PC44 Pattern Control: Part 108 099D

PC44 Pattern Control
Part 108 099D
NORDSON CORPORATION. AMHERST, OHIO. USA
Nordson Corporation welcomes requests for information, comments and inquiries about its products. Address all correspondence Nordson Corporation 555 Jackson Street Amherst, OH 44001 to
This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1992. 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 100 Plus, Blue Box, ChromaFlex, CleanSleeve, CleanSpray, Control Coat, Cross-Cut, Easy Coat, Econo-Coat, Excel 2000, Flow Sentry, Isocoil, Isocore, Iso-Flo, Nordson, the Nordson logo, PRX, Pro-Flo, RBX, Ready-Coat, Rhino, Select Coat, Select Cure, Shur-Lok, Smart Spray, System Sentry, Thread Coat, Tribomatic, and Versa-Spray are registered trademarks of Nordson Corporation. CPX, CanWorks, Excel 2000, PowderGrid, Pulse Spray, SCF, Versa-Coat, Versa Screen, Package of Values, and Swirl Coat are trademarks of Nordson Corporation.
Manual 108 089D
57-26 Issued 4197
0 1997 Nordson Corporatuon All rights reserved
o-1
VICES PROVIDED TO NORDSON CUSTOMERS

CustomerSupport Before And After The Sale
For more than 35 years Nordson has offered unparalleled service to its customers before, during and after the sale. Nordson representatives will work with you to choose the best system for your application. Well assist you during start-up and help train your employees to maintain and operate the equipment. Plus, parts and service are only a phone call away from one of our strategically located sales and service centers.
System Engineering
Custom designs and modification of standard equipment are available to meet your particular needs. From a complete new system for automotive assembly to a special nozzle used in the production of diapers, Nordson has the expertise to integrate adhesive and sealant equipment with your manufacturing operation.
Parts And Accessories
In addition to standard replacement parts, many accessories are available to help improve productivity and reduce downtime. For example, heated and non-heated in-line filters reduce stoppages from clogged nozzles, and nozzles in multi-orifice, offset, right-angle and other designs are available for special needs. Also, gloves, solvent, spare parts kits and other components are in stock for immediate delivery. Conversion kits for tapers, labelers and box-forming equipment are also available.
The Nor&on Package of Values
From specifications assistance to post-installation troubleshooting, the Nordson Package of Values is designed to keep our customers productive and profitalble by providing:
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Carefully engineered, durable products Strong service support The back-up of a well-established international company with financial and techniical strength A corporate commitment to deliver what was specified
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Pub. No. 106 OgeB 57-26 lo/92
770-497-3400 770- 497-3400
770-497-3500 770-497-3500
USA phone numbers updated 3/05
Table of Contents
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Table of Contents
Section I Safety Summary
1. introduction . . . . . . . . . . . . . . . . . . . . . * . . 2. Explanation of terms and symbols . . . . . . . 3. Safety during installation . . . . . . . , . . . . . .
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s............
.*........... . . . ..a...*...
l-l l-l 1-2
Section 2 Equipment Familiarization
1. Introduction ........................................ 2. PC44 Functional Description ........................... 3. PC44 User Interface .................................. LCD ............................................. 4. Nordson Photoelectric Sensors ......................... 5. No&on Encoder ................................... 6. PS40 Power Supply .................................. 7. Remote Communications .............................. Remote Memory Select .............................. Remote Lock Out Interface ...........................
2-1 2-2 2-4 2-5 2-6 2-7 2-9 2-l 0 2-10 2-10
Section 3 Installation
1. Introduction ........................................ 2. Inspection .......................................... 3. Safety During installation .............................. 4. fnstallation Tips and Considerations ..................... WireGauge ....................................... Gun Compensation Considerations ..................... Pattern Memory Considerations ....................... Avoiding inductive Interference (Electrical Noise) .......... Limit Switch Considerations .......................... 5. Mounting the PC44 Back Enclosure ..................... Wall or Machine Mounting ............................ DIN Rail Mounting1 .................................. 6. PC44 Electrical Connections ........................... Connecting Power to the PC44 ........................
3-l 3-l 3-1 3-2 3-2 3-2 3-3 3-3 3-3 3-3 3-4 3-6 3-8 3-8
7. Solenoid Wiring Installation ............................

Gun Solenoid Wiring ................................ 8. E700 Gun Driver installation ...........................
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3-13 3-15
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Tab/e of Contents
Section 3 lnstallation (continued)
9. Trigger (Sensor) Install,ation ............................ Trigger input Pin Characterization ...................... Current Sinking (NPN) Requirements ................... Tips for Minimizing Unwanted Triggering ................. Sensor Mounting Dimensions ......................... Mounting Nordson Sensors ........................... Nordson Photosensor Wiring Connections ............... Aligning Sensors ................................... 10. Encoder Installation ................................. Encoder Mounting .................................. Quadrature (Two-phase) Encoder Pin Characterization ..... Encoder Electrical Connections ........................ Nordson Encoder Drive Connection - Flexible Coupling ..... Nordson Encoder Drive Connection-Timing Belts ......... Nordson Encoder Drive Connection - Friction Wheel ....... 11. PC44 Remote Communications Installation ............... Remote Pin Characterization .......................... Remote Memory Selection and Memory Logic ............ Remote Memory Select Switch Installation ............... Keyed Lock Out Switch installation ..................... 12. PS40 Power Supply Installation ......................... Wall or Machine Moulnting ............................ DIN Rail Mounting .................................. PS40 Electrical Connections ..........................
3-l 7 3-17 3-l 8 3-l 8 3-19 3-20 3-24 3-25 3-27 3-27 3-29 3-29 3-31 3-35 3-39 3-41 3-41 3-42 3-42 3-46 3-50 3-50 3-53 3-53
Section 4 Operating Instructions
1. Introduction ......................................... 2. PC44 Parameters Overview ............................ Memory ........................................ Channel ........................................ Trigger ........................................... Transition ......................................... Stitch ............................................ Gun Disable Line Speed ............................. 3. Setting Up the Pattern ................................ Factors to Consider ................................. Example 1: Cartoning (One End Only) ................... Example 2: Cartoning with Stitch On ....................
4-l 4-2 ..4- 2 ..4- 2 4-4 4-5 4-7 4-7 4-8 4-8 4-9 4-14
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Corporation 1992 All Rights Reserved
Table of Contents
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Section
4 4. PC44 Start-up and Default Displays . . . . . . . . . . . . , . . . . . . . . PC44 Start-up Display ............................... PC44 Default Display ............................... 5. Program Mode ...................................... Purpose .......................................... Acccessing Program Mode ........................... Changing Selection Levels ........................... Exiting Program Mode ............................... Programming Memory ............................... Programming Channel ............................... Programming Trigger ................................ Programming Transition ............................. Programming Stitch ................................. Programming Gun Disable Line Speed .................. 6.RunMode .......................................... Purpose .......................................... Accessing Run Mode. ............................... Resetting the {Pattern During Normal Line Operation ....... Reviewing Parameters and Values ..................... 7. Configure Mode ..................................... Purpose .......................................... Accessing Configure Mode ........................... Changing Selection Levels ........................... Exiting Configure ................................... Selecting Available Parameters ........................ Programming Gun Disable Line Speed .................. 8.TestMode.. ........................................ Purpose .......................................... Accessing Test Mode ................................ Selecting a Channel ................................ Activating a Test Channel ............................ ExitingTest ....................................... Indicating Line Speed or Line Speed Problems ........... 9. PC44 Gear-to-Line Memory Operation ................... Introduction ....................................... Software Versions 1.12 or Later ....................... Software Versions 1.09 or Earlier ...................... Cancelling PC44 Gear-to-Line Pattern and Resetting Memory ............................ 4-16 4-16 4-16 4-17 4-17 4-18 4-18 4-18 4-l 8 4-19 4-24 4-25 4-27 4-30 4-31 4-31 4-31 4-31 4-32 4-33 4-33 4-33 4-33 4-33 4-34 4-38 4-39 4-39 4-39 4-39 4-39 4-39 4-39 4-40 4-40 4-40 4-42 4-43
Operating Instructions (continued)
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Table of Contents
Section 4 Operating Instructions (continued)
10. Setting Precise Gun Compensation Values ............... Fine-tuning Method ................................. Calculation Method .................................
4-43 4-43 4-44
Section 5 Troubleshooting
1. Introduction ......................................... 2. Safety Precautions ................................... 3. Troubleshooting Checklist Following Initial Installation ........ 4. Guns Not Firing, ..................................... 5. Guns Firing Between Patterns .......................... 6. Other Gun Firing Problems .............................
5-l 5-l 5-l 5-2 5-5 5-6
Section 6 Service Parts and Reference Data
1. Introduction ......................................... 2. Using the Parts List .................................. 3. Service Parts ....................................... PC44 Pattern Control Service Parts ..................... PS40 Power Supply Service Parts ...................... 4. Specifications ....................................... PC44 Specifications ................................. PS40 Power Supply Specifications ..................... Photosensors Specifications .......................... Encoder Specifications ...............................
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SECTION 1
## TABSHEET ##
Section I
Safety Summary
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Safety Summary
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Section 1 Safety Summary

1. Introduction
Section 1 of the applicator manual includes safety guidelines for the use of Nordson equipment. These guidelines apply to all operators and service personnel workiing with the PC44.
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WARNING: Allow only qualified personnel to perform installation and troubleshooting.
In addition to the safety information in the technical manuals, follow the specific safety precautions contained in this manual.
2. Explanation of Termsand Symbols
The following safety symbols and signal words are used throughout this publication, alerting the reader to personal safety hazards, or identifying conditions that can result in equipment or property damage. WARNING: General Warning. Failure to observe can result in personal injury or death. WARNING: Risk of electrical shock. Failure to observe can result in personal injury or death. WARNING: Risk of electrocution. Disconnect equipment from line voltage. CAUTION: General Caution. Failure to observe can result in equipment damage. NOTE: Important information.
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Safety Summary
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3. Safety During Installation v A 0
WARNING: Risk of serious personal injury or death. Failure to follow the safety and operation information in the technical manuals for the applicator and its associated equipment can result in personal injury or death. Before installing, servicing, or operating the PC44, thoroughly review Section 1, Safety Summary, in the applicator and its associated equipment technical manuals. WARNING: Risk of electrocution. The AC input power line to the PS40 (or customer-supplied 24 VDC power supply to the PC44) provides voltage that can cause personal injury or death. Before making any electrical connections, disconnect and lock out power to the main circuit breaker for the input power line.
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SECTION 2
## TABSHEET ##
Section 2
Equipment Familiarization
0 Nor&on Corporation 1992 All Rights Reserved
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Section 2 Equipment Familiarization

1. introduction
The Nordson@PC44 Pattern Control (Figure 2.1) makes it possible for you to quickly and easily set up, select, or change your material application patterns. When used with an encoder as a distance-based unit, the PC44 is designed to handle applications where material is applied to substrates moving at varying speeds. For applications that also require a constant bead width, use the Nordson PC44R.
Figure 2.1 - PC44 Pattern Control
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When used without an encoder as a time-based unit, the PC44 is designed to handle applications where material is applied to substrates moving at constant speeds. The PC44 is designed for use with 24 VDC solenoids. You will need a 24 VDC power supply. We recommend the Nordson PS40 Power SUPPlY* This section covers the following topics:
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A functional description of the PC44 A description of the PC44 user interface A description of the Nordson quadrature encoder A description of the PS40 Power Supply A description of the PC44 remote communication capabilities
. A description of the folur Nordson Photoelectric Sensors

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2. PC44 Functional Description
The PC44 controls the deposit of material on a moving surface (substrate). Figure 2.2 (two parts) is a block diagram that shows the equipment, and the inputs and outputs involved in the process. 1. A trigger device (e.g., a photoelectric sensor) senses the approach of the leading or trailing edge of the substrate. The trigger then sends an electrical signal to the PC44. 2. The PC44 begins to count pulses provided by a gear-to-line encoder. The PC44s ASIC (Aplplication Specific Integrated Circuit) executes a user-defined pattern based upon the number of encoder pulses. 3. The PC44 activates one to four output channels by sending an electrical signal to one or more gun solenoids. 4. Air moves through the solenoid and into the extrusion gun. This lifts a piston in the gun which allows hydraulically-fed material to flow out of the gun onto the sulbstrate. 5. When the user-defined pattern is completed, the PC44 stops sending an open signal to the channel(s). The solenoid closes, airflow to the gun piston ceases, air in the gun is released through the solenoid exhaust, the gun piston closes, and material stops flowing to the substrate.
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63 Nordson Corporation 1992 All Rights Resewed
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Figure 2.2 - PC44 block diagram A - PS40 DC Power Supply f3 CDEPC44 Pattern Control Applicator Solenoid Gun FGHJEncoder Line travel directions Substrate Kgger
Inputs: I - input voltage (24 VDC) 3 - Trigger signal 4 - Input air to solenoids
2 - P u/se signal
outputs: 5 - Output voltage (24 VDC) 6 - Hot me/t adhesive
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3. PC44 User Interface
The PC44 front panel (Figure 2.3) consists of an LCD, nine indicator LEDs, six membrane push buttons, a power switch and a fuse.
Figure 2.3 - PC44 front panel 7-LCD 2 - Output LEDs (green) 3 - Set push button 4 - Up push button 5 - Right push button 6 - Leff push button 7 - Down push button 10 - Nordson Oval push button 11 - Status LED: Green = power on, unit operational; Red = unit malfunction or remote communication 72 - Status indicator symbol 73 - Trigger input LEDS (amber) 74 - Selection levels 75 - Operating modes
error
8 - Fuse
9 - Power switch
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Eaubmen t Familiarization
2-5
LCD
Blue alphanumeric characters are displayed against a gray background (Figure 2.4). NOTE: Figure 2.4 is for familiarization only; these symbols are never all displayed at the same time.
13 12
Figure 2.4 - PC44 LCD 723456789Numerical display Leading or trailing edge symbols Selection level Stitch bead length symbol Stitch coverage symbol Stitch on symbol Stitch off symbol Transition symbols Two-trigger symbol
IO - Single trigger symbol 1I - Channel symbols 12 - Memory symbols 13 - Mode indicator arrows 14 - Lock indicator arrow
0 Nordsop CoporatIon All Rights Reserved
1992
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Eaubmen t Familiarization
4.
Nor&on Photoelectric Sensors
There are four photoelectric sensors that are available from Nordson for use as trigger devices with the PC44: (1) Opposed Mode (Through Beam) Sensor, which consists of an Emitter and a Receiver (1) Diffuse Reflective (Proximity) Sensor (2) Retroreflective Sensors
Opposed Mode (Through Beam) Sensor This sensor consists of trrvounits: an LED light source (emitter) mounted opposite a light-sensing phototransistor (receiver). The light beam is broken as the substrate passes between the emitter and the receiver (Figure 2.5). This sensor is effective up to a range of 10 ft (3 m).
Figure 2.5 - Opposed mode (through beam) sensor A - Emitter B - Substrate C - Receiver
Diffuse Reflectlve (Ptoxlmlty) Sensor This sensor (Figure 2.6) consists of a single unit that contains both the LED light source (emitter) and the light-sensing phototransistor (receiver). The diffuse mode sensor detects its own emitted light reflected off the substrate. The light beam is broken when there is no substrate opposite the sensor (no reflecting surface). This sensor is effective up to a range of 15 in. (38.1 cm).
Figure 2.6 - Diffuse relfective (proximity) sensor A - Emiti8r/fkC8iV8r B - Substrate
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Familiarization
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Retroreflective Sensors This sensor consists of a single unit that contains the LED.light source (emitter) and the light- sensing phototransistor (receiver). The emitter/receiver bounces its light off an opposing retroreflector or reflective tape and sees the reflected light. The light beam is broken as the substrate passes between the sensor unit and the reflector (Figure 2.7).
Figure 2.7 - Retroreflective sensor A - Emitter/R 8ceiver 6 - Substrate C - Refroreflector

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Retroreflective Polarizing Model - This anti-glare unit polarizes the emitted light and filters out unwanted reflections. It has an effective range of 2 in. (5.1 cm) to 7 ft (2.1 m). Retroreflective Model - This is a non-polarized sensor that is effective up to a range of 15 ft ( 4.5 m).
5. Nordson Encoder
The Nordson quadrature encoder (Figure 2.8) provides the PC44 with distance measurements needed for the correct placement of material on the substrate. The encoder provides 500 pulses per revolution. As the encoder shaft rotates, it turns a magnetized rotary drum. A thin-film sensing circuit responds to the encoded magnetic poles on the drum and sends a pulsed signal to the PC44. The encoders quadrature (dual) output enables the PC44 to sense increments of linear movement as well as the direction of movement. For example, if the line moves forward 10 pulses and the conveyor backlashes 5 pulses, the PC44 knows from the encoder output that the line only moved fotward a total of 5 pulses.
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EauiDmen t Familiarization
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MnlNa
UmALmx
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Figure 2.8 - Nordson incremental quadrature 8nCOd8r A - Front View 7 - 6-Pin Connector 2 - C W (Clockwise) 3-Shaft(I of2) Bside
Label
View (shaft end furthest from 6-pin connector)
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6. PS40 Power Supply
The Nordson PS40 is a 24 VDC switching power supply (Figure 2.9). The PS40 provides power to the PC44. AC input to the power supply can be 115 VAC or 230 VAC. The PS40 input voltage is factory set for 230 VAC. You can select 115 VAC input by changing a jumper plug on the PS40 printed circuit board. Details are provided in Section 3.
Figure 2.9 - PS40 Power Supply
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7. Remote Communications
Remote Memory Sekct~on
Purpose The PC44 has the capability to connect to a remote device which can change the active memory. The unit can also provide +12V power for the remote device. Wiring information for the Nordson Remote Memory Select Switch is included in Section 3, Installation.
Remote Lock OutInterface
Purpose The PC44 will prevent access to the PROGRAM, CONFIGURE, or TEST modes after receiving an input signal from a remote device. While in LOCK, programmling changes cannot be made using the PC44 user interface. Wiring information for the Nordson Keyed Lock Out Switch is included in Sectijon 3, Installation. Screen Display The arrow symbol in the mode segment of the LCD will point to LOCK when this feature is enabled.
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SECTION 3
Section 3
Installation
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Ins talla tion
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Section 3 Installation
1. Introduction
This chagter includes information on inspecting and installing the Nordson PC44 Pattern Control and associated equipment:
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the gun solenoids, the Nordson E700 gun driver the Nordson sensors, the Nordson quadrature encoder, the Nordson remote memory select switch, the Nordson keyed lock out switch, and the Nordson PS40 power supply.
2. Inspection
After unpacking, check that you have the PC44 and other equipment that you ordered (see Section 6 for part number information). Inspect all components for dents, cracks, scratches, or other evidence of physical damage. If you find any damage, contact your Nordson sales representative before installing the equipment.
3. Safety During Installation

1 A 0
WARNING: Personal injury hazard. Failure to review the safety information in Section 1, Safety Summary, of this manual can result in equipment damage, personal injury or death. Before installing this equipment thoroughly review Section 1. Also, follow the specific safety precautions in this section.
Q Nodson Corpratlon All Rights Reserved
1992
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Installation
4. InstallationTips and Considerations

Wire Gauge
The table below specifies the proper gauge wire for the various electrical connections, regardless of the wire length. Table 3.1 - Recommended Wire Guages Wire Gau e 14- 16
ISolenoids
Remote Memory Select Switch Keyed Lock Out Switch
i16-18
18-22
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Gun Compensation Considerations

