New Servo 2K Controller - Nordsonemanuals.nordson.com/automotive/zfiles/1006207a.pdf · 2019. 4. 8. · The servo 2K controller automates the application of two component (2K) adhesives

Servo 2K Controller

Customer Product ManualPart 1006207A

NORDSON CORPORATION � AMHERST, OHIO � USA

� 2001 Nordson CorporationAll rights reserved

1006207AIssued 6/01

Manual 25-22

Nordson Corporation welcomes requests for information, comments and inquiries about its products. Generalinformation about Nordson can be found on the Internet using the following address: http://www.nordson.com.

Address all correspondence to:

Nordson CorporationAttn: Customer Service

555 Jackson StreetAmherst, OH 44001

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2001. 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.

Trademarks

AccuJet, AquaGuard, Asymtek, Automove, Autotech, Blue Box, CF, CanWorks, Century, Clean Coat, CleanSleeve,CleanSpray, Compumelt, Control Coat, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, Durafiber, Durasystem,Easy Coat, Easymove Plus, Econo-Coat, EPREG, ETI, Excel 2000, Flex-O-Coat, FlexiCoat, Flexi-Spray, Flow Sentry,

Fluidmove, Fluidshooter, FoamMelt, FoamMix, Helix, Horizon, Hose Mole, Hot Shot, Hot Stitch, Isocoil, Isocore, Iso-Flo, JR,KB30, Little Squirt, Magnastatic, MEG, Meltex, MicroSet, Millenium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan,

Nordson, OmniScan, Opticoat, Package of Values, PluraFoam, Porous Coat, PowderGrid, Powderware, Pro-Flo, ProLink,Pro-Meter, Pro-Stream, PRX, RBX, Ready Cost, Rhino, S. design stylized, Saturn, SC5, SCF, Select Charge, Select Coat,Select Cure, Shur-Lok, Slautterback, Smart-Coat, Spray Squirt, Spraymelt, Super Squirt, Sure-Bond, Sure Coat, System

Sentry, Tela-Therm, Trends, Tribomatic, UniScan, UpTime, Veritec, Versa-Coat, Versa-Screen, Versa-Spray, Watermark, andWhen you expect more. are registered trademarks of Nordson Corporation.

ATS, Auto-Flo, AutoScan, BetterBook, Chameleon, CanNeck, Check Mate, CPX, Control Weave, Controlled Fiberization,EasyClean, Ebraid, Eclipse, Equi=Bead, Fillmaster, Gluie, Ink-Dot, Kinetix, Maxima, MicroFin, Minimeter, Multifil, OptiMix,Pattern View, PluraMix, Primarc, Prism, Process Sentry, PurTech, Pulse Spray, Seal Sentry, Select Series, Sensomatic,

Shaftshield, Spectral, Spectrum, Sure Brand, Swirl Coat, Vista, Walcom, and 2 Rings (Design)are trademarks of Nordson Corporation.

Table of Contents i


1006207AIssued 6/01

Manual 25-22

Table of Contents

1. Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Qualified Personnel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intended Use 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Regulations and Approvals 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Personal Safety 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-Pressure Fluids 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fire Safety 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Halogenated Hydrocarbon Solvent Hazards 5. . . . . . . . . . . . . . . .

Action in the Event of a Malfunction 5. . . . . . . . . . . . . . . . . . . . . . . . .

Disposal 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Description 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Components 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chassis 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Theory of Operation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Touchscreen 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Menu Tree 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Menu 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Security 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SETPOINT SCREEN 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GLOBAL SETTINGS #1 SCREEN 15. . . . . . . . . . . . . . . . . . . . . . .

GLOBAL SETTINGS #2 SCREEN 16. . . . . . . . . . . . . . . . . . . . . . .

RELIABILITY and MAINTAINABILITY (R&M)DATA SCREEN 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPLAY SCREEN 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEAR TO PURGE SCREEN 21. . . . . . . . . . . . . . . . . . . . . . . . . . .

PURGE SCREEN 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MANUAL MODE SCREEN 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIME SETUP SCREEN 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALARM LIGHTS SCREEN 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALARM HISTORY SCREEN 28. . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALARM BANNER 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYSTEM READY STATUS SCREEN 30. . . . . . . . . . . . . . . . . . . . .

SYSTEM DE–PRESSURIZEDSTATUS SCREEN 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SET INDEX POSITION SCREEN 33. . . . . . . . . . . . . . . . . . . . . . . .

DEVICENET COMMUNICATIONS SCREEN 34. . . . . . . . . . . . . .

Table of Contentsii


1006207AIssued 6/01

Manual 25-22

3. Installation 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Connections 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connector Panel 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Signal Configuration 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Signal #1 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Signal #2 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing Sequences 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Operation 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial Setup 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Settings 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Startup 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Conditions 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Base/Catalyst Exceeded Maximum Pressure 44. . . . . . . . . . . . . .

Mixer Tube Timeout Fault 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Restart 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutdown 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Maintenance 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Troubleshooting 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Repair 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Servo 2K Controller 47. . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Power Supply Module 47. . . . . . . . . . . . . . . . . . . . . . .

Replacing the SLC 5-04 CPU Module 48. . . . . . . . . . . . . . . . . . . . . .

Replacing the Input Module 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Output Module 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the DeviceNet Module 49. . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Touchscreen 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Parts 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Illustrated Parts List 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servo 2K Controller US Version 52. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servo 2K Controller CE Version 55. . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. Specifications 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servo 2K Controller 1


1006207AIssued 6/01

Manual 25-22

Servo 2K Controller

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.

Equipment owners are responsible for making sure that Nordsonequipment is installed, operated, and serviced by qualified personnel.Qualified personnel are those employees or contractors who are trainedto safely perform their assigned tasks. They are familiar with all relevantsafety rules and regulations and are physically capable of performingtheir assigned tasks.

Use of Nordson equipment in ways other than those described in thedocumentation supplied with the equipment may result in injury topersons or 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

Make sure all equipment is rated and approved for the environment inwhich it is used. Any approvals obtained for Nordson equipment will bevoided if instructions for installation, operation, and service are notfollowed.

1. Safety

Qualified Personnel

Intended Use

Regulations and Approvals

Servo 2K Controller2


1006207AIssued 6/01

Manual 25-22

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 bypassor disarm any safety devices.

� Keep clear of moving equipment. Before adjusting or servicingmoving equipment, shut off the power supply and wait until theequipment comes to a complete stop. Lock out power and secure theequipment to prevent unexpected movement.

� Relieve (bleed off) hydraulic and pneumatic pressure before adjustingor servicing pressurized systems or components. Disconnect, lockout, 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 carrymetallic objects such as jewelry or tools.

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

� Obtain and read Material Safety Data Sheets (MSDS) for all materialsused. Follow the manufacturer’s instructions for safe handling anduse of materials, 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,sharp edges, energized electrical circuits, and moving parts thatcannot be enclosed or otherwise guarded for practical reasons.

