Nordson PowderPilot HD User manual

PowderPilot™ HD
PowderPilot™ HD
Controls Manual
P/No.7192721_02
Issued 09/2017
NORDSON Deutschland GmbH –ERKRATH –GERMANY

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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............................................................................................................................ 8
Disposal ................................................................................................................................................. 11
Description ....................................................................................................................................... 12
Product Information................................................................................................................................ 12
Console dimensions............................................................................................................................... 13
Specifications......................................................................................................................................... 13
Booth Operation................................................................................................................................. 14
Start-up sequence:................................................................................................................................. 14
BOOTH CONTROL SCREEN ................................................................................................................ 15
Screen elements.................................................................................................................................... 17
GUNS TRIGGERED STATUS SCREEN................................................................................................ 21
GUN SET POINT STATUS SCREEN..................................................................................................... 22
GUN FEEDBACK SCREEN ................................................................................................................... 23
GUN SPRAY CONTROL........................................................................................................................ 24
Group set point adjust ............................................................................................................................ 26
GUN CONFIGURATION ........................................................................................................................ 27
BOOTH CONFIGURATION ................................................................................................................... 29
PUMP CONTROLLER CONFIGURATION ............................................................................................ 31
PURGE TIMING CONFIGURATION ...................................................................................................... 33
SpectrumHD CONTROL SECTION ......................................................................................................... 34
SpectrumHD MANUAL CONTROL SECTION ......................................................................................... 36
SpectrumHD CONFIGURATION SECTION 1 .......................................................................................... 37
SpectrumHD CONFIGURATION SECTION 2 .......................................................................................... 38
COLOUR CHANGE OPERATION.......................................................................................................... 39
Troubleshooting............................................................................................................................... 45
Repair ................................................................................................................................................ 45
Customer Specific Information ...................................................................................................... 47
Parts .................................................................................................................................................. 48
Console Parts......................................................................................................................................... 48

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Section 1
Safety
Introduction Read and follow these safety instructions. Task- and equipment-
specific warnings, cautions, and instructions are included in
equipment documentation where appropriate.
Make sure all equipment documentation, including these
instructions, is accessible to all persons operating or servicing
equipment.
Qualified Personnel
Equipment owners are responsible for making sure that Nordson
equipment is installed, operated, and serviced by qualified
personnel. Qualified personnel are those employees or contractors
who are trained to safely perform their assigned tasks. They are
familiar with all relevant safety rules and regulations and are
physically capable of performing their assigned tasks.
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.
Some examples of unintended use of equipment include
• using incompatible materials
• making unauthorized modifications
• removing or bypassing safety guards or interlocks
• using incompatible or damaged parts
• using unapproved auxiliary equipment
• operating equipment in excess of maximum ratings
Regulations and Approvals
Make sure all equipment is rated and approved for the environment
in 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.

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Personal Safety To prevent injury follow these instructions.
•Do not operate or service equipment unless you are qualified.
•Do not operate equipment unless safety guards, doors, or covers are
intact and automatic interlocks are operating properly. Do not bypass or
disarm any safety devices.
•Keep clear of moving equipment. Before adjusting or servicing any
moving equipment, shut off the power supply and wait until the
equipment comes to a complete stop. Lock out power and secure the
equipment to prevent unexpected movement.
•Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or
servicing pressurized systems or components. Disconnect, lock out, and
tag switches before servicing electrical equipment.
•Obtain and read Material Safety Data Sheets (MSDS) for all materials
used. Follow the manufacturer’s instructions for safe handling and use
of materials, and use recommended personal protection devices.
•To prevent injury, be aware of less-obvious dangers in the workplace
that often cannot be completely eliminated, such as hot surfaces, sharp
edges, energized electrical circuits, and moving parts that cannot be
enclosed or otherwise guarded for practical reasons.
Fire Safety To avoid a fire or explosion, follow these instructions.
•Do not smoke, weld, grind, or use open flames where flammable
materials are being used or stored.
•Provide adequate ventilation to prevent dangerous concentrations of
volatile materials or vapors. Refer to local codes or your material MSDS
for guidance.
•Do not disconnect live electrical circuits while working with flammable
materials. Shut off power at a disconnect switch first to prevent sparking.
•Know where emergency stop buttons, shutoff valves, and fire
extinguishers are located. If a fire starts in a spray booth, immediately
shut off the spray system and exhaust fans.
•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.

