Related Manuals for Nordson PowderPilot HD
Summary of Contents for Nordson PowderPilot HD
- Page 1 PowderPilot™ HD PowderPilot™ HD Controls Manual P/No.7192721_02 Issued 09/2017 NORDSON Deutschland GmbH – ERKRATH – GERMANY...
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Page 2: N 7192721
Powder Pilot™ HD P/N 7192721_02 Page | 2... - Page 3 Powder Pilot™ HD P/N 7192721_02 Page | 3...
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Page 4: Table Of Contents
Powder Pilot™ HD P/N 7192721_02 Table of Contents Safety ..............................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 .......................... -
Page 5: Safety
Intended Use Use of Nordson equipment in ways other than those described in the documentation supplied with the equipment may result in injury to persons or damage to property. -
Page 6: Personal Safety
• Clean, maintain, test, and repair equipment according to the instructions in your equipment documentation. • Use only replacement parts that are designed for use with original equipment. Contact your Nordson representative for parts information and advice. Page | 6... -
Page 7: Grounding
Powder Pilot™ HD P/N 7192721_02 Grounding WARNING: Operating faulty electrostatic equipment is hazardous and can cause electrocution, fire, or explosion. Make resistance checks part of your periodic maintenance program. If you receive even a slight electrical shock or notice static sparking or arcing, shut down all electrical or electrostatic equipment immediately. -
Page 8: Pe (Protective Earth) Grounding
Electrostatic discharges occur at very high frequencies, around 100 megahertz. An ordinary ground conductor does not conduct such high frequencies well enough to prevent damage to electronic components. Special flat braided cables are provided with your Nordson powder coating equipment to protect against ESD. Page | 8... - Page 9 Powder Pilot™ HD P/N 7192721_02 Gun Current Path Refer to Figure 1. All electrical circuits need a complete path for current to make its way back to the source (circle=circuit). Electrostatic spray guns emit current (ions) and therefore require a complete circuit. Some of the current emitted by the spray gun is attracted to the spray booth, but most is attracted to the grounded parts moving through the booth.
- Page 10 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 booth base, not to a panel, enclosure, or other component bolted to the base.
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Page 11: Disposal
Powder Pilot™ HD P/No.7192721_02 Action in the Event of a Malfunction If a system or any equipment in a system malfunctions, shut off the system immediately and perform the following steps: • Disconnect and lock out electrical power. Close pneumatic shutoff valves and relieve pressures. -
Page 12: Description
SpectrumHD GenII feed centre for fast and easy colour change. NOTE: The Nordson PowderPilot™ is a bespoke control system and is always designed according to customer requirements. Technical support is available from your local Nordson Representative. -
Page 13: Console Dimensions
Powder Pilot™ HD P/No.7192721_02 Console dimensions The PowderPilot HD is available with and without booth control section: ™ PowderPilot HD including booth control section PowderPilot HD without booth control section Specifications Electrical supply : 400 VAC /50Hz /3PH Rated power... -
Page 14: Booth Operation
Powder Pilot™ HD P/No.7192721_02 Section 3 Booth Operation WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Start-up sequence: 1. Ensure that the system is safe to start 2. -
Page 15: Booth Control Screen
Powder Pilot™ HD P/No.7192721_02 BOOTH CONTROL SCREEN Buttons A – auto start / stop - This button either starts or stops the booth and spray systems It places the booth in a production or standby mode Each press of this button toggles the mode When the booth is stopped, the oscillators and movers are automatically set to 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. - Page 16 Powder Pilot™ HD P/No.7192721_02 D – guns triggered display – This button displays a screen with an overview of which guns are triggered This screen is detailed in a later section of this manual E – gun feedback display – This button displays the gun set point and actual feedback screen All set and running spray values for each gun are displayed here This screen is detailed in a later section of this manual F –...
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Page 17: Screen Elements
Powder Pilot™ HD P/No.7192721_02 Screen elements 9 10 1 – program control – This data entry field has two functions It shows the program that is currently running in the system When pressed, it also allows the operator to create, delete, select or change programs. - Page 18 If any of these “LED-symbols” is drawn as red light, try to reset the fault by touching the reset button in the top right corner of the screen If the problem persists, contact your Nordson representative for information on these codes The fault codes indicated are explained as follows-...
- Page 19 Powder Pilot™ HD P/No.7192721_02 9 – mover control – Pressing this area on the main screen displays the mover control page as shown below :- Mover adjustment Auto / Manual selector Max Outer limit Max inner limit Current position Manual Mover out Manual Mover in Exit Mover adjustment –...
- Page 20 Powder Pilot™ HD P/No.7192721_02 Oscillator set up window Calls a small window used to setup dimensions on the oscillator – password required Oscillator on /off switch Starts or stops the Oscillator Oscillator set up window Oscillator stroke in mm Distance from 1 gun on oscillator to the part recognition array Distance of last gun on oscillator to the part...