Units with Software Versions 1.09 or Earlier . The PC44 updates gun compensation after each pattern based on the current line speed. Therefore, when the line first starts, initial gun compensation is zero. Units with Software Versions 1 .I 2 or Later . The PC44 updates glun compensation after each pattern based on the current line speed. Initial gun compensation is based on the Gun Disable Line Speed. Since outputs are disabled below this value, there is no need to apply any less compensation than required at the minimum line speed setting. Adjust the Gun Disable Line Speed as close to actual line speed as possible for best performance. . PC44 gun compensa.tion is fixed during a pattern. Lines that ramp up or down extremely fast can experience a shift in bead placement. Minimizing acceleration or deceleration will allow the PC44 to update compensation before the pattern shift is too great.
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In order to update gun compensation, the PC44 requires an idle period of 30 ms after pattern completion before a new trigger signal is received. If this idle time is not provided, the PC44 can miss the trigger signal. If your application requires less than a 30 ms idle time, two channels can be wired in parallel and triggered alternately. The PC44 does not allow a second pattern to start while a pattern is in progress. If you must space products closer than the sensor to gun distance, you should connect two channels in parallel and trigger them alternately.
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Pattern Memory Considerations
rth Some Versions 1.09 or Fa&er: These PC44s remember receiving a trigger signal regardless of the line condition (stopped, below minimum speed, or at speed). If this is a problem for your application, you should install an interlock device that cycles off power to the PC44 when the line stops. PC44 Gear-to-Line Memory Operation near the end of this section provides memory function details. IJZ or I ;ater:Trigger memory is not a -Wons feature in units that use these software versions. If trigger memory is important to your application, consider using the Nordson PC44R. Trigger memory is a selectable feature of that pattern control. PC44 Gear-to-Line Memory Operation near the end of this section provides memory function details.
A voiding Inductive interference (Electrical Noise)
0 Avoid routing wires near AC power lines, solenoid output lines, and electrical devices such as motors, contactors, and relays.
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Use shielded cable.
. Avoid using excess wire lengths, which can act as an antenna. Use only as much wire as needed to make connections.
Limit Switch Considerations
0 Limit switches should be normally closed. This will provide a stable sensor signal. . Limit switches can bounce when actuated. This can cause a false trigger. De-bounce limit switches by installing a 0.1 microFarad capacitor across the contacts.
5. Mounting the PC44 Back Enclosure
NQTE: In order to achieve an IP-54 Enclosure Rating (splash-resistant environment), Nordson recommends that you route all PC44 and PS40 input and output electrical connections through water-tight conduit and a junction box. Use 1 in. (2.5 cm) conduit fitting, and locate the conduit center line 1 in. (2.5 cm) from the wall. NOTE: Before mounting the PC44, make sure that you have sufficient space to mount it. The unit is 4.0 in. wide (10.2 cm) by 9.0 in. high (22.9 cm) by 4.44 in. deep (1-l.3 cm). If you will be using the Nordson PS40 Power Supply and want the PC44 front panel to mount flush with the PS40 front panel, go to PS40 Power Supply Installation (near the back of this section).
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Pub. No. 108 099s 57-26 W92
Wall or Machine Mounting
1. Loosen the six screws that secure the PC44 back enclosure to the front assembly (Figure 3.1).
Figure 3.1 - Removing the PC44 front assembly 7 - Back enclosure 2 - Front assembly 3 - Screw (I of 6)
2. Pull the front assembly away from the back enclosure. 3. Set the front assembly in a safe place. 4. Position the back enclosure knockout hole for the direction the electrical wiring will route into the PC44. 5. Place the back enclosure against the mounting surface at the location you want to mlount it. 6. Mark the centers of the two PC44 screw holes on the mounting surface. Make sure that the center of the marks are 6 in. (15.24 cm) apart from center to center. 7. Drill two ?42 in. (5 mm) holes in the mounting surface where marked
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Installation
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Wall or Machine Mbuntlng

(con timed)
8. Use the two M4 x 25 mm screws, nuts, and washers provided to fasten the back enclosure to the mounting surface (Figure 3.2).
Figure 3.2 - Mounting PC44 to wall or machine surface A - 6 in. (15.2 cm) 7 - Back enclosure 2 - Screw with washer (nut not shown): 1 of 2
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Ins talla tion
DIN Rail Mounting
NOTE: Before mounting the PC44, make sure that you have sufficient space to mount it. The unit is 4.0 in. wide (10.2 cm) by 9.0 in. high (22.9 cm) by 4.44 in. deep (11.3 cm). Use the parts provided with the PC44 (Figure 3.3) to install the unit to DIN rails as follows: Mountlng to Vertical Rallls I. Fasten the end bracket provided with the unit to the DIN rail by tightening the stop screw (Figure 3.3). 2. Use the two M4 x 12 mm screws to secure the two clips to the back enclosure; make sure that they are oriented for mounting to the vertical rail (Figure 3.3). 3. Fasten the back enclosure to the DIN rail by snapping the clips into the rail.
Figure 3.3 - Mounting PC44 to vertical DIN rails 123456Clip (1 of2) Back enclosure Screw with washer (I of 2) stop screw End bracket DIN rail
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DIN Rail Mounting

(con timed)
Mountlng to Horizontal Rails Make sure that the rails are 6.0 in. (15.24 cm) apart from center to center. Also make sure that the DIN rails are at least 4.0 in. (10.2 cm) in length. 1. Use the two M4 x 12!mm screws to secure the two clips to the back enclosure; make sure that they are oriented for mounting to the horizontal rails (Figure 3.4). 2. Fasten the back enclosure to the DIN rail by snapping the clips into the rails.
Figure 3.4 - Mounting to horizontal DIN rails 7234Clip (1 of 2) Back enclosure Screw and washer (I of 2) DIN rail
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Ins talla tion
6. PC44 Electrical Connections
NOTE: In order to achieve an IP-54 Enclosure Rating (splash-resistant environment), Nordson recommends that you route all PC44 and PS40 input and output electrical connections through water-tight conduit and a junction box. Use I in. (2.5 cm) conduit fitting, and locate the conduit center line I in. (2.5 cm) from the wall. NOTE: If you are using the Nordson PS40 Power Supply, refer to PS40 Power Supply Installation near the end of this section for procedures for connecting1DC power. 1. Install a I in. (2.5 cm) diameter strain relief connector (customer supplied) in ithe PC44 knockout. 2. Temporarily mount the front assembly to the back enclosure by doing the following: a. Loosen the six screws on the front assembly. b. Remove the top two screws (Figure 3.5).
ConnectingPower to the PC44
Figure 3.5 - Removing front assembly screws 1 - Screw (1 Of 6)
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(continued)
c. Rotate the front assembly 180 (Figure 3.6).
temporary mounting
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installation

(continued)
d. Push the two screws through the top two front assembly holes (Figure 3.7, view A). e. Insert the screws into the two back enclosure stand-offs (Figure 3.7, view A). f. Tighten the screws to secure the front assembly to the back enclosure (Figure 3.7, view B).
Figure 3.7 - Temporary mounting of front assembly AViewA 7 - Stand-off (7 of 2) 2 - Screw (7 of 2) B- View B
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Connecting
(continued)
Power to the PC44

@
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WARNING: Risk of electrocution. The AC input power line to

the PS40 (or other 24 VDC power supply) provides voltage that can cause personal injury or death. Before making any electrical connections, disconnect and lock out power to the main circuit breaker for the input power line (Figure 3.8).
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Figure 3.8 - Disconnect and lock out input power
WARNING: Shock hazard. Touching bare wires in the PC44

A $
can result in shock that can cause personal injury or death. When making electrical connections, make sure to strip only as much insulation from the wires as needed. Also, make sure that the insulation fits snugly against the PC44 terminal blocks.
3. Use 14-l 6 gauge electrical wire (customer supplied) to make the connections that are listed in Table 3.2. Terminal Block P2 is shown in Figure 3.9.
Table 3.2 - DC Power Connections and Pin Functions DC Power Supply Connection PC44 Connection Terminal Block P2 P2-3 (24V Return) P2-4 (+24V) Pin Function 24V Return +24 VDC input power supply connection
IGround
24 VDC output
4. If you are NOT connecting other devices at this time, do the following: a. Grasp the front assembly with one hand. Remove the two screws holding it to the back enclosure. b. Carefully rotate the front assembly 180 and place it on the back enclosure. c. Replace and tighten the two loose screws. d. Retighten the four remaining screws.
Pub. No. 108 0998 57-26 lOm2
3-12
Ins talla tion
Connecting Power to the PC44

;continued)
5. If you are connecting other devices at this time, proceed appropriate installation procedure(s) in this section.
to the
P2
PZ-1 P2-2 P2-3 P2-4 P2-5 P2-6 P2-7 P2-8 P2-9 P2-IO P2-II P2-12
3
P3-1 P3-2 P3-3 P3-4 P3-5 P3-6 P3-7 P3-8 P3-9 P3-IO
PI
PI-I PI-2 Pi-3 PI-4 PI-5 PI-6 PI-7 PI-8 P4-1 P4-2 P4-3 P4-4 P4-5 P4-6 P4-7 P4-8
Figure 3.9 - PC44 terminal block connections P2 (Power and Outputs): P2- 1 (NC) P2-2 (NC) P2-3 (24V Return) P 1 (Remote Con trot): PI - 1 (Shield) P l-2 (Ground) P7-3 (Common - connect to Ground or + 12V) P3 (Pulse Tach Connections): P3- 1 (+ 12V) P3-2 (Phase A) P3-3 (Phase B) P4 (Trigger Inputs): P4- 1 (c 12V) P4-2 (Trigger 1) P3-4 (Ground) P3-5 (Shield) P3-6 (NC) P3- .7(NC) P3-8 (NC) P3-9 (NC) P3-10 (NC) P2-4 (+24 V) P2-5 (Valve 1 Return) P2-6 (Valve 7)
P2-;7 (Valve 2 Return) P2-13(Valve 2) P2-9 (Valve 3 Return)
P2- 10 (Valve 3) P2- 11 (Valve 4 Return) P2- 72 (Valve 4)
Pl-4 (Lock) P l-5 (Remote Memory Select 3) PI-6 (Remote Memory Select 2)
P7-17 (Remote Memory Select 7)
PI -8 (+ 12V)
P4-3 (Ground) P4-4 (Shield)
P4-5 (+ 12V) P4-6 (Trigger 2)
P4-7 (Ground) P4-8 (Shield)
Pub No 108 099C 57-26 4194
0 Nordson Corporahon 1994 All Rights Reserved
installation
3-13
7.
Solenoid Wfing Installation

1. Install the gun solenoid(s) following the instructions provided in the manual you received with your applicator. 2. If you have not already done so, temporarily mount the front assembly to the back enclosure by doing the following: a. Loosen the six screws on the front assembly. b. Remove the two top screws (Figure 3.5). c. Rotate the front assembly 180 (Figure 3.6). d. Push the screws through the top two front assembly holes (Figure 3.7, view A). e. Insert the screws into the two back enclosure stand-offs (Figure 3.7, view A). f. Use the two srews to secure the front assembly to the back enclosure (Figure 3.7, view B). 3. Route the two leads (three if the solenoid has a ground wire) to the PC44 through watertight conduit (for an IP-54 enclosure rating) and the strain relief connector. WARNING: Risk of electrocution. The AC input power line to the PS40 (or other 24 VDC power supply) provides voltage that can cause personal injury or death. Before making any electrical connections, disconnect and lock out power to the main circuit breaker for the input power line (see Figure 3.8). WARNING: Shock hazard. Touching bare wires in the PC44 can result in shock that can cause personal injury or death. When makinlg electrical connections, make sure to strip only as much insulation from the wires as needed. Also, make sure that the insulation fits snugly against the PC44 terminal blocks. WARNING: Burns. Unexpected gun firing can occur during PC44 installation. The firing can be a response to trigger signals caused by foreign objects blocking the sensors, and by intentional and unintentional triggering that can occur during maintenance. Nordson recommends that you install quick-disconnect solenoid leads. Disconnect the leads during installation to disable the solenoid. Users may want to provide an additional measure of safety by disabling the trigger.
Gun Solenoid Wirhg
AZI
A5
Af
Pub. No. 108 CBS3 57-26 lW92
3-14
Ins talla tion
Gun Solenoid Wiring

(con timed)
4. Use 16-18 gauge electrical wire (customer supplied) to make the connections shown in Table 3.3. See Figure 3.9 for the location of terminal block, P2.
Table 3.3 - Solenoid Pin Connections and Functions Solenoid Connection PC44 Terminal Block-Pin Connection Function
Solenoid #l : Ground (if present) One lead to PC44 One lead to PC44 Solenoid #2: Ground (if present) One lead to PC44 One lead to PC44 Solenoid #3: Ground (if present) One lead to PC44 One lead to PC44 Solenoid #4: Ground (if present) One lead to PC44 One lead to PC44 P2-3 (GROUND) () P2-11 (VALVE 4 - RETURN) P2-12 (VALVE 4) Solenoid ground Solenoid return connection Solenoid source connection P2-3 (GROUND) () P2-9 (VALVE 3 - RETURN) P2-10 (VALVE 3) Solenoid ground Solenoid return connection Solenoid source connection P2-3 (GROUND) () P2-7 (VALVE 2 - RETURN) P2-8 (VALVE 2) Solenoid ground Solenoid return connection Solenoid source connection P2-3 (GROUND) () P2-5 (VALVE 1 - RETURN) P2-6 (VALVE 1) Solenoid ground Solenoid return connection Solenoid source connection
(I If all four solenoid grounds are present, they will not all1 fit onto P2-3. Connect the grounds together using a connector, wire nut, etc. before connecting to P2-3. *) Some patterns require more than eight transitions. Two channel outputs can be connected in parallel to a solenoid. Then you can program both channels transition values in sequence for a total of 16 transitions.
5. If you are NOTconnecting other devices at this time, do the following:

a. Grasp the front assembly with one hand. Remove the two screws holding it to the back enclosure. b. Carefully rotate the front assembly 180 and place it on the back enclosure. c. Replace and tighten the two loose screws. d. Retighten the four remaining screws.
Pub. No. 106 09X3 57-26 lo/92
Q Nordson Corporation 1992 All Rights Resewed
lnsfalla tion
3-15
Gun Solenoid Wring

(mtind)
6. If you are connecting other devices at this time, proceed to the appropriate installation procedure(s) in this section.
8. E700 Gun Driver Installation
1. Mount and connect power to the E700 Gun Driver as instructed in the E700 technical manual.
: @
WARNING: Risk of electrocution. The AC input power line to the PS40 (or other 24 VDC power supply) provides voltage that can cause personal injury or death. Before making any electrical coInnections, disconnect and lock out power to the main circuit breaker for the input power line (see Figure 3.8). WARNING: Shock hazard. Touching bare wires in the PC44 can result in shock that can cause personal injury or death. When making electrical connections, make sure to strip only as much insulation from the wires as needed. Also, make sure that the insulation fits snugly against the PC44 terminal blocks. WARNING: Burns. Leakage current from the PC44 will turn on the E700 input, which will result in constant gun firing. Connecting a resistor across the E700 Gun Driver input, as instructed below, will simulate the presence of a solenoid and eliminate constant gun firing.
A4
0 A!
2. If you have not alrealdy done so, temporarily mount the front assembly to the back enclosure by doing the following: a. Loosen the six screws on the front assembly. b. Remove the two top screws (Figure 3.5). c. Rotate the front assembly 180 (Figure 3.6). d. Push the screws through the top two front assembly holes (Figure 3.7, view A). e. Insert the screws into the two back enclosure stand-offs (Figure 3.7, view A). f. Use the two srews to secure the front assembly to the back enclosure (Figure 3.7, view B). 3. Make the electrical connections shown in Table 3.4. See Figure 3.9 for the location of terminal block, P2.
CpNo&on Corporation 1992 All Rights Reserved
Pub. No. 108 0998 57-26 lo/92
3-16
Ins talla tion
Table 3.4 - E700 Gun Driver Connections PC44 #1 Connection P2-5 (VALVE 1 - RETURN) E700 Connection J5-5: connect a 470 ohm, 1W resistor across this input J5-6
P2-6 (VALVE 1) PC44 #2 Connection (if used) P2-7 (VALVE 2 - RETURN)
P2-8 (VALVE 2) 4. If you are NOT connecl:ing other devices at this time, do the following: a. Grasp the front assembly with one hand. Remove the two screws holding it to the back enclosure. b. Carefully rotate the front assembly 180 and place it on the back enclosure. c. Replace and tighten the two loose screws. d. Retighten the four remaining screws. 5. If you are connecting other devices at this time, proceed to the appropriate installation procedure(s) in this section.
Pub. No. 1oB 099B 57-26 lo/92
Ins talla tion
3-l 7
9. Trigger (Sensor) installation

Triggerinput Pin Characterization
The trigger devices, usually photosensors, are connected to PC44 terminal block P4 (refer to Table 3.5 and see Figure 3,9). The signals from the trigger are resistively coupled and filtered into the PC44. Table 3.5 - Trigger Pin Characterization Terminal Block-Pin Connection Trigger #l P41 (+12V) DC power for first trigger. Maximum current available from +12V is 500 mA. This is the maximum current available for all connections to +12V including those loads on other PC44 connectors. Input signal from first trigger Ground connection for first trigger Shield connection for first trigger Function
P4-2 (TRIGGER 1) P4-3 (GROUND) P4-4 (SHIELD) Trlgger #2 (If used), P4-5 (+12V)
DC power for second trigger. Maximum current available from +12V is 500 mA. This is the maximum current available for all connections to +I 2V including those loads on other PC44 connectors. Input signal from second trigger Ground for second trigger Shield connection for second trigger
P4-6 (TRIGGER 2) P4-7 (GROUND) P4-8 (SHIELD)
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3-18
Ins talla tion
Current Sinking (NPIV) Requirements
A current sinking (NPN) device capable of sinking at least 10 mA must be used to stimulate the signal inputs. The internal circuitry for the Nordson photosensor is pre-wired to include the required NPN switching element. Figure 3.10 shows the wiring diagram for the Nordson photosensor.
B
8
Figure 3.10 - Nordson photosensor wiring diagram (wired as a sinking device) A - Photosensor I-+12VDC 2 - Signal 3 - Ground 4 - Shield 5 - Switching element (NPN transistor), pre-wired within sensor circuitry 6 - Pigtail wire for shield B-PC44 7 - To logic circuit 8-+12V
Tips for Minimizing Unwanted Triggering
The occurence of unwanted trigger signals can be reduced by following these recommendations:
l
Avoid routing sensor wires near AC power lines, solenoid output lines, or other electrical devices (i.e., motors, contactors, relays, etc.) that may cause electrical interference. Especially avoid routing wires in troughs or conduits with other high-current carrying conductors. Make sure that no objects other than the substrate pass between the sensor and substrate during line operation.
Q Mount the sensors within the recommended distance range of the substrate.
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3-19
77~sfor Mhimizhg Unwanted Triggering

(continued)
Mount the sensor to metal that is connected to earth safety ground (system ground). Adjust photosensor gain to minimum sensitivity. This will reduce both electrical and optical problems. CAUTION: Equipment damage or malfunction. There are two cases where grounding the shield at both ends of Nordson photosensors could result in equipment damage or malfunction. Do NOT ground the shield at both ends when csither:
f A 0
(1) Using a power supply with a return that is not grounded (earth ground) or (2) there is greater than a 50 ft (15.2 m) distance between the sensor and the PC44. NOTE: Rem (l), above, does not apply to the Nordson PS40, since its 24V return is grounded.
l
Except as noted in tile caution above, photosensor cable shield should be grounded at both ends. This will reduce the effects of electrical noise produced by contactors, motors, and arc-welders. Through-beam and retroreflective photosensors should be used in the light operate mode. This also will reduce the effects of electrical noise. Diffuse reflective photosensors should be used in the dark operate mode. This will reduce the effects of electrical noise.
Sensor nclaunthgDimensions
Figure 3.11 - Sensor dimensions 1 - 1.21 in. (30.7 mm) 2 - 0.95 in. (24.1 mm) 3 - 6 ft (183 cm) 4 - Mounting peg; 0.25 in. diameter x 0.10 in. (6.4 mm diameter x 2.5 mm) 5 - 0.75 in (19.1 mm) 6 - 1.5 in. (38.1 mm) 7 - 2.1 in. (53.3 mm) 13 - Gasketed, acrylic cover !3- 0.48 in. (12.2 mm) 10 - #4 screw clearance (2 places) I1 - 1.08 in. (27.4 mm) 12 - 0.71in. (18 mm) diameter; 18 x 1 mm thread 13 - Mounting nut (supplied), 0.95 in. (24.1 mm) diameter
Q Nwdson Corporation 1992 All Rights Reserved
Pub. No. 108 0998 57-26 1CW
3-20
Ins talla tion
Sensor Mounting Dimensions

(continued)
Figure 3.12 - Sensor bracket dimensions 1234560.10 in. (2.5 mm) 0.79 in. (20.1 mm) 1.79 in. (45.5 mm) 90 degees 0.80 in. (20.3 mm) 10 degees (typically) 7 - 0.170 in. (4.3 mm); 2 slots 8 - 1.25 in. (31.8 mm) 9 - 15 degrees (either direction) 10 - 0.120 in. (3.1 mm) 17 - 0.120 in. (3.1 mm)
Mounting Nordson Sensors
Instructions follow for mounting each type of Nordson sensor. Proceed to the instructions for the type of sensor you are using. Mountlng Dlffuse Sensors 1. Check the intended mounting position to make sure that there is enough space to mount the sensor(s) and bracket(s). See Figure 3.11 and Figure 3.12. 2. Check the intended mounting position to make sure that there are no objects other than the substrate that will pass between the sensor and substrate during fine operation. 3. Locate the sensor bracket so that the sensor is no closer than 2 in. (5.1 cm) nor further than 15 in. (38.1 cm) from the substrate. 4. Securely connect the sensor bracket to the mounting surface. Excessive movement or vibration can result in intermittent or false operation caused by lolss of alignment to the substrate.
Pub. No. 108 099B 57-26 1om
Ins talla tion
3-21

