Nordson 1064311A-02 User manual

CP Gun/SDS Meter-PCI Controller
with Integrated
Temperature Conditioning
Manual 1064311A−02
Issued 11/07
NORDSON CORPORATION • AMHERST, OHIO • USA

Part 1064311A−02 E 2007 Nordson Corporation
Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Qualified Personnel 1. . . . . . . . . . . . . . . . . . . . . . . . .
Intended Use 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulations and Approvals 1. . . . . . . . . . . . . . . . . .
Personal Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-Pressure Fluids 1. . . . . . . . . . . . . . . . . . . . .
Fire Safety 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Halogenated Hydrocarbon Solvent Hazards 2.
Action in the Event of a Malfunction 2. . . . . . . . . . .
Disposal 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Theory of Operation 3. . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Conditioning 3. . . . . . . . . . . . . . . . .
Alarms 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Treatment 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Types 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Corrosion Levels 6. . . . . . . . . . . . . . . . . . . . . . . . .
Biocide Water Treatment 6. . . . . . . . . . . . . . . . . .
Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guidelines 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configure the Robot Controller 8. . . . . . . . . . . . . . .
Analog #1 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog #2 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Set CP Gun Timing Sequences 9. . . . . . . . . . . . . . .
CP Gun RS4 Signal Sequence 9. . . . . . . . . . . .
CP Gun Non-RS4 Signal Sequence 10. . . . . . . .
Set SDS Meter Timing Sequences 11. . . . . . . . . . . .
RS4 Signal Sequence 11. . . . . . . . . . . . . . . . . . . .
Non-RS4 Signal Sequence 12. . . . . . . . . . . . . . .
SDS Meter Prepressure Setpoints 13. . . . . . . . . . . .
Operator Interface and Screens 13. . . . . . . . . . . . . . .
SYSTEM STATUS 14. . . . . . . . . . . . . . . . . . . . . . . . . .
VIEW FAULTS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TEST POINTS 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM SET-UP 19. . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Meter 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Meter Encoder Test 21. . . . . . . . . . . . . . . . . .
Purge 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CP Gun Delays 23. . . . . . . . . . . . . . . . . . . . . . . . . .
Clock 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Restore Configuration 26. . . . . . . . . . . . . . . . . . . .
Simulation Mode 27. . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Setpoint 28. . . . . . . . . . . . . . . . . . . .
Temperature Status 29. . . . . . . . . . . . . . . . . . . . . .
SDS Meter SYSTEM SET-UP 30. . . . . . . . . . . . . .
PROCESS DATA 32. . . . . . . . . . . . . . . . . . . . . . . . . . .
SDS Meter PROCESS DATA Part Charts 33. . . .
ONLINE MANUALS 34. . . . . . . . . . . . . . . . . . . . . . . . .
PREV. MAINT. 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEAD SIZE 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start the Temperature Conditioning Unit 38. . . . . . .
Verify Pipe and RTD Connections 38. . . . . . . . . .
Fill the Water Reservoir 38. . . . . . . . . . . . . . . . . . . . .
Start the Controller 39. . . . . . . . . . . . . . . . . . . . . . . . .
CP Gun System 39. . . . . . . . . . . . . . . . . . . . . . . . .
SDS Meter System 40. . . . . . . . . . . . . . . . . . . . . . .
Dispense Material 40. . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Messages 40. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CP Gun Alarm Settings 42. . . . . . . . . . . . . . . . . . . . .
SDS Meter Statistical Process Control Data 43. . . .
SDS Meter SPC Error
and System Status Codes 43. . . . . . . . . . . . . . . .
CP Gun Statistical Process Control Data 43. . . . . .
Accessing SPC Data 43. . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Chilled Water Flow 44. . . . . . . . . . . . .
Shutdown 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CP Gun System Problems 47. . . . . . . . . . . . . . . . . . .
SDS Meter Problems 48. . . . . . . . . . . . . . . . . . . . . . . .
Temperature Conditioning Section Problems 49. . . .
Cable Continuity 52. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Interface Panel 52. . . . . . . . . . . . . . . . . . . . .
Typical PCA Replacement 52. . . . . . . . . . . . . . . . . . .
Restoring PCI
Controller Programs 54. . . . . . . . . . . . . . . . . . . . . . . .
Saving and Loading PCI
Controller Configurations 56. . . . . . . . . . . . . . . . . . . .
Saving Configurations 56. . . . . . . . . . . . . . . . . . . .
Loading Configurations 57. . . . . . . . . . . . . . . . . . .
Parts 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Conditioning Sections 59. . . . . . . . . . .
Accessories and Kits 60. . . . . . . . . . . . . . . . . . . . . . . .
Cables 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CorrShield MD405 60. . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematics and Wiring Diagrams 60. . . . . . . . . . . . .
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 2005. 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 and the Nordson logo are registered trademarks
of Nordson Corporation.
All other trademarks are the property of their respective owners.

