thefollowing settings and input the desire maintenance interval.

� Pump Strokes

� Gun Cycles

� Vol (Volume) Dispensed Liters

NOTE: The maintenance intervals are dependant on the material beingused. Some materials will require a decrease in strokes, cycles orvolume intervals and some may be capable of increased intervals.

Figure 15 PM Set−up Screen



Delay Timers

See Figure 16.

Set the times for the following setting to between 0−2.000 seconds.

� Meter On Delay

� Gun On Delay

� Gun Off Delay

� Inlet Low Pressure

� Inlet High Pressure

Figure 16 Delay Timers Screen



Fault Setup

See Figure 17.

Set faults to MAJOR, MINOR or DISABLED.

NOTE: These faults will vary depending on the robot interface used.

Figure 17 Fault Set−up Screen



Signals I/O Trace

See Figure 18.

Shows the Analog Signals and the Timing Sequence of the robot interface.

Figure 18 Signals I/O Screen



Purge

See Figure 19.

Set the time and amounts for:

� Dispense Time (in seconds)

� Purge Speed (in cc’s/second)

� Purge Volume (in cc’s)

Figure 19 Purge Screen



Electric Heat Setup (If equipped)/Temperature Conditioning Unit (TCU) Setup (If equipped)

Electric Heat Setup (If equipped)

Refer to Table 6 and see Figure 20.

Click/touch the Temperature Setup button on the Program Screen to accessthe Heat Setup screen.

Table 6 Electric Heat Setup Screen

Description Setting

Auto SetbackEnabled

Disabled

Auto Shut OffEnabled

Disabled

Time to Auto Setback in Minutes Variable

Time to Auto Shut Off in Minutes Variable

Soak Time in Minutes Variable

Figure 20 Heating Screen



TCU Setup (If equipped)


Table 7 TCU Setup Screen

Description Heat Cool

Proportional Gain (Kp) Variable Variable

Integral Gain (Ki) 1/s Variable Variable

Derivative Time (Kd) s Variable Variable

Loop Update Time Sec. Variable Variable

Output Cycle Time Sec. Variable Variable

Temperature Offset to Start Variable Variable

Description Setting 1 Setting 2

Low Temperature Fault °F Variable

Major

Minor

Disabled

High Temperature Fault °F Variable

Major

Minor

Disabled

Soak Time in Minutes Variable —

Auto Off Time Minutes Variable —

Shut Down Enabled/Disabled

Click/touch EnableShut Dn

Shut DownEnabled

Click/touchDisable Shut Dn

Shut DownDisabled



Figure 21 TCU Setup Screen



Devices Enabled


Devices Enabled gives to access a list of devices, the status of thosedevices and the ability to ENABLE/DISABLE the devices.

Table 8 Devices Enabled Screen

Item Description Setting

1 Settings Column Enable or Disable features

2 Status ColumnGreen indicates an enabled feature

Yellow indicates a disabled feature

3 Purge Bucket Overridden Overrides the purge bucket detectedrequirement for purging



1 221

3

Figure 22 Devices Enabled Screen



Pump Stand Setup


Table 9 Pump Stand Setup Screen

Description Setting

Pump Stroke Volume in CC’s Variable

Material Per Drum in Gallons Variable

Auto−DepressurizeEnabled

Disabled

Time to Auto−Depressurize in Minutes Variable

Depressurize Timeout in Seconds Variable

Runaway Prox Trip Point (Pulses per Minute) Variable

Runaway Fault

Major

Minor

Disabled

One Drum Empty

Major

Minor

Disabled

Filter Plugged

Major

Minor

Disabled

Pumps per Stand Variable



Figure 23 Pump Stand Setup Screen



Simulation ModeRefer to Table 10 and see Figure 24. After inputting the simulation variables,click/touch the Run Simul. button to run the simulation.