Personal Safety



1006207AIssued 6/01

Manual 25-22

High-Pressure Fluids

High-pressure fluids, unless they are safely contained, are extremelyhazardous. Always relieve fluid pressure before adjusting or servicinghigh pressure equipment. A jet of high-pressure fluid can cut like a knifeand cause serious bodily injury, amputation, or death. Fluids penetratingthe skin can also cause toxic poisoning.

If you suffer a fluid injection injury, seek medical care immediately. Ifpossible, provide a copy of the MSDS for the injected fluid to the healthcare provider.

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 beserious. If you are injured or even suspect an injury:

� Go to an emergency room immediately.� Tell the doctor that you suspect an injection injury.� Show him this card.� Tell him 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 treatthe injury surgically as soon as possible. Do not delay treatment toresearch toxicity. Toxicity is a concern with some exotic coatings injecteddirectly into the 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 thebody, whether the substance hit something on its way in and deflectedcausing more damage, and many other variables including skinmicroflora residing in the paint or gun which are blasted into the wound.If the injected paint contains acrylic latex and titanium dioxide thatdamage the tissue’s resistance to infection, bacterial growth will flourish.The treatment that doctors recommend for an injection injury to the handincludes immediate decompression of the closed vascular compartmentsof the hand to release the underlying tissue distended by the injectedpaint, judicious wound debridement, and immediate antibiotic treatment.



1006207AIssued 6/01

Manual 25-22

To avoid a fire or explosion, follow these instructions.

� Ground all conductive equipment in the spray area. Use onlygrounded air and fluid hoses. Check equipment and workpiecegrounding devices regularly. Resistance to ground must not exceedone megohm.

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

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

� Do not disconnect live electrical circuits while 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,immediately shut 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 theinstructions in your equipment documentation.

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

Fire Safety



1006207AIssued 6/01

Manual 25-22

Halogenated Hydrocarbon Solvent Hazards

Do not use halogenated hydrocarbon solvents in a pressurized systemthat contains aluminum components. Under pressure, these solventscan react with aluminum and explode, causing injury, death, or propertydamage. Halogenated hydrocarbon solvents contain one or more of thefollowing elements:

Element Symbol Prefix

Fluorine F “Fluoro-”

Chlorine Cl “Chloro-”

Bromine Br “Bromo-”

Iodine I “Iodo-”

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

If a system or any equipment in a system malfunctions, shut off thesystem immediately 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 restartingthe system.

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

Action in the Event of aMalfunction

Disposal



1006207AIssued 6/01

Manual 25-22

NOTE: This manual describes a typical controller system which may notcompletely reflect your particular setup. Refer to your systemdocumentation for more information.

NOTE: This manual covers the US and European servo 2K controllers.Throughout this manual the European servo 2K controller is referred toas the CE version.

The servo 2K controller automates the application of two component (2K)adhesives to automotive parts and panels. The system includes astationary or robot-mounted dispense gun, dual unloaders, and a 2Kmeter with servo drive. The servo 2K controller works in conjunction withthe robot controller.

The servo 2K controller receives a 0–10 Vac analog signal from the robotcontroller to control the gun dispense rate and swirl air. A constant beadsize is maintained by adjusting the dispense rate for changes in robotspeed.

Diagnostic capabilities include self-testing and fault detection. The PLCconstantly monitors the dispense operation and relays fault conditions tothe robot. Fault conditions are displayed on the touchscreen display.

The servo 2K controller includes a Nordson-configured software programfor your specific application.

NOTE: The servo 2K controller configurations and control cabinetlayouts may vary slightly based on your specific system configuration.

See Figure 1.

Cable connections at the connector panel (5) or at the top of the controlcabinet, depending on your system layout, link the controller, the 2Kmeter junction box, the cell PLC, and the robot controller together. Thetouchscreen (10) includes the display and the hard keys.

The CE touchscreen has a language button to toggle between Englishand German.

The front panel also has the following components:

� ground status lights (8, 9)� emergency stop push button (7)� master power push button (6)

A secured latch (4) prevents unauthorized personnel from accessing theservo 2K controller interior.

The two-position main power switch (2 or 3) is either located on the rightside of the controller or on the front panel. The alarm light tower (1)mounts to the top of the cabinet for visibility from all directions.

2. Description

Controller Components



1006207AIssued 6/01

Manual 25-22

2522001A

1

8

9

6

7

4

3

10

5

2

Fig. 1 Typical Servo 2K Controller

1. Alarm light tower2. Main power switch(CE version only)3. Main power switch(US version only)4. Latch

5. Connector panel

6. Master power push button

7. Emergency stop push button

8. Ground status 19. Ground status 2

10. Touchscreen



1006207AIssued 6/01

Manual 25-22

Chassis

See Figure 2.

Table 1 lists the chassis components.

Table 1 Chassis Components

Item Description Function

1 Chassis power supply The 24 Vdc power supply provides power to the adjacent modules

2 SLC 5/04 CPU module Central processing unit that has the following indicators:

RUN–Indicates power to the module, no fault condition.

FORCE–When lit, input/output forces are enabled. When indicator is flashing,input/output forces are not enabled.

FLT–When this LED illuminates, a fault condition has occurred. Refer to theTroubleshooting section for more information.

DH+–When lit, a data highway communication is active. Refer to theTroubleshooting section for more information.

BATT–When lit, the battery should be replaced. Refer to your systemdocumentation

RS232–When lit, communication is active. Refer to the Troubleshootingsection for more information.

3 Input module Located in slot 1–When the module receives inputs, the corresponding channelindicators (0–15) light up.

4 Output module Located in slot 2–When the module sends output signals, the correspondingchannel indicators (0–15) light up

5 DeviceNet module Located in slot 4–MODULE and NET communication status is signaled throughtwo indicator lights. ADDRESS/ERROR codes appear underneath theindicator lights. Refer to your system manual for more information.

6 Key switch Removable three-position key switch that changes the module between threemodes:

RUN–The SLC 5/04 CPU module inputs/outputs are enabled.

REM–The mode is changeable with software.

PROG–The inputs/outputs are disabled.

Remove the key to prevent tampering by unauthorized personnel.

7 Wiring terminal

8 Jumper Located behind the hinged cover.

9 Fuse

g



1006207AIssued 6/01

Manual 25-22

2522026A

1 32 4 5

9

8

76

Fig. 2 Servo 2K Controller Modules

The robot controller sends a 0–10 Vdc analog signal proportional to therobot speed. The servo 2K controller uses that information to adjust theservo motor speed on the 2K meter and the dispense rate of the gun.

A second robot controller analog signal is used to control theproportioning valve air pressure for dispense guns with swirl air.According to the speed of the robot, the proportioning valve increases ordecreases the air flow to the dispense gun.

An alarm light tower on top of the cabinet alerts the operator when a faultoccurs. The software provides a description of the fault, the appropriatecorrective action to take, or how to contact your Nordson representativefor assistance.

If a fault occurs, the operator can either:

� Stop the system and correct the fault

or

� Run the system as is and correct the fault later.

Theory of Operation



1006207AIssued 6/01

Manual 25-22

See Figure 3.

