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Nordson Sure Coat Manual

Nordson Sure Coat Manual

Modular gun control system
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Sure Coat
Modular Gun Control System
Issued 4/03
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 change without notice.
Check http://emanuals.nordson.com for the latest version.
NORDSON CORPORATION  AMHERST, OHIO  USA

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  • Page 1 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 change without notice. Check http://emanuals.nordson.com for the latest version. NORDSON CORPORATION  AMHERST, OHIO  USA...
  • Page 2 Notice Nordson Corporation welcomes requests for information, comments, and This is a Nordson Corporation publication which is protected by copyright. inquiries about its products. General information about Nordson can be Original copyright date 2000. No part of this document may be...
  • Page 3 System Configuration System Configuration The Sure Coat modular gun control system is custom configured to fit your application requirements. Only the options that you requested were installed when the system was manufactured. Use the following chart to record the components contained in your system.
  • Page 4 Refer to the following chart for a list of documentation that is available for the Sure Coat modular gun control system. Use this list to order documentation 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 tabs A−G.
  • Page 5 ........... . Section D4 Part G: Application/Triggering Controller Part A: System Overview Part 331235C E 2003 Nordson Corporation...
  • Page 6 Table of Contents Part A: System Overview Part 331235C E 2003 Nordson Corporation...
  • Page 7 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 change without notice. Check http://emanuals.nordson.com for the latest version. NORDSON CORPORATION  AMHERST, OHIO  USA...
  • Page 8 Contact Us Trademarks Nordson Corporation welcomes requests for information, comments, and Nordson, the Nordson logo, Select Charge, Sure Coat, Tribomatic, and inquiries about its products. General information about Nordson can be Versa-Spray are registered trademarks of Nordson Corporation. found on the Internet using the following address: http://www.nordson.com.

  • Page 9: Table Of Contents

    ........A 4-6 Part A: System Overview Part 331235C E 2003 Nordson Corporation...
  • Page 10 A 7-26 Application/Triggering Controllers ......A 7-26 Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 11: Safety

    Regulations and Approvals Make sure all equipment is rated and approved for the environment in which it is used. Any approvals obtained for Nordson equipment will be voided if instructions for installation, operation, and service are not followed. All phases of equipment installation must comply with all federal, state, and local codes.

  • Page 12: 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. Part A: System Overview Part 331235C...

  • Page 13: Grounding

    Identify the reason for the malfunction and correct it before restarting the equipment. Disposal Dispose of equipment and materials used in operation and servicing according to local codes. Part A: System Overview Part 331235C E 2003 Nordson Corporation...
  • Page 14 A 1-4 Safety Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 15: Description

    Introduction The Sure Coat modular gun control system provides pneumatic and electrostatic controls for up to 16 Sure Coat, Versa-Spray, or Tribomatic automatic powder spray guns. The electrostatic functions of the guns can be controlled simultaneously by the central control unit. Each gun has an individual pneumatic controller.

  • Page 16: Central Control Unit

    Figure A 2-1 System Components Central Control Unit The Sure Coat central control unit provides electrostatic control and 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 panel controls and indicators.

  • Page 17: Front Panel

    Error Indicator Indicates an individual gun error. Gun Trigger Key Triggers or shuts off the corresponding gun. Gun Trigger LED Indicates that the corresponding gun is triggered. Continued... Part A: System Overview Part 331235C E 2003 Nordson Corporation...
  • Page 18 Switches the scaling of the gun bar graphs. The total bar graph range can be either 50 or 100 A for IPS; or 5 or 10 A for Tribomatic guns. Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 19: Display

    Lights when there is an alarm or error condition. This icon will not turn off until the unit is reset or all errors are cleared. Diagnostics Icon Lights when the system is in the diagnostics mode. Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 20: Back Panel

    Supplies power to the (optional) application or triggering controller. Power Switch Turns on or off the central control unit’s power. Connects the communication cable from the central control Cable/Feed-Through unit to the main control cabinet. Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 21: Ips Gun Operating Modes