Table 10 Simulation Type Setup Screen


Constant Cycle — —

� Set Time 1−99 Sec. Variable —

� Set Spd cc per sec. Variable —

Up/Down Cycle — —


Multiple On/Off — —


� Set Spd 1 cc per sec. Variable —



Simulation Type

Constant —

Step Up —

Step Down —

Multiple —

Disabled —

Press to Start Run Simul. —

Simul. Running —

Target Volume Variable —

Pre−Pressure Setpoint Variable —

High Volume Fault (1−99%) Variable

Major

Minor

Disabled

Low Volume Fault (1−99%) Variable

Major

Minor

Disabled

High Instantaneous Pressure Variable

Major

Minor

Disabled

Low Instantaneous Pressure Variable

Major

Minor

Disabled

Low Average Pressure Delta Variable

Major

Minor

Disabled

Dynamic Pre−Pressure —

Major

Minor

Disabled



Figure 24 Simulation Type Setup Screen



Pro−Meter S PLC Setup


Table 11 Pro−Meter S PLC Setup Screen

Description Setting

Refill After Number of Parts Variable

Meter Size in CC’s Variable

Screw Pitch in Inches Variable

Part Pre−Pressure bySetpoint

Dynamic

Air Pocket Diagnostic

Major

Minor

Disabled

Air Pocket Trip Size % Variable

Air Pocket Max Purge Limit Variable

Meter Transducer Range Variable

Refill Timeout in Seconds Variable

Pre−Pressure Timeout in Seconds Variable

Meter Over Pressure Limit in PSI Variable

Meter Not Full

Major

Minor

Disabled

Segment High Volume

Major

Minor

Disabled

Segment Low Volume

Major

Minor

Disabled

Jog Speed CC’s per Second Variable

Pressurize Speed CC’s per Sec. Variable

Depressurize Speed CC’s per Sec. Variable

Depressurize Settings in PSI Variable

Daub Speed CC’s per Second Variable

Refill Speed CC’s per Second Variable



Figure 25 Pro−Meter S PLC Setup Screen



Vision Setup (if equipped)


Table 12 Vision Setup Screen

Description Setting/Action

Enable Vision 1 Enables Vision

Disable Vision 1 Disables Vision

Vision 1 Enabled/Disabled Vision Status

Vision 1 Inspection Fail

Major

Minor

Disabled

Vision 1 Not Responding

Major

Minor

Disabled

Vision 1 Not in Automatic

Major

Minor

Disabled

Vision 1 Disabled

Major

Minor

Disabled

Vision 1 Bypass Mode

Major

Minor

Disabled

Vision 1 Learn Mode

Major

Minor

Disabled

Vision Unit 1 Setup Opens up a remote desktop screen to the visionPC. Refer to the Vision software manual.



Figure 26 Vision Setup Screen



Heating Screen (If equipped)Refer to Table 13 and see Figure 27.

The following section provides a description of the Heating Screen menu.

NOTE: The number of heating zones varies according to each systemconfiguration.

NOTE: The menu options and accessibility are subject to security level.

Table 13 System Temperatures Screen


System Temps Opens system temperatures screen

Manually Start Heater Press to manually start the heaters

Manually Stop Heater Press to manually stop the heaters

System Heater Started Manually Manual start is active, press to switch to auto start

System Heater Auto Start Auto start is active, press to switch to manual start

System Heaters Are On Press to turn the heaters off

System Heaters Are Off Press to turn the heaters on

Enable Auto Start System Heaters Press to enable system heaters auto start

Disable Auto Start System Heaters Press to disable system heaters auto start

Auto Start is Disabled Auto start is inactive, press to enable auto start

Auto Start is Enabled Auto start is active, press to disable auto start

Temperature Setpoints Opens temperature setpoints screen

Setback Setpoints Opens setback setpoints screen

High Temp Setpoints Opens high temperature setpoints screen

Low Temp Setpoints Opens low temperature setpoints screen

PID Settings Opens PID settings screen



System Temps

See Figure 27.

Access the System Temperatures screen to set the temperatures to changetemperatures for all active zones.


Figure 27 System Temperature Screen



Temperature Setpoints

See Figure 28.

Access the Temperature Setpoints button on the System Temperaturesscreen to change temperatures for all active zones.

To change the individual temperatures for the active zones, click/touch inthe box to the right of each zone and input the desired temperature. Tochange the temperature setting for active zones at once, put the desiredtemperature into the box to the right of Mass Setpoint and click/touch theSend Mass Setpoint To All Zones button.


Figure 28 Temperature Setpoints Screen



Setback Setpoints

See Figure 29.

Access the Setback Setpoints button on the System Temperatures screento change temperatures for all active zones.

The setback temperature is the temperature that the active zones go backto when the activity timer times out.

To change the individual temperatures for all active zones, click/touch in thebox to the right of each zone and input the desired temperature. To changetemperatures for all active zones, put the desired temperature into the boxto the right of Mass Setpoint and click/touch the Send Mass Setpoint To AllZones button.


Figure 29 Setback Setpoints Screen



High Temp Setpoints

See Figure 30.

Access the High Temp Setpoints button on the System Temperaturesscreen to change temperatures for all active zones..