The touchscreen represents the servo 2K controller user interface. Table2 lists the touchscreen components.

Table 2 Touchscreen Components

Item Description Function

1 Numeric key Enter numeric values and setpoints.

2 Enter key Enter key to activate inputs and screen selections, to execute or savesettings and values entered with the numeric keys.

3 Backspace/Escape key Moves the cursor to a different location on the touchscreen display ordeletes the previous entry.

4 Arrow key Moves the cursor to different touchscreen display locations.

5 F(x) keys Execute major operations–The function key operations are alsoselectable from touchscreen display fields. Refer to the Menu Treesection for more information.

6 Multi-Color backlit display Has menus to select functions, enter values, and correct faultconditions–The Nordson logo appears upon power-up. The CEtouchscreen has a language button to toggle between English andGerman.

2522004A

1

2

3

45

6

Fig. 3 Touchscreen

Touchscreen



1006207AIssued 6/01

Manual 25-22

See Figure 4.

The user interface consists of a multiple level menu tree. Move throughthe menus and screens by touching the back-lit, multi-color display.

2522003A

Main Menu

Part ID Setup ScreenGlobal Settings #1

R and M Data ScreenDisplay Screen

Time Setup ScreenAlarm Lights Screen

Nordson Logo Screen

Global Settings #2

Password Setup Screen

Clear to Purge Screen

Purge Screen

Manual Mode Screen

Clear to Purge Screen

System Read Status ScreenAlarm History Screen

System De–pressurized Status Screen

Set Index Position Status ScreenDevice Net Communication Status Screen

Alarm Banner Screen - appears when a fault condition occurs

Fig. 4 Menu Tree

See Screen 1.

Press the F10 function key on the Nordson logo screen to display theMAIN MENU screen. Use the buttons to access all other screens in thecontroller program. To select a function, press the appropriate button onthe touchscreen or press the corresponding function key below thetouchscreen display.

Menu Tree

Main Menu



1006207AIssued 6/01

Manual 25-22

Security

Refer to Table 3.

The security level determines which functions a user can access. Thereare three security levels:

Table 3 Security levels

Security Level Description

Operator Can access the following screens:

LOGO

MAIN MENU

DISPLAY

ALARM LIGHTS

ALARM HISTORY

ALARM BANNER

SYSTEM READY STATUS

PURGE

CLEAR TO PURGE

Maintenance All the privileges as Operator, plus access to:

PART ID SETPOINTS

GLOBAL SETTINGS #1

MANUAL MODE SCREEN

TIME SETUP SCREEN

SYSTEM DEPRESSURIZED STATUS

DEVICENET COMMS STATUS

SET INDEX STATUS

Supervisor All the privileges of Maintenance, plus access to:

GLOBAL SETTINGS #2

PASSWORD SETUP



1006207AIssued 6/01

Manual 25-22

2522005A

Screen 1 MAIN MENU



1006207AIssued 6/01

Manual 25-22

SETPOINT SCREEN

See Screen 2.

This screen stores up to 16 (0-15) separate numeric part identifications.Select the desired setpoint and enter part specific numeric values. Referto Table 4 and System Parameter Settings for more information.

Table 4 Setpoint Screen Functions

Function Key Description

PART ID F1 Selects one of 16 possible part identification settings.

SETPOINT F2 Desired part volume in cc.

HI LIMIT % F3 Defines high limit in %.

LO LIMIT % F4 Defines low limit in %.

PRE PRESSURE SETPOINT BASE F5 Defines pre pressure setpoint for base material in psi.

HI PRESSURE FAULT BASE F6 Defines high pressure fault level for base material in psi.

LO PRESSURE FAULT BASE F7 Defines low pressure fault level for base material in psi.

HI PRESSURE FAULT CATALYST F8 Defines high pressure fault level for catalyst material in psi.

LO PRESSURE FAULT CATALYST F9 Defines low pressure fault level the catalyst material in psi.

PRE PRESSURE SETPOINT CATALYST — Defines pre pressure setpoint for catalyst material in psi.

SAVE PART ID SETTING — Saves and stores the currently entered part ID settings.

RETURN TO MAIN MENU F10 Returns to the MAIN MENU.

2522006A

Screen 2 SETPOINT



1006207AIssued 6/01

Manual 25-22

GLOBAL SETTINGS #1 SCREEN

See Screen 3.

Refer to Table 5. This screen stores numeric values for the followingfunctions:

Table 5 Global Settings #1 Screen Functions


AUTO PURGE TIMER F1 Time interrupt in seconds between auto purges.

AUTO PURGE COUNTER F2 Preset number of auto purges before auto purges are stopped.

MIXER TUBE TIME OUT F3 Defines the mixer tube timeout in seconds.

REFILL TIME OUT BASE F4 Timed interval in seconds before a base refill fault.

REFILL TIME OUT CATALYST F5 Timed interval in seconds before a catalyst refill fault.

PARTS BEFORE REFILL F6 Defines the number of parts before the refill phase.

PURGE SPEED SETPOINT F7 Defines the setpoint for the purge speed in rpm.

PURGE VOLUME SETPOINT F8 Defines the setpoint for the purge volume in cc.

RATIO PURGE DELAY — Time interval in seconds before a metered purge begins.

GLOBAL SETTINGS#2 F9 Toggles between the global settings#1 and global settings#2 screens.


2522007A

Screen 3 GLOBAL SETTINGS #1



1006207AIssued 6/01

Manual 25-22

GLOBAL SETTINGS #2 SCREEN

See Screen 4.

Refer to Table 6. This screen stores numeric values for the followingfunctions:



MTR ENCODER PULSES F1 Defines the motor encoder pulses (2000).

GEARHEAD RATIO F2 Defines the gearhead ratio (7:1)

BELT RATIO F3 Defines the belt ratio (2:1)

BALL SCREW PITCH F4 Defines the ball screw pitch (10 mm/rev)

INITIATE SERVO F5 Initializes the servo by sending it through the homing sequence.

BASE CYLINDER VOLUME F6 Defines the volume of the base material cylinder (cc/mm)

CATALYST CYLINDER VOLUME F7 Defines the volume for the catalyst cylinder (cc/mm)

PASSWORD SET–UP SCREEN F8 Displays the PASSWORD SCREEN. Refer to PASSWORDSCREEN in this section for more information.

GLOBAL SETTINGS#1 F9 Toggles between the global settings#2 and global settings#1screens.


2522008A

Screen 4 GLOBAL SETTINGS #2



1006207AIssued 6/01

Manual 25-22

PASSWORD SET–UP SCREEN

See Screen 5.

Personnel with a Supervisor security level can assign passwords andsecurity levels to users from this screen.

2522009A

Screen 5 PASSWORD SCREEN



1006207AIssued 6/01

Manual 25-22

RELIABILITY and MAINTAINABILITY (R&M) DATA SCREEN

See Screen 6.

This screen displays the number of faults that occur during systemoperation along with RUN TIME HOURS, PARTS DISPENSED, andRESET MONTH/DAY functions. Refer to Table 7 for key functions.