CP Gun/SDS Meter PCI Controller with Integrated Temperature Conditioning 1
Part 1064311A−02
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Safety
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 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.
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 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.
SWhile operating manual spray guns, make sure you are
grounded. Wear electrically conductive gloves or a
grounding strap connected to the gun handle or other true
earth ground. Do not wear or carry metallic objects such as
jewelry or tools.
SIf you receive even a slight electrical shock, shut down all
electrical or electrostatic equipment immediately. Do not
restart the equipment until the problem has been identified
and corrected.
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.
SMake sure the spray area is adequately ventilated.
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.
High-Pressure Fluids
High-pressure fluids, unless they are safely contained, are
extremely hazardous. Always relieve fluid pressure before
adjusting or servicing high pressure equipment. A jet of
high-pressure fluid can cut like a knife and cause serious bodily
injury, amputation, or death. Fluids penetrating the skin can also
cause toxic poisoning.
If you suffer a fluid injection injury, seek medical care
immediately. If possible, provide a copy of the MSDS for the
injected fluid to the health care provider.
The National Spray Equipment Manufacturers Association has
created a wallet card that you should carry when you are
operating high-pressure spray equipment. These cards are
supplied with your equipment. The following is the text of this
card:
WARNING: Any injury caused by high pressure
liquid can be serious. If you are injured or even
suspect an injury:
SGo to an emergency room immediately.
STell the doctor that you suspect an injection injury.
SShow him this card
STell 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 treat the injury surgically as soon as possible. Do not delay
treatment to research toxicity. Toxicity is a concern with some
exotic coatings injected directly into the bloodstream.
Consultation with a plastic surgeon or a reconstructive hand
surgeon may be advisable.
The seriousness of the wound depends on where the injury is on
the body, whether the substance hit something on its way in and
deflected causing more damage, and many other variables
including skin microflora residing in the paint or gun which are
blasted into the wound. If the injected paint contains acrylic
latex and titanium dioxide that damage the tissue’s resistance to
infection, bacterial growth will flourish. The treatment that
doctors recommend for an injection injury to the hand includes
immediate decompression of the closed vascular compartments
of the hand to release the underlying tissue distended by the
injected paint, judicious wound debridement, and immediate
antibiotic treatment.

CP Gun/SDS Meter PCI Controller with Integrated Temperature Conditioning
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Part 1064311A−02 E 2007 Nordson Corporation
Fire Safety
To avoid a fire or explosion, follow these instructions.
SGround all conductive equipment. Use only grounded air
and fluid hoses. Check equipment and workpiece
grounding devices regularly. Resistance to ground must not
exceed one megohm.
SShut down all equipment immediately if you notice static
sparking or arcing. Do not restart the equipment until the
cause has been identified and corrected.
SDo not smoke, weld, grind, or use open flames where
flammable materials are being used or stored.
SDo not heat materials to temperatures above those
recommended by the manufacturer. Make sure heat
monitoring and limiting devices are working properly.
SProvide adequate ventilation to prevent dangerous
concentrations of volatile particles or vapors. Refer to local
codes or your material MSDS for guidance.
SDo not disconnect live electrical circuits when 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.
SShut off electrostatic power and ground the charging system
before adjusting, cleaning, or repairing electrostatic
equipment.
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.
Halogenated Hydrocarbon Solvent
Hazards
Do not use halogenated hydrocarbon solvents in a pressurized
system that contains aluminum components. Under pressure,
these solvents can react with aluminum and explode, causing
injury, death, or property damage. Halogenated hydrocarbon
solvents contain one or more of the following 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
more information. If you must use halogenated hydrocarbon
solvents, contact your Nordson representative for information
about compatible Nordson components.
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 system electrical power. Close
hydraulic and pneumatic shutoff valves and relieve
pressures.
SIdentify the reason for the malfunction and correct it before
restarting the system.
Disposal
Dispose of equipment and materials used in operation and
servicing according to local codes.

