Nordson Sure Coat User manual

Sure Coatr
Modular Gun Control System
Issued 4/03
NORDSON CORPORATION AMHERST, OHIO USA
For parts and technical support, call the Industrial Coating
Systems Customer Support Center at [phone] or
contact your local Nordson representative.
This document is subject to change without notice.
Check http://emanuals.nordson.com for the latest version.

Part 331235C E2003 Nordson Corporation Part A: System Overview
Contact Us
Nordson Corporation welcomes requests for information, comments, and
inquiries about its products. General information about Nordson can be
found on the Internet using the following address:
http://www.nordson.com.
Address all correspondence to:
Nordson Corporation
Attn: Customer Service
555 Jackson Street
Amherst, OH 44001
Notice
This is a Nordson Corporation publication which is protected by copyright.
Original copyright date 2000. 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
Nordson, the Nordson logo, Select Charge, Sure Coat, Tribomatic, and
Versa-Spray are registered trademarks of Nordson Corporation.

System Configuration i
Part 331235C
E2003 Nordson Corporation Part A: System Overview
System Configuration
The Sure Coat modular gun control system is custom configured to fit your
application requirements. Only the options that you requested were
installed when the system was manufactured.
Use the following chart to record the components contained in your system.
If you upgrade your system at a later date, be sure to update the information
listed in the chart.
Component Your System Date Installed
Number of guns in system
Type of pneumatic modules
Interface card
Gun purge module
Application/triggering controller
Photo eye junction box
(number of inputs)
Photo eyes (quantity)
PLC

List of Related Documentation
ii
Part 331235C E2003 Nordson Corporation
Part A: System Overview
List of Related Documentation
This manual is divided into alphabetical parts. Parts A and B cover
equipment that is included in all systems. Parts C−G cover optional
equipment that may be added on to a base system.
Your manual contains only the parts that are relevant to your system. If you
decide to add on to your system at a later date, you will receive additional
parts that explain the installation and operation of the options that you
receive.
Refer to the following chart for a list of documentation that is available for
the Sure Coat modular gun control system. Use this list to order
documentation if you misplace any parts of your manual.
NOTE: Parts A and B apply to all configurations of the system. If you order
part A, you will automatically receive parts A and B, a three-ring binder, and
tabs A−G. If you order part B, you will only receive part B.
Document
Part Number
Title
331235 Part A: System Overview
1007365 Upgrading the Sure Coat Modular Gun Control System
334658 Part B: Pneumatic Modules
334659 Part C: Purge Timer Interface Card
334660 Part C: Discrete I/O Interface Card
334661 Part C: UCS DeviceNet Interface Card
334662 Part C: UCS ProfiBus Interface Card
334663 Part D: Gun Purge Module
334666 Part G: Application Controller
334685 Sure Coat Application Controller Operator’s Card
334667 Sure Coat Application Controller Installation
1010255 Sure Coat Triggering Controller
(for Sure Coat Modular Gun Control Systems)
1017461 Sure Coat Triggering Controller Operator’s Card

Table of Contents i
Part 331235C
E2003 Nordson Corporation Part A: System Overview
Table of Contents
Part A: System Overview
Safety Section A1...................................................
Description Section A2..............................................
Installation Section A3...............................................
Configuration Section A4............................................
Operation Section A5...............................................
Troubleshooting Section A6..........................................
Parts Section A7....................................................
Part B: Pneumatic Modules
Description Section B1..............................................
Operation Section B2...............................................
Repair Section B3..................................................
Parts Section B4....................................................
Part C: Interface Card
Description Section C1..............................................
Installation Section C2...............................................
Part D: Gun Purge Module
Description Section D1..............................................
Installation Section D2...............................................
Repair Section D3..................................................
Parts Section D4....................................................
Part G: Application/Triggering Controller

Table of Contents
ii
Part 331235C E2003 Nordson Corporation
Part A: System Overview

Sure CoatrModular Gun Control System
Part A:
System Overview
Customer Product Manual
Part 331235C
Issued 4/03
NORDSON CORPORATION AMHERST, OHIO USA
For parts and technical support, call the Industrial Coating
Systems Customer Support Center at [phone] or
contact your local Nordson representative.
This document is subject to change without notice.
Check http://emanuals.nordson.com for the latest version.

Part 331235C E2003 Nordson Corporation Part A: System Overview
Contact Us
Nordson Corporation welcomes requests for information, comments, and
inquiries about its products. General information about Nordson can be
found on the Internet using the following address:
http://www.nordson.com.
Address all correspondence to:
Nordson Corporation
Attn: Customer Service
555 Jackson Street
Amherst, OH 44001
Notice
This is a Nordson Corporation publication which is protected by copyright.
Original copyright date 2000. 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
Nordson, the Nordson logo, Select Charge, Sure Coat, Tribomatic, and
Versa-Spray are registered trademarks of Nordson Corporation.