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Page 21: Guns Triggered Status Screen
Powder Pilot ™HD P/No.7192721_02 GUNS TRIGGERED STATUS SCREEN By pressing the button keyed as D located on the main screen, the system will display the guns triggered status page as shown below:- A – exit screen 1 – gun 1 triggered – The green background denotes that this gun is triggered 2 –... -
Page 22: Gun Set Point Status Screen
Powder Pilot ™HD P/No.7192721_02 GUN SET POINT STATUS SCREEN By pressing the button keyed as E located on the main screen, the system will display the guns triggered status page as shown below:- A – exit screen A – exit – This button exits the gun configuration screen and returns to the main screen. B –... -
Page 23: Gun Feedback Screen
Powder Pilot ™HD P/No.7192721_02 GUN FEEDBACK SCREEN A – gun set point screen – This button returns to the previous screen. B – exit – This button exits to the booth control screen. 1 – gun 1 assist air feedback – This bar displays the actual assist air value being generated currently by gun 7. -
Page 24: Gun Spray Control
Powder Pilot ™HD P/No.7192721_02 GUN SPRAY CONTROL By pressing the button keyed as F located on the main screen, the system will display the gun set point control page as shown below:- Screen elements: Buttons: A – exit – This button exits the gun configuration screen and returns to the main screen B –... - Page 25 Powder Pilot ™HD P/No.7192721_02 Gun setpoint control screen elements: 1 – powder output slider control – This slider control sets the powder output for the gun entered as a percentage. To set, touch the button and slide up or down to desired set point. 2 –...
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Page 26: Group Set Point Adjust
Powder Pilot ™HD P/No.7192721_02 Group set point adjust Pressing the button “C” on the gun spray control screen will show up the screen below: Exit screen Through this screen the operator can define set points to be adjusted by using the following symbols: 1 –... -
Page 27: Gun Configuration
Powder Pilot ™HD P/No.7192721_02 GUN CONFIGURATION Pressing the button on the gun spray control screen will show up the gun configuration screen below: Exit screen 1 – after spray – This value shows how many millimetres after the product has left that the gun will switch off. - Page 28 Powder Pilot ™HD P/No.7192721_02 5 – horizontal distance – This value shows the distance between the gun and the beam array in millimetres Touch the value and a keypad will appear to adjust it. 6 – total gun hours – This displays the total hours that the gun has triggered for If the gun is replaced, this number can be reset by touching the display and entering zero into the keypad that will appear.
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Page 29: Booth Configuration
Powder Pilot ™HD P/No.7192721_02 BOOTH CONFIGURATION Pressing the button on the main screen will evoke the screen below: Exit screen 8 9 10 11 12 13 14 19 20 1 - Conveyor index - This is the number of millimetres the conveyor has travelled during one pulse from the conveyor encoder. - Page 30 Powder Pilot ™HD P/No.7192721_02 8, 9 – Mover encoder resolution – enoder resolution of movers 1 and 2 are entered here in pulses per 10 - Movers in – This is the ultimate in position that the movers will be allowed to go to 11 - Movers purge –...
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Page 31: Pump Controller Configuration
Powder Pilot ™HD P/No.7192721_02 PUMP CONTROLLER CONFIGURATION This screen appears after pressing the symbol on the booth configuration screen. Pump controllers calibration values are displayed in groups of 4 gun on each page. The user has to select the correct group referring to the appropriate guns. - Page 32 Powder Pilot ™HD P/No.7192721_02 Read screen Exit screen 1 – Gun group – the 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.
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Page 33: Purge Timing Configuration
Powder Pilot ™HD P/No.7192721_02 PURGE TIMING CONFIGURATION Touching the - button will bring up a window, allowing the user to set up different times used during cleaning of the system Exit 1 – Gun pulses – specify the number of pulses for cleaning the gun here 2 –... -
Page 34: Spectrum Hd Control Section
Powder Pilot™HD P/No.7192721_02 Spectrum HD CONTROL SECTION Screen elements: Spectrum HD buttons A – Exit to booth control screen – This button takes the operator back to the booth control screen B, C, D, E, G,H I, – these are related to the same functions as on the main screen F –... - Page 35 Powder Pilot™HD P/No.7192721_02 Spectrum HD screen elements 1 – Powder level monitor – the cut out in the hopper is shown in 4 steps representing the actual powder level inside: Powder level high, hopper full Powder level medium, this is the working level which the system maintains using the virgin pump only.