CP Gun/SDS Meter PCI Controller with Integrated Temperature Conditioning 3
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Description
The CP Gun/SDS Meter PCI controller with integrated
temperature conditioning uses signals from the robot
controller and other sensors to control the gun
dispensing rate. A constant bead size is maintained by
adjusting the dispensing rate for changes in robot speed.
The PCI controller also
Sheats, cools, and circulates conditioned water through
the system.
Sdisplays recovery procedures if operation faults are
generated by the controller or gun.
Scommunicates faults to the robot controller.
The PCI controller has a software program configured by
Nordson Corporation for your application.
See Figure 1 and refer to Table 1 for a description of the
major components.
Theory of Operation
The robot controller sends a 0 to 10 volt DC analog
signal that is proportional to the speed of the robot. This
voltage can be a 12-bit word in the case of DeviceNet I/O
systems, or a single-ended voltage in a discrete I/O
system. This voltage controls material flow rate through
the CP Gun and SDS Meter.
A bead size adjustment is provided to allow global
increase or decrease of the amount of the robot analog
signal sent to the servomotor or CP Gun, giving the
operator the ability to increase or decrease the amount of
material dispensed without the need to change the robot
program.
If the air swirl option is used, a second analog signal from
the robot passes through the controller to a proportioning
air regulator. The proportioning air regulator controls the
amount of swirl air flowing to the nozzle.
Temperature Conditioning
The temperature conditioning system in the PCI
controller maintains temperature based on feedback from
an RTD in the material stream, typically in a coaxial
material hose.
Temperature is maintained by heating or chilling the
water that is circulated throughout the system.
Temperature setpoint and out-of-range limits are user
adjustable. If the process temperature goes outside of
this limit, a fault is posted, along with on-screen help
information for use in troubleshooting.
The heating element features an adjustable
overtemperature thermostat that will disable power to the
heater if the temperature of the water exceeds a
factory-set limit.
Alarms
The PCI controller alerts the operator when a fault occurs
by lighting the alarm tower. The fault screen on the
operator interface provides a description of the fault, the
appropriate corrective action to take, and how to contact
Nordson Corporation for assistance. A fault log screen
displays a list of faults.

CP Gun/SDS Meter PCI Controller with Integrated Temperature Conditioning
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Part 1064311A−02 E 2007 Nordson Corporation
2
1
3
SERVO DRIVE
FAULT RESET
PB822
ONOFF
TEMP COND 1POWER ON
SS166
ONOFF
TEMP COND 2
LT164
START
SS168PB162
STOP
PB162A
PB162
LT161ALT161
CENTERLINE
ENCL DOOR
L
CCENTERLINE
ENCL DOOR
L
C
LT161A
PB162
LT161A
6
9
10
8
5
4
7
1112
Figure 1 Typical PCI Controller

