Nordson iDry Series User manual

Nordson iDryrSeries
Induction Dryers
Customer Product Manual
Part 1075452-04
Issued 03/16
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 1075452−04 E2016 Nordson Corporation
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 2007. 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
iDry, Nordson, and the Nordson logo are registered trademarks of
Nordson Corporation.
Manuals on the Internet
For the convenience of Nordson customers and field service
representatives, copies of this manual can be downloaded from
http://emanuals.nordson.com/finishing.

Change Record i
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Change Record
Revision Date Change
04 03/16 Ambient Temperature Compensation instructions added

Change Record
ii
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Table of Contents iii
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Table of Contents
Safety 1..................................................
Qualified Personnel 1....................................
Intended Use 1.........................................
Regulations and Approvals 2.............................
Personal Safety 2.......................................
Fire Safety 3...........................................
Action in the Event of a Malfunction 3......................
Disposal 3..............................................
Description 4.............................................
Dryer Components 5....................................
Theory of Operation 6...................................
Specifications 8........................................
Manufacturing Date Code 8............................
Operating Parameters 8...............................
Power Supply Requirements 8..........................
System Weight (Crated) 8..............................
Operating Sound Levels 8..............................
Installation 9............................................
Inspection 9............................................
Lift Points 9............................................
System Positioning and Mounting 10.......................
Flow Direction 10......................................
Clearances 10........................................
Mounting and Line Connections 10......................
Coil and Tube Installation 11..............................
System Wiring 12........................................
Schematics and Wiring Diagrams 12.....................
Power Input 12........................................
External Interlock 14.....................................
Connecting the External Interlock 14.....................
Disabling Customer Interlock 15.........................
Optional Status Contact 15................................
Motion Sensor 15........................................
Magnetic Separator (Optional) 16..........................
Exhaust Ducting (Optional, Customer−Supplied) 16...........
Return Shipping Instructions 16............................
Domestic/USA 16.....................................
Export 16............................................
Setup 17.................................................
Preparation 17..........................................
Keyence Motion Sensor Sensitivity Adjustment 18...........
SICK Motion Sensor Sensitivity Adjustment 19..............
Language Selection 20...................................
Timer and Ramp Settings 21...............................
Ramp Mode Power Level Adjustment 21.................
Ramp Timer Setting 23.................................
Motion Timer Setting 23................................
Motion Detect Sensitivity Setting 23......................
External Interlock Timer Setting (Optional) 24.............
External Interlock Activation 24..........................

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Temperature Offset and Power Limit Settings 25.............
Temperature Offset 25.................................
Power Limits 25.......................................
PID Control Settings 26...................................
Temperature Setpoint, Display, and Alarm Settings 27........
Product Temperature Setpoint 27........................
Alarm Setpoints 27....................................
Temperature Alarm Delay 27............................
Temperature Display Selection 27.......................
Option Setup 28.........................................
Restore System Defaults 28............................
Operation 29.............................................
Dryer Controls 29........................................
Startup 29..............................................
Auto Mode 30...........................................
Adjusting the Temperature Setpoint 31...................
Manual Mode 31.........................................
Adjusting the Power Setpoint 32.........................
High and Low Alarms 32..................................
Faults 32...............................................
Navigation Screen 33....................................
Ambient Temperature Compensation 34.....................
Ambient Temperature Compensation Setup 34.............
How to Change the Setpoint Temperature from the Auto Run Screen 36
Ambient Temperature Comp. Cancellation 37..............
Ambient Comp. Data Monitor 38.........................
Shutdown 39............................................
Maintenance 40...........................................
Monthly 40..............................................
Quarterly 40.............................................
Troubleshooting 41.......................................
Thermocouple Troubleshooting 43.........................
Repair 45.................................................
Coil and Coil Tube Replacement 45........................
Thermocouple Replacement 47............................
Air Filter Replacement 48.................................
Spare Parts 49............................................
Service and Parts Ordering Information 49..................
Field Service Call Procedure 49...........................
Parts Ordering Information 49.............................
Temperature Conversions 50..............................
Celsius−Fahrenheit Temperature Table 50...................
Conversion Equations 50..................................

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Nordson iDryrSeries Induction Dryers
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 that
Shave experience operating and maintaining high-power and high-voltage
electrical equipment.
Scan safely perform their assigned tasks.
Sare familiar with all relevant safety rules and regulations and are
physically capable of performing their assigned tasks.
WARNING: The control enclosure and coil tray contain high voltages and
high power levels. Failure to ensure and employ all appropriate safety
measures may result in serious injury or death.
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 and atmospheres
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

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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.
Refer to the CE Declaration of Conformity for approvals standards.
WARNING: Never disarm any diagnostic or interlock devices including but
not limited to:
A. Current sensor
B. Overtemperature switches
C. Air pressure switch
D. Coil tray lid safety switches
Disarming these devices will void the warranty and may cause personal
harm or equipment failure.
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.
SMake sure that the ventilation system is operating properly to prevent
dangerous concentrations of volatile particles or vapors.
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.
SDisconnect, lock out, and tag switches before servicing electrical
equipment. Allow 10 minutes for all internal energy storage devices to
completely discharge before opening the enclosure.
SKeep parts of your body and metal implements away from the induction
heating zone while the system is energized. Metal objects will heat up
very quickly. Remove all jewelry, watches, and rings.
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.
SHearing protection is recommended.