    Refer to the Configuration section in this part of the manual for instructions for locking out set point adjustment or enabling set point adjustment. Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 22: Timers

    The total spray timer (gun on total hours) keeps track of the total time 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.
  • Page 23 PLC. Blank Card Slot (Slot 10) Allows the modular gun control system to be upgraded in the future. Power Supplies Distribute power to system components. Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 24: Back View

    A 2-10 Description Back View See Figure A 2-6 and refer to Table A 2-6. 1400862A Figure A 2-6 Main Control Cabinet Components—Back View Part A: System Overview Part 331235C E 2003 Nordson Corporation...
  • Page 25 Supplies main ac power for the modular gun control system. Cord/Feed-Through Ground Stud Grounds the modular gun control system enclosure and all components. System Power Switch Turns on and off all connected components. Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 26: Optional Equipment

    DeviceNet The UCS DeviceNet interface card is used with either the Sure Coat application controller or an optional PLC with a DeviceNet interface. It allows the modular gun control system to interface with the gun purge module.

  • Page 27: Specifications

    3.4 _C (38 _F) or lower dewpoint at 7 bar (100 psi). Install a filter system with prefilters and coalescent type filters capable of removing oil, water, and dirt in the submicron range. Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 28: Symbols

    A 2-14 Description Symbols See Figure A 2-7. FLOW-RATE ATOMIZING GUN AIR GUN PURGE TRIGGER SYSTEM PURGE DIAGNOSTICS ELECTROSTATICS GROUND ERROR MODE 1400863A Figure A 2-7 Symbols Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 29: Installation

    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.

  • Page 30: Electrical Connections

    6. Connect the the gun cables to the cable receptacles on the gun receptacle panel (4). NOTE: Sure Coat automatic gun cables connect directly to the modular gun control system. Versa-Spray and Tribomatic gun cables require an adapter between the cable and the modular gun control system. If you did not receive the necessary adapters, contact your Nordson representative.

  • Page 31: Changing Interlock Voltage From 120V To 240V

    After (240 V) 1400850A Figure A 3-1 Changing Conveyor Interlock Voltage from 120V to 240V Note: Refer to the Troubleshooting section for a full schematic of the main I/O panel. Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 32: Pneumatic Connections

    2. Install the ball valve (9) on the main air connection (10). 3. Connect the included red, flexible air hose (8) to the ball valve. Connect the other end to the main air supply line. Part A: System Overview Part 331235C E 2003 Nordson Corporation...
  • Page 33 10. Main air connection 4. Gun receptacle panel Note: The gun purge option is not shown in this illustration. Refer to the Gun Purge Module of this manual for purge air tubing connections. Part A: System Overview Part 331235C E 2003 Nordson Corporation...
  • Page 34 A 3-6 Installation Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 35: Configuration

    Default set points to the gun that STD and Nordson you are viewing on the display Default set points to all guns in the SET ALL, STD, and Nordson system All defaults set at the factory, STD and Nordson while the...

  • Page 36: Entering Configuration Mode

    LOCAL key (11) is lit, the central control unit is in Local mode. If the LED is not lit, press the LOCAL key. 1. See Figure A 4-1. Press the Nordson key (15). 2. When three dashes appear in the display (8), press the PGM key (16).

  • Page 37: Gun Mapping

    1−8 and the right column controls guns 9−16. The operator can reassign the location of the guns on the central control unit to meet changing application requirements. Part A: System Overview Part 331235C E 2003 Nordson Corporation...
  • Page 38 NOTE: To continue on to another configuration mode, press the corresponding configurable option key. Configurable option keys are indicated by blinking LEDs. 9. To exit the configuration mode, press the Nordson key (15). Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 39: Pneumatic Type

    Configurable option keys are indicated by blinking LEDs. 4. To exit the configuration mode, press the Nordson key (15). Select Charge AFC Enable/Disable The ability to adjust AFC set points in Select Charge mode 2 may be either enabled or disabled.

