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LA 404 Pattern Control System
Customer Product Manual
Part 1037527B
Issued 5/05
This equipment is regulated by the European
Union under WEEE Directive 2002/96/EC).
See www.nordson.com for information about
how to properly dispose of this equipment.
NORDSON CORPORATION • DULUTH, GEORGIA • USA
www.nordson.com
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Table of Contents
Troubleshooting
Related Manuals for Nordson LA 404
Summary of Contents for Nordson LA 404
- Page 1 LA 404 Pattern Control System Customer Product Manual Part 1037527B Issued 5/05 This equipment is regulated by the European Union under WEEE Directive 2002/96/EC). See www.nordson.com for information about how to properly dispose of this equipment. NORDSON CORPORATION • DULUTH, GEORGIA • USA www.nordson.com...
- Page 2 This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2003. 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. © 2003 All rights reserved.
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Page 3: Table Of Contents
..........Manual 66-LA404-MA-01 Part 1037527B E 2005 Nordson Corporation... - Page 4 ..........Declaration of Conformity Manual 66-LA404-MA-01 Part 1037527B E 2005 Nordson Corporation...
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Page 5: Safety
LA 404 Pattern Control System LA 404 Pattern Control System Safety Read this section before using the equipment. This section contains recommendations and practices applicable to the safe installation, operation, and maintenance (hereafter referred to as “use”) of the product described in this document (hereafter referred to as “equipment”). -
Page 6: Responsibilities Of The Equipment Owner
LA 404 Pattern Control System Responsibilities of the Equipment Owner Equipment owners are responsible for managing safety information, ensuring that all instructions and regulatory requirements for use of the equipment are met, and for qualifying all potential users. Safety Information... -
Page 7: User Qualifications
Familiarize yourself with the location and meaning of the safety warning labels and tags affixed to the equipment. If you are unsure of how to use the equipment, contact your Nordson representative for assistance. Manual 66-LA404-MA-01 Part 1037527B... -
Page 8: Installation Practices
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. -
Page 9: Maintenance And Repair Practices
Use only new factory-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 are available at www.nordson.com or by calling your Nordson representative. -
Page 10: General Safety Warnings And Cautions
General Safety Warnings and Cautions Table 1 contains the general safety warnings and cautions that apply to Nordson hot melt and cold adhesive equipment. Review the table and carefully read all of the warnings or cautions that apply to the type of equipment described in this manual. - Page 11 WARNING: Hazardous vapors! Before processing any polyurethane reactive (PUR) hot melt or solvent-based material through a compatible Nordson melter, read and comply with the material’s MSDS. Ensure that the material’s processing temperature and flashpoints will not be exceeded and that all requirements for safe handling, ventilation, first aid, and personal protective equipment are met.
- Page 12 WARNING: Risk of fire or explosion! Nordson cold adhesive equipment is not rated for use in explosive environments and should not be used with solvent-based adhesives that can create an explosive atmosphere when processed.