Table 7 R & M Data Screen Key Functions


RESETS COUNTERS F9 Resets each counter to 0.

RETURN TO MAIN MENU F10 Returns to MAIN MENU

2522010A

Screen 6 R&M DATA SCREEN



1006207AIssued 6/01

Manual 25-22

DISPLAY SCREEN

See Screen 7.

This screen displays the following system status information. None ofthese functions can be selected. The screen is for information purposeonly. Refer to Table 8 for DISPLAY SCREEN functions.

Table 8 DISPLAY SCREEN Functions

Function Description

ROBOT I/O Header title

MINOR FAULT Output to robot when a minor fault is present

MAJOR FAULT Output to robot when a major fault is present

SEALER READY Output to robot when the system is ready todispense

PRE-PRESSURE Output to robot when the system ispre-pressurized

PART ID Input from robot to give the current part ID

IGNORE ANALOG SIGNAL Not used

FLOW Input from robot to enable flow

PART STROBE Input from robot to signal part

START DISPENSE Input from robot to dispense from gun

PURGE Input from robot to start a metered purge

CLEAR TO PURGE Input from robot to signal clear to purge

F6: CLEAR TO PURGE STATUS Status of the clear to purge function

REFILL PROXIMITY SWITCHES FOR BASE AND CATALYST Status of refill proximity switches

BALL SCREW PROXIMITY SWITCH RETRACTED Status of ball screw proximity switch

BALL SCREW PROXIMITY SWITCH EXTENDED Status of ball screw proximity switch

SYSTEM IN AUTO Mode indication of system

RETURN TO MAIN MENU Returns to MAIN MENU



1006207AIssued 6/01

Manual 25-22

DISPLAY SCREEN (contd)

The numeric values displayed include:

� ACTUAL LAST PART VOLUME

� SETPOINT LAST PART VOLUME

� LAST PART DAY, HOUR, MINUTE

� BASE PRESSURE

� CATALYST PRESSURE

2522011A

Screen 7 DISPLAY



1006207AIssued 6/01

Manual 25-22

CLEAR TO PURGE SCREEN

See Screen 8.

Refer to Table 9. This screen is accessible through the DISPLAYSCREEN or the PURGE SCREEN and includes the following functions:

Table 9 Clear to Purge Screen


ROBOT CLEAR TO PURGE FROM CELL Indicator is red when the robot has not positioned the dispensinggun directly above the purge bucket of the cell.

ROBOT CLEAR TO PURGE FROM CELL Indicator is green when the robot has positioned the dispensing gundirectly above the purge bucket of the cell.

PURGE AREA GATE SWITCH OK Indicator is red when gate switch is open; indicator is green whengate switch is closed.

CLEAR TO PURGE Indicator is red when system is not ready to purge; indicator is greenwhen system is ready to purge.

PURGE SCREEN Accesses the PURGE SCREEN.

DISPLAY STATUS SCREEN Accesses the DISPLAY STATUS SCREEN.

2522013A

Screen 8 CLEAR TO PURGE



1006207AIssued 6/01

Manual 25-22

PURGE SCREEN

See Screen 9.

Refer to Table 10. This screen is accessible through either the MAINMENU or CLEAR TO PURGE screens. It has the following functions:

Table 10 PURGE SCREEN


RATIO CHECK PURGE F1 Initiates a metered purge after the set wait time; allows time forthe operator to get sample cups ready.

CLEAR TO PURGE F3 Indicator is red when system is not ready to purge; indicator isgreen when system is ready to purge. Allows operator to go tothe CLEAR TO PURGE screen.

METERED PURGE F5 Initiates a metered purge.

GO TO MANUAL MODE F9 Access the MANUAL MODE SCREEN.

RETURN TO MAIN MENU F10 Returns to MAIN MENU.

2522012A

Screen 9 PURGE SCREEN



1006207AIssued 6/01

Manual 25-22

MANUAL MODE SCREEN

See Screen 10.

Refer to Table 11. The operator can manually override settings for thefollowing functions:



IN AUTO MODE F1 Initiates which mode the system is in–on some systems,allows user to toggle between MANUAL and AUTO.

BASE VALVE IN F2 Overrides the base valve IN.

BASE VALVE OUT F3 Overrides the base valve OUT.

BASE VALVE GUN F4 Overrides the base valve gun.

METERED PURGE F5 Initiates the metered purge.

OVERRIDE AUX. VALVE F6 Overrides the auxiliary valve.

CATALYST VALVE IN F7 Overrides the catalyst valve IN.

CATALYST VALVE OUT F8 Overrides the catalyst valve OUT.

CATALYST VALVE GUN F9 Overrides the catalyst valve gun.


SEALER READY — Indicates that the sealer is ready.

CLEAR TO PURGE — Indicates that the system is ready to purge.

BASE PRESSURE/CATALYST PRESS. — Displays current pressure for each material.



1006207AIssued 6/01

Manual 25-22

MANUAL MODE SCREEN (contd)

2522014A

Screen 10 MANUAL MODE



1006207AIssued 6/01

Manual 25-22

TIME SETUP SCREEN

See Screen 11.

Refer to Table 12. This screen sets-up time stamp information for thesmall logic controller (SLC). Select the appropriate button to enterYEAR, MONTH, DAY, HOUR, MINUTE information. Press the RETURNTO MAIN MENU button to exit the screen.

Table 12 Time Setup Screen


SLC-5/04 YEAR F1 Displays current small logic controller year.

SLC-5/04 MONTH F2 Displays current small logic controller month.

SLC-5/04 DAY F3 Displays current small logic controller day.

SLC-5/04 HOUR F6 Displays current small logic controller hour.

SLC-5/04 MINUTE F7 Displays current small logic controller minute.


SLC-5/04 DAY OF THE WEEK — Displays current small logic controller day of the week.

DATE/PANELVIEW — Displays current PanelView date.

TIME/PANELVIEW — Displays current PanelView time.

2522015A

Screen 11 TIME SETUP



1006207AIssued 6/01

Manual 25-22

ALARM LIGHTS SCREEN

See Screen 12.

Refer to Table 13. This screen includes status buttons that change colorfrom green to red when an alarm is triggered. Press the FAULT RESETbutton to reset all alarm lights. Press the RETURN TO MAIN MENUbutton to exit the screen and to return to the MAIN MENU.

Table 13 Alarm Lights Screen


SERVO Indicates the status for the servo drive.

MIXER TUBE Indicates the status for the mixer tube.

BASE REFILL Indicates the status for the base refill.

CATALYST REFILL Indicates the status for the catalyst refill.

HIGH VOLUME Indicates the status for the high volume.

LOW VOLUME Indicates the status for the low volume.

HI BASE PRESS. Indicates the status for the high base pressure.

LO BASE PRESS.None

Indicates the status for the low base pressure.

HIGH CATALYST PRESS.None

Indicates the status for the high catalyst pressure.

LOW CATALYST PRESS. Indicates the status for the low catalyst pressure.

MAIN POWER Indicates the status for the main power.

J-BOX POWER Indicates the status for the junction box power.

MCR Indicates the status for the master control relay.