  • Page 40: Set Point Lockout

    NOTE: To continue on to another configuration mode, press the corresponding configurable option key. Configurable option keys are indicated by blinking LEDs. 4. To exit the set point lockout mode, press the Nordson key (15). Part A: System Overview Part 331235C...

  • Page 41: Operation

    This section explains basic operating procedures for the Sure Coat modular gun control system. Refer to your other powder application equipment manuals for additional operation instructions before operating the modular gun control system.

  • Page 42: System Keyswitch

    LOCKOUT On/Off keyswitch is in READY or BYPASS position NOTE: If the conveyor stops and the keyswitch is in the READY position, CON appears on the central control unit display. Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 43: Startup

    Flow Rate Air: 2 bar (30 psi) 4. If you have added or replaced a gun since the last time you operated the system, perform the Initial Gun Use procedure. 5. Perform the Daily Operation procedure. Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 44: Initial Gun Use

    Initial Gun Use Perform this procedure when a gun is first put into service. 1. Make sure that the maximum kV setting (95 kV Sure Coat guns; 100 kV Versa-Spray guns) appears on the digital display in the STD mode with the AFC function on.

  • Page 45: Daily Operation

    Figure A 5-3 Typical Display in STD Mode with Gun Triggered 3. If your system is connected to either Versa-Spray or Sure Coat automatic guns, select the appropriate operating mode for your application. Refer to IPS Gun Operating Modes in this section to select the appropriate operating mode for your application.
  • Page 46 6. Put the system keyswitch in the READY position. The system is now ready for normal operation when the conveyor starts. Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 47: Ips Gun Operating Modes

    Description Use the +/– keys to turn on/off the kV or adjust the set point. The controller stores the kV setting when powered off or the mode is changed. Setting Sure Coat Guns Versa-Spray Guns kV Set Point adjustable adjustable kV Range 0 then 25−95 kV...

  • Page 48: Select Charge

    1400871A Figure A 5-5 Gun Triggered in Select Charge Mode 2 Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 49: Set Point Adjustments

    2. Adjust the operating modes and set points as desired. 3. Press the gun’s trigger key (2) to test the spray pattern. All Guns in System NOTE: Different types of guns (Tribomatic, Versa-Spray, and Sure Coat) (SET ALL) cannot be simultaneously adjusted using SET ALL.

  • Page 50: Restoring Factory Default Settings

    Default set points to the gun that STD and Nordson you are viewing on the display Default set points to all guns in the SET ALL, STD, and Nordson system All defaults set at the factory, STD and Nordson while the...

  • Page 51: Daily Maintenance

    3. Check power and gun cable connections. 4. Make sure that the air being supplied is clean and dry. 5. Wipe powder and dust off the control system cabinet with a clean, dry cloth. Part A: System Overview Part 331235C E 2003 Nordson Corporation...
  • Page 52 A 5-12 Operation Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 53: Troubleshooting

    Refer to Error Codes and Gun Driver Cards in this section for explanations of the system fault indications. NOTE: Error codes can only be viewed in the diagnostic mode. Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 54: Diagnostics Mode

    The diagnostics mode is available at all times. The gun can still be triggered while the display shows the diagnostics information. Pressing the Nordson key at any time while in the diagnostics mode results in an automatic exit from this mode and a return to the previous operating mode.
  • Page 55 1400389A Figure A 6-2 Diagnostic Mode Display NOTE: Pressing the Nordson key during the diagnostics sequence aborts the sequence. a. An error code or dashes are shown on the digital display. Dashes indicate that no error or alarm condition is present.

  • Page 56: Error Codes

    If the error changes to E7, check the resistance of the multiplier as described in the gun manual. Not used in this system Contact your Nordson representative for assistance. Gun cable or multiplier open circuit If the current display is 1 A or less, check the multiplier cable and electrode assembly for loose connections.

  • Page 57: Clearing Error Codes

    An uncleared error code will cause the alarm to be on until the problem is solved. Press the Nordson key to override the alarm for 10 minutes. The alarm will turn on again in 10 minutes if the problem is not solved. If a new alarm condition occurs within the original 10-minute period, the alarm will turn on again.

