Nordson PC50 PC54, PC55 Pattern Controller Manual

PC50 Series Pattern
Controllers
PC54 and PC55
Part 107 126B
NORDSON CORPORATION D AMHERST, OHIO D USA
Nordson Corporation welcomes requests for information, comments and inquiries about its products.
Address all correspondence to
Nordson Corporation
555 Jackson Street
Amherst, OH 44001
Notice
This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1995. 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,
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, and Package of
Values are trademarks of Nordson Corporation.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Table of Contents
toc-i
Table of Contents
Section 1, Safety
1. Operate Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
3. Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
4. Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
5. Installation and Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . 1-4
6. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Less-obvious Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Action in the Event of Unit Malfunction . . . . . . . . . . . . . . . . . . . . . 1-5
Danger of Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
7. Maintenance/Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
8. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
9. Thermoplastic Hot Melt Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
10. Equipment and Material Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Section 2, Description
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2. PC50 Series Pattern Controller Components . . . . . . . . . . . . . . . . . . 2-2
Controller and Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
3. Keypad Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
4. Basic Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Stitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Output Groups and Operating Modes . . . . . . . . . . . . . . . . . . . . . . 2-6
5. Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Scale Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Programming Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Motion ANDing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
E 1995 Nordson Corporation
All rights reserved
107 126A
Issued 10/95
Manual 66--PC50--MA--01 (formerly
57--30)
toc-ii
Table of Contents
Section 2, Description (contd.)
5. Standard Features (contd.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Timed Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Gun Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Speed Enable/Disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Run Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
6. Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
7. System Configuration and Preprogramming Considerations . . . . . 2-9
Output Groups and
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Controller Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Output Group Programming . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
8. Gun Compensation and Operating Modes . . . . . . . . . . . . . . . . . . . 2-26
Gun Compensation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Device Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Gun Compensation and Operating Modes . . . . . . . . . . . . . . 2-26
Pull In/Drop Out Gun Compensation . . . . . . . . . . . . . . . . . . . . . . 2-27
Negative Gun Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
9. Controller Initial Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Section 3, Installation
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Resolver Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Resolver Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Controller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Module Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3. Controller Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Controller Wiring, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Power Supply Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Manual 66--PC50--MA--01
(formerly 57--30)
107 126A
Issued 10/95
E 1995 Nordson Corporation
All rights reserved
Table of Contents
Section 3, Installation (contd.)
toc-iii
Controller Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Input Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Sinking or Sourcing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Controller Input Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . 3-15
Input Terminal Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
PC54 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
PC55 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Program Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
BCD Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Binary Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Gray Code Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Controller Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Output Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
4. Keypad Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Number of Keypads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Programming Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
5. Controller/Keypad DIP Switch Configurations . . . . . . . . . . . . . . . . 3-24
DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Controller Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Keypad Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
DIP Switch Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
6. Communications Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
RS-232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
RS-485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
7. Initial Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Bench Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
E 1995 Nordson Corporation
All rights reserved
107 126A
Issued 10/95
Manual 66--PC50--MA--01 (formerly
57--30)
toc-iv
Table of Contents
Section 4, Programming
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Main Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Hardware Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Keyboard Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Increasing Dir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Scale Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Shaft Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Run Up Qty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Pgm Sel Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
2. Set -Up Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Gun Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Timed Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Speed Enable/Disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Run Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Stitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Channel Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Program Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Default Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
3. Input /Output Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Output Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Input Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
4. System Info Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Setpoint Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Firmware Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
5. Config Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Hardware Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Display Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Rate Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Toggle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Group Position Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Manual 66--PC50--MA--01
(formerly 57--30)
107 126A
Issued 10/95
E 1995 Nordson Corporation
All rights reserved
Table of Contents
Section 4,
Programming (contd.)
toc-v
5. Config Menu (contd.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Enable Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Chn ANDing Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Output Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
6. Test Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Section 5, Troubleshooting
and Repair
1. Controller Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Keypad Not Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Internal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
2. Keypad Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
3. Resolver Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Mechanical Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Electrical Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
4. General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5. Controller Fuse Tester & Fuse Replacement . . . . . . . . . . . . . . . . . . 5-9
Fuse Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
6. Electrical Schematics and Wiring Diagrams . . . . . . . . . . . . . . . . . . 5-10
Section 6, Parts
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Using the Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
2. PC50 Series Controller Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
PC50 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Controller Output Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Resolvers and Resolver Cables . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Keypad/Display and Keypad /Display Cables . . . . . . . . . . . . . . . 6-4
Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
E 1995 Nordson Corporation
All rights reserved
107 126A
Issued 10/95
Manual 66--PC50--MA--01 (formerly
57--30)
toc-vi
Table of Contents
Section 7, Specifications
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
PC50 Series Controller Cabinet Mounting . . . . . . . . . . . . . . . . . . 7-1
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
DC Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Run Up Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
RS-232 Serial Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Section 8, Options
1. Washdown Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Installing the Washdown Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
2. Program Enable and Select Switches . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Program Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Program Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
3. PC50 Series Controller Communication Software . . . . . . . . . . . . . 8-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Nordson Communication Software . . . . . . . . . . . . . . . . . . . . . . 8-4
Modbus Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Section 9, Communications
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Nordson Communication Software . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Modbus Communication Software . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
2. Modbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
3. Nordson Communication Software . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Index
Manual 66--PC50--MA--01
(formerly 57--30)
107 126A
Issued 10/95
E 1995 Nordson Corporation
All rights reserved
Section 1
Safety
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
1-0
Safety
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Safety
1-1
Section 1
Safety
1. Operate Safely
Section 1 of Nordson’s applicator product manuals provides safety
guidelines for use of Nordson equipment. The applicator safety
guidelines apply to all operators and service personnel working with
PC50 Series controllers.