DEVICENET COMMS Indicates the status for the DeviceNet communications.

BASE MAX NOT EXCEEDED Turns red when base pressure exceeds maximum setting.

CATALYST MAX NOT EXCEEDED Turns red when catalyst pressure exceeds maximum setting.

MIXER TUBE TIMEOUT RESET F8 Resets the mixer tube timeout.

FAULT RESET BUTTON F9 Resets all faults. If faults still exist, screen is refreshed.




1006207AIssued 6/01

Manual 25-22

2522016A

Screen 12 ALARM LIGHTS



1006207AIssued 6/01

Manual 25-22

ALARM HISTORY SCREEN

See Screen 13.

Refer to Table 14. This screen includes a list of alarm occurrences inchronological order. The ALARM HISTORY SCREEN can display up to100 lines of alarm history. Use the arrow keys to scroll through the alarmhistory list.

Table 14 Alarm History Screen


F1 Returns cursor to the top of the list.

F2 Moves cursor up one line at a time.

F3 Moves cursor rapidly up when depressed.

F6 Moves cursor to the end of the list.

F7 Moves cursor down one line at a time.

F8 Moves cursor rapidly down when depressed.

F9 Goes to alarm lights screen.

F10 Returns to the MAIN MENU.

2522017A

Screen 13 ALARM HISTORY



1006207AIssued 6/01

Manual 25-22

ALARM BANNER

See Screen 14.

The alarm banner is a pop-up screen that appears when a fault conditionoccurs. The fault condition that triggered the fault appears at the top ofthe screen. Additional fault conditions that occur appear in the list, whichholds up to 100lines (0–99). Refer to Table 15 for the key function.

Table 15 Alarm Banner


F5 Clears all alarm banner entries one at a time.

2522022A

Screen 14 HISTORY BANNER



1006207AIssued 6/01

Manual 25-22

SYSTEM READY STATUS SCREEN

See Screen 15.

This screen is accessible through the MAIN MENU screen. Press the F9function key or the corresponding button on the MAIN MENUtouchscreen to display the SYSTEM READY STATUS SCREEN. Greenindicators signal that the status is OK or within limits. Red indicatorssignal a fault condition or a value outside acceptable limits. Refer toTable 16 for screen functions.

Table 16 System Ready Status Screen


F1: SYSTEM DE-PRESSURIZED Press F1 to display the SYSTEM DEPRESSURIZED screen.

SYSTEM IN AUTO Green indicator signals that the system is in AUTO MODE.

MAIN POWER OK Green indicator signals that the MAIN POWER is OK.

J-BOX POWER OK Power to junction box is OK.

MCR OK Master control relay is OK

SERVO OK Servo drive is OK

MIXER TUBE OK Mixer tube is OK

F3: DEVICENET COMMS OK DeviceNet communications OK. Press F3 to display DEVICENET COMMS.

BASE UNDER 1500 PSI Red indicates base pressure under 1500 psi.

CATALYST UNDER 1500 PSI Green indicates catalyst pressure over 1500 psi

NO INTERNAL PURGE Green indicator signals internal purge in progress.

NORDSON SYSTEM READY Final indicator signals when Nordson system is ready.

RETURN TO MAIN MENU F10 Returns to MAIN MENU.



1006207AIssued 6/01

Manual 25-22

2522018A

Screen 15 SYSTEM READY STATUS



1006207AIssued 6/01

Manual 25-22

SYSTEM DE–PRESSURIZED STATUS SCREEN

See Screen 16.

This screen is accessible by pressing the corresponding button in theSYSTEM READY STATUS SCREEN or by pressing the F1 function keyon the front panel. The screen informs about the reason why the statusSYSTEM DE-PRESSURIZED has not been achieved when trying to getSYSTEM READY. Refer to Table 17 screen functions.

Table 17 System De–pressurized Status Screen


F1: SET INDEX POSITION Press F1 to display the SET INDEX screen.

START INDEX FOR DE-PRESSURIZE Indicates the index start for depressurization

SEQUENCE COMPLETE FROM DRIVE Indicates when sequence is complete from drive.

SYSTEM DE-PRESSURIZED Indicates when the system is depressurized.

SYSTEM READY STATUS SCREEN Press F10 to display the SYSTEM READY STATUS SCREEN.

25220016A

Screen 16 SYSTEM DE-PRESSURIZED STATUS



1006207AIssued 6/01

Manual 25-22

SET INDEX POSITION SCREEN

See Screen 17.

This screen is accessible by pressing the corresponding button in theSYSTEM DE-PRESSURIZED STATUS SCREEN or by pressing the F1function key on the front panel. The screen informs why the SET INDEXPOSITION was not achieved when trying to get the SYSTEMDE-PRESSURIZED. Press F10 to display the SYSTEMDE-PRESSURIZE STATUS SCREEN.

2522020A

Screen 17 SET INDEX POSITION



1006207AIssued 6/01

Manual 25-22

DEVICENET COMMUNICATIONS SCREEN

See Screen 18.

This screen is accessible by pressing the corresponding button in theSYSTEM READY STATUS SCREEN or by pressing the F3 function keyon the front panel. The screen informs what type of DeviceNetcommunication fault occurred. Press F10 to display the SYSTEMREADY STATUS SCREEN.

2522021A

Screen 18 DEVICENET COMMUNICATIONS



1006207AIssued 6/01

Manual 25-22

WARNING: Allow only qualified personnel to perform thefollowing tasks. Follow the safety instructions in this documentand all other related documentation.

Unpack the servo 2K controller and inspect it for dents, scratches,corrosion, or other physical damage. If there is any visible damage, callyour Nordson representative immediately.

Install the servo 2K controller cabinet in close proximity to the dispensegun and the 2K meter with servo drive. Use customer-supplied bolts tosecure the servo 2K controller cabinet to the shop floor. Refer to theSpecifications section for dimensions.

Refer to your electrical schematics included in your systemdocumentation for more information:

WARNING: Before making any connections or opening anyenclosures, disconnect and lock out all electrical power.

NOTE: Electrical connections should be made by a qualified electrician.

1. Connect a dedicated power source to the servo 2K controller toprovide safe operation and to reduce interference from electricalnoise.

2. Follow local code when making electrical connections.

3. Install a locking disconnect switch or breaker in the service line aheadof any electrical equipment.

4. Use supplied cables to connect the servo 2K controller with the robotcontroller, and connect the 2K meter with servo drive and thedispense gun.

NOTE: Make sure there is enough slack in the cables to allow free robotmovement. Use extension cables if necessary.

3. Installation

Electrical Connections



1006207AIssued 6/01

Manual 25-22

Connector Panel

See Figure 5.

Depending on your system layout, the connector panel is located eitheron the left side or on the top of the servo 2K controller. The connectorpanel consists of electric connectors, interface inputs, and interfaceoutputs. Refer to Table 18 for a detailed description of the connectorpanel.

Table 18 Connector Panel

Item Connector Description

1 PLC programming port Cable connection for a laptop computer to perform PLC programming.

2 DeviceNet OUT Bus connection to the 2K servo drive junction box.

3 5P (5 pin) Links the servo 2K controller to the robot analog signals.