  • Page 58: Gun Driver Cards

    Foldback Lights when the over-current Check the gun and cable for protection circuit has been shorts. triggered because of high current draw from the gun drive circuitry on even-numbered gun. Part A: System Overview Part 331235C E 2003 Nordson Corporation...
  • Page 59 1. SW1 4. Yellow service LED 7. Yellow foldback A LED 2. SW2 5. Green status LED 8. Yellow foldback B LED 3. Red alarm LED 6. Green power LED Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 60: Electrical Schematics

    A 6-8 Troubleshooting Electrical Schematics Central Control Unit See Figure A 6-4. 1400851A Figure A 6-4 Central Control Unit Electrical Schematic Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 61: Solenoid And Gun Control Panels

    A 6-9 Troubleshooting Solenoid and Gun Control Panels See Figure A 6-5. 1400873A Figure A 6-5 Solenoid and Gun Control Panels Electrical Schematic Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 62: Main Control Cabinet

    A 6-10 Troubleshooting Main Control Cabinet See Figure A 6-6. MAIN OUTPUT SK 7 1400852A Figure A 6-6 Main Control Cabinet Electrical Schematic Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 63: Main I/O Panel

    A 6-11 Troubleshooting Main I/O Panel See Figure A 6-7. 1400853A Figure A 6-7 Main I/O Panel Electrical Schematic Part A: System Overview Part 331235C E 2003 Nordson Corporation...
  • Page 64 A 6-12 Troubleshooting Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 65: Parts

    A dash (—) is used when the part number applies to all parts in the illustration. The number in the Part column is the Nordson Corporation part number. A series of dashes in this column (- - - - - -) means the part cannot be ordered separately.

  • Page 66: System Components And Hardware

    C: Refer to Pneumatic Section in this section for a breakdown of parts in this assembly. D: Refer to the Parts section of Part B, Pneumatic Modules, for a breakdown of parts in this assembly. AR: As Required Part A: System Overview Part 331235C E 2003 Nordson Corporation...
  • Page 67 A 7-3 Parts 1400855A Figure A 7-1 System Components and Hardware—Front View Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 68: Back

    SCREW, pan, recessed, M5 x 10, with integral lock washer, bezel 970980 CLAMP, cable, 0.5 in. 334774 CABLE, 4 connector, solenoid interface, 5 ft 334818 LABEL, numbers, repeat, 1−16 303098 BRACKET, support, no. 1 AR: As Required Part A: System Overview Part 331235C E 2003 Nordson Corporation...
  • Page 69 A 7-5 Parts 1400874A Figure A 7-2 System Components and Hardware—Back View Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 70: Sheet Metal Covers

    WASHER, lock, m, split 982128 SCREW, hex, machine, M6 x 10 341643 COVER KIT, upgrade, 6−7 gun, dress out, sliding - - - - - - COVER, dress out, side AR: As Required Part A: System Overview Part 331235C E 2003 Nordson Corporation...
  • Page 71 A 7-7 Parts 1400856A Figure A 7-3 Sheet Metal Covers Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 72: Main Control Cabinet

    B: Order this switch if your system does not have an FM-approval label on the main I/O panel. C: Order this switch and contact block if your system has an FM-approval label on the main I/O panel. AR: As Required NS: Not Shown Part A: System Overview Part 331235C E 2003 Nordson Corporation...
  • Page 73 A 7-9 Parts DETAIL A DETAIL A 1400875A Figure A 7-4 Main Control Cabinet—Front View Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 74: Back

    B: Refer to Main Input/Output Panel in this section for a breakdown of the parts included in this assembly. C: Refer to Solenoid Panel in this section for a breakdown of the parts included in this assembly. AR: As Required NS: Not Shown Part A: System Overview Part 331235C E 2003 Nordson Corporation...
  • Page 75 A 7-11 Parts 1400876A Figure A 7-5 Main Control Cabinet—Back View Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 76: Gun Control Panel

    ADAPTER, gun cable, Versa-Spray, PE (gray) 334784 ADAPTER, gun cable, Tribomatic NOTE A: Use these adapters to connect Versa-Spray or Tribomatic guns to the Sure Coat modular gun control system. Sure Coat guns do not require an adapter. AR: As Required...