CP Gun/SDS Meter PCI Controller with Integrated Temperature Conditioning 5
Part 1064311A−02
E 2007 Nordson Corporation
Table 1 Major Components
Item Description
1Alarm Tower—Alerts the operator that a fault condition exists within the system.
2Touch Screen—Operator interface for the system.
Refer to the Operator Interface section for more information.
3Operator Controls:
POWER ON—Main power pilot light.
START—Enable power to the controller.
STOP—Disable power to the controller.
TEMP COND 1 and TEMP COND 2—Enables temperature conditioning section.
SERVO DRIVE RESET—Resets the SDS Meter after a fault occurs.
4From Process—Return water hose connection; 1/2−in. JIC fitting.
5Flow-setters—One located in the main water loop between the inlet and outlet of the water chiller that meters
the correct amount of chilled water into the main loop when the solenoid valve opens.
NOTE: The flow-setters should not be fully open or closed during normal operation.
6Circulation Heater—Heats the water in the process loop. An adjustable high-temperature thermostat
disables the heater circuit and sets the HEATER HIGH TEMP FAULT if the water gets too hot, whether or not
the controller sends a signal for heat.
7To Process—Supply water hose connection; 1/2−in. JIC fitting.
8Chiller—Cools water for use in maintaining the material process setpoint temperature. The internal water
reservoir uses a thermostat set at approximately 50 _F to maintain the water temperature.
NOTE: The chiller is only available on the Heat and Cool versions.
9Circulation Pumps—Maintain continuous water flow through the closed-loop temperature control circuit.
10 Water Reservoir—Has a float switch that senses the water level. If the water drops below the normal level,
the temperature conditioning section shuts down and a fault message appears on the controller screen.
! CAUTION ! To prevent damage to the system, refer to the Water Treatment section for information on the
types of water, corrosion inhibitors, and Biocides to use.
11 Needle Valve—Typically set at approximately 1/2 gpm; provides circulation in the water reservoir to prevent
stagnant water.
12 Solenoid Valve—Closes to prevent water from the main circulation loop to flow through the chiller when
cooling is not required; opens when cooling is required.
Items not Shown
Water Traced Covers—consist of layers of nylon-reinforced fabric with high-density thermal insulation. They are
wrapped around the hose and zipped closed. The covers also have a series of parallel passages that contain flexible
polyurethane tubing. Conditioned water from the temperature conditioning section circulates through the poly tubes,
thereby maintaining the material temperature inside the hose.
Electrical Cables—for connecting the controller to the gun, robot controller, and optional equipment.

CP Gun/SDS Meter PCI Controller with Integrated Temperature Conditioning
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Part 1064311A−02 E 2007 Nordson Corporation
Water Treatment
The temperature conditioning section is constructed of
the following materials. Always refer to this list if different
water, corrosion inhibitors or biocides other than those
listed in the following sections are used.
Black Iron Pipe Stainless steel Nylon
Brass PVC Plastic Copper
Buna Rubber Aluminum Polyurethane
Steel EPDM Rubber PTFE
Water Types
Refer to Table 2. To minimize the introduction of
contaminants that may degrade system components,
review these guidelines before selecting the type of
water to use.
NOTE
Water types are listed in order of preference.
Corrosion Levels
To maintain proper performance, minimum levels of
corrosion to aluminum and copper must be maintained.
To maintain safe operation keep the corrosion levels of
Saluminum at or below 3 mil/year (0.003 in./yr).
Scopper at or below 1 mil/year (0.001 in./yr).
When adding water to the system, corrosion inhibitor
must be added. CorrShield MD405 corrosion inhibitor is
shipped with the PCI controller. This is a
Molybdate-based corrosion inhibitor that contains an
Azole additive to protect copper and is used in the
concentration of 1.5 ounces per gallon of water to
maintain a concentration of 250−350 ppm.
The Ford Tox number for CorrShield MD 405 is 149163
The GM FID number for CorrShield MD 405 is 225484
Refer to the Parts section to order CorrShield MD 405.
Biocide Water Treatment
Do not use the following Biocides:
Soxidizers, such as chlorine, bromine, hydrogen
peroxide, iodine, ozone, etc.
Scationic, or positively charged biocides.
Biocides for use with CorrShield MD405 are
BetzDearborn Spectrus NX114. The recommended
concentration of Spectrus NX114 is 150−PPM which is
0.017 oz./gal (0.5 ml/gal).
The Ford Tox Number for Spectrus NX114 is 148270.