4 2P (31 pin) Links the servo 2K controller to the robot digital signals.

5 Servo motor Links 2K servo motor to the2K controller.

6 12P US version only—Links cell PLC to servo 2K controller.

7 Junction box (female) Connects the 2K junction box to the servo 2K controller.

8 DeviceNet IN (female) Cable connection for a laptop computer to perform DeviceNetcommunication.

9 Robot Interface CE version only—Links the servo 2K controller to robot theanalog/digital signals.



1006207AIssued 6/01

Manual 25-22

2522002A

8 2

1

7

6

5

4

3

8

2

1

7

5

9

U.S. Version

European VersionSide View

Top View

Fig. 5 Typical Connections



1006207AIssued 6/01

Manual 25-22

Perform these steps to configure the robot controller analog signals:

Analog Signal #1

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

2. Configure the robot controller to send an analog signal #1 of +10 Vdcwhen the robot is moving at or slightly above maximum speed.

3. Configure the robot controller to send an analog signal #1 of 0 Vdcwhen the robot is stationary.

A robot speed of 80% should now correspond to 8 Vdc, a robot speed of40% should now correspond to 4 Vdc.

Analog Signal #2

Configure the robot controller to send an analog signal #2 of 2, 4, 6, and8 Vdc when the pressure supplied to the proportioning valve is 1.5, 3,4.5, and 6 psi.

See Figure 6.

Adjust the timing sequence of output signals from the robot controller tosuit the servo 2K controller. Refer to your robot controller manual to setthe signal timing sequences.

Analog Signal Configuration

Timing Sequences



1006207AIssued 6/01

Manual 25-22

2522024A

Robot Inputs

Robot Outputs

Dispense Ready

Pre–Pressurized

Major Fault

Minor Fault

Part ID

Part Strobe

Gun On

Flow

50ms

minimum

Fig. 6 Timing Sequence



1006207AIssued 6/01

Manual 25-22


This section includes instructions for initial setup and servo 2K controlleroperation via the control panel menus and screens. The controller isconfigured by Nordson. Contact your Nordson representative if theconfiguration needs to be changed.

NOTE: Nordson Corporation highly recommends having a Nordsonrepresentative present during the initial setup.

CAUTION: Make sure that you teach the robot controller theproper tool path before operating the servo 2K controller.Failure to observe may result in equipment damage.

Use this procedure to make one-time adjustments to the controller beforebeginning production for the first time.

NOTE: Make sure all other system components are operational. Referto the individual component manuals for startup and operatingprocedures.

1. Turn on the following components:

� Servo 2K controller� 2K Meter� Unloaders� Temperature conditioning system

After power-up, the servo 2K controller performs a self-test routine toverify system status and proper operation.

2. For CE servo 2K controllers—Either press the German button or F6to change all screen displays to German language.

3. Perform the System Settings procedures in this section.

4. Operation

Initial Setup



1006207AIssued 6/01

Manual 25-22

System Settings

Enter the following system settings listed in Tables 19 through 23. Somesettings may vary, depending on the application you are running.

Table 19 Rhino Unloader 65:1 System Settings

Parameter Setting

Unloader pressure part A 1.7 bar (25 psi)

Elevator pressure part A 2.8 bar (40 psi)

Header pressure part A 110.3 bar (1600 psi)

Unloader pressure part B 1.7 bar (25 psi)

Elevator pressure part B 2.8 bar (40 psi)

Header pressure part B 110.3 bar (1600 psi)

2K system pressure 55.2 bar (800 psi)

Table 20 Customer Standalone Temperature Control System Settings

Parameter Setting

Temperature setpoint 37.8 °C (100 °F)

Table 21 Part ID Setpoint Screen Settings

Parameter Setting

PART ID 0 (Auto Purge)

SETPOINT 28 cc (1.7 cu-in.)

HI LIMIT% 100%

LO LIMIT% 100%

PRE PRESSURE SETPOINT BASE 58.6 bar (850 psi)

HI PRESSURE FAULT BASE 103 bar (1500 psi)

LO PRESSURE FAULT BASE 3.4 bar (50 psi)

PRE PRESSURE SETPOINT CATALYST 0 bar/psi

HI PRESSURE FAULT CATALYST 103 bar (1500 psi)

LO PRESSURE FAULT CATALYST 3.4 bar (50 psi)



1006207AIssued 6/01

Manual 25-22

System Settings (contd)

Table 22 Global Settings 1

Parameter Setting

AUTO PURGE TIMER 300 sec

AUTO PURGE COUNTER 12

MIXER TUBE TIME-OUT 330 sec

REFILL TIME-OUT BASE 20 sec

REFILL TIME-OUT CATALYST 20 sec

PARTS BEFORE REFILL 1

PURGE SPEED SETPOINT 500 rpm

PURGE VOLUME SETPOINT 20 cc (1.2 cu-in.)

Table 23 Global Settings 2

Parameter Setting

MTR ENCODER PULSES 2000

GEARHEAD RATIO 7:1

BELT RATIO 2:1

BALL SCREW PITCH 10 mm/rev

BASE CYLINDER VOLUME 0.7918 cc/mm

CATALYST CYLINDER VOLUME 4:1 0.198 cc/mm

CATALYST CYLINDER VOLUME 2:1 0.388 cc/mm



1006207AIssued 6/01

Manual 25-22

Perform these steps to startup the servo 2K controller at the beginning ofthe shift.

1. Install a new mixer tube and tip.

2. Make sure the illumination of the grounding buttons on the front panelis dim, not bright.

NOTE: A dim illuminated ground button means that all components aregrounded properly. A bright ground light indicates that there is a wireunintentionally making contact with ground.

3. Press F10 to go to the MAIN MENU.

4. Make sure that system is in the AUTO mode.

5. Perform a METERED PURGE. Make sure the SEALER READYLIGHT is green. If the light is red, return to the MAIN MENU.

6. Select ALARM LIGHTS SCREEN (F7) and press MIXER TUBETIME-OUT RESET (F8) or the FAULT RESET BUTTON (F9).

7. Watch for material coming out of the mixer tube. Make sure thematerial stream is straight.

NOTE: Monitor the material stream during the entire shift. Change themixer tube with tip if the material stream is not straight.

Startup



1006207AIssued 6/01

Manual 25-22

The Alarm screen overrides every other screen in the event of a faultcondition and displays the fault. In addition, the red light in the alarm lighttower illuminates.

Base/Catalyst Exceeded Maximum Pressure

Perform these steps to reset this fault:

1. Replace the mixer tube with tip if the HI BASE PRESSURE indicatoron the alarm lights screen is red.

2. Press RETURN TO THE MAIN MENU (F10) and go to the DISPLAYSCREEN (F4).

3. Restart the system while monitoring the base and catalyst pressureson the display screen.

4. If the pressures stays below the maximum, confirm that the system isin the AUTO mode.

5. Press RETURN TO THE MAIN MENU (F10) and go to the ALARMLIGHTS SCREEN (F7) to activate the MIXER TUBE TIME-OUTRESET (F8) or the FAULT RESET BUTTON (F9).