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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. Do not restart the equipment until the problem has
been identified and corrected.
Grounding inside and around the booth openings must comply with NFPA
requirements for Class 2, Division 1 or 2 Hazardous Locations. Refer to
NFPA 33, NFPA 70 (NEC articles 500, 502, and 516), and NFPA 77, latest
conditions.
•All electrically conductive objects in the spray areas shall be electrically
connected to ground with a resistance of not more than 1 megohm as
measured with an instrument that applies at least 500 volts to the circuit
being evaluated.
•Equipment to be grounded includes, but is not limited to, the floor of the
spray area, operator platforms, hoppers, photoeye supports, and blow-
off nozzles. Personnel working in the spray area must be grounded.
•There is a possible ignition potential from the charged human body.
Personnel standing on a painted surface, such as an operator platform,
or wearing non-conductive shoes, are not grounded. Personnel must
wear shoes with conductive soles or use a ground strap to maintain a
connection to ground when working with or around electrostatic
equipment.
•Operators must maintain skin-to-handle contact between their hand and
the gun handle to prevent shocks while operating manual electrostatic
spray guns. If gloves must be worn, cut away the palm or fingers, wear
electrically conductive gloves, or wear a grounding strap connected to
the gun handle or other true earth ground.
•Shut off electrostatic power supplies and ground gun electrodes before
making adjustments or cleaning powder spray guns.
•Connect all disconnected equipment, ground cables, and wires after
servicing equipment.
Proper grounding of all conductive components of a powder coating system
provides both shock and electrostatic discharge protection for both operators
and sensitive electronic equipment. Many system components (booth, collector,
color modules, control consoles, and conveyor) are connected both physically
and electrically. It is important that the proper grounding methods and equipment
are used when installing and operating the system.

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PE (Protective Earth) Grounding
PE grounding is required on all conductive metal electrical enclosures in a
system. PE grounding is provided by a ground conductor wire bonded to a true
earth ground. PE grounding protects operators from electrical shock by providing
a path to ground for electrical current if a conductor contacts an electrical
enclosure or other conductive component. The ground conductor wire carries
the electrical current directly to ground and short circuits the input voltage until a
fuse or circuit breaker interrupts the circuit.
The green/yellow ground wires bundled with the AC input power cable are used
only for PE grounding and their sole purpose is to protect personnel from a
shock. These ground wires do not protect against electrostatic discharge.
Electrostatic Grounding
Electrostatic grounding protects electronic equipment from damage caused by
electrostatic discharges (ESD). Some electronic components are so sensitive to
ESD that a person can deliver a damaging static discharge without feeling even
a mild shock.
Proper electrostatic grounding is mandatory in an electrostatic powder coating
system. Powder spray guns generate electrostatic voltages up to 100,000 volts.
It does not take long for ungrounded system components to build up an
electrical charge strong enough to damage sensitive electronic components
when discharged.
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.

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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. The current attracted to the parts
flows through the part hangers to the conveyor and to the building ground, back
to the controller through a ground braid and back to the spray gun through the
gun driver board. The current attracted to the booth is returned through the
booth ground to the controller and back to the gun.
It is very important to provide a complete circuit for the gun current. A break in
the circuit conductors (conveyor, booth, braided ground cables, controller) can
cause voltage to build up on the conductors up to the maximum output of the
spray gun voltage multiplier (up to 100 kV). The voltage will eventually discharge
in a high frequency arc and cause damage to the controller electronics (gun
driver board and power supply).
Figure Electrostatic Current Path
Powder
Pilot™ HD
Control Panel

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ESD Ground Procedures and Equipment
The best protection against ESD is to keep the ground braids as short as
possible and connect them to a central point on the booth base as shown in the
Star diagram. Under normal conditions making Star connections is not a
problem, but in some systems, such as roll-on/roll-off booths, the ground braids
required for a Star connection are too long to be effective against ESD. In this
case, a Daisy Chain ground configuration is acceptable.
Figure 2 ESD Grounding Procedures and Equipment
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. Keep the cables as short as possible. If using a
grounding block kit, make sure the block is installed directly to the welded base
with the included self-drilling screws.
An ESD grounding block kit is available for connecting the ground braids to the
booth base. The kit contains two 6-position grounding blocks, fasteners,
terminals, and 15 meters (50 feet) of braided ground cable. If additional kits are
required, order:
1067694 Kit, ground bus bar, ESD, 6−position, with hardware

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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.
•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.
Safety Labels
Table 1 contains the text of the safety labels on the Powder Pilot HD
console. The safety labels are provided to help you operate and maintain
your console safely. See Figure 3 for the location of the safety labels.
Item
Part
Description
1.
1034161
WARNING: Disconnect power before servicing.