CP Gun/SDS Meter PCI Controller with Integrated Temperature Conditioning 7
Part 1064311A−02
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Table 2 Water Types
Water Description
1. Distilled No minerals and chemicals
Lacks the nutrients necessary to support biological growth and the minerals that wear away at
system components
Neutral nature reduces interaction with additives used to protect the system
NOTE
Distilled water is the best choice for use in the
temperature conditioning section.
2. Well Contains an abundance of minerals that can support plant and animal life
Contains minerals like calcium and iron that are abrasive; accelerates wear and tear on
components
NOTE
If well water is the only option available, it must
be softened to reduce the mineral content.
3. City Contains chlorine that can degrade all metals including stainless steel
Hard on most non−metals
Usually contains an abundance of minerals that are capable of supporting plant and animal life;
accelerates wear on components
4. Weld (Tower) Often heavily treated both for bacterial suppression and to make it more compatible with the
welding and cooling tower processes
Treatment process usually involves some aggressive chemicals that can degrade metals,
plastics and other materials
Usually contains an abundance of metals and other contaminants picked up from the welding
and cooling tower processes that can interfere with the components of the temperature control
system
5. DI ! CAUTION !
Do not use DI water in this system. DI water draws
free electrons from metal to normalize ion levels.
This process causes degradation of metals.

CP Gun/SDS Meter PCI Controller with Integrated Temperature Conditioning
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Part 1064311A−02 E 2007 Nordson Corporation
Installation
WARNING
SAllow only qualified personnel to perform the
following tasks. Follow the safety instructions in
this document and all other related
documentation.
SThe robot controller contains electrical potentials
that can be fatal. Disconnect and lock out
electrical power before making connections.
1. Unpack the PCI controller and inspect it for dents,
scratches, corrosion, or other physical damage. If
there is any visible damage, call your Nordson
Corporation representative immediately.
2. Install the controller as close to the robot controller
as possible.
Guidelines
Review the following guidelines:
SHard-wire the controller to a dedicated power supply
to provide safe operation and reduce interference
from electrical noise.
SInstall all electrical connections to local code.
SInstall a locking disconnect switch or breaker in the
service line ahead of any electrical equipment.
SElectrical, fluid, and air connections are dependent
upon application requirements. Use the System
Layout and Interconnect drawings provided with the
system documentation for all connections.
SMake sure that there is enough slack in all hose and
cable routings to allow for proper system operation.
Configure the Robot Controller
Use the following data to configure the robot controller
analog signals.
Analog #1
See Figure 2. Configure your robot controller to vary the
analog #1 (or tool speed) signal from 0 to 10 Vdc over
the full range of robot speed.
1. Determine the highest and lowest robot speeds to be
used in production.
2. Configure the robot controller to output an analog #1
signal of +10 Vdc when the robot is moving at, or
slightly above maximum speed.
3. Configure the robot controller to output the analog #1
signal of 0 Vdc when the robot is stationary.
NOTE
Figure 2 presents an example of the
approximate relationship between robot speed
and analog #1 voltage as a guide for the
operator. A robot speed of 80% corresponds to
8 Vdc. A robot speed of 40% corresponds to
4 Vdc.
Analog #2
If the air swirl option is used, a second analog signal from
the robot passes through the controller to a proportioning
air regulator. The proportioning air regulator controls the
amount of swirl air flowing to the nozzle.
10
9
8
7
6
5
4
3
2
1
0
0 40 80 100
(Min.) (Max.)
Analog Signal (Volts)
Robot Speed (Percent)
Figure 2 Relationship between Analog Signal #1 and Robot Speed