Table of Contents i
Part 331235C
E2003 Nordson Corporation Part A: System Overview
Table of Contents
Safety A 1-1..................................................
Introduction A 1-1.............................................
Qualified Personnel A 1-1......................................
Intended Use A 1-1...........................................
Regulations and Approvals A 1-1...............................
Personal Safety A 1-2.........................................
Fire Safety A 1-2.............................................
Grounding A 1-3..............................................
Action in the Event of a Malfunction A 1-3........................
Disposal A 1-3...............................................
Description A 2-1.............................................
Introduction A 2-1.............................................
System Components A 2-1....................................
Central Control Unit A 2-2......................................
Front Panel A 2-3...........................................
Controls and Indicators A 2-3..............................
Display A 2-5............................................
Back Panel A 2-6...........................................
IPS Gun Operating Modes A 2-7..............................
Timers A 2-8...............................................
Pneumatic Modules A 2-8......................................
Main Control Cabinet A 2-8.....................................
Front View A 2-8............................................
Back View A 2-10............................................
Optional Equipment A 2-12......................................
Gun Purge Module A 2-12....................................
Automated Triggering Controls A 2-12..........................
Interface Cards A 2-12........................................
Specifications A 2-13...........................................
Electrical A 2-13.............................................
Pneumatic A 2-13............................................
Operating Air Pressures A 2-13..............................
Typical Air Pressures A 2-13................................
Air Supply Quality A 2-13...................................
Symbols A 2-14................................................
Installation A 3-1.............................................
Introduction A 3-1.............................................
Mounting A 3-1...............................................
Electrical Connections A 3-2....................................
Changing Interlock Voltage from 120V to 240V A 3-3............
Pneumatic Connections A 3-4...................................
Configuration A 4-1..........................................
Introduction A 4-1.............................................
Restoring Factory Default Settings A 4-1.........................
Entering Configuration Mode A 4-2..............................
Gun Mapping A 4-3...........................................
Pneumatic Type A 4-5.........................................
Select Charge AFC Enable/Disable A 4-5.........................
Set Point Lockout A 4-6........................................

Table of Contents
ii
Part 331235C E2003 Nordson Corporation
Part A: System Overview
Operation A 5-1..............................................
Interface and Conveyor Interlock Signals A 5-1...................
Interface Modes A 5-1.......................................
System Keyswitch A 5-2.....................................
Conveyor Interlock for Automatic Triggering A 5-2..............
Startup A 5-3.................................................
Initial Gun Use A 5-4..........................................
Daily Operation A 5-5.........................................
IPS Gun Operating Modes A 5-7..............................
Standard A 5-7...........................................
Select Charge A 5-8......................................
Set Point Adjustments A 5-9....................................
Setting Up Groups of Guns A 5-9................................
Restoring Factory Default Settings A 5-10.........................
Shutdown A 5-10...............................................
Daily Maintenance A 5-11.......................................
Troubleshooting A 6-1........................................
Identifying Errors A 6-1........................................
Diagnostics Mode A 6-2........................................
Operation A 6-2............................................
Error Codes A 6-4..........................................
Clearing Error Codes A 6-5...................................
Alarm Override A 6-5..........................................
Gun Driver Cards A 6-6........................................
Switches A 6-6.............................................
LEDs A 6-6................................................
Electrical Schematics A 6-8.....................................
Central Control Unit A 6-8....................................
Solenoid and Gun Control Panels A 6-9........................
Main Control Cabinet A 6-10...................................
Main I/O Panel A 6-11........................................
Parts A 7-1...................................................
Introduction A 7-1.............................................
Using the Illustrated Parts List A 7-1..........................
System Components and Hardware A 7-2........................
Front A 7-2................................................
Back A 7-4.................................................
Sheet Metal Covers A 7-6...................................
Main Control Cabinet A 7-8.....................................
Front A 7-8................................................
Back A 7-10.................................................
Gun Control Panel A 7-12..................................
Solenoid Panel A 7-13......................................
Sub Panel Assembly A 7-14...................................
Card Frame A 7-16........................................
Pneumatic Section A 7-18.......................................
Main Input/Output Panel A 7-20..................................
Central Control Unit Assembly A 7-22.............................
Front Panel A 7-22...........................................
Rear Panel A 7-24...........................................
Optional Equipment A 7-26
......................................
Interface Cards A 7-26........................................
Gun Purge Module A 7-26....................................
Application/Triggering Controllers A 7-26........................

A 1-1
Safety
Part 331235C
E2003 Nordson Corporation Part A: System Overview
Section A 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
Susing incompatible materials
Smaking unauthorized modifications
Sremoving or bypassing safety guards or interlocks
Susing incompatible or damaged parts
Susing unapproved auxiliary equipment
Soperating 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.