To change the individual temperatures for the active zones, click/touch inthe box to the right of each zone and input the desired temperature. Tochange temperatures for all active zones, put the desired temperature intothe box to the right of Mass Setpoint and click/touch the Send MassSetpoint To All Zones button.


Figure 30 High Temperature Setpoints Screen



Low Temp Setpoints

See Figure 31.

Access the Low Temp Setpoints button on the System Temperatures screento change temperatures for all active zones.

To change the individual temperatures for the active zones, click/touch inthe box to the right of each zone and input the desired temperature. Tochange temperatures for all active zones, put the desired temperature intothe box to the right of Mass Setpoint and click/touch the Send MassSetpoint To All Zones button.


Figure 31 Low Temperature Setpoints Screen



PID Settings

See Figure 32.

Click/touch the PID Settings button on the System Temperatures screen tochange the Kp, Ki, Kd and Loop time for the active zones.

The names of the zones can also be changed by clicking/touching under thecurrent zone name and inputting the new name.




Figure 32 PID Settings Screen



Temperature Control Unit (TCU) (If equipped)Refer to Table 14 and see Figure 33.

The temperature control must be enabled before the PS PLC controller canoperate it. Perform the following to enable the temperature control:

1. Click/touch the Program Screen button.

2. Click/touch the Devices Enabled button.

3. Click/touch the Enable TCU button.

NOTE: The Enable TCU button (if equipped) will be in the Settingscolumn shown in Figure 22.

4. Click/touch the TCU Screen button.

5. Click/touch the Start TCU button to activate the TCU. The yellowTCU is Off indicator will turn green and change to TCU is On indicatingthat the TCU is on. Select BACK to go back to the Program screen.

Table 14 TCU Screen

Description Setting

Current Temperature F Variable

Setpoint Temperature F Variable

Conservation Min. Remaining Variable

Heat Output % Variable

Heater SSR OFF/ON

Cool Output % Variable

Cooling Solenoid OFF/ON

Start/Stop TCUTCU is On

TCU is Off



Figure 33 TCU Screen



Pumps Screen See Figure 34.

Click/touch the Pressurize/Depressurize Pumps button to change thepressurize or depressurize the pumps. When the pumps are pressurized,the indicator turns green and says Pumps Are Pressurized. Click/touch thePressurize/Depressurize Pumps button to depressurize the pumps. Whenthe pumps are depressurized, the indicator turns yellow and says Pumpsare Depressurized.

To switch between pumps, click/touch the Switch to Pump X button underthe applicable pump. The indicator below the pump turns green andchanges to display Pump X Active. Inactive pumps are yellow and displayPump X Inactive.

X

X

Figure 34 Pump Stand Setup Screen



Diagnosis Screen See Figure 35.

Click/touch the Diagnosis Screen button to access the Diagnosis Screen.

The Diagnosis Screen shows the highest priority fault and possible solutionsfor that fault.

Description Action

Fault Reset Reset all faults

Fault Log Brings up Fault Log Screen

Fault Status Brings up Fault Status Screen

XXX

Figure 35 Diagnosis Screen



Fault Log Screen


Table 15 Fault Log Screen

Item Description Setting/Action

1 Value Fault list

2 QTY (Quantity) Displays amount of fault occurrences

3 Acc (Accumulative) Time Varies

4 Message Fault Description

5 Display Mode

Active Alarms

Past Alarms

All Alarms

6 Silence Alarms Silences Alarms

7 Last Time Reset: Displays last reset date and time

8 Menu Navigation Scroll through the fault list

9 Print Print the fault list

10 Alarm History Alarm History screen

11 Close Exits the Fault Log screen

5 116 8 109

7

1 2 3 4

Figure 36 Fault Log Screen



Fault ResetSee Figure 37.

Select Fault Reset to clear the current faults.

NOTE: This only applies to non-self-clearing faults.

Select Fault Log/Fault Status to toggle between the fault log and helpscreens.

Select Fault Log to view the history of faults by time and date (highestpriority is displayed).

Figure 37 View Faults Screen



Statistics ScreenRefer to Table 16 and see Figure 38.

Access Preventative Maintenance screen by using the Statistics Screenbutton.

The Preventative Maintenance screen shows the pump and gun statisticsfor preventative maintenance purposes and allows the counts to be reset.

Table 16 Preventative Maintenance Screen

Description Action

Pump A Strokes Since Last Maintenance Reset

Pump B Strokes Since Last Maintenance Reset

Gun On Cycles Since Last Maintenance Reset

Volume Liters Disp. Since Last Maintenance Reset

Figure 38 Preventative Maintenance Screen



Manual OperationsRefer to Table 17 and see Figure 39.