(continued)
5. Using the two mounting bolts provided with the sensor bracket, secure the sensor to the bracket (Figure 3.13).
Figure 3.13 - Connecting the sensor and bracket 1 - #4 mounting bolts (2 supplied) 2 - Bracket 3 -Lens centerline, 1.12 in. (28.5 mm) 4 - Front of sensor tilts vertically +/ - 15 degrees from horizontal
6. If you have not already done so, temporarily mount the front assembly to the back enclosure by doing the following: a. Loosen the six screws on the front assembly. b. Remove the two top screws (Figure 3.5). c. Rotate the front assembly 180 (Figure 3.6). d. Push the two screws through the top two front assembly holes (Figure 3.7, View A). e. Insert the screws into the two back enclosure stand-offs (Figure 3.7, View B). f. Tighten the two screws to secure the front assembly to the back enclosure (Figure 3.7, View B). 7. Route the sensor leads through water-tight conduit (for an IP-54 enclosure rating) and the strain relief connector and into the PC44. 8. Skip to Nordson Photosensor Wiring Connections.
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Ins talla tion

(continued)
Mounting Opposed Sensors 1. Check the intended mounting position to make sure that there is enough space to mount the sensor(s) and bracket(s). See Figure 3.11 and Figure 3.12. 2. Check the intended mounting position to make sure that there are no objects other than the substrate that will pass between the sensor and substrate during linle operation. 3. Locate the emitter bracket so that the emitter is no further than 10 ft (304.8 cm) from the receiver. 4. Securely connect the emitter bracket to the mounting surface. Excessive movement or vibration can result in intermittent or false operation caused by loss of alignment to the substrate. 5. Securely connect the receiver bracket to the mounting surface. 6. Using the two mounting bolts provided with each bracket, secure the emitter and receiver to their respective brackets (Figure 3.13). 7. If you have not already done so, temporarily mount the front assembly to the back enclosure by doing the following: a. Loosen the six screws on the front assembly. b. Remove the two top screws (Figure 3.5). c. Rotate the front assembly 180 (Figure 3.6). d. Push the two screws through the top two front assembly holes (Figure 3.7, View A). e. Insert the screws into the two back enclosure stand-offs (Figure 3.7, View B). f. Tighten the two screws to secure the front assembly to the back enclosure (Figure 3,7, View B). 8. Route the sensor leads through water-tight conduit (for an IP-54 enclosure rating) and the strain relief connector and into the PC44. 9. Skip to No&on Pholosensor Wiring Connections.
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Ins talla tion
3-23

(cw7tinued)
Mounting Retroreflectlve Sensors 1. Check the intended mounting position to make sure that there is enough space to mount the sensor(s) and bracket(s). See Figure 3.11 and Figure 3.12. 2. Check the intended mounting position to make sure that there are no objects other than the substrate that will pass between the sensor and substrate during line operation. 3. Locate the emitter/receiver bracket so that the emitter/receiver is no further from the reflector than 7 ft (2.13 m) for the polarized model or no more than 15 ft (4.5 m) from for the non-polarized model. 4. Securely connect the emitter/receiver bracket to the mounting surface. Excessive movement or vibration can result in intermittent or false operation caused by loss of alignment to the substrate. 5. Using the two mounting bolts provided with the bracket, secure the emitter/receiver to its bracket (Figure 3.13). 6. Secure the reflector lo the mounting surface opposite the emitter/receiver. 7. If you have not already done so, temporarily mount the front assembly to the back enclosure by doing the following: a. Loosen the six front assembly screws. b. Remove the two top secrews from the front assembly (Figure 3.5). c. Rotate the front assembly 180 (Figure 3.6). d. Push the screws through the top two front assembly holes from the rear (Figure 3.7, view A). e. Insert the screws into the two stand-offs on the back assembly. f. Use the two srews to secure the front assembly to the back enclosure (Figure 3.7, view B). 8. Route the sensor leads through water-tight conduit (for an IP-54 enclosure rating) and the strain relief connector and into the PC44. 9. Proceed to Nordson Photosensor Wiring Connections.
0 No&on Corporation lg%? All Rights Reserved
Pub. No. 108 0998 57-26 lo/g2
3-24
Ins talla tion
Nordson Photosensor Wiring Connections
: @
WARNING: Risk of electrocution. The AC input power line to the PC44 or PS40 (or other 24 VDC power supply) provides voltage that can cause personal injury or death. Before making any electrical connections, disconnect and lock out power to the main circuit breaker for the input power line (see Figure 3.81).
1. Connect the wires for each photosensor as indicated in Table 3.6 or Table 3.7. See Figure 3.9 for the location of terminal block P4. Table 3.6 - Nordson Photosensor Wire Connections (except Through-beam Emitter, P/N 737 473) Wire Color Red Green White Black Shield Function +VDC Sourcing output Sinking output Common Shield Trigger #I Connection P4-1 (+I 2V) None; clip lead. P4-2 (TRIGGER I) P4-3 (GROUND) P4-4 (SHIELD) Trig er #2 Connection (if use3 ) P4-5 (+I 2V) None; clip lead. P4-6 (TRIGGER 2) P4-7 (GROUND) P4-8 (SHIELD)
Table 3.7 - Nordson Through-beam Emitter, P/N 737 473 Wire Color Code
I I I I
Wire Color Brown Blue
Function +VDC Common
Trigger #I Terminal Connection P4-1 (+l,V) P4-3 (GROUND)
Trigger #2 (if used) Terminal Connection P4-5 (+12V) P4-7 (GROUND)
A
t 0
CAUTION: Equipment damage or malfunction. There are two cases where grounding the shield at both ends of Nordson sensors could result in equipment damage or malfunction. Do NOT ground the shield at both ends when either:
(1) Using a power supply with a return that is not grounded (earth ground) or (2) there is greater than a 50 ft (15.2 m) distance between the sensor and the PC44. NOTE: Item (I), above, does not apply to the Nordson PS40, since its 24V return is grounded. 2. Except as noted in the caution above, ground the other end of each photosensor shield near the sensor.
Plrb. No. 108 0998 57-26 lo/Q2
Ins talla tion
Nordson Photosensor Wiring Connections

(cm tinued)
3. If you are NOT connecting other devices at this time, do the following:
a. Grasp the front assembly with one hand. Remove the two screws holding it to the back enclosure. b. Carefully rotate the front assembly 180 and place it on the back enclosure. c. Replace and tighten the two loose screws d. Retighten the four remaining screws. 4. Align the sensors by following the appropriate procedure below for the type of sensor you are using.
Aligning Sensors
Allgnment Indicator Nordson photosensors have an alignment indicator (LED). The LED pulse (flash) rate increases as alignment improves. The sensor is adjusted so that the LE!Dis off (not flashing) in the dark condition or is on (flashing) at a fast rate in the light condition. The LED flash rate also indicates when sensor maintenance is needed. Whenever the flash rate is slow, the sensors lenses should be cleaned and sensor alignment checked. Allgnlng Dlffuse Reflective (Proxlmlty) Sensors NOTE: Before adjusting the gain control, make sure that any background objects (e.g., moving machine parts which would pass through the sensors field of view during operation) are present in the sensors line of sight during adjustment. 1. Remove the gasketed acrylic cover located above the sensor electrical cable. 2. Turn on power to the sensor. 1 3. Direct the infrared sensor light beam at the substrate and observe the red alignment LED (Figure 3.14). 4. Turn the gain control until the LED is flashing on and off. 2 5. Move the substrate and, if possible, any background objects out of the sensors field of view. If the LED stays off, no further adjustment is necessary.
3 I I
Figure 3.74 - Alignment LED and gain control locations 7 - Gain control 2 - Light/dark operate switch 3 - Cable opening 4 -Alignment LED
Q Nordson Corporation 1gg2 All RigMs Reserved
Pub. No. 108 0998 57-26 lmz
3-26
Ins talla tion
Aligning Sensors
(mtinnued)
NOTE: The gain control is a 15-turn pot which does not have a stop position. The gain control ratchets at the end of its travel. 6. If the LED remains on, turn the gain control counterclockwise by 19 turn increments until thIe sensor comes on only when it sees the substrate, but goes off <when the substrate is removed. If the LED still remains on after you turn the gain control fully counterclockwise, remount the sensor furlher from the substrate (but no further away than 15 in. or 38.1 cm). 7. If you are connecting other devices at this time, proceed to the appropriate installation procedure(s) in this section. Allgnlng Opposed (Through Beam) Sensors 1. Remove the gasketed acrylic cover located above the sensor electrical cable. 2. Turn on power to the sensor. 3. Direct the emitter at the receiver and observe the red alignment LED on the receiver (Figure 3.14). 4. Turn the gain control to the fully clockwise position. The LED should be flashing on and off. 5. Adjust the position of the emitter and/or receiver to achieve the maximum alignment LED flash rate. 6. Move the substrate between the emitter and receiver. If the LED stays off, no further adjustment is necessary. 7. If the LED continues to flash on and off, or remains on, turn the gain control counterclockwi:se by 14 turn increments until the LED goes out and stays off. 8. If you are connecting other devices at this time, proceed to appropriate installation procedure(s) in this section. Allgnlng Retroreflectlve Sensors 1. Remove the gasketed acrylic cover located above the sensor electrical cable. 2. Turn on power to the sensor. 3. Direct the infrared light beam on the emitter/receiver at the reflector and observe the red alignment LED (Figure 3.14). 4. Turn the gain control to the fully clockwise position. The LED should be flashing on and off. 5. Move the substrate between the emitter/receiver and reflector. If the LED stays off, no further adjustment is necessary. 6. If the LED continues to flash on and off, or remains on, turn the gain Control counterclockwise by 1h turn increments until the LED goes out and stays off. If thle LED still remains on after you turn the gain Control fully counterclockwise, take steps to reduce the reflectivity of the substrate. 7. If you are connecting other devices at this time, proceed to appropriate installation procedure(s) in this section.
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Ins talla tion
3-27
IO. Encoder installation

Encoder Mounting
NOTE: The maximum encoder frequency is 10,000 pulses per second. The encoder mounts on the parent machine and must be installed so it accurately registers the speed of the substrate on the line. In most cases, this involves selecting an idler shaft on the parent machine and using it to drive the encoder.
1. Before starting to install the encoder, ensure that you have

sufficient space to mount it (dimensions are shown in Figure 3.15). 2. Select a flat, stable mounting surface on the parent machine for the encoder. 3. Four mounting holes are located on the left, right, and bottom faces of the encoder. DeWmine which face will attach to the mounting surface to provide the encoder position required by your line. 4. Use four screws (to fit the 6-32 UNC-LBx .167 in. or 4.24 mm threaded mounting holes) to secure the encoder to the mounting surface.
Pub. No. 108 0998 57-26 lo/Q2
3-28
installation
Encoder Mounting
(continued.)
IL----v
16mm (.63 in.)
A I
19.1 mm (.75 in.) --I-57.2 mm (2.25 in.) --I 1.5mm (.06 in.) I 1
--)
~ +-~
57.2 mm (2.25 in.) y 23.9 mm I (.94 in.)
20.6 mm (.81 in.)
57.2 mm (2.25 in.) I 1 I --L.-
t
28.6 mm (1 .125 in.)
L
I
A B
@ ;
9.5 mm (.375 in.)
5701001
Fig. 3-l
Nordson quadrature encoder dimensions B. Front view
A. Right side view
35.9 mm (1.414 in.)

570100:
Fig. 3-2
Mounting hole pattern showing diameter between ten ters
P/N 108 0990 57-26 4197
Q 1997 Nor&on Corporamn All nghts reserved
ins talla tion
3-29
Quadrature(Two-phase)Encoder Pin Characterization NOTE: The PC44 is designed for use with Nordsons quadrature
(two-phase) encoder. The PC44 will also operate from a single-phase input. If used with a single-phase input, a jumper wire must be installed connecting pins P3-2 and P3-3 on PC44 terminal block P3 (Figure 3.9). Table 3.8 - Quadrature Encoder Pin Characterization Terminal Block - Pin Connection P3-1 (+12V) (I Function DC power to encoder. Comments The enlcoder must receive power from this pin connection if the PC44 is to operate in the gear-to-line mode. Otherwise, it will operate as a time-base unit.
P3-2 (PHASE A) P3-3 (PHASE B)
Phase A input signal to PC44. A current sinking (NPN) device capable of sinking at least 10 mA must be used to stimulate this input. Phase B input signal to PC44. A current sinking (NPN) device capable of sinking at least 10 mA must also be used to stimulate this input. Ground from encoder. Shield (if present) from encoder. Case lead (green) from encoder can be attached here. This connection is not necessary if the encoder is mounted securely to a grounded surface.
P3-4 (GROUND) P3-5 (SHIELD)
(I Maximum current available from +12V is 500 mA. This is the maximum current available for all connections to +12V including loads on other PC44 pin connections.
Encoder Electrical Connections
1. If you have not already done so, temporarily mount the front assembly to the back enclosure by doing the following: a. Loosen the six screws on the front assembly. b. Remove the two top screws (Figure 3.5). c. Rotate the front assembly 180 (Figure 3.6). d. Push the screws through the top two front assembly holes (Figure 3.7, view A). e. Insert the screws Iinto the two back enclosure stand-offs (Figure 3.7, view A). f. Use the two srews to secure the front assembly to the back enclosure (Figure 3.7, view B).
Pub. No. 108 0998 57-26 1ol92
3-30
ins talla tion
Encoder Ektrkal
(continued)
Connections
WARNING: Risk of electrocution. The AC input power line to the PS40 (or other 24 VDC power supply) provides voltage that can cause personal injury or death. Before making any electrical connections, disconnect and lock out power to the main circuit breaker for the input power line (see Figure 3.8). WARNING: Shlock hazard. Touching bare wires in the PC44
can result in shock that can cause personal injury or death. When making electrical connections, make sure to strip only as much insulation from the wires as needed. Also, make sure that the inlsulation fits snugly against the PC44 terminal blocks. There are two diffent Nordson encoder cables. The most commonly used is a six-wire cable (P/N 132 836). There is also a nine-wire cable that is needed when using the Nordson encoder with MPC (motor and pressure control) applicators. 2. Depending on the cable that you are using, make the connections shown in Table 3.9 or Table 3.10 (also, see Figure 3.9). Table 3.9 - 6-wire Quadrature Encoder Cable (P/N 132 836) Wiring Connections Encoder Lead Red Brown Orange Black Black shield Green Function Power input, +12V Signal A Signal B 12V Return Shield Case (ground) PC44 Pin Connection Terminal block P3-1 Terminal block P3-2 Terminal block P3-3 Terminal block P3-4 Terminal block P3-5 Terminal block P3-5 (I
(I This connection isI not necessary if the encoder is mounted securely to a grouinded surface.
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Encoder Electrical Connecflons

(continued)
Table 3.10 - g-wire Quadrature Encoder Cable (P/N 148 751) Wiring Connections
F
t
Encoder Lead
Function
PC44 Pin Connection
3-lead group (for connection to MPC) Black Brown Black shield 6-lead group Red Brown Orange Black Black shield Green Power input, +12V Signal A Signal B 12V Return Shield Case (ground) Terminal block P3-1 Terminal block P3-2 Terminal block P3-3 Terminal block P3-4 Terminal block P3-5 Terminal block P3-5() Common Signal A2 Shield None; refer to applicator manual None; refer to applicator manual None; refer to applicator manual
I) This connection is not necessary if the encoder is mounted securely to a grounded surface. 3. Ensure that the encoder is turning clockwise (as viewed from the end of the encoder shaft furthest from the 6-pin connector; see Figure 3.15, View B). If it is NOT turning clockwise, do one of the following: . remount the encoder so the shaft is turning clockwise, or
l
reverse the wiring connections of the Phase A and Phase B wires.
Nordson Encoder Drive Connecfion- FIexible Coupring
Three methods of connecting the encoder are covered in this section, They are presented in recommended order:
l
Flexible Coupling Timing Belt
Measuring Wheel If you are using a timing belt or measuring wheel, skip to the appropriate procedure in this section.
l
Q Nodson Corporation 1992 All Fhghts Resen/ed
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Nordson Encoder Drive Connections- Fkxibe Coupling

(continued)
lntroductlon
A flexible coupling compelnsates for the misalignment between the encoder shaft and the parent machine. An anti-backlash coupling prevents the transfer of bearing run out and misalignment to the encoder from the connecting shaft. The coupling also prevents frequency modulations dule to mechanical eccentricities. Nor&on specifically recommends the use of Rembrandt and Rexnord couplings. Contact either of these companies at: Rexnord Coupling Main and Biddle Street Warren, PA 16315 (814) 723-6600 Rembrandt Inc. 6 Parmelee Street Boston, MA 02118 (617) 445-8910
lnstalllng Flexlble Coupllng 1. Before starting to install the encoder, ensure that you have sufficient space to mount it (dimensions are shown in Figure 3.15). ? A a WARNING: Personal injury risk. A protective guard should be installed over the moving parts of any encoder drive system to prevent possible injury to personnel working near the machine.
2. Select a flat, stable mounting surface on the parent machine for the encoder. 3. Four mounting holes are located on the left, right, and bottom faces of the encoder. Determine which face will attach to the mounting surface to provide the encoder position required by your line. 4. Use four screws (to fit the 6-32 UNC-2B x .167 in. or 4.24 mm threaded mounting holes) to secure the encoder to the mounting surface. NOTE: The flexible coupling should be installed in its natural, uncompressed, position. If installed in a compressed condition, its ability to flex adequately is limited. If installed in a stretched condition, the life of the coupling may be shortened. 5. Check for excessive misalignment of the encoder and parent machine shafts: a. Place a steel rule on one shaft. Use a set of feeler gauges to determine if there is space between the rule and the other shaft (Figure 3.16). b. Correct misalignment, if any, by loosening either the encoder or the parent machine and moving the shafts into alignment.
Figure 3.16 - Checking shafts for horizontal alignment
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Nordson Ekod& Drive Connecfion- Flexible Coupling

(twntin:nued)
c. Move the rule and feeler gauge 90 from the first check-point (Figure 3.17) and repeat steps a and b.
Figure 3.17 - Checking shafts for vertical alignment
6. Remove any oil or foreign substance from the encoder shaft, the parent machine shaft, and the coupling bores.
f A
l
CAUTION: Equipment damage. Do NOT drive couplings and pinions on the Nordson encoder shafts. Couplings and pinions should slide onto the encoder shafts.
7. Slide the coupling onto the encoder shaft (Figure 3.18).
Figure 3.18 - Sliding coupling on to encoder shafi
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Nordson Encoder Drive Connection- Flexible Coupling

(continued)
8. Fasten the coupling to the encoder shaft (Figure 3.19).
Figure 3.19 - Fastening coupling onto encoder shaft
9. Insert the parent machiine shaft into the coupling bore. Rotate the coupling on the shaft, aJlowing the coupling to find its normal position (Figure 3.20) Do NOT compress or extend the coupling after it has reached its normal, misaligned position.
Figure 3.20 - inserting coupling in normal position
mm
Figure 3.21 - Fastening coupling onto parent machine
Plrb. No. 108 09f1B 57-26 lam
10. Fasten the coupling to the second shaft (Figure 3.21).
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Nordson Encoder Drive Connection - Flexible Coupling

(continued)
11.
Check for excessive misalignment of the flexible coupling:
a. Place a steel rule on one hub of the coupling, Use the feeler gauges to determine if there is space between the rule and the other hub (Figure 3.22).
Figure 3.22 - Checking for space between hubs
b. Correct misalignment, if any, by loosening either the encoder or parent machine and moving either one until the coupling hubs are aligned. c. Move the rule and feeler gauge 90 from the first check-point (Figure 3.17) and repeat steps a and b. d. Make sure that the coupling is not compressed by checking to see that light can be seen clearly between the coupling beams. e. If you cannot see light between all the beams, repeat steps 8 through 10 until you can see light between them.
Nordson Encoder Drive Connectisn - 77mingBelts
Typically, using a timing belt involves selecting an idler shaft on the parent machine to drive the encoder. Notched belts are preferred, since they tend to slip much less than V-belts and pulley arrangements or flat belt drives. Before starting to install the encoder, make sure that you have sufficient space to mount it (dimensions are shown in Figure 3.15).
A
1 0
WARNING: Risk of personal injury. A protective guard should be installed over the moving parts of any encoder drive system to prevent possible injury to personnel working near the machine.
Determine Gear Rat110 Method #l - Use this method if you can use a tachometer generator to measure the line speed. 1. Measure the line speed. 2. Measure the drive shaft rpm (at the line speed measured in step 1).
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Ins talla tion
Nordson Eimder Drive Connection- 77mingBelts