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Page 13: Other Safety Precautions
CAUTION: Nordson hot melt equipment is factory tested with Nordson Type R fluid that contains polyester adipate plasticizer. Certain hot melt materials can react with Type R fluid and form a solid gum that can clog the equipment. -
Page 14: First Aid
LA 404 Pattern Control System First Aid If molten hot melt comes in contact with your skin: 1. Do NOT attempt to remove the molten and/or solidified hot melt from your skin. 2. Immediately soak the affected area in clean, cold water until the hot melt has cooled. -
Page 15: System Overview
LA 404 Pattern Control System System Overview The LA 404 Pattern Control System generates the signals required to accurately dispense adhesive on a variable speed production line. The system monitors the production line position through a pulse encoder. The pattern controller detects a product traveling down the production line using a photosensor, and then activates the glue guns which dispense the programmed pattern. -
Page 16: System Features
Programmable gun driver Software Upgrade The pattern controller’s software can be upgraded, and the user programs can be saved or restored in the field by using the Nordson Configuration Manager (NCM). The NCM is a Windows -based application that allows the pattern controller to communicate with a personal computer (PC). -
Page 17: Specifications
LA 404 Pattern Control System Specifications Operating Conditions Item Specification Ambient temperature 32_ – 104_ F (0_ – 40_ C) range Enclosure rating IP30 Humidity 5% – 95% non-condensing Altitude -20 – 5000 feet above sea level Non-Operating Conditions Item... -
Page 18: Performance
LA 404 Pattern Control System Performance Item Specification Maximum operational 600 m/min, 1 p/mm encoder gearing line speed Maximum pulse 100 Khz frequency Encoder resolution 0.1 p/mm – 20 p/mm Bead resolution 1.0 mm Adhesive placement 1.0 mm under the following conditions: accuracy a. -
Page 19: Front Panel
LA 404 Pattern Control System Front Panel The front panel is used for entering and displaying the user inputs, and transmitting the inputs to the pattern generation engine. 6640002A Figure 3 Location of Front Panel Controls and Indicators Item Controls and Indicator... -
Page 20: Rear Panel
LA 404 Pattern Control System Rear Panel The rear panel contains several input/output (I/O) connectors that connect the pattern controller to other devices. 6640003A Figure 4 Rear Panel I/O Pin Connectors 1. TRIGGER 1–4 4. ENCODER 7. REMOTE INPUT and OUTPUT 2. -
Page 21: I/O Connector Pin Layout
LA 404 Pattern Control System I/O Connector Pin Layout The I/O connector pin layouts are shown below to make the appropriate cable connections. Runup 1 and 2 This is a female connector, the drawing shows the front view (pin side). - Page 22 LA 404 Pattern Control System Trigger Input and Tip Seal Input This is a female connector, the drawing shows the front view (pin side). Signal 6644008A Trigger (NPN or PNP) 24 VDC (0.1 A maximum) 24 VDC common Tip Seal Output This is a female connector, the drawing shows the front view (pin side).
- Page 23 LA 404 Pattern Control System Remote Purge Input This is a 25-pin female D-shell connector, the drawing shows the front view (pin side). 6644024A Signal Purge channel 1 Purge channel 2 Purge channel 3 Purge channel 4 24 VDC common...
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Page 24: Installation
LA 404 Pattern Control System Installation This section provides pattern controller positioning information and basic startup instructions. Pattern Controller Ship-With Kit The following contents are included in the pattern controller ship-with kit: Kit Contents Quantity Fuses Mounting bracket Remote input plug... -
Page 25: Remote Input Plug
LA 404 Pattern Control System Remote Input Plug The remote input plug provided in the ship-with kit connects to the Remote Input connector, it is typically used to prevent the pattern controller from dispensing adhesive until a melter or parent machine is ready as shown in Figure 5. - Page 26 LA 404 Pattern Control System This page intentionally left blank. Part 1037527B Manual 66-LA404-MA-01 E 2005 Nordson Corporation...
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Page 29: System Setup
LA 404 Pattern Control System System Setup The pattern controller can be customized with several setup options by using the Administrator or the Normal operating modes. Refer to the Quick Programming Guide for the sequence of menu screens that are used to program the pattern controller. -
Page 30: Production Data
LA 404 Pattern Control System Production Data The setup menu offers the following parameters: Speed displays the line velocity as measured by the encoder. The units maybe displayed either as meters per minute or feet per minute, refer to System Settings 1 menu. -
Page 31: Trigger Assignment
LA 404 Pattern Control System Trigger Assignment In this menu each of the four channels can be activated and assign one of the four trigger inputs. Trigger Assignment Channel #1 Active Trigger 6640010A 1. To select Channel number’s 1 – 4, press the CHANNEL SELECT button on the front panel of the patten controller. -
Page 32: Trigger Settings (1 - 4)
LA 404 Pattern Control System Trigger Settings (1 – 4) After activating Triggers’ 1 – 4 in Trigger Assignment, use this menu to set the masking distance, jam detect option, and jam distance for each trigger. Masking is a length used to lockout the photosensors for a predetermined distance. -
Page 33: Pressure 1 And 2 Settings
LA 404 Pattern Control System Pressure 1 and 2 Settings The pattern controller accurately regulates the system pressure to maintain proper adhesive volume during line speed changes. This menu is used to set the two-point linear pressure profile for each runup. - Page 34 LA 404 Pattern Control System Pressure 1 and 2 Settings (contd) Pressure 1 Settings Speed 1 Speed 2 Min 0% 100% 6640012A 1. To set speed 1: a. Press the A or " button for the cursor to appear beside the numeric value.