Click/touch the Manual Operations button to access the Manual Operationsscreen. The Manual Operations screen allows the user to perform a fewtasks manually for maintenance purposes.

Table 17 Manual Operations Screen


Open Inlet Valve Maintained Opens the inlet valve

Open Outlet Valve Maintained Opens the outlet valve

Open Inlet Valve Momentary Temporarily opens the inlet valve

Open Outlet Valve Momentary Temporarily opens outlet valve

Jog Actuator Forward Moves the actuator forward

Jog Actuator Reverse Moves the actuator in reverse

Refill Meter Manually refills the meter

CC’s Remaining Variable

Pressure Variable

Purge Volume Variable

Drive Current Variable

Cont. Current Variable

8

9

10

11

12

Figure 39 Manual Operations Screen



Data LogSee Figure 40.

The Data Log screen shows a log of parts and segments and statistics foreach procedure performed. If a fault is shown in the Fault Code column,click/touch fault number to access the Fault Decoder screen.

Scroll through the log by clicking/touching the Last Page, Page Up, andPage Down buttons.

To access a specific data, click/touch to box under the Go to Data: field andinput the data number.

Figure 40 Data Log Screen



Fault Decoder Screen

See Figure 41.

On the Data Log Screen (see Figure 40), touch/click anywhere in the FaultCode, 0=No Fault column to access the Fault Decoder Screen.

Input the fault code number from the Process Data Screen to see the faults.

Figure 41 Fault Decoder Screen



Product ManualsSee Figure 42.

The Product Manuals screen shows a list of drawings and manuals for thesystem at the time of original equipment shipping. For revisions or updates,consult emanuals.nordson.com.

Figure 42 Product Manuals Screen



BackSee Figure 43.

The Back button allows the user to go back one page at a time.

Figure 43 Back button



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

1. Press the “START” button on the controller to power on the system.

2. Access the applicable heating screen (TCU or electric heat/if equipped)and bring the zones to temperature.

3. Access the pump screen and pressurize the pumps.

4. When the screen indicates that the dispenser is ready, go to thesimulation screen and run a simulation or go to the manual operationsscreen and manually purge the system.

Optional Controller ConfigurationsNOTE: Contact a Nordson representative regarding this data ifnecessary.

The PS PLC controller can be configured for use with multiple components.

� TCU

� Pro-Meter S PLC Dispenser

� Vision Sensors

� Robot Interface/Communication Ethernet

NOTE: The PS PLC controller can also be configured for use with theCP gun. Refer to the Controlled Pressure (CP) Gun manual forinstructions on configuration.

Refer to the following sections for additional data for each configuration.



Part ID Setup ScreenSee Figure 44.

The amount of available parts and segments available varies according tothe system configuration. The part ID screen will also vary according to thesystem configuration. The Target Volume, Fault Limits and SegmentVolumes (1-30 and 31-60) can be set by selecting the appropriatebutton or field.

To change the Target Volume, click/touch the box to the right of the Part IDand input the desired volume.

Figure 44 Part ID Setup Screen



LimitsRefer to Table 18 and See Figure 45.

Click/touch the change (CHG) button on the Limits column for the desiredPart ID to set the faults for each individual part.

Table 18 Limits Part ID Screen


High Volume Fault (1−99%) Variable

Major

Minor

Disabled

Low Volume Fault (1−99%) Variable

Major

Minor

Disabled

High Instantaneous Pressure Variable

Major

Minor

Disabled

Low Instantaneous Pressure Variable

Major

Minor

Disabled

Low Average Pressure Delta Variable

Major

Minor

Disabled

Enabled

Disabled



Figure 45 Limits Screen



Segment VolumesSee Figure 46.

Click/touch the change (CHG) button under the Segment Volume (1−30 or31−60 if available) for each part, then set the individual Segment Volume,Segment Type, and High Vol %, Low Vol % for each Seg #.

Figure 46 Segment Target Volumes Part ID Screen



Pre−Pressure SetupSee Figure 47.

This screen is used on some configurations and is accessible if the systemis different than the Part ID Screen show in the Operator Interface, Screensand Setup section.

Click/touch the box to the right of the Part ID and input the desire SetpointPressure.

Figure 47 Pre−Pressure Setup Screen



Pro-Meter S PLC Dispenser

Installation

Configure the Robot Communication

The following steps provide procedures for configuring the robotcommunication DeviceNet.