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Fire Safety
WARNING: The iDry system is designed for use with water-based sealing
compounds only. It is not approved for used with solvent-based
compounds.
To avoid a fire or explosion, follow these instructions:
SAll equipment must be grounded and bonded to the building ground.
SDo not heat materials to temperatures above those recommended.
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 while working with flammable
materials. Shut off power at a disconnect switch first to prevent
sparking. Allow 10 minutes for all internal energy storage devices to
completely discharge.
SKnow where emergency stop buttons, shutoff valves, and fire
extinguishers are located.
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.
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.
SIdentify the reason for the malfunction and correct it before restarting the
system.
Disposal
Dispose of equipment and materials used in operation and servicing in
accordance with applicable laws, regulations, or codes.

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Description
The Nordson iDry Series Induction Dryers provide simple, efficient, and
uniform drying of water-based end-sealing compounds applied to can ends.
The dryers use solid-state induction heating to generate heat within the can
ends and dry the sealing compound, at line speeds of up to 2200 ends a
minute. The dryers can be designed for can end diameters from 57 to
170 mm.
The dryers are available with single or dual channels and can be configured
to mate to almost any line height. Each dryer is designed to handle a
particular material and can end size or limited range of can end sizes,
according to the customer’s specifications.
Figure 1 iDry Series Induction Dryer (with Optional Magnetic Separator)
iDry Features
Instant On/Off When the line starts, heating within the can ends instantly starts. Since heat is
created directly within the ends, there is no thermal inertia. When the line
stops, heating instantly stops. This produces a very uniform product.
No Jams The short length of the dryer and the straight-through design minimizes jams.
Energy Savings Solid state induction heating is extremely efficient. Greater than 80% of the
power consumed is directly realized as heat in the can ends. When the line
stops, almost no power is consumed.
Reliability The solid-state design of the dryers minimizes downtime. There are few
moving parts to wear out.
Small Footprint Because induction drying is so effective, the dryer is much smaller than
conventional ovens.
Temperature Control The dryer continuously monitors the temperature of the can ends as they exit
the dryer and adjusts coil power to maintain the desired setpoint temperature,
providing uniform control of product quality.
Magnetic Separator An optional magnetic separator can be installed at the dryer exit.

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Dryer Components
See Figure 2.
Item Description
1Coil Tray—Contains the induction coil, glass coil tube, auxiliary air heater, heater blower, and
exhaust blower. The can ends travel through the glass tube and are heated by the induction
coil. Cabinet air is heated and forced through the tube to carry off the moisture vaporizing out
of the sealing compound. The exhaust blower draws the heated air and moisture out of the
tube. The coil tray attaches to the customer infeed and outfeed system.
2Motion Sensor—A laser sensor that monitors the movement of can ends at the entrance to
the dryer. The controller will only apply power to the induction coil when the motion sensor
detects can ends moving through the dryer.
3Operator Control Console—Contains the operator interface terminal (touch screen) which
contains all operator control functions including warnings and faults. The console includes an
Emergency Stop button and system on/off push buttons.
4Control Enclosure—Contains the system controller (PLC), cooling air filters and fan, and
power inverter devices and circuit boards.
5Temperature Sensor—Senses the can end temperature as the ends exit the coil tray. The
temperature controller then regulates the power applied to the induction coil to produce the
desired can end exit temperature. The sensor is a low-mass type K thermocouple.
1
2
4
6
0N
CH AL
5
7
3
PRODUCT FLOW
Figure 2 iDry Series Induction Dryer (Shown with Optional Magnetic Separator)
1. Coil tray
2. Motion sensor
3. Operator panel
4. Control enclosure
5. Thermocouple
6. Magnetic separator (optional)
7. Induction coil and coil tube