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Page 35: Channel Compensation
(drop-out compensation). Typical values for pull-in and drop-out are as follows: liquid adhesive electric guns: 2 – 8 ms high-performance air-operated guns (such as Nordson H400 Series guns): 5 – 12 ms standard air-operated guns: 8 – 20 ms... - Page 36 LA 404 Pattern Control System Channel Compensation (contd) Chan # 1 Compensation Pull in 00.0 mm Drop out 00.0 mm Set speed 60m/min 6640014A 1. To select Chan (channel) number’s 1 – 4, press the CHANNEL SELECT button on the front panel of the patten controller.
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Page 37: Bead Type
LA 404 Pattern Control System Bead Type This setting allows the user to select one of the seven different bead types. Bead Type Channel #1 Normal Continuous Modulate Stitched Autospot Random Dot 6640015A 1. To select Channel number’s 1 – 4, press the CHANNEL SELECT button on the front panel of the patten controller. - Page 38 LA 404 Pattern Control System Normal Beads (contd) 1. To set Dly (delay): a. Press the A or " button for the cursor to appear beside the numeric value. b. Press the Y or B button to to set the desired delay value from 0 –...
- Page 39 LA 404 Pattern Control System Continuous Beads When this bead type is selected, the outputs are activated if the line speed is above the start speed, and deactivated if the line speed drops below the stop speed. With continuous gluing no pattern is programmed, and no trigger signal is required.
- Page 40 LA 404 Pattern Control System Modulate Beads Modulated bead patterns provide a nearly constant bead volume below a set line speed. When the production line slows down to a user-selected speed, the control begins dividing the beads into smaller spaced sub-beads to prevent the bead volume from increasing.
- Page 41 LA 404 Pattern Control System NOTE: Interval (also known as pitch) is the distance from the start of one bead to the start of the next bead. Modulated Bead Speed 0 m/min Interval 3 mm 6640018A 1. To set speed: a.
- Page 42 LA 404 Pattern Control System Stitched Beads Each channel may be programmed to deposit beads in a stitched fashion in order to conserve adhesive. The beads are broken into a series of shorter beads. A percent glue savings and an interval value will need to be entered.
- Page 43 LA 404 Pattern Control System Stitched Bead Glue Savings Interval 3 mm 6640019A 1. To set glue savings: a. Press the A or " button for the cursor to appear beside the numeric percentage value. b. Press the Y or B button to set the desired glue savings value from 10 –...
- Page 44 LA 404 Pattern Control System Autospot Beads With this bead type the channel output operates in dot mode when the pattern controller is below the activation speed, and operates in normal mode when above the activation speed. This bead type is used to relieve residual pressure after a sudden machine stop.
- Page 45 LA 404 Pattern Control System 3. To set the activation speed (normal): a. Press the A or " button for the cursor to appear beside the numeric value. b. Press the Y or B button to set the desired normal value from 0 –...
- Page 46 LA 404 Pattern Control System Random Beads The random-length bead mode provides a way to mix products of differing length on the production line during the same production run. For example, when alternating between short and long products on the production line, the control will produce continuous beads that fit each product.