Safety
A 1-2
Part 331235C E2003 Nordson Corporation
Part A: System Overview
Personal Safety
To prevent injury follow these instructions.
SDo not operate or service equipment unless you are qualified.
SDo 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.
SKeep 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.
SRelieve (bleed off) hydraulic and pneumatic pressure before adjusting or
servicing pressurized systems or components. Disconnect, lock out,
and tag switches before servicing electrical equipment.
SObtain 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.
STo 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.
SDo not smoke, weld, grind, or use open flames where flammable
materials are being used or stored.
SProvide adequate ventilation to prevent dangerous concentrations of
volatile materials or vapors. Refer to local codes or your material MSDS
for guidance.
SDo not disconnect live electrical circuits while working with flammable
materials. Shut off power at a disconnect switch first to prevent
sparking.
SKnow 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.
SClean, maintain, test, and repair equipment according to the instructions
in your equipment documentation.
SUse only replacement parts that are designed for use with original
equipment. Contact your Nordson representative for parts information
and advice.

A 1-3
Safety
Part 331235C
E2003 Nordson Corporation Part A: System Overview
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.
All work conducted inside the spray booth or within 1 m (3 ft) of booth
openings is considered within a Class 2, Division 1 or 2 Hazardous location
and must comply with NFPA 33, NFPA 70 (NEC articles 500, 502, and 516),
and NFPA 77, latest conditions.
SAll 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.
SEquipment 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.
SThere 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.
SOperators 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.
SShut off electrostatic power supplies and ground gun electrodes before
making adjustments or cleaning powder spray guns.
SConnect all disconnected equipment, ground cables, and wires after
servicing equipment.
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:
SDisconnect and lock out electrical power. Close pneumatic shutoff
valves and relieve pressures.
SIdentify 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
A 1-4
Part 331235C E2003 Nordson Corporation
Part A: System Overview

Description A 2-1
Part 331235C
E2003 Nordson Corporation Part A: System Overview
Section A 2
Description
Introduction
The Sure Coat modular gun control system provides pneumatic and
electrostatic controls for up to 16 Sure Coat, Versa-Spray, or Tribomatic
automatic powder spray guns. The electrostatic functions of the guns can
be controlled simultaneously by the central control unit. Each gun has an
individual pneumatic controller.
System Components
Refer to Table A 2-1 and see Figure A 2-1 for an overview of the modular
gun control system’s major components.
NOTE: Your system may not have all of the equipment listed. Refer to the
Parts section in this part of the manual for ordering information.
Table A 2-1 System Components
Item Component Description
1 Application/Triggering
Controller (Optional)
Automates triggering for all guns in the system. Refer to
Optional Equipment in this section for more information.
2Central Control Unit Provides electrostatic controls, dc power, grouping, triggering,
and monitoring functions for all guns in the system.
3Pneumatic Modules Control the flow rate and atomizing air to the guns. Each gun
is controlled by an individual pneumatic module.
4Main Control Cabinet Provides electrical connections for all guns and solenoids in
the system. Houses the system power supply and driver
cards for all guns and optional equipment.
5Main Pneumatic Section Distributes air pressure to pneumatic modules and purge
modules.
NS Gun Purge Module
(Optional)
Purges the guns’ powder paths. The gun purge module is
located in the main pneumatic section (5).

Description
A 2-2
Part 331235C E2003 Nordson Corporation
Part A: System Overview
System Components (contd)
1400858A
2
5
3
4
1
Figure A 2-1 System Components
Central Control Unit
The Sure Coat central control unit provides electrostatic control and
monitoring functions for all automatic powder spray guns connected to the
Sure Coat modular gun control system.
The control status information and parameters are adjusted and viewed
from the front panel controls and indicators. A liquid crystal display provides
status information to the operator to identify the mode of operation, control
parameter set point values, and the status of the controller’s output for each
gun connected to the system.

Description A 2-3
Part 331235C
E2003 Nordson Corporation Part A: System Overview
Front Panel
Controls and Indicators
See Figure A 2-2 and refer to Table A 2-2.
1400859A
22
72 4 13 143 5 6 119 10 12
18
20
19
16
15
24
117
21
8
23
Figure A 2-2 Front Panel Controls and Indicators
Table A 2-2 Front Panel Controls and Indicators
Item Component Description
1Gun Panels Display the status and errors for each individual gun.
2Gun Location Label Indicates which gun is controlled by each individual gun panel.
3Gun Display LED Indicates which gun is currently being viewed on the display.
Indicates which gun’s set points may be adjusted.
4Gun Select Key Selects an individual gun to be viewed on the display. The
selected gun’s set points may be adjusted after the gun has
been selected.
5Bar Graph Shows a bar graph of the set point indicated on the digital
display for each individual gun. The bar graph lights when the
gun is triggered.
6Error Indicator Indicates an individual gun error.
7Gun Trigger Key Triggers or shuts off the corresponding gun.
8Gun Trigger LED Indicates that the corresponding gun is triggered.
Continued...