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Section 2
Description
Product Information
The Nordson PowderPilot™is an easy−to−use control system, with
software and hardware specifically designed for automated powder
coating systems.
The spray control system is based around a Siemens S7−315 PLC
unit providing plant control, and a Siemens PC−677 providing
Human-Machine-Interface.
The spray control system is based around a Siemens S7-300 Soft-
PLC unit providing plant control via a Siemens S1200 PLC, and a
Siemens PC-277D panel PC providing Human-Machine Interface
A touch sensitive screen is used for all interactions between the
operator and the machine. In addition the control panel is fitted with
an Emergency Stop push−button, a Reset push−button and a klaxon
unit.
The 15” touch sensitive screen is used for all interactions between
the operator and the machine In addition, the control panel is fitted
with an Emergency Stop push-button, a Reset push-button and a
light stack with klaxon unit.
This manual describes in detail, the operation required to control the
plant via the operator interface.
This manual describes the operation required to control the plant via
the operator interface as well as operating the 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.

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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 : 31 kVA
Panel environmental rating : IP54
The cabinet must be operated outside hazardous areas or zones
Operating environment
Temperature : +15oC –+40oC
Humidity : 5 –95%, non condensing
Application : 24 guns max.

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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. Power-up the control panel via the isolator located on the front of the
panel door
3. Power-up the after filter control panel via the isolator located on the front
of the panel door
4. Ensure the emergency stop button is pulled out Also ensure the
emergency stop button is pulled out on the after filter panel
5. Press the Control Reset push-button on the main control panel
6. Safety circuits will now energise and after a short delay, the main screen
will be displayed on the operator panel

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BOOTH CONTROL SCREEN
A B C D E F G H I J K L
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.
B - park –This button stops the oscillators and movers if running and moves them to their pre set park
positions It will also stop the guns if they are spraying.
C –guns auto / manual –This button toggles the state of the gun control between auto and manual
In auto mode, the guns only trigger when product is in front of them and the conveyor is running
In manual mode, the guns will fire all of the time.

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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 –gun spray control –This button displays the gun spray control page From here, the guns flow,
atomising pressures and KV can be adjusted as well as gaining access to the guns positional
dimension control
Full details are described in a later section of this manual
G –booth lights –This button turns the booth lights on or off Each subsequent press of this button
toggles the lights state between on and off
H –gun pressure trim –This button when pressed, reveals a pop up window to control the
percentage offset that will be applied to the powder and pattern air set points
I –mute –Any fault that occurs with the system will enable an audible Klaxon alarm to attract the
operators’ attention to the fault Pressing this key silences the alarm The yellow light within the light
stack will continue to illuminate until the fault is cleared
J –alarm summary –All faults are logged with a time & date at which they occurred
Pressing this button will display an alarm log showing a brief description of the fault and its current
status If the status shows as K, then the alarm is active If the alarm is listed with a status of K(G), the
alarm is cleared
Pressing the “ ” in the top right hand corner of this screen will exit the log
K –configuration –This button jumps to the configuration screen The booth system parameters can
be adjusted from here
Note:- This screen is only adjusted occasionally and by authorised personnel only Therefore, this
screen has been password protected
A subsequent section of this manual details the parameters available from this screen
L –shut down –touching this button will close all applications and shuts down the PC
Important: before switching off the system use this function to securely disable the soft-PLC and save
all data stored in its memory.
Stay patient before switching off power.