6. If the pressure rises above 1500 psi, open the top cover on the Festovalve pack on the 2K shot meter with servo drive to manually overridethe valves.

7. Use a paper clip to manually open the valve OUT and the dispensegun ON for the base and catalyst side, depending on where theoverpressure occurred.

Refer to your 2K meter with servo drive documentation for moreinformation.

Mixer Tube Timeout Fault

Perform these steps to reset a Mixer Tube Timeout fault condition:

1. Replace the mixer tube.

2. From the MAIN MENU, press ALARM LIGHTS SCREEN (F7).

3. Press MIXER TUBE TIME-OUT RESET (F8).

4. Press FAULT RESET BUTTON (F9) to reset any other fault condition.

Fault Conditions



1006207AIssued 6/01

Manual 25-22

Restart

Perform these steps to restart the system after a fault condition:

1. From the MAIN MENU, press PURGE SCREEN (F5).

2. Press METERED PURGE ( F5) to purge the system and fill the mixertube.

3. Make sure the SEALER READY light is green. If the light is notgreen, press RETURN TO MAIN MENU (F10) and press ALARMLIGHTS SCREEN (F7).

4. Press the MIXER TUBE TIME-OUT RESET (F8) or the FAULTRESET BUTTON (F9).

NOTE: Monitor the material stream during the entire shift. Change themixer tube with tip if the material stream is not straight.

Perform these steps to shut down the servo 2K controller at the end ofthe shift.

1. Place the system in the MANUAL mode

2. Remove the mixer tube with tip and clean the base and catalyst portsat the bottom of the dispense gun.

3. Apply a thick layer of grease to the base and catalyst ports at thebottom of the dispense gun.


Perform the following maintenance activities:

� Check cables periodically and replace worn or frayed leads.

� Check all cable connections and connectors for a tight fit.

� Use an ohmmeter to check the cables for continuity. Refer to theelectronic schematics in the system documentation for routinginformation.

CAUTION: Do not spray cleaning solution directly on the touchscreen. The display may get damaged and short out.

� Apply a non-abrasive cleaning solution to a soft cloth and clean thecontroller cabinet and the front panel components.

Shutdown

5. Maintenance



1006207AIssued 6/01

Manual 25-22


This section contains troubleshooting procedures. These procedurescover only the most common problems that you may encounter. If youcannot solve the problem with the information given here, contact yourlocal Nordson representative for help.

Problem Possible Cause Corrective Action

1. Gun not dispensing Clogged nozzle Replace mixer tube and tip.

No analog signal Check robot and cable.

Gun not opening Check solenoid valve and tubing.

2. Gun not changingdispense rate to controlbead size

Analog signal bad Check robot and cable.

Servo drive fault Check for drive faults and settings.

3. Gun dispensing early,before robot moves

Robot programming error Verify and adjust current robot program.

4. DH+ communicationport error

Duplicate node address Verify all node addresses on the DH+network with the appropriate software.

5. Gun dispensing aftercycle, gun closed

Faulty robot programming Verify and adjust current robot program.

Sticking gun module Replace gun.

Low air pressure Increase the air pressure.

6. Dispensing delayed Faulty robot programming Verify and adjust current robot program.

Sticking gun module Replace gun.

Low air pressure Increase the air pressure.

7. Swirl pattern irregular Faulty analog signal from robot Verify the analog signal from the robot.

Excess air turbulence Reduce and control the air flow aroundthe bead.

Blocked air ports Clean or replace the air tip

Blocked nozzle tip Replace the mixer tube and the tip.

8. SLC 5/04 CPU modulefault

CPU run time fault Document the fault in the processor andcontact your Nordson representative.

6. Troubleshooting



1006207AIssued 6/01

Manual 25-22


WARNING: Failure to observe may result in personal injury,death, or equipment damage.

Perform these steps to replace the servo 2K controller:

1. Turn off and lock out external electrical power to the controller.

2. Disconnect all cables and power leads to the controller.

3. Remove the bolts that hold the cabinet in place and remove the oldservo 2K controller.

4. Place the new controller in the same position and install the bolts thathold the cabinet in place.

5. Connect all cables and power leads. Refer to the wiring diagram inyour system documentation package for more information.

6. Turn on electrical power to the controller.

The servo 2K controller is modular in design, with easily removable andreplaceable components. Refer to the Parts section for componentdescription, location, and part number information. If the red diode on thepower supply is not illuminated after power-up, open the power supplycover and check the fuse. Replace if necessary.

Perform these steps to replace the power supply:

See Figure 1.

1. Turn off and lock out all external electrical power to the controller, andturn off the main power switch (2 or 3).

See Figure 8 for US version. See Figure 10 for CE version

2. Disconnect all wiring from the power supply (18).

3. Use a screw driver to remove the two black screws that secure themodule to the chassis rack.

4. Insert the new power supply module until it seats into the chassis.

5. Insert and tighten the two black screws securing the module to thechassis.

6. Connect all wiring to the power supply. Refer to the wiringschematics in your system documentation for more information.

7. Repair

Replacing the Servo 2KController

Replacing the Power SupplyModule



1006207AIssued 6/01

Manual 25-22

Perform these steps to replace the SLC 5-04 central processing unit:

1. Lock out and disconnect the servo 2K controller.

2. Open the servo 2K controller cabinet door.


3. Disconnect all wiring to the SLC 5-04 CPU module (19).

4. Press the latches at the top and bottom of the SLC 5-04 CPU moduleand slide the module out of the chassis (17).

5. Insert the new SLC 5-04 CPU module into the chassis until thelatches engage.

6. Connect all wiring to the SLC 5-04 CPU module. Refer to the wiringschematics in your system documentation for more information.

7. Download the most current program and switch to RUN MODE.

Perform these steps to replace the input module:




3. Disconnect all wiring to the input module (20).

4. Press the latches at the top and bottom of the input module and slideit out of the chassis (17).

5. Insert the new input module into the chassis until the latches engage.

6. Connect all wiring to the module. Refer to the wiring schematics inyour system documentation for more information.

Replacing the SLC 5-04 CPUModule

Replacing the Input Module



1006207AIssued 6/01

Manual 25-22

Perform these steps to replace the output module:




3. Disconnect all wiring to the output module (21).

4. Press the latches at the top and bottom of the output module andslide the output module out of the chassis (17).

5. Insert the new output module into the chassis until the latchesengage.


Perform these steps to replace the DeviceNet module:




3. Disconnect all wiring from the DeviceNet module (22).

4. Press the latches at the top and bottom of the DeviceNet module andslide the module out of the chassis (17).

5. Insert the new DeviceNet module into the chassis until the latchesengage.


7. Download the most current DeviceNet program into the DeviceNetmodule.

Replacing the Output Module

Replacing the DeviceNetModule



1006207AIssued 6/01

Manual 25-22

Perform these steps to replace the touchscreen:

See Figure 1.