(con tit-wed)
3. Calculate the gear ratio:

l
Metric Gear Ratio = Drive RPM / Line Speed (rn/min) x 0.5 (1 pulse = 1 mm)
. English Gear Ratio = Drive RPM / Line Speed (ft/min) x 4.17 (1 pulse = 0.1 in.) Method #2 - Use this method if your line set-up prohibits you from using a tachometer generator to measure line speed or if you do not want to run the line. 1. Rotate the drive shaft one revolution. 2. Measure how far the line moved (Figure 3.23).
Figure 3.23 - Measuring line movement (method #2) 1 - Drive shaft, one revolution 2 - Distance moved 3 - Line travel
3. Calculate the gear ratio:

l
Metric Gear Ratio = 500/ X (mm) (1 pulse = 1 mm) English Gear Ratio = 50 / X (in.) (1 pulse = 0.1 in.)
Selecting Gears There are three related formulas for determining the gear sizes you need: 1. Gear Ratio = Encoder Gear Size/Drive Gear Size Example, the encoder gear has 15 teeth and the drive gear has 10 teeth: Gear Ratio = 15/l 0 = 1.5 2. Encoder Gear Size = Drive Gear Size x Gear Ratio Example, the drive gear has 17 teeth and the gear ratio is 1.3: Encoder Gear Size = 17 x 1.3 = 22.1 = 22 (always round gear sizes, in teeth, to the nearest whole number)
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Nordson Encoder Drive Connection- 7lming Belts

(axltinnued)
3. Drive Gear Size = Encoder Gear Size/Gear Ratio
Example: the encoder gear has 20 teeth and the gear ratio is 0.7: Drive Gear Size = 20/0.7 Drive Gear Size = 28.57 = 29 (always round gear sizes, in teeth, to the nearest whole number) lnstalllng the Tlmlng Belt 1. Before starting to install the encoder, make sure that you have sufficient space to mount it (dimensions are shown in Figure 3.15).
A
t l
WARNING:: Risk of personal injury. A protective guard should be installed over the moving parts of any encoder drive system to prevent possible injury to personnel working near the machine.
2. Select a mounting site on the parent machine for the encoder 3. Four mounting holes are located on the left, right, and bottom faces of the encoder. Determine which face needs to attach to the mounting surface to position the encoder as required by your tine. 4. Use four screws (to fit the 6-32 UNC-2B x .167 in. or 4.24 mm threaded mounting holes) to secure the encoder to the mounting surface. NOTE: Use only very light XL Series timing belts for the Nordson Encoder. Do NOT exceed 13 lb (5.9 kg) constant or transient overhang load. 5. Check for debris (Such as wads of masking tape) between the cogs on the pulleys. Even though belt tension may be set correctly, debris in the cogs of the pulleys will cause belt flutter (Figure 3.24). This will result in a rough running drive. 6. Slip the timing belt onto both gears. 7. Set belt tension (Figure 3.25) for l/4 to l/2 in. (6.35 to 12.7 mm) deflection using finger pressure (10 to 15 lb, or 4.5 to 6.8 kg). NOTE: If the belt is too tight, the bearings and shaft will fail prematurely. If the belt is too loose, belt flutter will occur which will result in a rough running drive. 8. If you are NOT connecting other devices at this time, do the following: a. Grasp the front alssembly with one hand. Remove the two screws holding it to the back enclosure. b. Carefully rotate the front assembly 180 and place it on the back enclosure. c. Replace and tighten the two loose screws.
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Nordson Encoder Drive Connection- liming Belts

(continued)
d. Retighten the four remaining screws.
9. If you are connecting other devices at this time, proceed to the appropriate installation procedure(s) in this section.
Figure 3.24 - Be/? flutter
Figure 3.25 - Setting belt tension 1 - 0.25 to 0.50 in. (8.4 to 12.7mm)
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Corporation 1992 All Rights Resend
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Nordson Encoder Drive Connection- Friction Wtreel

lnstallatlon Conslderratlons:
l
A rubber-faced friction wheel can be used to drive the encoder as long as positive contact with the line is maintained.
0 Do NOT attempt to drive the friction wheel by point contact with a metal shaft or other smooth surface.
l
For most accurate measurements, the encoder should be mounted on a hinged bracket and held in place against the drive surface by adjustable spring tension. WARNING: Risk of personal injury. A protective guard should be installed over the moving parts of any encoder drive system to prevent possible injury to personnel working near the machine.
A
t l
1. Install the friction wheel on the encoder shaft. 2. Before starting to install the encoder, make sure that you have sufficient space to mount the bracket and encoder to the mounting surface (dimensions, for the encoder are shown in Figure 3.15). 3. Select a mounting site on the parent machine for the encoder. 4. Decide whether the ,four mounting holes on the left, right, or bottom faces of the encoder will be used to secure the encoder to the bracket. 5. Use four screws (to ,fitthe 6-32 UNC-2B x .167 in. or 4.24 mm threaded mounting holes) to secure the encoder to the bracket. 6. Select a flat, stable mounting surface on the parent machine for the bracket and encoder. 7. Attach the bracket to the mounting surface. NOTE: The larger the contact area (Figure 3.26) between a friction wheel and the parent machine drive surface, the less radial pressure is required.
Figure 3.26 - Friction wheel contact area A - Contact area
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Installation
Nordson Encoder Drive Connection- Friction Wheel

(continued)
8. Using the adjusting spring, set the friction wheel pressure against the drive surface sufficient enough to prevent skipping and false readings, but no greater than 13 lb (5.9 kg). 9. If you are NOT connecting other devices at this time, do the following: a. Grasp the front asselmbly with one hand. Remove the two screws holding it to the back.enclosure. b. Carefully rotate the front assembly 180 and place it on the back enclosure. c. Replace and tighten the two loose screws. d. Retighten the four remaining screws. 10. If you are connecting other devices at this time, proceed to the appropriate installation procedure(s) in this section.
Plrb. No. 100 0998 57-26 lo/Q2
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Corporation 1892 Ail Rights Reserved
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II. PC44 Remote Communicationslnstallation
The following information is provided if you will be using a remote device to select active memory and/or lock out input through the PC44 user interface. Remote connections are made to PC44 terminal block Pl (Figure 3.9). Signals connected to Pl are optically isolated from the remote system. The opts-isolators can be turned on by either current sourcing or current sinking devices.
Remote Pin Chamcterkatlon

Tab/e 3.7 1 - Remote Communication Pin Characterization in Pl-1 (Shield) Pl-2 (Ground) Pl-3 (Common) Function Provided for field wiring convenience. Provided for field wiring convenience. Provides for one half of the connection for all of the opto-isolators. Comments Connected to the remote device l/O printed circuit board. Connected to the remote device I/O printed circuit board. For sourcing (PNP) devices, Pl-3 should be connected to Pl -2 (Ground). For sinking (NPN) devices, Pl-3 should be connected to Pl-8 (+12V).
Pl-4 (Lock) Pl-5 (Remote Memory Select 3) Pl-6 (Remote Memory Select 2) Pl-7 (Remote Memory Select 1) Pl -8 (+12V)
Provides for a remote signal to disallow access to the PC44 Program Mode. Provides connection to allow a remote device to change the active memory. Provides connection to allow a remote device to change the active memory. Provides connection to allow a remote device to change the active memory. Provides 12 VDC input power for any remote device that requires it. Maximum current available from Pl-8 is 500 mA. This is the maximum current available for all connections to P1-8 including loads on other PC44 connectors.
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Ins talla tion
Remote Memory Selection and Memory Logic
The logic levels should be held continuously. Remote selection will take place after the levels have been there for at least 500 ms. If you try to select a non-configured memory, the current memory remains in effect and the PC44 status LED will light red. The LED will stay on until you select a configured memory or configure the memory you were attempting to select. When the PC44 senses al remote memory selection, the unit checks to see if any patterns are in progress. If no patterns are in progress, the memory change will take place. However, if a pattern is in progress, the memory change will be inhibited until all patterns are completed. Table 3.12 shows the logic that is used to select a memory. Logic OFF or ON refers to the state of the device connected to PC44 terminal block Pl (pins 5,6, and 7). The device can be NPN or PNP depending on how Pl-3 is wired (refer to Table 3.11). Table 3.12 - Remote Memory Select Logic selection Remote Disabled Memory A Memory B Memory C Memory D For Future Use For Future Use For Future Use IPl-5 off off off Off On On On On Pl-6 Off Off On On Off Off On On Pl-7 Off On off On off On Off On
Remote Memory Select Switch Instalk3 tion
NOTE: This switch is not intended to be installed in the PC44. It can be mounted on a remote panel, etc. The Nordson Remote Memory Select Switch is a 4position, rotary switch that enables you to remotely select which PC44 memory is active. 1. Secure the switch to the mounting surface. 2. If you have not already done so, temporarily mount the front assembly to the back enclosure by doing the following: a. Loosen the six screws on the front assembly. b. Remove the two top screws (Figure 3.5). c. Rotate the front assembly 180 (Figure 3.6). d. Push the screws through the top two front assembly holes (Figure 3.7, view A). e. Insert the screws into the two back enclosure stand-offs (Figure 3.7, view A).
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Remote Memory Select Switch lnstallatlon
f. Use the two srews to secure the front assembly to the back enclosure (Figure 3.7, view B).
: @
WARNING: Risk of electrocution. The AC input power line to the PS40 (or other 24 VDC power supply) provides voltage that can cause personal injury or death. Before making any electrical connections, disconnect and lock out power to the main circuit breaker for the input power line (Figure 3.8). WARNING: Shock hazard. Touching bare wires in the PC44
can result in shock that can cause personal injury or death. When making electrical connections, make sure to strip only as much insulation from the wires as needed. Also, make sure that the insulation fits snugly against the PC44 terminal blocks.
t A
3. Use 18-22 gauge wire (customer supplied) to make the switch and PC44 jumper wire connections shown in Figure 3.27.
Figure 3.27 - Remote memory select switch jumper connections 1 -Jumper #I 2 -Jumper #2 3 - Jumper #3
Q No&on Corporation 1g!32 All Rights Resecved
Pub. No. 108 0996 57-26 lo/g2
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Ins talla tion
Remote Memory Select Switch Installation

(contin@
NOTE:When both the Rotary Select Switch and Keyed Lock Out Switch are installed, both Imustbe connected as either sourcing devices
or as sinking devices. Figure 3.28 shows the wiring for the Rotary Select Switch as a sourcing device. Figure 3.29 shows the wiring for the switch as a sinking device. 4. Make the Rotary Select Switch to PC44 connections by doing one of the following:
l
Switch Used as a Sourcing Device- Use 18-22 gauge wire

(customer supplied) to Imakethe connections shown in Figure 3.28. Make sure to install the jumper from PC44 connection Pl -2 to Pl-3.
Figure 3.28 - Current sourcing remote memory switch ABC5 Pl-8 PI-7 PI-6 PI-5 (+12V); (Remote (Remote (Remote a/so, installjumperfrom Memory Select 7) Memory Select 2) Memory Select 3) Pl3 to Pl-2
Plrb. No. 108 0998 57-26 lo/92
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3-45
Remote Memory Select Switch Installation

(continued)
Switch Used as a Slnking Device
Use 18-22 gauge wire (customer supplied) to make the connections shown in Figure 3.29. Make sure to install the jumper from PC44 connection Pl-3 to Pl-8.
Figure 3.29 - Current sinking remote memory switch A8 CDPI-2 (Ground); also, install jumper from Pl-3 to PI-8 P7- 7 (Remote Memory Select 7) PI-6 (Remote Memory Select 2) PI-5 (Remote Memory Select 3)
5. If you are NOT connecting other devices at this time, do the following: a. Grasp the front assembly with one hand. Remove the two screws holding it to the black enclosure. b. Carefully rotate the front assembly 180 and place it on the back enclosure. c. Replace and tighten the two loose screws. d. Retighten the four remaining screws. 6. If you are connectinlg other devices at this time, proceed to the appropriate installalion procedure(s) in this section.
Q N&son Caporation All RigMs Reserved
1992
Pub. No. 108 OWB 57-26 la92
3-46
Ins talla tion
Keyed Lock Out Switch InstalkNion
NOTE: This switch is not intended to be installed in the PC44. It can be mounted on a remote panel, etc. The Nordson Keyed Lock Out Switch is an A-lock type, 4-tumbler switch that prevents any input via the PC44 user interface. NOTE: When both the Keyed Lock Out Switch and Rotary Select Switch are installed, both must be connected as either sourcing devices or as sinking devices. Figulre 3.30 shows the wiring for the Keyed Lock Out Switch as a sourcing device. Figure 3.31 shows the wiring for the switch as a sinking device., 1. Secure the switch to the! mounting surface. 2. If you have not already done so, temporarily mount the front assembly to the back enclosure by doing the following: a. Loosen the six screws on the front assembly. b. Remove the two top screws (Figure 3.5). c. Rotate the front assembly 180 (Figure 3.6). d. Push the screws through the top two front assembly holes (Figure 3.7, view A). 8. Insert the screws into the two back enclosure stand-offs (Figure 3.7, view A). f. Use the two srews to secure the front assembly to the back enclosure (Figure 3.7, view B). WARNING: Risk of electrocution. The AC input power line to the PS40 (or other 24 VDC power supply) provides voltage that can cause personal injury or death. Before making any electrical connections, disconnect and lock out power to the main circuit breaker for the input power line (Figure 3.8).
A
t
WARNING: Shock hazard. Touching bare wires in the PC44 can result in shock that can cause personal injury or death. When making electrical connections, make sure to strip only as much insulation from the wires as needed. Also, make sure that the in:sulation fits snugly against the PC44 terminal blocks.
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Keyed Lock Out Switch Installation

(ccxrtinued)
3. Make the Keyed Loclk Out Switch to PC44 connections by doing one of the following:
Switch Used as a Sourcing Device - Use 18-22 gauge wire (customer supplied) to make the connections shown in Figure 3.30. Make sure to install lhe jumper from PC44 connection Pl-2 to Pl-3.
PI B
Figure 3.30 - Current sourcing keyed lock out switch wiring A - Front assembly (rear view) 6 - Install jumper wire C - Keyed lock out switch (rear view) PI (Remote Control): P 1-2 (Ground) PI-3 (Common) PI-4 (Lock)
Q Ncdson Corporation 1982 All Rights Reserved
Pub. No. 108 0998 57-26 l(y9ez
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Installation
Keyed Lock Out Switch Installation

(continued)
Switch Used as a Slnkllng Device - Use 18-22 gauge wire (customer supplied) to make the connections shown in Figure 3.31. Make sure to install the jlumperfrom PC44 connection Pl-3 to Pl-8.
Pl
Fk~~re 3.31 - Current sinking keyed lock out switch wiring

A - Front assembly (rear view) 6 -Install jumper wire C - Keyed lock out switch (rear view) P7 (Remote Control): PI-2 (Ground) PI-3 (Common) PI-4 (Lock) PI-8 (+ 12V)
Pub. No. 108 0998 57-26 lom
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349
Keyed Lock Out Switch InstaNation
4. If you are NOT connecting other devices at this time, do the following: a. Grasp the front assembly with one hand. Remove the two screws holding it to the back enclosure. b. Carefully rotate the front assembly 180 and place it on the back enclosure. c. Replace and tighten the two loose screws. d. Retighten the four remaining screws. 5. If you are connecting other devices at this time, proceed to the appropriate installation procedure(s) in this section.
Q Nordson Corporation 1gg2 All RigMs Resend
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12. PSdOPower Supply Installation

Wallor A&chineMounting
The S mounting bracket provided with the PS40 provides the capability to mount the PSI0 Power Supply and the PC44 Pattern Control side by side with their front panels flush. The bracket is symmetrical: Figure 3.32 shows the bracket orientation for mounting the PS40 to the right of the PC44; if you wish to mount the PS40 on the left, simply rotate the bracket so the recess is on the left side. 1. Position the S bracket at the mounting location. Make sure to allow for a mounting area with a height of 9 in. (22.9 cm) and a width of 8.2 in. (20.8 cm) (dimensions A and B, Figure 3.32).
Figure 3.32 - PS40 S bracket A - 9.0 in. B - 8.2 in. C-2.Oin. 5 - 7.5 in. E - 6.0 in. (22.9 cm) (20.8 cm) (5.1 cm) (3.8 cm) (15.2 cm)
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3-51

@OfhUed)
2. Mark the centers of the two bracket holes on the mounting surface. Make sure lhat the center of the marks are 6 in. (15.2 cm) apart from center to center. 3. Drill two 732 in. (5 mlm) holes in the mounting surface at the location of the two marks for the M4 screws provided. 4. Loosen the six screws that secure the PS40 front assembly to the back enclosure (Figure 3.33).
Figure 3.33 - Separating PS40 front and back enckxures

1 screw,
not captive, 1 of 6
5. Carefully pull the PS40 back enclosure away from the front assembly and unplug the power supply connector. 6. Set the PS40 front assembly aside. 7. Use the two M4 x 2!5mm screws, nuts, and washers to fasten the PS40 back enclosure and the S bracket to the mounting surface (Figure 3.34). 8. Do the following to lmount the PC44 to the S bracket: a. Grasp the PC44 front assembly with one hand. With your other hand, loosen the six screws that secure the back enclosure to the front assembly (IFigure 3.1).
Q N&son Corporation 1992 All Rights Reserved
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Ins talla tion

(cmtinnued)
b. Pull the PC44 front assembly away from the back enclosure.
c. Set the PC44 front assembly aside. d. Position the PC44 back enclosure knockout hole for the direction the electrical wiring will route into the PC44. 8. Use the two M4 x 25 mm screws, nuts, and washers provided with the PC44 to fasten the PC44 back enclosure to the other side of the 3 bracket.
Figure 3.34 - Mounting PS40 and S bracket A - S bracket 6 - PS4O back
8ndOsur8
C - PC44 mounting location
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DIN Rail Mounting
Use the parts provided with the PS40 (which are the same as the parts shown for the PC44 in Figure 3.3) to install the unit to the DIN rail as follows: Mounting to Vertical Rails Make sure that the DIN rail is at least 9.0 in. (22.9 cm) in length. 1. Fasten the end bracket provided with the unit (Figure 3.3) to the DIN rail. 2. Use the two M4 x 1:2mm screws, nuts, and washers to fasten the two clips to the PS40 back enclosure; make sure that they are oriented for mounting to a vertical rail (as shown in Figure 3.3). 3. Fasten the back enclosure to the DIN rail by snapping the clips into the rail. Mounting to Horizontal Rails Make sure that the raills are 6.0 in. (15.2 cm) apart from center to center. Also make sure that the DIN rails are at least 4.0 in, (10.2 cm) in length. 1. Use the two M4 x 1:2mm screws and washers to fasten the two clips to the PS40 back enclosure; make sure that they are oriented for mounting to horizontal rails (as shown in Figure 3.4). 2. Set the front assembly aside. 3. Fasten the back enclosure to the DIN rail by snapping the clips into the rail.
PS40 Electrical Connections
WARNING: Risk of electrocution. The AC input power line to the PS40 plower supply provides voltage that can cause personal injury or death. Before making any electrical connections, disconnect and lock out power to the main circuit breaker for the input power line. WARNING: Shock hazard. Touching bare wires in the PC44 and PS40 can result in shock that can cause personal injury or death. When making electrical connections, make sure to strip only as much insulation from the wires as needed. Also, make sure that the insulation fits snugly against the PC44 and PS40 terminal blocks.
A
5
NOTE: In order to achieve an IP-54 En-closure Rating (splash-resistant environment), Nordson recommends that you route all PC44 and PS40 input and output electrical connections through water-tight conduit and a junction box. Use 1 in. (2.5 cm) conduit fitting, and locate the conduit center line I in. (2.5 cm) from the wall.
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PS40 Ektrlcal ConneCtiOnS

(cofltinlJe9
1. Install a 1 in. (2.5 cm) diameter strain relief connector (customer supplied) in the PC44 and PS40 knockouts. 2. Route the AC power line through water-tight conduit (if you want an IP-54 enclosure rating) and the strain relief connector. 3. If you have not already done so, temporarily mount the PC44 front assembly to the PC44 back enclosure by doing the following: a. Loosen the six screws on the front assembly. b. Remove the two top screws from the front assembly (Figure 3.5). c. Rotate the front assembly 180 (Figure 3.6). d. Push the two screws through the top two front assembly holes (Figure 3.7, View A). e. Insert the screws inlo the two back enclosure stand-offs (Figure 3.7, View A). f. Tighten the screws to secure the front assembly to the back enclosure (Figure 3.7, View B). Selecting 120V Input Power NOTE: The PS40 is factory set to use 240V input power. To use 12OVinput, do the following (otherwise skip to Selecting 240V Input Power). 1. Remove the screw for the power unit cage (Figure 3.35) and remove the cage.
t--lgure 3.3s - tiemoving power supply cage (rear view) A - Cage screw
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PS40 Electrical Connect/ens