- Page 47 LA 404 Pattern Control System Random Bead Start Gap 0 mm Stop Gap 0 mm 6640021A 1. To set start gap: a. Press the A or " button for the cursor to appear beside the numeric value. b. Press the Y or B button to set the desired value from 0 – 8191 mm.
- Page 48 LA 404 Pattern Control System Dot Beads (contd) Dot Parameters Time 5.0 ms Pitch 3 mm 6640022A 1. To set the size of each dot (time): a. Press the A or " button for the cursor to appear beside numeric value.
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Page 49: Programs (1 - 50)
LA 404 Pattern Control System Programs (1 – 50) This setup menu screen can be used to save and recall any of the 50 programs, as well as copy one channel to another. Program 01 Save as Recall Copy CH1 6640023A 1. -
Page 50: Warnings
LA 404 Pattern Control System Warnings The pattern controller monitors warning conditions like: Trigger 1 – 4 too short (clipping), T1 – 4 max distance exceeded (jamming), Ch1 – 4 short circuit, etc. A blinking CHANNEL LED on the front panel of the pattern controller notifies the user that there is a fault or a warning condition, see Warnings in Appendix A. -
Page 51: Channel Driver Settings
LA 404 Pattern Control System Channel Driver Settings Each of the four channels has a programmable voltage-mode gun driver. The user may program the spike time duration and holding voltage for each channel. Chan # 1 Driver Setup Spike Time 1.8 ms... -
Page 52: Encoder Scaling
LA 404 Pattern Control System Encoder Scaling This menu is used to display the encoder type and configure the encoder scaling. The pattern controller automatically detects the type of encoder installed. If no encoder is detected the pattern controller is set to timer mode. -
Page 53: Low Speed Settings
LA 404 Pattern Control System Low Speed Settings This setup menu is used to configure the minimum operational line speed above which the guns will begin dispensing, and below which the guns will stop dispensing adhesive. Setting this feature prevents a puddle of adhesive from forming when the line stops. -
Page 54: Trigger Setup (1 - 4)
LA 404 Pattern Control System Trigger Setup (1 – 4) This setup menu is used to configure the trigger polarity and the distance between the gun and each trigger. For leading edge triggering select Light On. For trailing edge triggering select Dark On. The GTO (gun-to-trigger offset) is used by the pattern controller to set the distance between each photosensor and its corresponding gun. -
Page 55: Purge Pressure
LA 404 Pattern Control System Purge Pressure The setup menu is used to configure the run-up pressures when purge is activated. In addition the user may configure the operational mode of the purge button on the front panel. When set to purge, the gun outputs are maintained as long as the button is activated. -
Page 56: System Settings 1
LA 404 Pattern Control System System Settings 1 This setup menu is used to configure the operational language, the units of measure for speed display, and the gun compensation method. System Settings 1 Language English Speed Display m/min Compensation 6640030A 1. -
Page 57: System Settings 2
LA 404 Pattern Control System System Settings 2 This setup menu is used to configure automatic and manual startup of the pattern controller, the trigger memory function, and to enable and disable the remote recall of programs. When the autostart feature is on the pattern controller will automatically be placed in run mode when the unit is powered. - Page 58 LA 404 Pattern Control System System Settings 2 (contd) 3. To enable remote recall: a. Press the A or " button for the cursor to appear beside On/Off. b. Press the Y or B button to select On or Off.