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Page 36: Spectrum Hd Manual Control Section
Powder Pilot™ HD P/No.7192721_02 Spectrum HD MANUAL CONTROL SECTION Pushing the button on the Spectrum HD control screen will display controls for manual operation of various devices of the feed centre. Note: the operator takes full responsibility of his actions on the system. All automatic functions of the Spectrum are inactive while on that screen. -
Page 37: Spectrum Hd Configuration Section 1
Powder Pilot™ HD P/No.7192721_02 Spectrum HD CONFIGURATION SECTION 1 Pushing the button on the Spectrum HD control screen will display the configuration screens described below. Note: configuration shall only be done by authorized and trained personnel! Exit screen Next screen 1 –... -
Page 38: Spectrum Hd Configuration Section 2
Powder Pilot™ HD P/No.7192721_02 Spectrum HD CONFIGURATION SECTION 2 Previous screen Exit screen 1 – run pumps while purging – set the pumps to automatically run during a purge or don’t run 2 – pump purge pulse on time – the on time of a cleaning pulse to the HDLV transfer pumps in seconds 3 –... -
Page 39: Colour Change Operation
Powder Pilot™ HD P/No.7192721_02 COLOUR CHANGE OPERATION To start a colour change routine the operator pushes this button Step 1 – approve colour change: On the screen above the operator can choose to carry on colour changing by touching this button to cancel the procedure and go return to the Spectrum HD screen. - Page 40 Powder Pilot™ HD P/No.7192721_02 Step 2 – place box underneath hopper: 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 this button to release the powder out of the hopper and go to the next step.
- Page 41 Powder Pilot™ HD P/No.7192721_02 Step 3 – drain the hopper: When this screen is shown, the dump 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 configuration.
- Page 42 Powder Pilot™ HD P/No.7192721_02 Step 4 – hoses to purge position: Color change position Painting position This screen is shown to remind the operator to turn the extraction 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 out there during hopper purge.
- Page 43 Powder Pilot™ HD P/No.7192721_02 Step 4 – hopper purge: During this step the hopper is cleaned from inside using the pumps and according to timings set up during configuration. While cleaning the inside of the hopper, it should be avoided to open the cyclone hopper or anything else effecting the extraction.
- Page 44 Powder Pilot™ HD P/No.7192721_02 Step 5 – manual cleaning: This is the last step of the sequence; the screen below reminds the operator to manually clean cyclone and hopper Cleaning of the pumps can be activated or stopped by touching the pump symbols on the right side of the screen.
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Page 45: Troubleshooting
P/No.7192721_02 Section 4 Troubleshooting In case of problems with the system or any equipment within the system call your local Nordson representative. Contacts can be found at the beginning of this manual. Section 5 Repair WARNING: Allow only qualified personnel to perform the following tasks. - Page 46 Powder Pilot™ HD P/No.7192721_02 Gun Control Card Removal/Installation WARNING: Shut off console power before removing and installing gun control cards. Failure to observe this warning could result in damage to the cards, and could result in personal injury or even death. CAUTION: Do not turn off console power without first performing a program shutdown.
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Page 47: Customer Specific Information
Powder Pilot™ HD P/No.7192721_02 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. Wiring diagram • Electrical Parts list • Page | 47... -
Page 48: Parts
Powder Pilot™ HD P/No.7192721_02 Section 7 Parts To order parts, call the Nordson Customer Service Center or your local Nordson representative. http://www.nordson.com/en/global-directory Console Parts Item Part Description Quantity Note 1023939 PCA, backplane, iControl 2 1023877 PCA, dual gun driver, iControl... - Page 49 Powder Pilot™ HD P/No.7192721_02 Console Parts – cont. Item Part Description Quantity Note 1031501 RECEPTACLE, 8-position, gun, 70 in 1023695 SEAL, bulkhead, 7/8−16 thread 984526 NUT, lock, 1/2 in. conduit 939122 SEAL, conduit fitting, 1/2 in 334800 PLUG, 1/2 in NOTE A: One receptacle is required for each automatic spray gun.
- Page 50 Powder Pilot™ HD P/No.7192721_02 Console Parts – cont. Item Nordson DESCRIPTION Quantity Part No. 1031501 RECEPTACLE,8 POSITION,GUN,70 IN 1 per gun 939122 SEAL,CONDUIT FITTING,1/2 1 per gun 984526 NUT,LOCK,1/2 CONDUIT 1 per gun 1031485 HARNESS,NET,CPU,ICONTROL 1 per 16 guns 1107144...
- Page 51 Powder Pilot™ HD P/No.7192721_02 1031501 RECEPTACLE,8 POSITION,GUN,70 IN 1 per gun 939122 SEAL,CONDUIT FITTING,1/2 1 per gun 984526 NUT,LOCK,1/2 CONDUIT 1 per gun Page | 51...
- Page 52 Powder Pilot™ HD P/No.7192721_02 1 per 16 guns 1027564 POWER SUPPLY,400W,+24V,+/-12V,+5V 1027140 HARNESS,POWER,+5,+12,-12V,ICONTROL 1 per 16 guns 1107144 PCA, AUTO DUAL GUN DRIVER, ENCORE 1 per 2 guns 1098444 GUIDE,PCB CARD, CONDUCTIVE, 7 INCH 20 per 16 guns 334755 BRACKET,CARDFRAME,CTRL CAB 1 per 16 guns 1023939 PCA,BACKPLANE,ICONTROL...