(cm tinued)
2. Locate the 12OVand 240V sockets, which are marked as l15V and 230V on the printed circuit board (Figure 3.36).
Fkyre 3.36 - PS40 AC input voltage A - Voifage sockets B - Power supply PC9
sock8ts
3. Make sure that the connector is plugged into the socket marked 115V. If not, remove it from the socket marked 230V and plug it into the socket marked 115V. 4. Replace the power unit cage and tighten the securing screw. Selecting 240V Input Power To use 240V input, do the following: (if you are using 120 VAC, skip to Input Electrical Connections to the PS40). 1. Remove the screw for the power unit cage (Figure 3.35) and remove the cage. 2. Locate the 12OVand 240V sockets, which are marked as 115V and 230V on the printed circuit board (Figure 3.36). 3. Make sure that the connector is plugged into the socket marked 230V. If not, remove it from the socket marked 115V and plug it into the socket marked 230V. 4. Replace the power unit cage and tighten the securing screw.
Pub. No. 108 0996 57-26 1w
3-56
Ins talla tion

(continued)
Input Electrlcal Connections to PS40 Use 14-l 6 gauge electrical wire (customer supplied) to make the input connections shown in Table 3.13. Table 3.13 - input Electrical Connections to PS40 Input Connection AC power AC neutral Ground PS40 Connection Pin 1 (Ll) Pin 3 (L2/NEUT) Ground stud on terminal block bracket
PS40 to PC44 Electrical Connections 1. Using 14-l 6 gauge wire (customer supplied), make the electrical connections from the P!540output to the PC44 shown in Table 3.14 and in Figure 3.37. Table 3.74 - PS40 to PC44 Electrical Connections PS40 Connection Pin 7 (24V RTN) Pin 8 (+24V) PC44 Connection P2-3 (GRN) P2-4 (+24V) I
2. Plug the power supply connector to the PS40 terminal block. 3. Place the PS40 front assembly onto the PS40 back enclosure and retighten the six screws that hold the two parts together. 4. If you are NOT connecting other devices at this time, do the following: a. Grasp the PC44 front assembly with one hand. Remove the two screws holding it to tlhe back enclosure. b. Carefully rotate the PC44 front assembly 180 and place it on the back enclosure. c. Replace and tighten ithe two loose screws. d. Retighten the four remaining screws. 5. If you are installing other devices at this time, go back to the appropriate installation procedure(s) in this section.
Pub. No. 108 0998 57-26 IQ192
0 No&on
Ins talla tion
3-57

(continued)
Figure 3.37 - PS40 electrical input and output connections 7 - Back enclosure ABCDEInput, Pin #1 (L I), from AC Input, Pin #3 (L2/Neutral), from AC Input, Pin #5 (Ground) for AC Output, Pin #7 (24V Rtn) to PC44 P2-3 Output, Pin #8 (+24V) to PC44 P2-4
Pub. No. 108 099B 57-26 lo/92
## TABSHEET ##
SECTION 4
Section 4
Operating Instructions
PM 108 eggs 57-26 lm2
4-l
Section 4 Operating Instructions

1. Introduction
Through descriptions and examples, this section will provide the tools that will help you identiii what patterns you want and how to get those patterns. In PC44 Parameters Overview we will define the terminology associated with pattern control and identify the decision factors that you will consider when setting up your application pattern. In Setting Up the Pattern you are given a step-by-step procedure !or measuring your pattern, calculating values and making decisions which will be required when you program the PC44. A pattern log is provided at the end of the section. You can use copies for recording your choices and values in preparation for programming. In PC44 Start-up and Default Displays you will become familiar with the power-up and normal operation displays that you will see. In Program Mode, Fun Mode, and Configure Mode, you will learn which buttons to press to make selections and enter the values that you calculated in setting up your pattern. You will also learn how to eliminate unneeded parameters to make programming as easy as possible for your application. In Test Mode we will explain how to access this mode of the PC44. TEST is used when you need to manually fire or purge the guns. In PC44 Gear-to-Line Function you will learn how the unit responds to changes in line speed and trigger signals during and between patterns. Finally, in Setting Precise Gun Compensation Values you will be given two methods for precisely setting pull-in and drop-out compensation. Throughout this section, the Nordson Oval push button will be referred to as the Nordson Oval; the Set push button as SET; and the four arrow-shaped push buttons as UP, DOWN, LEFT, and RIGHT.
P/N 108 oggB 57-26 10192
4-2
Operating Ins true tions
2. PC44 Parameters Overview
Parameters are the choices and values that you have to program into the PC44. These choices and values, when properly set, will give you the material bead pattern(s) you want on the substrate. The following paragraphs provide information on the different decisions involved in setting each parameter at each selection level. The initial display for each selection level is shown.
Memory
Deflnltlon Four registers or locations in the PC44 microcomputer where patterns are saved.
Decision Factor
l number of patterns to :store The number of memories you select depends on how many separate patterns you plan to use. You can store from one to four patterns each consisting of up to four independent bead sequences (channels).
Channel
Deflnltlon: The electronic timing circuitry in the PC44 that directs the output of one or more gun solenoids.
11234
Declslon Factors
l
XI
the number of different bead sequences being applied to a substrate within a given pattern, and/or
the number of gun solenoids that are needed to put down that pattern, and/or &ad Se- Figure 4.1 shows the bead sequence of a pattern. If beads in parallel sequences have the same length, same spacing between them, and same gun-to-gun response time, only one channel is needed to produce the pattern. If any one of these factors are different from sequence to sequence, more than one channel will be needed to produce the pattern.
l
PIN 1080998 57-26 lo/Q2
4-3
Channel
(cafdnued)
Solenoids - Any number of solenoids can be fired by one channel as long as the combined gun solenoid demands do not exceed 1 amp.
Figure 4.1 - Bead s8qu8nces IBead (gun on)
Gun Compensatlon Guns and solenoids have fixed mechanical response times. In some applications, this can c:ausethe bead to shift as line speed varies. lnltlal Pull-In and Drop-out Displays
There are two types of compensation: ii il
pull-in compensation, which allows for the mechanical delay that occurs while the solenoid valve and gun open (pull-in), and drop-out compensation, which allows for the mechanical delay that occurs while the solenoid valve and gun close (drop-out).
I
151
(i3 Nordson Corporation 1gg2 All Rights Reserved
PM 1080998 57-26 lcm
4-4
Trigger
>-depicts Symbol depicts sensor off to on
sensor on to off
Definition: A device (e.g., photosensor) that senses the approach of a substrate and sends a trigger signall to the PC44. Decision Factors:
l
one or two triggers needed for the application assign a trigger to each channel
l for each channel, choose an edge symbol for triggering m - Whenever the sensor receiver does not see light, the sensor output device is on..
Light - Whenever the sensor receiver does see light, the sensor output device is on.. NOTE: No&on sensors are factory-set for light operate mode. Table 4.1 tells you which edge symbol to select for each operating circumstance. lmtt SW- These can be used as a trigger device with the PC44. For better accuracy and reliability, though, use Nordson photosensors. Table 4.7 - Trigger Device Mode and Location, and Corresponding PC44 Edge Symbol Selection
. . .
T
Opposed (ThroughBeam) (P/N 131 473 and 131 486) Retroreflective (P/N 131 474 or 131 475) Diffuse Reflective (Proximity) (P/N 131 476)
Dark Operate Mode (I ITrailing Edge
ILight Operate Mode (*I I- Leading Edge Trailing Edge
Leading Edge
-u
m--m
(1 For diffuse reflective sensors, this is the preferred mode for minimizing false triggers. t2)For opposed and retroreflective sensors, this is the preferred mode for minimizing false triggers.
PM 1080998 57-26 lo/92
0 Nordson Corporation 1CM2 Ail Rights Reserved
4-5
Transition
I
Definition:
A change from one interval to the other: either a change from a delay to a duration or from a duration to a delay. The combination of delays and durations makes up a transition sequence (Figure 4.2).
Figure 4.2 - Delays and durations A - Delay (Off) B - Duration (On) 1 -Gun 2 - Trigger 3 - Transition sequence 4 - Line travel direction
Decision Factors:
l
number of transitions - dependent upon number of delays and durations delays - lengths of spaces between beads durations - material bead lengths
transition set-points - cumulative sum of delay and duration values The placement of every bead of material on the substrate requires at least two intervals to be completed: one delay (gun off) followed by one duration (gun on). NOTE: Nordson pattern controls commonly use the first pattern interval
as a delay. In Figure 4.2, the pattern consists of a delay, a duration, a
second delay, and a second duration. Each new pattern starts with the first delay interval. The PC44 allows you to program from one to four delays and from one to four durations for ealch channel.
0 No&on Corporation 1gg2 All Rights Reserved
P/N 108 0996 57-26 lam
4-6
Operating instructions
Transition
(continued)
In programming the PC44, the transition values refer to the end-point of each delay and each duration. Each end-point is defined in relation to the trigger signal, which is the starting point of the entire transition sequence. Each transition value is a distance measure that is converted to encoder pulse values. NOTE: The initial delay for an application with a leading edge trigger has to account for the trigger to gun distance (A in Figure 4.3) plus the distance from the leading edge to the first transition (B in Figure 4.3). The first transition (Tl) in IFigure4.3 is 50 pulses. The 50 pulse length includes the trigger to gun1interval of 30 pulses plus the 20 pulses from the leading edge of the substrate to the first delay interval. The second transition (T2) is 70 pulses, which is the end point of the first duration in relationto the triggersignal.It is important not to confuse the length of the duration, 20 pulses, with the transition, T2, which is 70 pulses.
14
Figure 4.3 - Determining transition lengths A - Gun to trigger distance B - Leading edge to first duration distance I-Gun 2 - Trigger 3 - Transition sequence 4 - Line travel 5 - Transition lengths (in pulses) 6 - Delay/duration lengths (in pulses)
PM 1080998 57-26 lam?
0 Nordson Corporation 1g92 All Rights Resewed
4-7
stitch
Deflnltlon: Material application with a duration that consists of a repeating pattern of short material beads (stitch lengths) with uniform spaces (stitch gaps) between them. Decision Factors:
l
material savings pattern requirement
NOTE: Stitch is not intended to provide precise bead placement. If you need precise placement of small beads, channels can be used in parallel with stitch off to achieve up to 32 transitions (for 4 channels in parallel). NOTE: The PC44 attempts to adjust the stitch parameters in response to changes in line speed. This compensation will affect stitch bead and gap size. At lower speeds, you may get fewer stitch beads. Nordson recommends that you set up the stitch pattern at maximum line speed. In the stitch level, you can select a percentage of coverage and stitch bead length for a given1 duration Selecting less than 100% coverage during durations may still meet your application needs, plus allow you to save on material costs. During each duration in a pattern, a bead of material is deposited. However, when stitching is selected, this bead is broken up into a number of smaller beads (stitch lengths) with uniform spaces (stitch gaps) between them (Figure 4.4).
Figure 4.4 - Continuous and stitch beads 7 - Stitch off 2 3 4 5 Stitch on Stitch length Stitch gap Duration
6 - Delay
PM loeosse
57-26 la42
4-8
Gun Disable Une Speed
Definltlon This is a threshold for turning off PC44 outputs when the line speed goes below the value YOUI set. Decision Factors:
l
minimum line speed threshold required while jogging the line during servicing or set-up.
3. Setting Up the Pattern
Because the PC44 is digitally programmed, all pattern values can be calculated and programmed in advance. It may be helpful to draw a simple diagram of the pattern you want (like the one shown in Figure 4.5). Leave sufficient space on your diagram for recording trigger to gun and bead measurements. Measurements should be made in millimeters or inches. The following example aslsumes that the trigger and an appropriate number of guns have already been installed. Typically, one output channel fires one gun to produce one bead sequence. More than one gun may be controlled by an output channel if two or more identical bead sequences are required and if the gun response times do not vary significantly.
Factors to Consider
1. Gun compensation is updated after each pattern. 2. Line speed is checked every 250 ms. 3. The PC44 does not allow a second pattern to start until the pattern in progress is completed. In addition, the PC44 requires a 30 ms reset time after a pattern ends. - . 4 1.09 or eam 4. Bare versron a. Unexpected gun firing can occur with these units. Refer to PC44 Gear-to-Line Operation near the end of this section. b. The initial gun compensation used is zero, unless you press the Nordson Oval after the line starts and before the first product. 5. Units software ver&n 1.13 or I;ater:when line speed goes below the minimum spiied setting, the pattern resets. Refer to PC44 Gear-to-Line Operation near the end of this section.
PIN 108oQQB 57-26 lfm2
4-9
Errample1: Cartoning (One End Only)
Figure 4.5 - Example 7 pattern I- This flap folded first 2 - This flap folded second and adheres to the top of the other flap
Assume the following:

l
This is a dedicated line (only one carton size will be run with the same pattern for each carton). Line speed varies. Maximum line speed is 300 meters per minute. There are differences in gun-to-gun response time which can significantly effect bead positions. A diffuse reflective sensor is being used in dark operate mode, and is located to sense the leading edge of the substrate. 8 watt solenoids are being used. The Gun Disable Line Speed default value (17 pulses) is acceptable for this line operation.
P/N 1oaoggB 57-26 lo/92
4-10
Example I: CartonIng (One End Only) (CCi?tif?ued)

Measurlng Distances After you draw your pattern (as shown in Figure 4.5), you will need to measure the length of each delay and duration of your pattern. Write the measurements on the drawing as shown in Figure 4.6. NOTE: The first delay measurement must include the gun to trigger distance (A) plus the distance from the edge of the substrate to the start of the first duration (B).
225
300 -55-
800
075
Figure 4.6 - Measuring delays/durations A - Gun to trigger distance
for example 1
B - Leading edge to first duration distance I- Gun 1; assigned to separate channel from guns 2 and 3 (see items 6 and 7, above) 2 - TfkJger 3 - Cumulative distances (mm) 4 - Delay/duration distanC8S (mm) 5 - Line travel direction 6 - Gun 2 (assigned to Channel 2) 7 - Gun 3 (assigned to Channel 3)
PIN 1cbBoQSe 57-26 lcvQ2
Q Nordson Cbporation 1982 All Rights Reserved
4-11
Example I: Cartoning (One End Only

(mtinnued)
Converting Distance Measurements to Pulse Values If the encoder is geared so 1 mm of line travel equals 1 pulse, distance values can be entered without converting them to pulse values. If you are usinig flexible coupling or if gearing is such that 1 mm does NOT equal 1 pulse, each of the distances MUST be converted to pulse valiues. I. Measure the distance the conveyor line travels in one encoder revolution. ()
l
Metric: measure in millimeters per revolution English: measure in inches per revolution
2. Determine the distance-to-encoder pulse conversion factor. (2) NOTE: This assumes the use of a 500 pulse per revolution encoder. Round all pulse values to the nearest whole number (i.e., 59.4 = 59, 59.5 = 60, etc.).
l
Metric: English:
500 mm = M (pulses per mm) s 500 = E (pulses per inch)
3. Verify that the maximum encoder frequency is not exceeded: pulses/second = (meters/minute x revolutions/meter x 0.0167 minutes/second x 500 pulses/revolution) In this example: pulses/second = (300 x 1.60 x 0.0167 x 500) = 4000 This value does not exceed the maximum encoder frequency of 10,000 pulses per second. 3. Multi ly each of the delay and duration clistances by the pulse conversion factor. 8) 4. Calculate all the pulse (transition) values for your pattern by adding up the delays and durations. Write them on your pattern drawing. () For this example, the line travels 625 mm for one revolution. See Figure 4.7. (*) The metric conversion factor for this example is 0.80. 500 ~ - 0.80 (pulse factor) 625 mm(3)In the gun 1 bead in this example, the first delay (TI) includes the gun to trigger distance of 150 mm plus the 75 mm distance from the substrate edge to the start of the first duration. This cumulative distance (225 mm) was then converted to the pulse (transition) value: 225 mm x 0.80 (pulse conversiIon factor) = 180 pulses
Q Ncdson Corporation 1992 All Rights Reserved
P/N 1080998 57-B loI
4-12
Example I: Cartoning (One End Only

(CWllti~ued)
Illustrated Pattern Parameters- Figure 4.7 shows the converted pulse values (transitions) for this example. Figure 4.8 shows how the parameters are recorded on the pattern log for this example.
l-
5 I
T2 I
I
T3
I I
T4
I I I
67--*3k120j
I I
*o,ij-oo-,fj,
180 240 640 700
L4
3 -5--
Figure 4.7 - Example 1 transitions in pulse values ABI234567Gun to trigger distance Leading edge to first duration distance Gun I; assigned to separate channel from guns 2 and 3 (see items 6 and 7, above) Trigger Cumulative distances (mm) Delay/duration distances (mm) Line travel direction Gun 2 (assigned to Channel 2) Gun 3 (assigned to Channel 3)
ProgrammlngDeclslon Factors for Thls Example:

Mew - One memory is needed. Memory B is circled on the pattern log, but any configured memory could be selected. Channel - Three channels are needed because:
l
Three gun solenoids are used, since there are differences in gun-to-gun response time.
There are three sets of transition values. Channels 1, 2, and 3 are circled on the pattern log.
l
PM 1oaoQQB 57-26 lo/w
4-13
(cmtinui3@J
Example I: C&-toning (One End Only
MEMORY
GUN DISABLE
A
LINE SPEED
0B
= 250
CHANNEL I,1 = - 6 I
TRIGGER TRANSITION -
1 I III =- 5
1
H
0 1
2 m -
n
1 -.%
1801 7281 --p--p

STITCH
1
e
1 -
1 ~
-m
JO
I
111 =-
CHANNEL I,1 = - 15 I
0 1
n
16
2 m -m -
0
m-
q
/ -%
q
1 1
-1801 -2401 -6401

STITCH
7001 --
1 p
-
CHANNEL 111= 20
I
3
I IJ = 20
0 12
Ip #
-m
-
0 w
q
9
2401 -6401 -1801 STITCH
7001 --
~
-
1 -*%
1 -
1 ----I
L/O
-0
Figure 4.8 - Pattern bg for exampie I
Gun Comoensation - For variable line speed applications, the delay in opening (pull-in) and closing (drop-out) must be accounted for. Determining and adjusting gun compensation values is discussed later in this section (Program Mode). Triaaa - Only one trigger is needed. The diffuse sensor is being used in dark operate mode and is mounted to sense the leading edge of the substrate. By referring to Table 4.1, the appropriate edge symbol was determined. That symbol is circled on the pattern log for all three channels.
Q No&on Corporation 1992 All RigMs Resewed
P/N 108 0998 57-26 lo/Q2
4-14
Example 1: Catfoning (One End Only

(continued)
l
Two transitions are needed for the gun 1 bead shown in the Figure 4.6: one delay and one duration. The values are written on the pattern log for channel 1.
. Four transitions are needed for the gun 2 and 3 bead sequences: two delays and two durations. The values are written on the pattern log for channels 2 and 3. Stitch - This pattern does not require stitching, so the stitch off symbol is checked on the pattern log for all three channels. Example 2, which follows, shows a pattern that requires stitching. I ine SPeed ..This value was left at the default value of 17 pulses per second.
Example 2: Catfoning with Stitch On
The assumptions, distances, and time values are the same as in Example 1. The stitch bead sequence for gun 1 (assigned to channel 1) requires stitching (Figure 4.9).
180
240
840
700
r-----s-Figure 4.9 - Example 2: stitch pattern A - Gun to trigger distance 6 - Leading 8dg8 to first duration distance I- Gun 7; assigned to separate channel from guns 2 and 3 (see items 6 and 7, above) 234567fiigger &mu/a tive distances (mm) Delay/duration distances (mm) Line travel direction Gun 2 (assigned to Channel 2) Gun 3 (assigned to Channel 3)
PM 1080998 57-26 10182
8 No&on
4-15
Example 2: Cartoning with Stitch On

(mhued)
cad using the following general rule:
- We determined this value
Duration length (in pulses) x 0.20 = Max. stitch bead length (in pulses)
The PC44 stitch capability would allow us to specify stitch beads as long as 110 pulses each:
l 0.548
x 0.20
110 pulses
However, we wanted more and shorter stitch beads for our application. We specified beads 75 pulses long at 50% coverage. These values were recorded on the pattern log (Figure 4.10).
MEMORY
GUN DISABLE LINE SPEED = 250
CHANNEL 12 I =- 5
TRlCGER TRANSITION -
1 I =- 5 111
0 1
--1801
7281
0 n 1 - 1 -- 1- 1- 1- 1
2 -m
-
m-
STlTCH
0
I = 111
m
Jo
50
/.
761
CHANNEL 111 I = - 16
TRIGGER TRANSITION
0 1
15 2
-
n
7001 --
n
1 -
0
m-
n
1 P 1
1801 --STITCH
2401
6401
1 -
q
3 I III =
20
CHANNEL 111 I = 20
TRIGGER TRANSITION
0 1111 ----_---0 1
2 -m
-
m-
1801
2401
6401
7001
0
STITCH
/O
Figure 4.10 - Pattern log for example 2
CaNodson Corporation 1992 All Rights Reserved
PM1oaoDQe 57-26 1om
4-16
Opera tina Ins true tions
4. PC44 Start-up and Default Displays