  • Page 77: Solenoid Panel

    S WASHER, flat, e, 0.203 x 0.406 x 0.040 in., brass 983401 S WASHER, lock, M, split, M5 984702 S NUT, hex, M5, brass 900338 S CAP, flush, -in. dia AR: As Required 1400878A Figure A 7-7 Solenoid Panel Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 78: Sub Panel Assembly

    Part Description Quantity Note - - - - - - PANEL, sub, main controller, Sure Coat 334799 S SCREW, pan, recessed, M5 x 10, with integral lock washer bezel - - - - - - S FRAME, card, Sure Coat...
  • Page 79 A 7-15 Parts DETAIL A DETAIL A 1400879A Figure A 7-8 Sub Panel Assembly Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 80: Card Frame

    334801 GUIDE, printed circuit board, 7 in. 308178 PCA, Sure Coat dual gun driver - - - - - - PCA, interface NOTE A: Each gun driver card controls up to two guns. B: Refer to Optional Equipment—Interface Cards in this section for ordering information for the correct interface card for your application.
  • Page 81 A 7-17 Parts 1400880A Figure A 7-9 Card Frame Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 82: Pneumatic Section

    S MOUNT, cable strap 900481 S ADHESIVE, pipe/thread/hydraulic sealant 982825 SCREW, pan, recessed, M4 x 12, with integral lock washer, bezel 148256 PLUG, 10 mm, tubing AR: As Required NS: Not Shown Part A: System Overview Part 331235C E 2003 Nordson Corporation...
  • Page 83 A 7-19 Parts DETAIL A DETAIL A 1400881A Figure A 7-10 Pneumatic Section Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 84: Main Input/Output Panel

    Part Description Quantity Note — - - - - - - PANEL, input/output, main, Sure Coat 334806 S SWITCH, round, 2 position, 90 degree 288806 S CONTACT BLOCK, 2 normally open contacts - - - - - - S PANEL, input/output 983021 S WASHER, flat, e, 0.203 x 0.406 x 0.040 in.,...
  • Page 85 A 7-21 Parts L1 L1 L2 L2 1400857A Figure A 7-11 Main Input/Output Panel Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 86: Central Control Unit Assembly

    - - - - - - S CABINET, central control unit, Sure Coat - - - - - - S PANEL, rear, central control unit, Sure Coat 982825 S SCREW, pan, recessed, M4 x 12, with integral lock washer, bezel...
  • Page 87 A 7-23 Parts 1400882A Figure A 7-12 Central Control Unit Assembly Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 88: Rear Panel

    Part Description Quantity Note — - - - - - - PANEL, rear, central control unit, Sure Coat 984702 S NUT, hex, M5, brass 983401 S WASHER, lock, M, split, M5, steel, zinc 983021 S WASHER, flat, e, 0.203 x 0.406 x 0.040 in.,...
  • Page 89 A 7-25 Parts AC OUT AC IN 1400854A Figure A 7-13 Central Control Unit Rear Panel Part A: System Overview Part 331235C E 2003 Nordson Corporation...

  • Page 90: Optional Equipment

    Part Description Note 1040836 KIT, Sure Coat, gun purge, upgrade Application/Triggering Controllers NOTE: To integrate these controllers into your system, you also must order other equipment (such as photoeyes, junction boxes, and an encoder). Contact your Nordson representative for more information.
  • Page 91 DECLARATION of CONFORMITY PRODUCT: Versa-Spray II or Sure Coat (bar or tube mount) IPS Automatic Powder Spray Applicators; Tribomatic or Tribomatic II, Automatic Tribo charging applicators. Used with Sure Coat Automatic Stackable Control System. APPLICABLE DIRECTIVES: 89/37/EEC (Machinery) 73/23/EEC (Low Voltage Directive)

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