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Screen elements
1 2 3 4 5 6 7
8 9 10 11
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. These procedures are described in detail in a subsequent section of this manual.
2 –fan status –This symbols’ colour indicates the current state of the extract fan.
These are as follows:-
Grey - The fan is stopped
Green - The fan is running
Flashing Red - The fan is in fault
3 –alarm symbols –These symbols are flashing in case of any alarm occurs on the system The
corresponding message can be seen in the alarm summary list (J).
4 –gun to part distance –This data entry sets the distance the gun will position itself away from the
product regardless of the product size There is one entry for the mover on the left side of the booth
and one for the mover on the right side.
5 –conveyor status / speed –This displays the condition of the conveyor When in static grey, the
conveyor is stopped When flashing two tone green, the conveyor is running A component will also
appear hanging from the conveyor when the booth has product within it The number displays the
conveyor speed in metres / minute for indication purposes only .
6 –production data –These displays from top to bottom are:-
Shift product count –This is the total number of products sprayed since the last reset
Total product count –This is the total number of products sprayed since commission
Shift production hours –This is the total number of hours the system has sprayed for with the
conveyor running since the last reset
Total production hours –This is the total number of hours the system has sprayed for with the
conveyor running since commission

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7 –reset production data –this button will reset the shift counters mentioned above
To reset the shift counters, touch the counters and the button will appear Pressing this button will reset
them and the button will then automatically disappear again
8 –gun fault status –This button will display the gun fault screen where a more detailed fault code
can be obtained for any gun
Exit screen Reset errors
1 2
1 –KV node errors for Gun 5 –fault occurred on KV side of gun number 5
2 –Pump node errors for Gun 5 –fault occurred on KV side of gun number 5
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-
KV card faults-
Pump card faults-
E1
uA has not reached alarm set point. This is used with Tribo
guns where a low charge uA value is set for alarm
F1
Communication. The pump card has lost
communication with the gateway
E2
Fold back. The gun is trying to draw more than 100uA
F2
No 24V. The 24V supply to the pump system
has been lost
E3
Feedback. The uA feedback wire is broken in the gun
cable
F3
General alarm. On for any other fault that
cannot be detailed in this list
E4
Open circuit. The voltage multiplier is open circuit
F4
Reserved for future use.
E5
Short circuit. The voltage multiplier is short circuit
F5
Powder air is higher than set point
E6
Hardware. The KV card itself has a fault
F6
Pattern air is higher than set point
E7
General alarm. On for any other fault that cannot be
detailed in this list
F7
Powder air is lower than set point
E8
No 24V. The 24V supply to the KV system has been lost
F8
Pattern air is lower than set point

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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 –This field displays the offset value that determines the actual distance of the
guns from the conveyor centre line As an example, if the gun is actually 500mm from the conveyor
centre line, but the screen displays only 440mm, adding 60 to the adjust value will correct the position
display .
Note This value was set up during commissioning and should only be modified by authorised
personnel. Therefore, this entry has been password protected
Auto / manual selector –This button toggles between mover auto and manual control In auto mode,
the mover profiles around any product that enters the booth maintaining a fixed distance from the work
This value is set up on the main screen (See main screen elements 4)
In manual mode (denoted by the symbol of a hand on a yellow background), the mover stays where it
is and only moves in and out between the ultimate limits by the operator pressing either key D1 to
move in or E1 to move out of the booth
CAUTION –The operator has total responsibility for the operation of the movers when in manual
control Permanent gun damage may occur if running in manual and the guns have not been set
correctly to spray the product entering the booth
maximum outer limit –This value displays the maximum position that the mover can withdraw to in
millimetres (This value is set in the configuration screen and is represented as the distance from the gun
nozzle to the conveyor centre line)
current mover position –This displays the current gun position in relation to the conveyor centre line
maximum inner limit –This value displays the maximum position that the mover can move in to in
millimetres (This value is set up in the configuration screen and is represented as the distance from the
gun nozzle to the conveyor centre line)
mover out –This button when pressed will drive the mover out as long as manual control is selected
mover in –This button when pressed will drive the mover in as long as manual control is selected
exit –This button closes the mover control window
10 –Oscillator control - This button displays the Oscillator control page as shown below

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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 1st gun on oscillator to the part
recognition array
Distance of last gun on oscillator to the part
recognition array
Exit
11 –Spectrum HD feed centre control - touching this area switches the screen to the feed centre
control section as shown in a separate chapter of this manual