PO?4 Start-up D/splay
LOCK CONFIGURE PROGRRM RUN TEST
MEMORY
Figure 4.11 - Start-up display (software version number may be different)
This is the display appears for approximately 2-3 seconds while the unit performs a short diagnostic sequence. During the diagnostics, the Status LED on the front plane1 is red. After the diagnostic sequence ends, the default display shows and the Status LED turns green. The unit is ready for operation.
PC44 Default D&play
The active memory letter is displayed on the Memory selection level (Figure 4.12). This tells you which pattern is ready to use.
LOCK CONFIGURE PROGRfWl RUN TEST MEMORY
-A
Figure 4.12 - Default (RUN mode) display
The program returns to thiis display whenever:

l
any mode is exited, or there is a 10 minute period in which no push buttons are pressed.
PM 1OsoQw 57-26 lo/Q2
Q Nordson Caporation 1992 All Rights Reaervd
4-l 7
5. Program Mode
LOCK CONFIGURE PROGRM RUN TEST
MEMORY
Figure 4.13 - Initial PROGRAM mode display (memory A active) 7 - x flashing
NOTE:
If you are programming a PC44 that has previously been programmed, not all the parameters you want to program may be available. Follow the instructions in Run Mode (Reviewing Parameters and Values) later in this section. If the parameters you want to program are displayed in the review, return to this section and proceed with the following instructions. If the parameters you want to program are not displayed in the parameter review, follow the instructions in Configure Mode (in this section) to make the parameters available. Then, return to this section and proceecl with the following instructions.
NOTE: If power is interrupted while changes are being made in the

Program mode, those changes will not be stored in memory. As soon as you are finished making changes, be sure to exit the Program mode. This saves all changes;.
Purpose
This mode provides yolu with the ability at system start-up or while the unit is operating to
l
program or change the active memory; program inactive memories; activate or deactivate channel, trigger, transition, and stitch selections; and set or change the numerical values.
0 Nodson Corporation 1992 All Rights Reserved
PM 108 OgM 57-26 1Om
4-18
Accessing Program Mode
Press and hold SET. The initial Program mode display appears (Figure 4.13). While X is flashing, press DOWN or UP. While X is flashing on any selection level, press SET. The default display will appear (Figure 4.12).
ChangingSelection Levels Exiting Program Mode
Pqramming Memory
NOTE:Only one memory letter is initially displayed (Figure 4.12). This is the active memory. You can program the active memory or any of the inactive memories. NOTE:Changes you make to the active memory pattern take effect
in-process with the next trigger signal. During set-up, press the Nordson Oval to activate changes made between trial patterns. Changes to inactive memories can be stored for later use. Changes are not saved as you make them. To save changes in memory, you must exit the Program mode.
Selecting a Memoryto Program

1Push Button Sequence 1Result
fliashing letter indicating the current selection the desired memory is flashing, press SET to program the parameters.
l
The program automatically moves to the Channel selection level. X is flashing at the right of the level.
Changingthe Actlve Memory

Push Button Sequence 1. Press and hold SET.
ReWIt
l
The active memory letter is displayed constantly (not flashing). X is flashing on the memory selection level.
.
2. Press LEFT or RIGHT to
2. The memory letter is flashing.
move to the letter that you want to select as the active memory. 3. Press the Nordson Oval to activate that memory.
l
The letter is displayed constantly (not flashing). X flashing at the Memory level.
PM 1080898 57-26 Km2
4-19
Ptvgrammlng Channel
Default Display
Programmlng SelectIons for the Channel Level

l
the number of channels the pull-in compensation, if any, for each channel the drop-out compensation, if any, for each channel
Selecting A Channel for Programmlng (I
IPush Button Sequence

1. Press LEFT or RIGHT to move to the channel number that you want to program
2. Press SET.
Result 1.The channel number is flashing.
9
l
The channel number stays on constantly (without flashing). The program remains in the Channel level. The current gun pull-in compensation value is displaved. See Fiaure 4.15.
I() Activated or deactivated channels can be programmed. The DlfferenCQ Between Activated and Deactivated Channels Activated channels are those that are turned on (provide gun output) for a selected memory. Deactivated channels are those that are turned off (provide no gun output). The PC44 has four memories, each of which can save one pattern. However, it is possible to save more than one pattern per memory If some of the patterns require less than four channel outputs. Figure 4.14 shows an example of how this can be done by deactivating and reactivating channels. By keeping channels I and 4 activated, and deactivating channels 2 and 3, you could save and use the pattern in View A. By deactivating channels 1 and 4, and reactivating channels 2 and 3, you could save and use the pattern in View B.
P/N 108 OWE 57-26 lo/92
4-20
ProgrammlngChannel (crxltiflued)
2 3
t
A
Figure 4.74 - Activating/deactivating A - First pattern 7 - Channels 1 and 4 activated 6 - Second pattern 2 - Channels 2 and 3 activated
example patterns
NOTE: Only the channels that are activated for a memory are shown in the Channel selection level display. NOTE: When reactivating and deactivating channels, previously programmed values are maintained. Programming Steps to Reactivate or Deactivate a Channel Push Button Sequence 1. Look at the initial Channel selection level display to determine which channel(s) are activated (I2. Press LEFT or RIGHT to move to the channel number that you want to change. 3. Press UP and DOWN at the same time. 2. Tlhe selected channel number is flashing. Result
3. Tlhe program remains in the Channel level and displays the new active channel. The channel state, activated or deactivated, is reversed.
4. Repeat steps 1 through 3 to change additional channels. (I Activated channel numbers are displayed on the LCD.
PM 1080998 57-28 lam
4-21
Programming Channel
(cfmtinnued)
Determlnlng the Need for Gun Pull-In Compensatlon
NOTE: The PC44 updates gun compensation after each pattern. The PC44 does not allow alnother pattern to start until the pattern in progress is completed. In addition, the PC44 requires a 30 ms reset time after the end of a pattern. 25 ms is a good starting value for pull-in and drop-out compensation. After programming all the PC44 parameters, you can determine the precise values using either one of two methods presented at the end of this section. Refer to Setting Precise Gun Compensation Values. Setting Pull-In Compensation Values NOTE: The pull-in compensation value for a channel can be accessed from any memory. However, the PC44 saves only one compensation value for each channell. since one gun type is typically used for a given channel.
LOCK CONFIGURE PROGRM RUN

TEST
MEMORY CHANNEL TRIGGER TRANSITION STITCH
F@ure 4.15 - Pull-in compensation display (default value shown)
Push Button Sequence 1. Press LEFT or RIGHT to select a digit position.
Result 1. The digit flashes.
2. Press UP (to increase the digit 2. The digit value increases or decreases. value) or press DOWN (to decrease the value). 3. Repeat the steps 1 and 2 until pull-in is set to the value you want. 4. Press SET.
l
The value is entered into memory. The program displays the current drop-out compensation value in the numerical display area. See Figure 4.16.
P/N 108 0998 57-26 l&92
4-22
Programming Channel
(continued)
LOCK
CONFIGURE PROGRM RUN TEST
F@ure 4.76 - Drop-out compensation display default value shown)
Settlng Drop-out Compensation Values NOTE: Like pull-in compensation, the drop-out value for a channel can be accessed from any memory. However, the PC44 saves only one compensation value for each channel. regardless of which memory uses that channel in a pattern. 1Push Button Sequence 1. Press LEFT or RIGHT to select a digit position. I Result 1. Tlhe selected digit is flashing on the LCD. I
2. Press UP (to increase the digit 2. Tlhe digit value increases or decreases. value) or press DOWN (to decrease the value). 3. Repeat the steps 1 and 2 until drop-out is set to the value you want.
l
The value is entered into memory. The program automatically moves to the Trigger selection level: 1
Press SET
PM 1000996 57-26 lam2
0 Nordson Corporation 1982 All Rights Reeenmd
4-23
Programming Channel
(cwntinnued)
Implementing Pull-in and Drop-out Changes Between Patterns You may want to enable changes to these values between patterns in set-up or during intermittent operation. Push Button Sequence 1. Press UP.
,2. Make value changes by repeating the
Result 1. The program returns to the Channel level.
steps in Setting Pull-in Compensation Values and Setting Drop-out Compensation Values. 3. Press the Nordson Oval.
l
The pattern in progress is interrupted. The PC44 memory resets. The unit resumes operation (using the new values) when it receives the next trigger signal.
NOTE: If the line is moving at or above the minimum line speed setting, the pattern in progress will be interrupted when the Nordson Oval is pressed. The PC44 will reset and resume operation when it receives the next trigger signal.
P/N 108 099B 57-26 lo/92
4-24
Ptagmmming Trigger
Default Display
x-ll
(FLASHING)
Programmlng SelectIons for the Trigger Level Trigger 1 or 2 Edge symbol
Maklng a Trigger Cholce!
2. When the desired trigger is
flashing, press SET .
The flashing trigger number stays on constant. X is flashing on the Trigger selection level.
Making an Edge Choice Push Button Sequence Result selected edge symbol is flashing on the /1. Tlhe L,cD.
2. Press SET.
The selected edge symbol is displayed constantly (not flashing). x is flashing on the Trigger selection level.
Moving to the TRANSITION Selection Level 1Push Button Sequence Press DOWN. I Result
l
The transition symbols are displayed constantly (not flashing). X is flashing on the Transition selection level.
PM 1080998 57-26 lot92
8 Nordson Corporation 1W2 All Rights Reserved
4-25
Programming Translion
Default Display 1 )+(FLASHING)
Selecting a hansltlon Push Button Sequence 1. Press LEFT or RIGHT to select a transition symbol. 2. Press SET. IResult
l
The selected symbol is flashing.
The current value for that transition is displayed in the numerical display area. The selected symbol is flashing. The right-most digit of the value is flashing (Figure 4.17). --
a
l
LOCK CONFIGURE PROGRAM RUN TEST
-1
-2
Figure 4.17 - Program mod8 TRANSITION value display 7 - Right-most digit flashing 2 - Selected transitbn wib flash
8 Nadson Corporation 1992 AU Rights Reserved
PIN108 0990
57-a 1cb9z
4-26
Programming Tmnsition
Settlng - the Transltlon Value Push Button Sequence 1. Press LEFT or RIGHT to select a digit position. 2. Press UP (to increase the digit value) or press DOWN (to decrease the value). 3. Repeat the steps 1 and 2 until all the digits are set to the value you want. 4. Press SET. 1~ The value is entered into memory. 0~ The program moves to the next transition symbol to the right (which is flashing; and the current value for that transition is displayed), or 4. If this is the eighth transition or last transition, the program moves to X, which is flashing on the Transition level. 5. Repeat steps 1 through 4 until you have the values that you want for all the transitions. lmplementlng Transltlon Changes Between Patterns You may want to enable changes to these values between patterns in set-up or during intermittent operation. Push Button Sequence 1. Repeat the steps in Selecting a Transition and Setting the Transition Value. f A
l
Result 1. The selected digit is flashing on the LCD. 2. The digit value increases or decreases.
Result 1. The transitions are set to new values.
WARNING: Risk of bums. Unexpected gun firing can occur if you attempt to make changes while the line is moving below minimum line speed. Before pressing the Nordson Oval, make sure that the line is moving at or above minimum speed.
l
2. Press the Nordson Oval.
The pattern in progress is interrupted. The PC44 memory is reset. Operation resumes (using the new values) when the next trigger signal received.
is
PM 1080998 57-26 lom
Q Nordson Corporation 1992 Ail Rights Reserved
4-27
Prugramming TwWtlon tmtiued)

I Movlng to the STITCH Selection Level Push Button Sequence 1. If x is not flashing on the Transition level, press LEFT or RIGHT. Result
l
The transition symbols flash as you press LEFT or RIGHT. X is flashing on the Transition level. The stitch symbol is displayed constantly (not flashing). x is flashing on the Stitch selection level.
. 2. Press DOWN.
Pqpamming Stitch
NOTE: The program will not allow you to access Stitch mode if you selected Stitch Off in the Configure mode. Refer to Configure Mode later in this section. NOTE: The PC44 attempts to adjust the stitch parameters in response to changes in line speled. This compensation will affect stitch bead and gap size. At lower speeds, you may get fewer stitch beads. No&on recommends that you set up the stitch pattern at maximum line speed. Default Display
IO
Deactlvatlng Stitch
et-
(FLASHING)
NOTE: Deactivating stitch turns stitching off for the channel that you are programming. However, the values for % coverage and bead length are still saved in memory for later use if you reactivate stitch for this channel. 1Push Button Sequence 1. Press LEFT or RIGHT to move to the stitch off symbol. 2. Press SET. I Result I. The stitch off symbol is flashing: I
The stitch off symbol is displayed constantly (not flashing). x is flashing on the Stitch level (see the default display above).
Q Ncdson Corporation 1992 AU Rights Resend
PIN 1oB 0998 57-26 10192
4-28
Pmramming Stitch (conhued)

Reactlvatlng Stitch 1Push Button Sequence 1. Press LEFT or RIGHT to move to the stitch on symbol. Result
l
The stitch off symbol is displayed constantly and The stitch on symbol is flashing:
(FLASHING) i -e I
.
c
2. Press SET
The stitch on symbol is displayed constantly (not flashing). The stitch percentage symbol is flashing. The right-most digit of the current stitch percentage value is flashing in the numerical display area Figure 4.18).
LOCK CONFIGURE PROGRRH
-1
RUN TEST MEMORY
CHANNEL
TRIGGER
TRANSITION
STITCH
-2
Figure 4.18 - Program mode, STITCH percentage display 1 - R&ht-most digit flashing 2 - PetCent Symbol flashing
Detetmlnlng % Coverage You can set coverage frolm O-100%.Of course, if you select 0% or some other small value, you will have either no stitch beads or extremely small stitch beads. If you select 100% coverage or some other large value, you will have either one continuous bead or an almost continuous bead. To achieve a useful stitch pattern, we recommend that you begin with 50% coverage. From there, you can increase or decrease the coverage to suit your application.
P/N 1080!3M3 57-26 lww
63 No&on
4-29
ProgrammingStitch
(cantinued)
Entering % Coverage Values Push Button Sequence I. If the setting is 100% and you want to set it at a lower percentage: a. Press LEFT or RIGHT to move to the left-most digit. b. Press DOWN. ?. Press LEFT or RIGHT to select a digit position. a. The left-most digit is flashing. b. The value changes to 0. 2. The selected digit is flashing on the LCD. Result
3. Press UP (to increase the digit 2. The digit value increases or decreases. value) or press DOWN (to decrease the value). I. Press SET.
l
The percentage value is saved in memory. The stitch bead length symbol is flashing. The current bead length value is displayed and the right-most digit is flashing (Figure 4.19).
*
LOCK CONFIGURE PROGRdM RUN TEST MEMORY CHANNEL TRIGGER TRANSITION STITCH
i-ii-i~-
I I --nI II r-i
A 1
1
2 c ,
Figure
4.79 - Program mode, STITCH bead display
I - Right-most d&it flashing 2 - Bead length symbol flashing
Q Nodson Corporation 1992 All Rights Reserved
P/N 108 0998 57-26 lam
4-30
Prvgramming Stitch
(continued)
Determlnlng Stitch Bead Length This setting defines the length of each stitch bead that will be deposited during each stitched duration. You can set the length from 0 to 1023 pulses. Similar to setting % values, selecting a very small stitch bead value will result in an almost continuous bead and may exceed the mechanical response time capabilities of the gun and solenoid. Depending on how large a stitch bead value is selected, you may have only one bead deposited during any duration. To achieve a useful stitch pattern, Nordson recommends that you begin with a stitch bead that equals l/s,of the duration length( unless you have other specific requirements). For example, a 500 pulse duration should have no more than 100 pulse stitch bead lengths. Based on test patterns, you can then increase or decrease the bead length to suit your application. Enterlng Bead Length Values Push Button Sequence 1. Press LEFT or RIGHT to select a digit position. 1Result 1. The selected digit is flashing on the LCD.
2. Press UP (to increase the digit 2. The digit value increases or decreases. value) or press DOWN (to decrease the value). 3. Repeat the steps 1 and 2 until bead length is set to the value you want. 4. Press SET. (4. X is flashing on the Stitch level.
Moving to Other Selectlon Levels Press UP to move to any previous level. Exttlng PROGRAM Mode While X is flashing on any selection level, press SET.
ProgrammIng Gun Disable Line

speed
Gun disable line speed is programmed in the Configure Mode. Refer to Programming Gun Disablle Line Speed in the Configure Mode portion that is covered later in this section.
PIN 1080998 57-26 lo&2
Q No&on
Corporation 1992 All Rights Resewed
4-31
6. Run Mode
Run Mode enables you to
l
reset the pattern during normal line operation (the line is running at or above minimum line speed), or
review the programmed parameters and values. This is the PC44 operational mode. You must be in this mode in order to access any other mode or to view program parameters.
l
Accessing Run Mode
After start-up, the PC44 automatically defaults to this mode. The unit returns to this mode whenever:
l
SET is pressed while X is flashing in any selection level., or there is a 10 minute period in which no push buttons are pressed. WARNING: Severe burns can occur from unexpected gun firing. Use the Nordson Oval function described below only when the line is operating at or above minimum line speed. WARNING: Whenever the line moves below minimum speed, reset memory by interrupting and restoring input power to the PC44 Do not activate a trigger until normal line operation resumes. For further details, review PC44 Gear-to-Line Memory Operation near the end of this section.
Resetting the Pattern During Normal Line Operation
A A
1 0 f 0
Press the Nor&on Oval push button to reset the pattern. The pattern will restart when the PC44 receives the next trigger signal.
Q No&on Corporation 1gg2 AU Rights Reserved
PM 1060998 57-26 lam2
432
Rev&wing Pammeters and Values
Parameter Review Sequence The selections programmed for each available memory can be reviewed in the Run mode. Result 1. The LCD displays the active memory; X is flashing on the Memory level.
>ush Button Sequence . Press DOWN.
!. Press LEFT or RIGHT until the memory symbol 2. The selected memory letter is flashing. that you want to review is flashing. 1.Press SET.
l
The selected memory letter is displayed constantly on (not flashing). The active channel numbers for this memory are displayed. X is flashing on the Channel level. The selected channel number is flashing and the memory letter is displayed. Pull-in and drop-out values for the channel are displayed. The selecited memory letter is displayed. The channel number is displayed. The trigger and edge symbol are displayed. The transition symbols are displayed and X is flashing on the Transition selection level.
a I. Press LEFT or RIGHT until the channel symbol that you want to review is flashing.
l
i. Press SET.
.
l
j. Press LEFT or RIGHT until the transition symbol that you want to review is flashing. ? To view other transitions, repeat step 6. 3.To view the Stitch level: a. Press LEFT or RIGHT until x is flashing on the transition level. b. Press DOWN. 3. If stitching was deactivated in the Program mode for the channel you are reviewing, do one of the following: a. Press UP to move to any previous level. b. Press SET to exit the parameter review. 10. If stitching was activated in the Program mode for the channel you are reviewing:
l
6. The selected transition symbol is flashing and its value is displayed.
The stitch symbol is displayed and x is flashing on the Stitch level.
x will flash on the selected level. The program returns to the default (Run) mode.
percentage or bead length symbol.
Press LEFT or RIGHT to move to the stitch
The selected symbol is flashing and its value is displayed
11. When you are finished viewing the Stitch level, do one of the following:
l
Press UP to move to any previous level. Press SET to exit the parameter review.
.
l
x will flash on the selected level. The program returns to the default (Run) mode.
PM lQ0w00 57-26 lo/Q2
Q No&on
4-33
7,
Configure Mode
Purpose
A
f 0
CAUTION: Removing memories in Configure mode erases all parameter values for those memories. Removing parameters can erase programmed values for some or all memories and/or channels, Only the parameters you select in Configure will be accessible in the Program and Run modes. Nor&on recommends that the Configure mode be utilized onlyin initial set-up or for intended system modifications. To routinely activate and deactivate parameters, use the Program mode.
This mode gives you the ability to:

l
program gun disable line speed, and select the parameters av(ail&&for the PC44. programming and operation of
Accessing Configm? /Mb&?
Press the Nor&on Oval and SET buttons at the same time. The Configuration mode display is shown (Figure 4.20).
LOCK CONFIGURE PROGRAM RUN TEST
MEMORY CHANNEL
TRIGGER TRANSITION STITCH
Figure 4.20 - Configure mode dispiay (defaults shown) 1 - X flashing
Changing SelectIon Levels Exiting ConfIgure
While x is flashing, press DOWN or UP. While X is flashing, press SET.
0 Nadson Corporation 1962 All Rights Reserved
P/N 108 OMB 57-26 la92
434
Operating instructions
Selecting Available Parameters