CP Gun/SDS Meter PCI Controller with Integrated Temperature Conditioning 9
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Set CP Gun Timing Sequences
There are two CP Gun signal sequence configurations;
RS4 and Non-RS4. Review the applicable paragraph for
the desired signal sequence.
CP Gun RS4 Signal Sequence
Refer to Table 3 and see Figure 3 for a description of a
CP Gun RS4 signal sequence.
Table 3 CP Gun RS4 Signal Sequence
Sequence Description
1Robot checks for Dispenser
Ready input.
2Robot raises Robot In Process output.
3Robot raises desired Part ID output
bits for part to be dispensed.
4Robot pulses Style Strobe output.
Pulse must be at least 100mS long.
5Part ID bits are dropped at this time.
6Robot sends analog flow voltage and
raises Dispense On output as required
to apply desired material bead.
7At end of part, robot pulses Dispense
Complete output. Pulse must be at
least 100 mS long.
8Robot drops Robot In Process output.
9Robot checks for presence of Volume
OK input to verify part volume was
within the acceptable limits.
ROBOT IN PROCESS
ROBOT OUTPUTS
ROBOT INPUTS
NOTE: ANALOG SIGNAL NOT SHOWN; TIMING IS NOT CRITICAL.
PART ID BITS
STYLE STROBE
DISPENSE ON
(as required)
DISPENSE COMPLETE
DISPENSER READY
VOLUME OK
> 50 mS
Figure 3 CP Gun RS4 Signal Timing Chart

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CP Gun Non-RS4 Signal Sequence
Refer to Table 4 and see Figure 4 for a description of a
CP Gun Non-RS4 signal sequence.
Table 4 CP Gun Non-RS4 Signal Sequence
Sequence Description
1Robot checks for Dispenser
Ready input.
2Robot raises desired Part ID output
bits for part to be dispensed.
3Robot raises Style Strobe output.
4Part ID bits are dropped at this time.
5Robot sends analog flow voltage and
raises Dispense On output as required
to apply desired material bead.
6At end of part, robot drops Style
Strobe output.
7Robot checks for presence of Volume
OK input to verify part volume was
within the acceptable limits.
NON-RS4 STYLE SIGNAL TIMING CHART
NOTE: ANALOG SIGNAL NOT SHOWN; TIMING IS NOT CRITICAL.
PART ID BITS
STYLE STROBE
DISPENSE ON
(as required)
DISPENSER READY
VOLUME OK
ROBOT OUTPUTS
ROBOT INPUTS
Figure 4 CP Gun Non-RS4 Signal Timing Chart

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Set SDS Meter Timing Sequences
There are two signal sequence configurations; RS4 and
Non-RS4. Review the applicable paragraph for the
desired signal sequence.
RS4 Signal Sequence
Refer to Table 5 and see Figure 5 for a description of an
RS4 signal sequence.
Table 5 RS4 Signal Sequence
Sequence Description
1Robot checks for Dispenser
Ready input.
2Robot raises Robot In Process output.
3Robot raises desired Part ID output
bits for part to be dispensed.
4Robot pulses Style Strobe output.
Pulse must be at least 100mS long.
5Robot waits for Meter
Prepressurized input.
6Part ID bits are dropped at this time.
7Robot sends analog flow voltage and
raises Dispense On output as required
to apply desired material bead.
8At end of part, robot pulses Dispense
Complete output. Pulse must be at
least 100 mS long.
9Robot drops Robot In Process output.
10 Robot checks for presence of Volume
OK input to verify part volume was
within the acceptable limits.
ROBOT IN PROCESS
ROBOT OUTPUTS
ROBOT INPUTS
NOTE: ANALOG SIGNAL NOT SHOWN; TIMING IS NOT CRITICAL.
PREPRESSURIZING
DISPENSING
REFILLING
PART ID BITS
STYLE STROBE
DISPENSE ON
(as required)
DISPENSE COMPLETE
DISPENSER READY
METER PREPRESSURIZED
VOLUME OK
> 50 mS > 50 mS
Figure 5 SDS Meter RS4 Signal Timing Chart

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Non-RS4 Signal Sequence
Refer to Table 6 and see Figure 6 for a description of a
Non-RS4 signal sequence.
Table 6 Non-RS4 Signal Sequence
Sequence Description
1Robot checks for Dispenser
Ready input.
2Robot raises desired Part ID output
bits for part to be dispensed.
3Robot raises Style Strobe output.
4Robot waits for Meter
Prepressurized input.
5Part ID bits can dropped at this time.
6Robot sends analog flow voltage and
raises Dispense On output as required
to apply desired material bead.
7At end of part, robot drops Style
Strobe output.
8Robot checks for presence of Volume
OK input to verify part volume was
within the acceptable limits.
NON-RS4 STYLE SIGNAL TIMING CHART
NOTE: ANALOG SIGNAL NOT SHOWN; TIMING IS NOT CRITICAL.
PREPRESSURIZING
DISPENSING
REFILLING
PART ID BITS
STYLE STROBE
DISPENSE ON
(as required)
DISPENSER READY
METER PREPRESSURIZED
VOLUME OK
> 50 mS
ROBOT OUTPUTS
ROBOT INPUTS
Figure 6 SDS Meter Non-RS4 Signal Timing Chart