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Theory of Operation
See Figures 3 and 4.
The can ends move through a glass coil tube inside the coil tray. The tube
is surrounded by the induction coil. As can ends enter the dryer, the motion
sensor at the entrance signals the controller. The controller causes the
power inverter to apply alternating current to the coil windings. The coil
windings generate an alternating magnetic field that creates large eddy
currents in the can ends. The resistance to the eddy currents generates
heat within the can ends and dries the sealing compound. If the can end
line stops, the motion sensor signals the controller, which shuts off power to
the coil windings.
The temperature sensor (thermocouple) at the exit senses the can end
temperature and signals the temperature controller, which adjusts the power
going to the coil windings to maintain the temperature at the setpoint. The
controller uses a PID (Proportional-Integral-Derivative) algorithm that
automatically adjusts the amount of power supplied to the coil to eliminate
temperature variations due to line voltage fluctuations, applied compound
weight, and can end start temperature.
A blower in the controller/power inverter enclosure pulls in room air and
directs it over the electrical components to cool them. The air then flows
into the coil tray and over the coil to cool it. An air heater mounted on the
tube hub at the entrance end of the coil tray interior then adds additional
heat to the air as it enters the coil tube to carry off moisture vaporizing out of
the sealing compound. An exhaust blower mounted in the tube exit hub
draws the air out of the tube and exhausts it out into the room. If an
optional magnetic separator is installed at the tube exit, heated air is also
ducted directly into the separator.
Safety interlocks include door interlock switches, thermocouples, and a
pressure switch. A customer interlock is also provided. Interlock status is
indicated on the operator control panel.
WARNING: Never disarm any diagnostic or interlock devices including but
not limited to:
A. Current sensor
B. Overtemperature switches
C. Air pressure switch
D. Coil tray lid safety switches
Disarming these devices will void the warranty and may cause personal
harm or equipment failure.

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Coil Tray
Coil and Tube
Assembly
Motion
Sensor
Thermocouple
Feed Direction
0N
CH AL
Entrance
Exit
Controller and Power
Inverter Enclosure
Figure 3 Theory of Operation
Coil Windings
Can Ends
Eddy Current
Coil Current
Figure 4 Coil Operation

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Specifications
Manufacturing Date Code
Serial Number: BK X X X X −X X X
year month
Operating Parameters
Ambient Temperature Range: 5 to 45 _C (40−112 _F).
Humidity: 0−70% for full system functionality
Elevation (Altitude): Less than 1524 meters (5000 ft)
Above 5000 ft system must be de-rated.
Contact your Nordson representative.
Power Supply Requirements
360−415 Vac 50 Hz or 440−480 Vac 60 Hz, 3 phase
Class J Bussman TCF fusing required.
System Weight (Crated)
Varies, 363−635 kg (800−1400 lbs)
Operating Sound Levels
39.40 in. (1.00 M)
39.40 in. (1.00 M)
39.40 in. (1.00 M)
74 DB
74 DB 72 DB
74 DB 39.40 in. (1.00 M)
TOP VIEW
Measurements taken 1.6 m (5 ft-4 in.) from floor
Figure 5 Operating Sound Levels

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Installation
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
Inspection
The iDry system is shipped fully assembled, except for the glass coil tube
and coil, which are packed separately to prevent breakage. Unpack and
carefully inspect the dryer, coil tube, and coil for obvious shipping damage
and shortages. If you see any damage or shortages, notify the shipper and
your Nordson representative immediately.
NOTE: A 5/16 inch hex wrench is required to unlock and lock the coil tray lid
and control enclosure doors.
Lift Points
CAUTION: Never lift or move dryers with the glass coil tube installed. If
installed, remove the coil tube before lifting and moving dryer. When lifting
dryers with tandem coil trays (iDry 6 through iDry 9), both coil trays must be
supported.
Lift points with or without Magnetic Separator
Lift Point Lift Point
0N
CH AL
Figure 6 Lift Points for iDry Series Induction Dryer (Shown with Optional Magnetic Separator)

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System Positioning and Mounting
See Figure 6 for lift points.
Flow Direction
The dryer must be positioned so that can ends pass through it in the correct
direction. When moving the dryer into position in the production line, note
the position of the motion sensor head. This is the dryer entrance. A flow
direction arrow is also located inside the coil tray.
NOTE: Optional magnetic separators are always installed at the exit end of
the dryer.
Clearances
Provide clearances around dryer as follows:
SMake sure blower intake (filters) and vents are not obstructed.
SProvide 1 meter (39 in.) of space at the rear of the dryer to remove the
access panel for power and interlock connections and repairs.
SProvide 1 meter (39 in.) of space in front of the dryer to open the
enclosure doors.
Mounting and Line Connections
The dryer legs are set at the factory to approximately the height listed on
the customer approval form supplied with the purchase order. Level the
dryer and bolt it to the floor.
See Figure 7. Six evenly spaced 1/4−20 NCB threaded holes are provided
in the dryer exit and entrance hubs. Secure your can end rod cages or
trays to the entrance and exit hubs as required.
CAUTION: Do not apply excessive force to the hub assemblies. The
ancillary track work or rod cage assemblies must carefully fitted to prevent
applying strain to the hubs, which will be transmitted to the glass coil tube
and cause the tube to fracture.