Available Memories 1Configuration Choice One Memory Push Button Sequence 1, Press LEFT or RIGHT until memory letter, A, is flashing. 2. Press SET. Two Memories 1. Press LEFT or RIGHT until memory letter, B, is flashing. 2. Press SET. Three Memories 1. Press LEFT or RIGHT until memory letter, C, is flashing. 2. Press SET. Four Memories 1. Press LEFT or RIGHT until memory letter, D, is flashing. 2. Press SET. Configuration Choice r~~ One Channel Available Channels Push Button Sequence 1. Press LEFT or RIGHT until channel number, 1, is flashing. 2. Press SET. 1. Press LEFT or RIGHT until channel number, 2, is flashing. 2. Press SET. Three Channels 1. Press LEFT or RIGHT until channel number, 3, is flashing. 2. Press SET. Four Channels 1. Press LEFT or RIGHT until channel number, 4, is flashing. 2. Press SET.
r-
Two Channels
PM 1080998 57-26 lo/Q2
(B Nordson Corporation 1992 All Rights Reserved
4-35
SelectingA vailableParameters (ahued)

Available Trlgger and Edge Choices NOTE: Two selections are made in this level: trigger (1 or 2), and edge symbol (leading or trailing edge). 1Trigger Choice One Trigger Push Button Sequence 1. Press LEFT or RIGHT until trigger number, 1, is flashing. 2. Press SET. 3. Press LEFT or RlGHT to select an edge symbol, below. Two Triggers 1. Press LEFT or RIGHT until trigger number, 2, is flashing. 2. Press SET. 3. Press LEFT or RIGHT to select an edge symbol, below. 1Edge Symbol Choice Push Button Sequence 1. Press LEFT or RIGHT until the symbol is flashing. 2. Press SET.
-H
0 Nordson Corporation 1g82 All Rights Resewed
P/N 108 0998 67-26 la42
4-36
Sekcting Available Parameters (CWltil7ued)

Avallable Transltlons NOTE: Transitions are madeavailable in pairs (one delay and duration). Configuration Choice 3ne Transition Pair: m Y (FLASHINQ) Two Transition Pairs: 1. Press LEFT or RIGHT until the second transition pair from the left is flashing. 2. Press SET. LT-1 (FLASHING) Three Transition Pairs: Y (FLASHING) Four Transition Pairs: m Y (FLASHING) 1. Press LEFT or RIGHT until the right-most transition pair is flashing. 2. Press SET. 1. Press LEFT or RIGHT until the third transition pair from the left is flashing. 2. Press SET. Push Button Sequence 1. Press LEFT or RIGHT until the left-most transition pair is flashing. 2. Press SET.
Pit4 1080998 57-26 lww
Q No&on
Corporation 1992 All Rights Reswvsd
4-37
Sekcthg Available Parameters (cov7tin~
NOTE: The stitch choice applies to all availabte memories and channels. For example, selecting stitch-off in Configuration makes stitch unavailable for use in any pattern, NOTE: To selectively turn stitch on or off for some patterns, select stitch-on in Configuration mode. Then use Program mode to turn stitch off or on for a particular pattern.
Configuration Choice Stitch-off Push Button Sequence 1. Press LEFT or RIGHT until the stitch-off symbol is flashing.
0
0
2. Press SET. 1. Press LEFT or RIGHT until the

stitch-on symbol is flashing.
Stitch-on
2. Press SET.
0 Ncdson Corporation 1gg2 All Rights Reserved
PM 1080998 67-26 la92
4-38
Prugtamming Gun Disable Une

speed
Purpose - In pattern control applications, gun outputs are turned off when line speed goes below the gun disable line speed. Settlng Gun Disable Line! Speed
Push Button Sequence 1. Press and hold the Nordson Oval and SET.
2. Press UP.
Result 1. The Configure Mode initial display appears. See Figure 4.20. 2. The default or last saved value is displayed (all digits flashing). See Figure 4.21. () 3. The right-most digit is flashing. 4. The selected digit is flashing. 5. The value changes.
3. Press SET.
4. Press LEFT or RIGHT to select a digit position. 5. Press UP (to increase the value of the digit) or DOWN (to decrease the value of the digit). 6. Repeat steps 4 and 5 until the value is set. 7. Press SET to enter the value.
7. X is flashing on the memory selection level.
8. Press SET again to store the gun dis- 8. The unit exits Configure mode and able line speed value in memory. returns to RUN mode. (I To exit without changing the gun disalble line speed value, press DOWN. This will return you to the opening display (Figure 4.20). Press SET to exit the Configure mode.
LOCK CONFIGURE PROGRAM RUN TEST I -m II I I I + i-Ii-l I-=!! 1
MEMORY CHANNEL TRIGGER TRANSITION STITCH G
ABCD 1234 12-mm-0 .
Figure 4.21 - Configure mode, gun disable line speed initial display 7 - All digits flashing (defaultor last saved value displayed)
PM 1080998 57-26 la92
4-39
8. Test Mode PWpose

This mode provides the following capabilities and information:
l
it allows you to manually activate (fire) an output channel (gun) and it displays actual line speed or indicates certain line speed problems.
Accessing TBt Mode
Press and hold the Nordson Oval until the initial Test mode display appears (Figure 4.22) I
LOCK CONFIGURE PROGRRW RUN TEST MEMORY CHANNEL TRIGGER TRANSITION STITCH c i-ii-ii
I II--I-II I I
l1
----
Figure 4.22 - TEST mode initial display A - Actual line speed (all digits constantly on) 1 - Flashing
Selecting a Channel
Press LEFT or RIGHT to move between the channel symbols. The selected channel symbol flashes. Press SET to activate the output for the channel selected. Press LEFT or RIGHT until X is flashing. Press SET. Typically, when you enter Test mode, the actual line speed is displayed with all digits constantly on (see Figure 4.22). However, there are two other displays in Test that may appear. In these displays, all four digits will flash at the same time. These indicate a problem (refer to the table below). Test Mode Line Speed Problems
Activating a Test Channel Exiting Test indicating Line Speed or Line Speed Problems
Value Display 0000 flashing
Indication . The line is moving backward, or

l
the encoder phase connections are reversed, or the encoder is mounted so the shaft is turning in the wrong direction.
9999 flashing
The line speed exceeds 9,999 pulses per second.
Q Nor&on Corporation 1992 All Rights Resewed
P/N 108 OggB 57-26 lwQ2
4-40
Operating ins true tions
9. PC44 Gear-to-LineMemory Operation

lntroductlon
Understanding the gear-to-line memory function of the PC44 is important when dealing with three conditions that can occur while patterns are in progress or during maintenance:
l
line stoppages, changes in line speed, and intentional or unintentional trigger signals.
NOTE: This does not include time-base operation of the PC44. In time-base operation, the FC44 reacts to intentional and unintentional triggers by finishing any pattern in progress or by starting a new pattern.
Software Versions 1.12 and Later
NOTE: The software version is displayed when the PC44 power is turned on. These units react to intentional and unintentional triggers when the line speed drops below the minimum line speed setting by resetting any pattern in progress. The PC44 will not react to additional triggers until the line speed is at or above the minimum line speed setting. We will use a packaging application as an example of the PC44 memory function. This packaging application will use one trigger and one aun (Fiaure 4.23).
Figure 4.23 - Sample pattern l-Gun
2 - Tr@ger
3 - Line travel direction
0 Nor&on Corporation 1992 All Flights Reserved
P/N 108 0998 57-26 lw92
4-41
Software Versions 1.12 and Later (CXhlued)

Tab/e 4.1 - PC44 Gear-fo-Line Operation, Software Versions 1.72 and Later, Run Mode ,ine Speed =o attern Status Unit i<le. Awaiting next trigger. Line stops during delay or duration interval. < minimum line speed setting Unit idle. Awaiting next trigger. Line goes below minimum line speed during delay or duration interval. Unit idle. Awaiting next trigger. In progress, delay or duration interval. Reaction :o Trigger Ignores. Iff ect >n Memory
None. Ignores. Resets pattern. Starts new pattern when line reaches minimum speed and next trigger is received. None. Starts new pattern when line reaches minimum speed and next trigger is received. Resets pattern. Starts new pattern when line reaches minimum speed and next trigger is received.
Ignores.
< minimum line speed setting
Ignores.
None.
= or > minimum line speed = or > minimum line speed
Accepts.
Starts pattern.
Memory active. Starts pattern. None: starts new pattern when next trigger received.
Ignores.
Completes pattern in progress
PM 108owEt 57-26 lQl92
Q Nordson Gnpomtiin 1992 All Rights Reserved
4-42
Software Versions 1.09 and Earlier
NOTE: The software version is displayed when the PC44 power is turned on. We will use a packaging a,pplication as an example of the PC44 memory function. This packaging application will use one trigger and one gun (Figure 4.23). WARNING: R&k of burns. Unexpected gun firing can occur during line stoppages. The firing can be a response to trigger signals caused by foreign objects blocking the sensors, and by intentional and unintentional triggering that can occur during maintenance. Nordson recommends that you install quick-disconnect solenoid leads. Whenever the line stops, disconnect the leads to disable the solenoid. Users may want to provide an additional measure of safety by disabling the trigger when the line stops.
f A 0
The memory function of the PC44 with these versions of software is always active when used with a gear-to-line encoder. Gun firing resulting from this function can be mistaken for false triggering. Table 4.2 - PC44 Gear-to-Line Operation, Software Versions 1.09 and Earlier, Run Mode Line Speed =o Pattern Status Unit idle. Awaiting next trigger. Line stops during delay or duration interval. Unit idle. Awaiting next trigger. Reaction to Trigger Accepts. Effect on Pattern Pattern enabled, waiting for line to move. Pattern in progress, waiting for line to move. Effect on Memory Memory active. Starts new pattern. Memory active. Continues pattern in progress.
=0
Ignores.
Accepts.
Gun disabled while below minimum line speed setting. Pattern completed when line speed = or > minimum line speed setting. Gun disabled for pattern in progress while below minimum line speed setting. Remainder of pattern completed when line speed = or > minimum line speed setting. Starts and completes entire pattern.
Line goes below minimum line speed during delay or duration interval. Unit idle. Awaiting next trigger. In progress, delay or duration interval.
Ignores.
None: starts new pattern when next trigger received.
= or > minimum line speed = or > minimum line speed
Accepts.
Ignores.
None: starts new pattern when next trigger Completes pattern in progress. received,
0 Nadson Corporation 1992 AH Rights Reserved
PIN 108 0990 57-26 lo/g2
4-43
WARNING: Severe burns can occur from unexpected gun firing. To reset PC44 memory and insure that the pattern is cancelled, always interrupt and restore Input power to the PC44. Do not activate a trigger until normal line operation resumes.
Use the Nordson Oval push button to make PC44 set-up and pattern changes only while the line is running at or above minimum line speed. Do not rely on the Nordson Oval push button as a PC44 memory reset.
10. Setting Precise Gun Compensation Values Fine-tuning AMhod

1. Run the line at the lowest operating speed and observe the bead placement. 2. Run the line at the highest operating speed and observe any difference in bead placement. 3. If there are differences in bead placement, adjust pull-in and/or drop-out compensation. () a. Pull-in Compensation . If the bead moves away from the substrate leading edge, increase the pull-in compensation. . If the bead moves toward the substrate leading edge, decrease pull-in compensation. b. Drop-out Compensation . If the bead ends too late, increase drop-out compensation. . If the bead ends too soon, decrease drop-out compensation. 4. Repeat steps 1 through 3 until bead placement consistently starts and ends at the same place on the substmte whether the line is operating at the lowest or highest speed. (I If either gun compensation value is set at the PC44 minimum value of 0 ms or the maximum value of 200 ms, you will have to correct the pattern by adjusting the transition values.
PM 1080998 57-26 lwQ2
(a No&bon Copofation 1992 All Rights Reserved
4-44
CalculationMethod
Instead of using test runs to fine-tune gun compensation, you can mathematically determine what adjustment is needed. NOTE: Distance measurements should be made in millimeters (Metric) or inches (English). Line speed measurements should be made in meters per minute (Metric) or feet per minute (English). Calculating Gun Compensation 1. Run the pattern: a. Run the pattern at the minimum operational line speed; record the line speed. b. Run the pattern at the maximum operational1line speed; record the line speed. 2. Measure pull-in bead distances. a. For the minimum line speed, run each channel and measure the distance from the leading edge of the substrate to the beginning of the first bead in the output sequence (A in Figure 4.24). b. For the maximum line speed, run each channel and measure the distance from the leading edge of the substrate to the beginning of the first bead in the output sequence (B in Figure 4.24).
2
I I I r3
; 120 j I mm I LB-4
Figure 4.24 - Calculating pull-in compensation A - Leading e@e to bead at minimum line speed B - Leading edge to bead at maximum line speed 1 -Gun 2 - Leading edge of substrate 3 - Minimum line speed bead 4 - Maximum line speed bead 5 - Line travel direction
0 N&son Corporation 1QS? AU Rights Resewed
P/N 108 09QB 57-26 lo/Q2
4-45
Calcuh3tfon Method
Calculating Gun Comlpensatlon (Continued) 5. Determine the pull-in shift: * Pull-inShift =&A() 1. determine the pull-in correction factor: (*)
l
Metric (LS = Line Speed): PM- in Shift x 60 Pull - in Correction Factor (in ms) = Max. LS - Min. LS (m per min ) English (LS = Line Speed): PUN-in Shift x 5000 Pull - in Correction Factor (in ms) = inav Ls Min LS fi
5. Determine the adjusted pull-in compensation value: a. If the maximum line speed bead moves further away from the substrate leading edge than the minimum line speed bead, add the correction factor to the current pull-in compensation value. b. If the maximum line speed bead moves closer to the substrate leading edge than the minimum line speed bead, subtlract the correction factor from the current pull-in compensation value. (3) ) Using the measurements shown in Figure 4.24, the pull-in shift would be calculated as follows: Pull-in Shift = B - A Pull-in Shift = 120 - 100 = 20 2, Assuming a minimum line speed of 30 m/min and a maximum line speed of 130 m/min, the pull-in correction factor for the example shown in Figure 4.24 would be: 20x60 Pull-in Correction Factor (in ms) = 130 - 30 (m per min ) 1200 Pull-in Correction Factor (in ms) = 100 = 12 ms 3, In the example in Figure 4.24, the maximum line speed bead moved further away from the substrate leading edge than the minimum line speed bead. We would add the pull-in correction factor of 12 ms to the 25 ms starting value recommended in Program mode. Pull-in compensation for this example would be 37 ms.
P/N 1oaoQ9e 57-26 10/%?
@ No&on
Coqmation 1992 All Rib l3esefvd
4-46
CalculationMethod (cOnti;nued)
Calculating Gun Compensatlon (Continued) 6. Measure the drop-out bead distances: a. For the minimum line speed, run each channel and measure the distance from the leading edge of the substrate to the end of the first bead in the output sequence (C in Figure 4.25). b. For the maximum line speed, run each channel and measure the distance from the leading edge of the substrate to the end of the first bead in the output sequence (D in Figure 4.25). 7. Determine the drop-out shift: (4)
DropoutShift = DC
(4Using the measurements shown in Figure 4.25, the drop-out shift would be calculated as follows: Drop-out Shift = D - C Drop-out Shift = 225 - 200 = 25
I -C--): I
200
mm
I I
f
225 mm
;
I I rl
k---DI
F@ure 4.25 - Calculating drop-out compensation C - Leading edge to end of first bead at minimum line speed D - Leading edge to end of first bead at maximum bne Speed I-Gun 2 - Leading 8dg8 of substrat8 3 - Minimum line speed bead 4 - Maximum line speed bead 5 - Line travel direction
0 Nor&on Corporation 1992 AU Rights Reserved
P/N 108 0998 57-26 lw92
4-47
Cakulation Mthod
(wJhue9 Calculating Gun Compensation (Continued) 3. Determine the drop-out correction factor:
l
Metric (LS = Line Speed): Drop - out Correction Factor (in ms) -= Drop - out Shift x 60 Max. LS- Min. LS (m per min )
English (LS = Line Speed):
Or0 - out Shift x 5000 Drop - out Correction Factor (in ms) == Max L[ Min LS fi . 3. Determine the adjusted drop-out compensation value: a. If the end of the maximum line speed bead moves closer to the substrate leading edge than the end of the minimum line speed bead, add the correction factor to the current drop-out compensation value. b. If the end of the maximum line speed bead moves further away from the substrate leading edge than the end of the minimum line speed bead subtract the correction factor from the current drop-out compensation value. (6 10. In Program mode, program your gun compensation values for each channel. ) Assuming a minimum line speed of 30 m&in and a maximum line speed of 130 m/min, the drop-out correction factor for the example shown in Figure 4.25 would be: 25 x60 Drop-out Correction Factor (in ms) = 130 -- 30 (mpef min ) 1500 Drop-out Correction Factor (in ms) = E= 15 ms 6, In the example in Figure 4.25, the end of the maximum line speed bead moved further away from the substrate leading edge than the end of the minimum line speed bead. We would subtract the drop-out correction factor of 15 ms from the 25 ms starting value recommended in Program mode. Drop-out compensation for this example would be 10 ms.
PM 1080998 57-26 lo/92
8 Nordmn Cotpodin 1992 All Right8 Reaawed
4-48
MEMORY
GUN DISABLE
A
LINE SPEED = -
B
1
CHANNEL I,1 = I TRIGGER TRANSITION ---STITCH -0 -
I 111 =12
u I I I 0 m I ------
-E
I .%
E-
n
I
I -I
m I
CHANNEL Cl = I TRIGGER TRANSITION ---STITCH
2 I
111 = -
1 -E-E-E-E I I - I
-E
I -----I .%
EI -I I I
-0
I
13 = -
CHANNEL 1, -_
I TRIGGER TRANSITION ---STITCH -0 -
3
12
m I I -0 I 1 I ------
-E
I .A m
EI -E I m I
CHANNEL
111 =
I
I
111 = -
TRIGGER TRANSITION ---STITCH I I I
12
I -e I I
-E
-p---p I -.% I
II I I I
-0
Figure 4.26 - Sample pattern log
Ca No&on Corporation 1%I2 Al Rights Reserved
P/N 108 0998 57-26 lo/g2
## TABSHEET ##
SECTION 5
Section 5
Troubleshooting
Q No&on Corporation lgg2 All Rights Reserved
P/N 108 o&If3 57-26 lo/92
Troubleshooting
5-l
Section 5 Troubleshooting
1. Introduction
In this section, you will find fault isolation and correction procedures. Obvious causes of malfunction, such as broken wires, missing or loose fasteners, etc. should be noted during daily visual inspection and corrected immediately.
2. Safety Precautions f A 0
WARNING: Before performing any troubleshooting procedures, thoroughly review Section 1, Safety Summary, in this manual. Only qualified personnel are to perform any troubleshooting procedures. WARNING: Risk of electrocution. The AC input line to the PS40 (or other 24V power supply) provides voltage that can cause personal injury or death. Before opening any of these units to check or make electrical connections, disconnect and lock out power to the main circuit breaker !or the input power line. WARNING: Shock hazard. Touching bare wires in the PC44 can result in shock that can cause personal injury or death. When checking electrical connections, avoid touching bare wires. When making electrical connections, strip only as much insulation from the wires as needed, and make sure that the insulation fits snugly against the PC44 terminal blocks.
: @
-4 A
3. TroubleshootingChecklist Foliowing Initial Installation
Check for the items listed below if the PC44 is not operating after you initially install it:
l
proper power, PC44 and PS40 (if used) power switches in the on position, PC44 and PS40 (if used) fuses good, correct sensor seleded, encoder installed correctly and rotation in correct direction, installation section guidelines followed.
. minimum line speed set properly, and

l
If the unit still is not operating, go to the detailed troubleshooting procedures that follow in this section.
6) Nordson Corporation 1992 All Rights Reserved
P/N 108 0996 57-26 lo/92
5-2
Troubleshooting
4. Guns Not Firing
Problem PC44 status LED red. (NOTE: It is normal for this LED to light red at unit power-up. After a brief self-test, it will
light green.)
Possible Reason Selecting an unconfigured memory via remote memory select line. PC 44 has failed internal diagnostics check. Power supply switch in OFF position. Power supply fuse defective. No input to PS40 or other power suPPlY* Incorrect or missing power supply input wire connections.
Corrective Action Select configured memory or make unconfigured memory available. Replace unit; contact your Nordson representative. Move switch to ON position. Check; replace if necessary. Check that line voltage and any circuit breakers are ON.
Refer to Sec. 4, Configure Mode.
PC44: - status LED dark, - (PS40, if used) power on LED dark
Turn power to PS40 OFF; remove Figure 5.2. front a:ssembly; check input connections; correct or make connections as necessary; close PS40 and restore power: if PS40 power on LED is now on and the PC44 status LED is still dark, continue to next problem. If the PS40 power on LED remains dark, the PS40 has failed; replace the unit. Turn power to PS40 OFF; move PC44 power switch to OFF position; remove front assembly of PC44 and PS40; check connections. Replace; contact Nordson representative. Figure 5.1 and Figure 5.2.
PC44: - status LED dark, - (PS40, If used) power on LED lighting.
Incorrect or missing wire connections.
PC44 failure.
PIN 108 0998 57-26 1092
Troubleshooting
5-3
4. Guns Not Firing
(continued)
Problem
Possible Reason No applicator power.
Corrective Action Check that applicator breaker switch ON; check for input line voltage if necessary. Check for proper pressure and adjust if necessary. Select Test mode (press and hold Nordson oval until arrow on LCD points to TEST; press LEFT or RIGHT to select channel; press SET and check for 24 VDC at solenoids; if no power present, turn PC44 power OFF, remove front assembly, and check output connections. Follow troubleshooting procedure in gun and/or solenoid manual. Mount within proper range. Check; align if necessary. Clean lenses and/or retroreflector. Inspect and replace or repair as necessary. Turn power to PC44 OFF; remove front assembly and check connections. Replace; contact your Nordson representative. Replace; contact your Nordson representative.
Refer to Applicator manual. Applicator manual.
PC44 output LED(s) lighting.
lnsuff icient system pressure. Incorrect or missing wire connections in PC44.
Gun and/or solenoid problem.
Gun and/or solenoid manual.
PC44 trigger input LED(s) dark.
Sensors not mounted within operating range. Sensor misaligned. Dirty sensor lenses and/or retroreflector. Damaged sensor wires. Incorrect or missing wire connections. Sensor failure. PC44 failure.
(1) Nordson Corporation 1992 All Rights Reserved
PIN 108 0990 57-26 lOi
5-4
Troubleshooting
4. Guns Not Firing