1. Disconnect and lock out all external electrical power to the controller.Move the main power switch (2 or 3) to OFF.

2. Open the servo 2K controller cabinet to access the rear of thetouchscreen (10).

3. Disconnect the wiring from the rear of the touchscreen.

4. Use a screw driver to remove the four touchscreen mounting screwsand brackets.

5. Slide the touchscreen out through the front of the cabinet door.

6. Insert the new touchscreen.

7. Install the four touchscreen mounting screws and brackets.

8. Connect the wiring to the rear of the touchscreen. Refer to the wiringdiagram in your system documentation for more information.

9. Close the servo 2K controller cabinet door and restore all power.

10. Download the most current program into the DeviceNet module.

Replacing the Touchscreen



1006207AIssued 6/01

Manual 25-22

To order parts, call the Nordson Customer Service Center or your localNordson representative. Use the parts list, and the accompanyingillustration, to describe and locate parts correctly.

Numbers in the Item column correspond to numbers that identify parts inillustrations following each parts list. The code NS (not shown) indicatesthat a listed part is not illustrated. A dash (—) is used when the partnumber 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 beordered separately.

The Description column gives the part name, as well as its dimensionsand other characteristics when appropriate. Indentions show therelationships between assemblies, subassemblies, and parts.

Item Part Description Quantity Note

— 0000000 Assembly 1

1 000000 � Subassembly 2 A

2 000000 � � Part 1

� If you order the assembly, items 1 and 2 will be included.� If you order item 1, item 2 will be included.� If you order item 2, you will receive item 2 only.

The number in the Quantity column is the quantity required per unit,assembly, or subassembly. The code AR (As Required) is used if thepart number is a bulk item ordered in quantities or if the quantity perassembly depends on the product version or model.

Letters in the Note column refer to notes at the end of each parts list.Notes contain important information about usage and ordering. Specialattention should be given to notes.

8. Parts

Using the Illustrated PartsList



1006207AIssued 6/01

Manual 25-22

See Figures 7 and 8.


— - - - - - - Assembly, 2K controller 1

1 1005870 � Terminal, panelview 600, color, DH+ and RS-232 1

2 306019 � Lamp, indicator, red, 20 V, 32 mA 7 W 1

3 336096 � Light, cover and base for alarm light tower 1

4 336091 � Light tube, 4-in., alarm light tower, stackable 1

5 336095 � Light mounting tulip, alarm light tower, stackable 1

6 336098 � Gasket, mounting tulip, alarm light tower 1

7 336097 � Lamp, 120 Vdc, alarm light tower, stackable 1

8 1002383 � Fuse, T-D, rejection, 600 V, 2 A, (small motor) 2

9 939829 � Fuse, 25 A, time-delay, 600 V 2

10 1005877 � Module, active shunt 1

11 346074 � Drive, servo, 300 W, 30 A, servo 2K 1

12 346075 � Terminal, break out board, servo 2K 1

13 341368 � End anchor, NEMA 4

14 1005874 � Power supply, 85–264 Vac IN, 24 Vdc, 2 A OUT 2

15 287726 � Master control relay, 20A 1

16 1002389 � Fuse, T–D, rejection, 600 V, 20 A, (small motor) 2

17 184109 � Chassis, 7-slots, I/O assembly 1

18 184108 � Power supply, SLC5, 5 A 1

19 1007757 � SLC 5/04 processor module, 64K 1

20 184115 � 120 Vac discrete input,16 points 1

21 184116 � 120 Vac discrete output, 16 points 1

22 1007758 � DeviceNet status module 1

23 176270 � Filler, blank for PLC 3

24 346077 � Cable, encoder feedback, S1K 1

25 346076 � Cable, motor power, S2K 1

Servo 2K ControllerUS Version



1006207AIssued 6/01

Manual 25-22

2522024A

234567

12425

Fig. 7 Controller Parts (exterior)



1006207AIssued 6/01

Manual 25-22

2522025A

19 2018

16

15

9

10

11

12

8

13

17

14

21 22 23

Fig. 8 Controller Parts (interior)



1006207AIssued 6/01

Manual 25-22

See Figures 9 and 10.


— - - - - - - Assembly, 2K controller 1

1 1005870 � Terminal, panelview 600, color, DH+ and RS-232 1

2 306019 � Lamp, indicator, red, 20 V, 32 mA 7 W 1

3 336096 � Light, cover and base for alarm light tower 1

4 336091 � Light tube, 4-in., alarm light tower, stackable 1

5 336095 � Light mounting tulip, alarm light tower, stackable 1

6 336098 � Gasket, mounting tulip, alarm light tower 1

7 336097 � Lamp, 120 Vdc, alarm light tower, stackable 1

8 - - - - - - � Operating handle, disconnect switch 1

9 346077 � Cable, encoder feedback, S1K 1

10 346076 � Cable, motor power, S2K 1

11 1002383 � Fuse, T-D, rejection, 600 V, 2 A, small motor 2

12 939829 � Fuse, 25 A, time-delay, 600 V 2

13 1005877 � Module, active shunt 1

14 346074 � Drive, servo, 300 W, 30 A, servo 2K 1

15 346075 � Terminal, break out board, servo 2K 1

16 341368 � End anchor, NEMA 4

17 184109 � Chassis, 7-slots, I/O assembly 1

18 184108 � Power supply, SLC5, 5A 1

19 1007757 � SLC 5/04 processor module, 64K 1

20 1007904 � DC digital input module,16 point, sink, 24 Vdc 1

21 1007906 � DC digital output module, 16 point, 10/50 Vdc 1

22 1007758 � DeviceNet status module 1

23 176270 � Filler, blank for PLC 3

24 1002389 � Fuse, T–D, rejection, 600 V, 20 A, small motor 2

25 - - - - - - � Master control relay, 24 Vdc, 4 N.O. contacts 1

26 1005874 � Power supply, 85–264 Vac IN, 24 Vdc, 2 A OUT 2

Servo 2K ControllerCE Version



1006207AIssued 6/01

Manual 25-22

2522028A

234567

1910

8

Fig. 9 CE Servo 2K (Exterior Parts)



1006207AIssued 6/01

Manual 25-22

2522029A

19 2018

24

25

12

13

14

15

11

16

26

21 22 23

17

Fig. 10 CE Servo 2K (Interior Parts)



1006207AIssued 6/01

Manual 25-22

See Figure 11.

This section includes specifications and dimensions for the Servo 2Kcontroller.

Incoming power: 480 Vac single phase 25 A

2522023A

398.53 mm(15.69 in.)

31.75 mm(1.25 in.) 186.18 mm

(7.33 in.)

1066.8 mm(42.00 in.)

609.60 mm(24.00 in.)

797.05 mm(31.38 in.)

584.20 mm(23.00 in.)

838.20 mm(33.00 in.)

76.20 mm(3.00 in.)

Fig. 11 Typical Dimensions

9. Specifications

Documents

New Servo 2K Controller - Nordsonemanuals.nordson.com/automotive/zfiles/1006207a.pdf · 2019. 4. 8. · The servo 2K controller automates the application of two component (2K) adhesives