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105 mm (4.13 in.)
to 175 mm (6.89 in.)
End Sizes
100 mm (3.94 in.)
End Sizes
Up to 83 mm (3.26 in.)
End Sizes
1/4−20 NCB
Threaded Insert
(6) holes eq. sp.
on 9.00 B.C.
1/4−20 NCB
Threaded Insert
(6) holes eq. sp.
on 6.50 B.C.
1/4−20 NCB
Threaded Insert
(6) holes eq. sp.
on 5.50 B.C.
60_
60_60_
Figure 7 Entrance and Exit Hub Mounting Hole Pattern
Coil and Tube Installation
See Figure 8. Install the coil and glass coil tube as follows:
1. Disconnect and lockout power to the dryer.
2. Use a 5/16 in. hex wrench to unlock the locks at each end of the coil tray
lid. Lift the lid to the full up position.
3. Remove the screws (1) securing the air heater and exhaust vent to the
entrance and exit hubs. Move the air heater and exhaust vent away
from the hubs.
4. Remove the coil tube hold-down screws and cushions (2) from the
entrance and exit hubs.
5. Unpack the coil (4) and glass coil tube (3). Carefully insert the tube
through the coil.
6. Carefully install the coil and tube assembly in the coil tray, positioning
the ends of the tube into the hubs. Unless the coil is marked with the
flow direction, it does not matter which end of the coil is at the entrance
or exit.
7. Re-install the coil tube cushions and hold-down screws (2) on the exit
and entrance hubs.
8. Re-install the heater blower and exhaust vents on the entrance and exit
hubs with the screws (1).

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Coil and Tube Installation (contd)
9. Connect the coil wiring to the bus bar terminals (5). Attach the wiring
per the markings on the insulation jacket and the bus bar numbering.
One end of the coil attaches to the first bus bar while the opposite end
attaches to the second bus bar.
NOTE: Bi-Filar and multiple terminated coils have more than one terminal
at each end of the coil. Attach all terminations at one end to the common
bus bar, and all terminations at other end to other common bus bar.
1234 5
Figure 8 Coil and Tube Installation
1. Air heater and exhaust vent screws
(4 on each hub)
2. Cushion and hold-down screws
3. Glass coil tube
4. Coil
5. Bus bar terminals
System Wiring
Schematics and Wiring Diagrams
Refer to the Addendum to this manual for dryer schematics and wiring
diagrams.
Power Input
See Figure 9 for connections. Service requirement is 360−415 Vac 50 Hz or
440−480 Vac 60 Hz, 3 phase at 50 amperes. Class J fusing required.
WARNING: If plant supply is not through current-limiting Class J 50 amp
fusing, customer is required to follow arc flash hazard criteria and label
appropriately.

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WARNING: Install a locking breaker or disconnect in the electrical supply
line ahead of the dryer so that power to the dryer can be disconnected and
locked out when repairs are made. All electrical connections must be made
according to code, including a proper ground connection. Failure to
observe this warning could result in severe personal injury or death from
electrical shock.
See Figure 9. Line power is supplied to the system through a 3/4-in.
(1.9-cm) conduit fitting in the lower left-hand corner of the dryer exit end.
NOTE: Wire gauge must be copper and comply with local and national
electrical codes.
1. Route three #6 AWG (13.3 mm2) wires to the input terminal block (TBL)
on the input side of the line filter.
2. Route one #6 AWG (13.3 mm2) ground wire to the cabinet grounding
terminal (PE) located next to the input terminal block.
WARNING: DANGER! Line filter terminals remain live even with the dryer
main disconnect in the Off position.
L3
L2
L1
GND
Figure 9 Power and Ground Connections

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External Interlock
The external interlock is an optional connection that indicates to the dryer
that the production line is running. When the interlock is used, the dryer
controller will not apply power to the induction coil if there is no interlock
signal.
CAUTION: Nordson engineering recommends that the external interlock be
connected and enabled. Without the interlock, random line motion can
cause the controller to apply power to the coil while the line is stopped,
which could overheat and damage stationary can ends inside the coil.
Connecting the External Interlock
The external interlock requires an external 24 Vdc source at 100 mA to
power an internal relay coil (refer to Note below). The external 24 VDC
power source is not referenced to the dryer ground. The interlock indicates
to the dryer system that the production line is running. Without this signal,
the controller will not apply power to the induction coil.
NOTE: The interlock relay coil is relay CR4 (IDEC part number RY22S).
Additional relay voltages are available through an IDEC distributor.
The interlock terminals are located behind the control enclosure doors, in
the front of the enclosure.
1. See Figure 10. Drill a hole or use a knockout tool to bring your interlock
cable into the enclosure. Install a properly sized strain relief or conduit
connector in the knockout.
2. Connect your interlock wiring to the terminal TB31.
1
2
Figure 10 External Interlock and Status Contact Connections
1. External Interlock terminal TB31 2. Status Contact terminal TB32