1. Click/touch the Program Screen and then click/touch the Pro−Meter SSetup button.

2. Set up the Pro−Meter S PLC specifications.

Configure the Robot Controller Analog Signal

See Figure 48.

Configure the robot controller to vary the analog (or tool speed) signal from0 to 10 Vdc over the full range of robot speed.

1. Determine the highest and lowest robot speeds to be used inproduction.

2. Configure the robot controller to produce an analog signal of + 10 Vdcwhen the robot is moving at or slightly above maximum speed.

3. Configure the robot controller to produce the analog signal of 0 Vdcwhen the robot is stationary.

NOTE: A robot speed of 80% corresponds to 8 Vdc. A robot speed of40% corresponds to 4 Vdc. This percentage (1) is shown in the lower,right corner of the Inputs From Robot screen. To access this screen,click/touch the Test Points button (2) then click the Inputs from Robotbutton (3).



3

2

1

Figure 48 Inputs From Robot Screen

Robot Interface/Communication EthernetRefer to the documentation provided with the system to information on therobot interface and communication Ethernet.



Repair Repairs consist of replacing the operator interface panel and the PLC parts.

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

Disconnect equipment from line voltage. Failure to observe this warningmay result in equipment damage, personal injury, or death.



Troubleshooting

Problem Possible Cause Corrective Action

1. Meter does notdispense

Major fault. Access the View Faults screen todetermine the cause of the faultcondition.

Controller in Manual Mode. Set PS PLC controller to the Automode.

No air to meter solenoids . Check supply air to the gun and refillmeter solenoids. Make sure theregulator is set to at least 70 psi.

Robot signals not in the propersequence.

See the I/O timing chart for properrobot I/O sequence.

2. Meter does not refill Low unloader pressure. Confirm that pump has beenpressurized. Check the air pressureto the bulk unloaders. Make surethere is enough air pressure to refillthe meter cylinders.

No air to meter solenoids. Check supply air to the gun and refillmeter solenoids. Make sure theregulator is set to at least 70 psi.

Clogged refill valve(s). Remove the refill valve and eitherclean or replace the refill valvecartridge.

3. Bead depositioninconsistent

Nozzle too high above work piece. Modify robot path to lower the nozzle.

Material speed through nozzle toolow.

Increase the bead size setting orrobot analog voltage. Refer toStartup in the Operation section.

Nozzle not large enough. Install a larger nozzle. Contact aNordson representative for partnumbers.

4. Unexpected bead sizechange

Nozzle partially blocked. Remove nozzle; clean or replace.

Material exceeded shelf life. Use fresh material.



Parts

PS PLC Controllers PS PLC’s without Vision

Part Voltage Pro−Meter Type Temperature Control Notes

1615341 120 Single Electric A, B

1615349 120 Double Electric A, B

1615339 480 Single Ambient

1615343 480 Single Electric A, C

1615345 480 Single TCU

1615347 480 Double Ambient

1615351 480 Double Electric A, C

1615353 480 Triple Ambient

PS PLC’s with Vision

1615340 480 Single Ambient

1615342 120 Single Electric A, B

1615344 480 Single Electric A, C

1615346 480 Single TCU D

1615348 480 Double Ambient

1615350 120 Double Electric A, B

1615352 480 Double Electric A, C

NOTE A: Partial Heat

B: 4 Heat Zones

C: 6 Heat Zones

D: Heat only



See Figure 49 and refer to the following table for available parts and partnumbers.

2

3

6

1

4

5

Figure 49 PS PLC Parts

Item Part Description1 1614202 INTERFACE, operator, 10-in. color, touch screen, standard1 1614203 INTERFACE, operator, 10-in. color, brandless, enhanced1 1614207 INTERFACE, operator, 15-in. color, brandless, enhanced2 1614198 SWITCH, ethernet, 16-port, unmanaged2 1514505 SWITCH, ethernet, 8-port, unmanaged3 1614191 POWER SUPPLY, 90−264 Vac, 24 Vdc out, 240 W4 1614210 MODULE, CPU, ethernet, 2-port, 600 Kb4 1614211 MODULE, CPU, ethernet, 2-port, 1 Mb4 1614212 MODULE, CPU, ethernet, 2-port, 2 Mb5 1614208 MODULE, input, digital, 16-channel, sink5 1614213 MODULE, output, digital, 16-channel, source5 1614215 MODULE, spring−terminal, 18 pin6 1614217 MODULE, spring-terminal, 4/6−pin

Ordering PartsAdditional parts are application-specific, refer to the system documentationthat shipped with the controller to order additional parts.



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