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SDS Meter Prepressure Setpoints
To optimize the start of the dispensed bead, the
Prepressure Setpoint parameter is entered in the Setup
menu. This menu is hidden in the Service Menu to limit
access.
The value entered for prepressure should be close to the
dynamic value seen during dispensing of the part.
When the style strobe is received, the SDS ball screw
will begin moving forward until the prepressure value
entered for the current Part ID is reached. At this point,
the ball screw will stop and the Meter Prepressurized
signal is sent to the robot, indicating that dispensing
can begin.
Operator Interface
and Screens
NOTE
Typical screens are shown. Screens may vary in
appearance due to specific application requirements.
See Screen 1.
Touch the screen to select one of seven main menus (1):
SYSTEM STATUS PROCESS DATA
VIEW FAULTS ONLINE MANUAL
TEST POINTS PREV. MAINT.
(Preventive Maintenance)
SYSTEM SET-UP
PREV. MAINT.
(Preventive Maintenance)
Refer to Table 7 for a description of the operator
interface functions.

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SYSTEM STATUS
See Screen 1.
The SYSTEM STATUS menu is the default screen. It
monitors material dispensing characteristics during
production.
Touch a system component to view the
Ssystem illustration that flashes when a fault condition
occurs. To view the fault, touch the flashing part or
touch the VIEW FAULTS button.
Sstatus of STYLE STROBE, GUN ON, ANALOG IN,
and DISPENSE COMPLETE signals.
2 4
36
17
12 11 9 8
5
11
13
Screen 1 CP Gun Operator Interface

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Table 7 Operator Interface Functions
Item Description Function
1Menu Buttons Set and view parameters of the application.
2Dispenser field Indicates the status of the dispenser: Ready or Not Ready.
3Fault Indicator field Displays fault messages.
4CURRENT
PART VOLUME Visually indicates the percent of the job which is completed and the actual dispensed volume at the end of the part cycle.
5NEXT
CONTROLLER Toggle between dispensing systems if using a Dual-PCI controller.
6 Label User-defined label; indicates the current operator interface that is displayed on the
screen. The user-defined label can be up to 10 charaters.
7SYSTEM STATUS Appears as the default screen; displays the system configuration.
8MATERIAL TEMP Indicates material temperature.
9PRESSURE Indicates system operating pressures.
10 BEAD SIZE Displays bead size. Bead size is an arbitrary number between 1 and 99.
Touch BEAD SIZE to increase or decrease bead size.
11 PURGE ON
PURGE OFF CP Gun only—Starts and stops the CP Gun purge function. Not available on SDS Meter system.
12 PART I.D. Displays the current part I.D.
13 I/O Indicators Displays robot signals—Non-RS4 I/O configuration shown.
DISPENSE COMPLETE appears on RS4 I/O configuration.

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VIEW FAULTS
See Screen 2.
The VIEW FAULTS menu displays the description a fault
and the corrective action.
NOTE: Touch any of the bold or underlined text to
proceed directly to the correction.
Touch VIEW FAULTS>VIEW HELP to view the corrective
action for a fault.
Screen 2 View Faults

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See Screen 3.
Touch VIEW FAULTS>FAULT LOG to view the name of
the fault and that date and time that the fault occurred.
Touch VIEW FAULTS>CLEAR ALL FAULTS to clear
the fault.
Screen 3 Fault Log

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TEST POINTS
See Screen 4.
These menus are used to verify that the robot signals are
being sent and received by the PCI controller.
Touch either Physical I/O or DeviceNet I/O to toggle
between the screens
Physical I/O Screen
DeviceNet I/O Screen
Screen 4 TEST POINTS