Description
A 2-4
Part 331235C E2003 Nordson Corporation
Part A: System Overview
Controls and Indicators (contd)
Table A 2-2 Front Panel Controls and Indicators (contd)
Item Component Description
9VIEW Key Selects the display of gun current or gun voltage when the
corresponding gun is triggered.
Selects the display of gun current, voltage, or trigger hours
while the corresponding gun is not triggered.
Values appear on the gun’s bar graph and the digital display.
The maintenance timer cannot be viewed while the gun is
triggered.
10 AFC Key Turns on and off the AFC function.
11 STD Key Turns on and off the standard mode.
12 SELECT CHARGE Key Turns on and off the various Select Charge modes.
13 Display Refer to Display in this section.
14 SET ALL Key Allows the operator to adjust set points of all like guns in the
system at the same time.
15 + Key Increases the set point value. Pressing the button
continuously causes the value to increase until the maximum
value is reached.
16 −Key Decreases the set point value of the selected gun. Pressing
the button continuously causes the set point value to decrease
until the minimum value is reached.
17 Gun Type LEDs Indicates the type of gun (IPS or Tribomatic) connected to the
system.
18 Group Triggering Keys Allows the operator to set up and trigger gun groups.
PGM: Activates the program mode so that guns may be put in
groups.
A, B, C, D: Triggers an individual group of guns.
ALL: Simultaneously triggers all guns in the system.
19 LOCAL Key If applicable, switches system control from the central control
unit to the application/triggering controller or remote PLC. The
central control unit has control of system when the LOCAL
LED is lit.
20 F1/F2 Key Flow 1/Flow 2 Systems Only: Switches from flow rate 1 to
flow rate 2 air pressure setting.
21 PURGE Keys GUN: Purges the powder paths of all of the guns in the
system
SYST: Not used
NOTE: The GUN key is only functional in systems with the
gun purge module.
22 Nordson Key Puts the system into the diagnostics mode to view error codes.
23 A Display LEDs Indicates which bar graph scaling option is currently active.
24 A Key Switches the scaling of the gun bar graphs. The total bar
graph range can be either 50 or 100 A for IPS; or 5 or 10 A
for Tribomatic guns.

Description A 2-5
Part 331235C
E2003 Nordson Corporation Part A: System Overview
Display
See Figure A 2-3 and refer to Table A 2-3. The display contains the status
of the powder spray, electrostatics, and the set points.
1400378A
1 2 356
7
8
9
10
11
4
Figure A 2-3 Front Panel Display
Table A 2-3 Front Panel Display
Item Component Description
1Select Charge Value Indicates which Select Charge value is currently active.
Number range is from 1 to 3.
2 F1/F2 Flow 1/Flow 2 Systems Only: Indicates which flow rate
setting is active.
3Powder Icon Indicates that guns are triggered and powder flow is on. This
icon will flash if an error in the solenoid circuit is detected.
4Digital Display Shows the digital number of the set point and actual
parameter information. Additional information that may be
shown is gun on hours, total hours, error codes, kV set point,
A set point, and actual A value. The display is blank when
no appropriate value can be displayed.
5Gun kV or Electrostatics
Icon
Lights to indicate that the selected gun is triggered. The icon
will flash if an error in a gun drive circuit is detected.
6Purge Icon Lights to indicate that the gun purge function is active.
7Unit Indicators Lights to indicate the selection of KV, A, HRS, x10, or
ALARM.
8Bar Graph Units Shows the unit of measure displayed on the bar graph.
9Bar Graph Shows the parameter displayed on the digital display as a bar
graph. The bar graph is only active while a gun is triggered.
10 Fault Icon Lights when there is an alarm or error condition. This icon will
not turn off until the unit is reset or all errors are cleared.
11 Diagnostics Icon Lights when the system is in the diagnostics mode.

Description
A 2-6
Part 331235C E2003 Nordson Corporation
Part A: System Overview
Back Panel
See Figure A 2-4 and refer to Table A 2-4.
1400860A
4
3
1
2
5
AC OUT
AC IN
OI
NET
Figure A 2-4 Central Control Unit Back Panel Components
Table A 2-4 Back Panel Components
Item Component Description
1Ground Stud Grounds the central control unit enclosure.
2AC IN
Cable/Feed-Through
Connects main ac power to the central control unit.
3AC OUT Knockout Supplies power to the (optional) application or triggering
controller.
4Power Switch Turns on or off the central control unit’s power.
5 NET
Cable/Feed-Through
Connects the communication cable from the central control
unit to the main control cabinet.