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Page 59: System Settings 3
LA 404 Pattern Control System System Settings 3 This setup menu is used to configure the remote enable and the trigger clipping function. If remote enable is set to ACTIVE then an external contact closure is required on the remote input plug to activate pattern generation. -
Page 60: Tip Sealer Settings
LA 404 Pattern Control System Tip Sealer Settings This setup menu is used to configure the operation of the tip sealer output. The tip seal output is capable of driving a 24 VDC solenoid valve. A dedicated photosensor input in addition to the four-triggers has been provided to trigger the tip seal logic. -
Page 61: Normal Mode
LA 404 Pattern Control System Normal Mode Use the Normal mode for daily operation of the pattern controller. In this mode only the following screens can be accessed: Production Data Trigger Assignment Trigger Settings Pressure 1 and 2 Settings Channel Compensation... -
Page 62: Troubleshooting
Troubleshooting Refer to the flow chart on the opposite page to troubleshoot basic pattern controller problems. If the problem persists, contact your local Nordson representative for help or, call customer service at 1-877-667-3782. The Nordson customer service representative will need the panel and engine software versions in order to assist in troubleshooting the pattern controller effectively. -
Page 63: Basic Troubleshooting Flowchart
LA 404 Pattern Control System Basic Troubleshooting Flowchart Start Here: fires? Plug in Power power supply plugged supply Increase speed Is line Power Turn speed above switch on? switch on cut-out? Line Start line running? Trigger Trigger and cabling light active? -
Page 64: Parts Information
LA 404 Pattern Control System Parts Information Use this recommended parts list to order the required parts. Call the Nordson Customer Service Center or your local Nordson representative to order the required parts. Pattern Controller Part Description 1039520 LA 404 pattern controller... -
Page 65: Encoder
372759 Cable, encoder/remote output extension, 5 meters 377227 Cable, splitter, encoder repeater, 5 meters 377228 Cable, extension, encoder, 5 meters 738648 Cable, encoder, GSITE to LA 404, 5 meters Additional Parts Part Description 296144 Metric friction wheel 377230 Cable, remote outputs, 10 meters... -
Page 66: Glossary
LA 404 Pattern Control System Glossary Auto Spotting Refer to Modulated Bead Type. Auto Scaling A feature of the pattern control that allows the user to determine the encoder gearing ratio without any calculations. There are three different methods of autoscaling: product-length method, line-jog length method, and line-speed method. - Page 67 LA 404 Pattern Control System Drop out The distance from the start of the bead to the end of the bead. Duration The distance from the start of the bead to the end of the bead. Edge The edge parameter sets the photosensor to sense either the leading edge or the trailing edge of the product as a trigger.
- Page 68 LA 404 Pattern Control System High Time Refer to Spike TIme. Interval Refer to Pitch. Jam Detect This feature activates a warning when a photosensor is active longer than the user defined product length. Select Jam Detect on, then press the product length text box, enter a value greater than the product length being glued.
- Page 69 LA 404 Pattern Control System Palletizing A feature of the pattern control that handles pallet-stabilization applications. Use this feature to set the number of consecutive products that receive adhesive and the number of consecutive products that are skipped before pattern generation starts again.
- Page 70 LA 404 Pattern Control System Sensor Refer to Trigger. Set Mode The glue gun stops when the machine stops, and resumes to complete the current gluing cycle when the machine restarts. Spike Time The duration of high voltage or current spike at the initiation of an electric gun firing.
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Page 71: Appendix A Warnings
This warning appears when one or more encoder signals stop transitioning. Noisy encoder To correct this, check for secure connections at both ends of the encoder cable. If the problem persists, replace the cable or encoder. Continued... Manual 66-LA404-MA-01 Part 1037527B E 2005 Nordson Corporation... - Page 72 This warning appears when there is an unspecified problem with the LA404. Communications error If the problem persists, contact your Nordson representative for assistance. This warning appears when the encoder signal is not detected (encoder did not move while the system was in the Run mode and at least 2 trigger Lost encoder signal signals were received).
- Page 73 DECLARATION of CONFORMITY PRODUCT: LA 404 Pattern Controller APPLICABLE DIRECTIVES: 73/23/EEC ( Low Voltage) 89/336/EEC (Electromagnetic Compatibility) STANDARDS USED TO VERIFY COMPLIANCE: EN61000-6-4 EN61010-1 EN61000-6-2 PRINCIPLES: This product has been manufactured according to good engineering practice. The product specified conforms to the directive and standards described above.