Problem PC44 output LED(s) dark.
(continued)
Possible Reason Sensor or sensor wiring problem.
Corrective Action Check if PC44 input LEDs also dark; if so, go to PC44 trigger input L.EDsdark earlier in this section. Select the correct memory.
Refer to
Wrong memory selected.
Sec. 4, Programming Memory. Sec. 4, Selecting Available Parameters. Sec. 4, Programming Channel.
Channel not configured.
Configure channel.
Channel not activated.
Activate channel.
PC44 failure. Line stopped or moving slower than the gun disable line speed. Encoder phase connections are reversed, or the encoder shaft is turning in the wrong direction.
Replace; contact your Nordson representative. Increase line speed or program gun disable line speed to a lower value. Use TEST mode to check line speed. If 0000 is flashing, the PC44 1:hinksthe line is moving backw,ard. Rewire the phase connections or mount the encoder correctly. Sec. 4, Configure Mode Sec. 4, TEST Mode and Sec. 3, Encoder Electrical Connections.
P/N 108 0998 57-26 lCY92
0 Nordson Corporaboon1992 All Rights Resewed
Troubleshooting
5-5
5. Gun(s) Firing Between Patterns
Problem Sun(s) firing between patterns, diffuse

reflective sensors.
Possible Reason Sensor mode set incorrectly. PC44 sensor mode, location, and edge symbol parameters set incorrectly. Sensors not mounted within operating range. Dirty lenses and/or retroreflector. Sensor responding to objects in line background, such as cams, levers, etc.
Corrective Action Adjust light/dark operate switch to intended mode.
Refer to Sec.4, Table 4.1.
Correct settings in Program mode. Sec. 4, Programming Trigger. Mount within proper range. Clean lenses and/or retroreflector. Observe sensor LED to see if sensor responding to background objects; if so, adjust gain setting and/or follow alignment tips. Sec. 3, Aligning Sensors and Tips for Minimizing Unwanted Triggering. Sec. 7.
Inductive interference (electrical noise) from power or solenoid cables. Guns firing between patterns, opposed and retroreflective sensors. Sensor mode set incorrectly. PC44 sensor mode, location, and edge symbol parameters set incorrectly. Sensors not mounted within operating range. Dirty sensor lenses and/or retroreflector. Emitter and receiver/reflector misaligned.
Rolute sensor cables away from power and output wiring. Adjust light/dark operate switch to intended mode. Sec. 4, Table 4.1.
Coirrect settings in Program mode. Sec. 4, Programming Trigger. Mount within proper range. Clean lenses and/or retroreflector. Align sensor components. Sec. 3, Aligning Sensors. Sec. 7.
P/N 108 0998 57-26 lo!92
5-6
Troubleshooting
5. Gun(s) Firing Between Patterns (continued)
Problem Guns firing between patterns, opposed and retroreflective sensors (continued).
Possible Reason
Corrective Action
Refer to Sec. 3, Aligning Sensors.
Observe sensor LED to see if (Retroreflective sensor only) sensor reacting to reflections from sensor reacting to reflections; if so, adjust gain setting; if sensor substrate. still reacts to reflections, mount emitter and reflector to an angle to line travel or use Nordson polarized retroreflective sensor. Inductive interference (noise) from power or solenoid cables. Route sensor cables away from power and output wiring.
6. Other Gun Firing Problems
Problem Gun(s) firing coincidently with other machine operation.
Possible Reason Sensor mode set incorrectly.
Corrective Action Correct settings.

,
Refer to Sec. 4, Programming Trigger.
Sensors wired incorrectly. Inductive interference (noise) from machine control or other relay. Noise from machine operation occurs at the end of the substrate and causes a false trigger. Limit switch bounce at end of the substrate causes a false trigger.
Correct wiring. Install a noise suppressor across the coil of the relay and/or contactor. Adjust the last transition to occur beyond the sensor reset point. Adjust last transition to occur beyond the switch reset point, Adjust the spacing of the substrate, and/or the gun and sensor. Or, if spacing cannot be changed, consider using two channels wired in parallel and triggered alternately. If this does not solve the problem, contact your Nordson representative.
Figure 5.1 or 5.2.
Sec. 4, Programming Transition. Sec. 4, Programming Transition.
Gun(s) firing for every other product, or intermittently skips products.
Product spaced too closely (pattern overlap is not allowed by PC44). Subsequent products arrive before the 30 ms reset time.
P/N 108 0998 57-26 lo/92
Troubleshooting
5-7
6. Other Gun Firing Problems

(cfmtinu6d)
Problem Pattern shifts.
Possible Reason Units with software versions 1.09 or earlier: Pattern shifts for the first substrate: PC44 gun compensation does not occur for the first pattern. Units with software versions 1.11 or later: Gun disable line speed value set too far from actual line speed. ii+L$?g the first substrate reaches the Considerations.
Adjust gun disable line speed value closer to actual line speed.
Sec. 3, Installation Tips and Considerations, and Sec. 4, Programming Gun Disable Line Speed. Sec. 3, Installation Tips and Considerations.
Pattern shifts during rapid Limit the rate of line speed acceleration or deceleration of the change. line: gun compensation is updated after each pattern (not during), line speed is sampled every 250 ms. Gun fires for no apparent reason after the line jams or stops. The PC44 memory remembers that it saw a trigger. Turn the power to the PC44 OFF during line jams or line stop conditions.
(r1 Nordson Corporatron 1992 All Rights Reserved
P/N 108 CQ9B 57-26 KY92
5-8
Troubleshooting
P2
P2-1 P2-2 P2-3 P2-4 P2-6 P2-6 P2-7 P2-8 P2-9 P2-IO P2-ii P2-12 3 P3-I P3-2 P3-3 P3-4 P3-5 P3-6 P3-7 P3-8 P3-9 P3-10
Pl
Pl-1 Pl-2 Pi-3 Pl-4 Pl-5 Pl-6 PI-7 Pl-8 P4-1 P4-2 P4-3 P4-4 P4-5 P4-6 P4-7 P4-8
Figure 5.1 - PC44 terminal block connections P2 (Power and outputs): P2- 1 (NC) P2-2 (NC) P2-3 (24V Return) PZ-4 (+24 V) P 1 (R8mOt8 Control): Pl-1 (Shield) P l-2 (Ground) PI-3 (Common; se8 note below) P3 (Pulse Tach) P3- 1 (t 12V) P3-2 (Phase A) P3-3 (Phase B) P3-4 (Ground) P4 (Trigger Inputs): P4- 1 (t 12V) P4-2 (Trigger 1) P4-3 (Ground) P3-5 P3-6 P3-7 P3-8 (Shield) (NC) (NC) (NC) P3-9 (NC) P2-5 (Valve 1 Return) P2-6 (Valve I) P2-7 (Valve 2 Return) P2-8 (Valve 2)
P2-9 (Valve 3 Return) Pi!-10 (k/V8 3) P2-11 (Valve 4 Return) P2- 12 (Valve 4)
PI-4 (Lock) PI-5 (Remote M8mOry S8/8Ct 3) Pl-6 (RemOf h!emory Sekt 2)
PI-7 (Remote Memory S8kt PI-8 (t 12V)
1)
Pi,- 70 (NC)
P4-4 (Shield) P4-5 (t 12V) P4-6 (Trigger 2)
P4- 7 (Ground) P4-8 (Shield)
NOTE: Connect to Ground or t 12V; refer to Remote Pin Characterization,
in Section 3.
Troubleshooting
5-9
Figure 5.2 - PS40 electrical input and output connections IAf3 CDEBack enclosure Input, Pin #1 (L l), from AC Input, Pin #3 (LL?/Neutral), from AC Input, Pin #5 (Ground) for AC Output, Pin #7 (24V Rtn) to PC44 P2-3 Output, Pin #8 (+24V) to PC44 P2-4
P/N 108 OiXB

57-26lW92
SECTION 6
## TABSHEET ##
Section 6
Service Parts and Reference Data
P/N 108 CWS 57-25 lo/92
6-I
Section 6 Service Parts and Reference Data

1. Introduction
This section contains the service parts list, plus the PC44 and PS40 specifications. Table 6.1 lists the service equipment for the PC44 Table 6.2 lists the service equipment for the PS40.
2. Using the Parts List

l
The part number column gives the Nordson part number. A dash indicates that the item is not for sale or is a subassembly of a saleable assembly. The description column provides the parts name, dimensions and the physical properlies. A part preceded by one bullet (e) is a component of the assembly above it. The quantity required (Qty. Reqd.) column indicates the quantity requirements per unit or assembly. If the item is listed for reference only, Ref appears in the column.
P/N 108 V39B 57-26 lo/92
6-2
~~
3. Service Parts PC44 Pattern Control Service Parts
Figure 6.1 - PC44 front assembly, rear view
Figure 6.2 - PC44, front view

0 Nordson Corporatm 1994 All Rghts Reserved
P/TI 108 OQQC 57-26 4i94
6-3
PC44 Pattern Control Service Parts

(continued)
Table 6.1 PC44 Service Equipment

Item Number QW Reqd.
Part Number
Description
131 715 972 802 972 801 972 803 972 800 981 524 981 525 114 875 146 379 134 789 116 566 117 896 131 473 131 486 131 474 131 475 131 476 145 278 145 279 145 974 148 150 132 836 148 151 160 001 160 002
PC44 Timer
l
Ref
1O-pin connector 8-pin connector, right 12-pin connector 8-pin connector, left Truss head screw, #4-40x1.5 in. Truss head screw, #4-40x2 in.
a
l
Fuse, 5A, 250V Back Enclosure Remote Memory Select Switch, 4 Position () Knob (2J Keyed Lock Out Switch, DPDT Emitter for Opposed Mode (Through-beam) Receiver for Opposed Mode (Through-beam) Retroreflective Sensor Sensor Sensor Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref @) Ref Ref
Polarizing Retroreflective Sensor Diffuse Mode Sensor Bifurcated Fiber Optic Cable (3) Replacement Cover for Diffuse Mode Sensor (4) Lens Kit @) Quadrature Encoder (dual shaft), 500 pulse/revolution Single Output Encoder Cable, 6-wire!, 30 ft (10 m) Dual Output Encoder Cable, g-wire, 30 ft (10 m) Sealed Optical Encoder (single shaft)) 500 pulse/revolution Sealed Encoder Cable, 30 ft (10 m) (I
(I Also order Knob, P/N 116 566. 12) Required with Remote Memory Select Switch, P/N 134 789. (3)Required to convert Diffuse Mode Sensor, P/N 131 476, to fiber optic operation. Also, order Replacement Cover, P/N 145 279. (4)Required with Bifurcated Fiber Optic Cable, P/N 145 278. @)Provides fiber optic retro-reflective @)For environments capability for Diffuse Mode Sensor, P/N 131 476.
requiring water-sealed equipment. Also order Sealed Encoder Cable, P/N 160 002. -______
(7)Required with Sealed Optical Encoder, P/N 160 001. -__ ---_ _--
GNordson Corporatcm lYQ4 All Rlghts Reserved
P/N 108 OQQC 57-26 4194
6-4
PS40 Power Supply Service Paris
Figure 6.3 - PS40 service parts
Table 6.2 - PS40 Service Equipment Part Number 131 739 1 2 981 525 131 477 Description PS40 DC Power Supply
l
QtY. Reqd . Ref 6 1
Screw,4-40 x 2 in. Fuse, 25OV,2 amp
P/N lof30998 57-26 lcY92
Q Nordson Corporation 1992 All Rghls Reserved
6-5
4. Specifications P specifications
Programming Flexibility Output Channels Pattern Storage Four (4) independent outputs fc- multipre c! ?VWattctiosc: Four memories selectable via front panel interface or remote inputs; each memory capable of storing a pzttern for each of the four output channels. Eight (8) transitions per channel: four delays (gun off) and four durations (gun on). Two (2) trigger inputs which can operate as either leading or trailing signals. One trigger can initiate all four outputs, or outputs may be assigned independently to either leading or trailing trigger. Dynamic programming caoabi!ity allows changes to pattern while unit is operating. Remote memory selection allows memory selection from a central location. Can be set independently for each channei; provides pattern flexibility and reduces material usage.
Pattern Complexity Triggers
Pattern Changes Remote Memory Capability Stitching Capability Pattern Parameters Distance Base Time Range Setting Precision Accuracy Temperature Drift Compensation
.
Determined by encoder resolution and gearing. In a typical set-up, 1 pulse = 1 mm (for a range of 2-9999 mm).
2 - 9999 pulses.
+ / - 1 pulse. +O,-1 pulse for the first delay. Beyond the first delay, accurate to encoder pulses. 0.01% of set time over the operating range. O-200 ms gun pull-in. O-200 ms gun drop-out. Updated at the completion of each pattern. Line speed is sampled every 250 ms. 1Ok Hz. Once a pattern is in progress, trigger signals are ignored until the pattern is complete. After the completion of a pattern, the PC44 requires 30 ms to update compensation. Any trigger signal during this interval may be ignored. Consider using channels in parallel and triggering them alternately if either of these conditions causes a problem.
Update of Compensation
Maximum Encoder Frequency Pattern Contraints
P/N 108 099B 57-26 lw92
6-6
PC44 Specifications
(continue9 User Interface LCD Screen 4digit, 7-segment numlerical display area plus selection level displays MEMORY, CHIANNEL,TRIGGER, TRANSITION, and STITCH. Trigger inputs, timer outputs, power on, and error conditions allow quick verification. Up, down, left, and right arrow push buttons for numerical increment and decrement, and for choosing program level selections; SET (enter); Nordson Oval (test and critical parameter control) push buttons. EEPROM with 10,000 read/write capabilities.
LED Indicators Setup Controls
Data Retention Inputs aInput Voltage Trigger Inputs
24 VDC. Accepts sensor with NPN (current sinking type) output or contact closure.
outputs
l
Sensor supply DC model solenoid
12 VDC, 500 mA maxirnum including all connections to +12V connections. 24 VDC, 1A max. per c,hannel.
Environmental Parameters Operating Temperature Operating Humidity Storage Temperature Mechanical Dimensions Height: 9 in. (22.9 cm); Width: 4 in. (10.2 cm); Depth: 4.4 in. (11.2 cm). On wall, machine surface, or DIN rail. Meets IP-54 requirements for moisture and dust protection when fitted with electrical conduit. Control module: 32 to 150 F (0 to 65 C). 5% to 95% non-condensing. 4 to 185 F (20 to 85 C).
Mounting Enclosure Rating
Approvals Designed for TUV, U.L., and C.S.A. Approvals Package, components, and construction.
PM 108o!xx3 57-26 lw92
6-7
PS40 Power Supply Specifications

Operating Temperature Input Voltage Output Voltage Full rating to 120 F (50 6). Factory set at 180-264 VAC (240 VAC nominal), 513/60 Hz. User selectable 90-l 32 VAC (120 VAC nominal). Provides 24 VDC (2.5A max.).
Photosensors SpecYfkations
Input Voltage Output Configuration Output Rating Response Time indicator LED Operating Range Effective Ranges
l
1O-30 VDC at less than 25 mA (exclusive of load). One current sourcing (PNP) and one current sinking (NPN) open collector transistor. 150 mA max. each output at 77 F (25 C); derated to 100 mA at 158 F (77 6). Derates approx. 1 mA per C. 1 ms. Signal strength indicator. 4 F (20 C) to 158 F (70 C).
Opposed Mode Sensors Diffuse Reflective Sensors Retroreflective Sensors (Non-polarized) Retroreflective Sensors (Polarized)
Up to 10 ft (304.8 cm). 2 in. (5.1 cm) to 15 in. (38.1 cm). Up to 15 ft (457.2 cm). Up to 7 ft (213.4 cm).
a . .
Encoder Spedfkations
Input Voltage outputs 9 Sink 5-26 VDC at 80 mA. Current sink (open collector with 2.2 kOhm pull-ups). 40 mA. 500 pulses per shaft revolution. 32 to 158 F (0 to 70 C). -40 to 194 F (-40 to 90 C).
Resolution Operating Temperature Storage Temperature
P/N 108 0998

57-26 10192

PC44 Pattern Control: Part 108 099D

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PC44 Pattern Control

Part 108 099D

NORDSON CORPORATION. AMHERST, OHIO. USA

Manual 108 089D

57-26 Issued 4197

0 1997 Nordson Corporatuon All rights reserved

VICES PROVIDED TO NORDSON CUSTOMERS

Parts And Accessories

The Nor&on Package of Values

Q Nordson Corporation 1992 All Rights Reserved

Pub. No. 106 OgeB 57-26 lo/92

770-497-3400 770- 497-3400

USA phone numbers updated 3/05

l-l l-l 1-2

Section 2 Equipment Familiarization

7. Solenoid Wiring Installation ............................

Q Nor&on Corporation 1992 All RigMs Reserved

PM 108 OggB 57-26 lo/g2

Section 3 lnstallation (continued)

Section 4 Operating Instructions

PM 10809% 57-28 l(Yg2

Corporation 1992 All Rights Reserved

Operating Instructions (continued)

Q No&on Corporation 1g92 All Rights Reserved

P/N 108 0990 67-26 lo&2

Section 4 Operating Instructions (continued)

4-43 4-43 4-44

5-l 5-l 5-l 5-2 5-5 5-6

Section 6 Service Parts and Reference Data

PM 1080998 57-26 lo192

Corporation 1892 All Rights Reserved

ci3Nor&on Corporation 1992 All Rights Reserved

PM 108 0998 57-26 10192

Section 1 Safety Summary

WARNING: Allow only qualified personnel to perform installation and troubleshooting.

2. Explanation of Termsand Symbols

0 No&on Corporation 1gQ2 All Rights Reserved

Pub. No. 108 CM8 67-26 lwg2

3. Safety During Installation v A 0

PIA No. 108 OWE 57-28 lo/Q2

0 Nordaon Corporation 1882 All Rights Reserved

0 Nor&on Corporation 1992 All Rights Reserved

P/N 108 099B 57-26 lam

Section 2 Equipment Familiarization

Figure 2.1 - PC44 Pattern Control

Q No&on Corporation 1992 All Rights Reserved

Pub. No. 108 099B 57-26 lo/92

. A description of the folur Nordson Photoelectric Sensors

2. PC44 Functional Description

Pub. No. 108 093B 57-26 lot92

63 Nordson Corporation 1992 All Rights Resewed

8 Ncdson Corporation 1gg2 All Rights Reserved

Pub. No. 108 0998 57-26 lo/92

3. PC44 User Interface

P&L No. 100 OS96 57-26 lom

Q Nordson Corporation 1992 All Rights Reserved

0 Nordsop CoporatIon All Rights Reserved

Pub. No. 108 0998 57-26 10192

Nor&on Photoelectric Sensors

Figure 2.6 - Diffuse relfective (proximity) sensor A - Emiti8r/fkC8iV8r B - Substrate

Pub. No. 108 099B

Q Nordson Corporation 1992 AllRights Resewed