Safety instructions contained in this section and throughout this
document apply to tasks that may be performed with or on the applicator
unit and with or on associated adhesive application equipment, including
the PC50 Series controller. Warnings related to specific safety concerns
are included within the text as appropriate. It is very important that these
safety instructions are always followed. Failure to do so could result in
personal injury and/or damage to the PC50 Series controller, the
applicator or other equipment.
With this in mind, here are some basic safety recommendations:
S Read and become familiar with this Safety section prior to installing,
operating, maintaining, or repairing the unit.
S Read and follow the warnings which appear within the text and are
related to specific tasks.
S Store this document within easy reach of personnel operating or
maintaining the unit.
S Wear personal protective equipment and clothing such as safety
goggles and gloves.
S Familiarize yourself with and follow all safety instructions prescribed
by your company, general accident-prevention regulations, and
government safety regulations.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
1-2
Safety
2. Safety Symbols
The following symbols are used to warn against dangers or possible
sources of danger. Become familiar with them! Failure to heed a
warning could lead to personal injury and/or damage to the unit or other
equipment.
WARNING: Failure to observe may result in personal injury,
death, or equipment damage.
WARNING: Risk of electrical shock. Failure to observe may
result in personal injury, death, or equipment damage.
WARNING: Disconnect equipment from the line voltage.
WARNING: Hot! Risk of burns. Wear heat-protective clothing,
safety goggles, and/or heat-protective gloves depending on the
symbols shown.
WARNING: Risk of explosion or fire. Fire, open flames, and
smoking prohibited.
WARNING: System or material pressurized. Relieve pressure.
Failure to observe may result in serious burns.
CAUTION: Failure to observe may result in equipment
damage.
CAUTION: Hot surface. Failure to observe may result in
burns.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Safety
1-3
3. Qualified Personnel
“Qualified personnel” is defined here as individuals who thoroughly
understand the equipment and its safe operation, maintenance, and
repair. Qualified personnel are physically capable of performing the
required tasks, familiar with all relevant safety rules and regulations, and
have been trained to safely install, operate, maintain, and/or repair the
equipment. It is the responsibility of the company operating the
equipment to see that its personnel meet these requirements.
4. Intended Use
The unit is designed and intended to be used only for the purpose
described in the Description section. Uses not in accordance with that
section or as described in this document are considered unintended uses
and not in accordance with governing regulations.
WARNING: Use of this equipment in ways other than
described in this document may result in personal injury, death,
or equipment damage.
The following actions of the owner or operator of the unit are some, but
not all, examples of unintended use which would permit Nordson to claim
it is not responsible for personal injury or property damage arising from
such unintended use:
S Unapproved modifications or changes to the unit
S Failure to comply with the safety instructions
S Failure to comply with instructions concerning installation, use,
operation, maintenance, or repair, or when these tasks are carried out
by unqualified personnel
S Use of inappropriate or incompatible foreign materials or auxiliary
equipment
S Failure to observe workplace safety rules or regulations issued by
government authorities or safety councils
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
1-4
Safety
5. Installation and Electrical
Connections
WARNING: Failure to follow the safety procedures can result in
injury or death.
S All electrical, pneumatic, gas, and hydraulic connections and
installations of hot melt equipment may only be carried out by
qualified personnel. Be sure to observe installation instructions for
components and accessories.
S Equipment must be properly grounded and fused according to its
rated current consumption (see ID plate).
S Cables which run outside the unit must regularly be checked for wear
or damage.
S Power supply wire gauge and insulation must be sufficient to handle
rated current consumption.
S Cables must never be squeezed or pinched. Do not locate cables or
hoses in high traffic areas.
6. Operation
The unit should be operated by qualified personnel in accordance with
the instructions presented in this document.
WARNING: Failure to follow the safety procedures can result in
injury or death.
S Never allow the unit to be operated by personnel under the influence
of substances which reduce their reaction times, or who are not able
to operate the equipment for physical reasons.
S Prior to each start-up of the unit, check protection and warning
devices and make sure they are fully functional. Do not operate the
unit if these devices are not functioning properly.
S When the removal of safety equipment is required for installation,
maintenance, or repair of the unit, it must be re-connected
immediately upon completion of the work.
S Prior to start-up of the unit, check to make sure all safety guards and
safety equipment are in place and functioning properly.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Safety
6. Operation (contd.)
1-5
S In a humid environment, only equipment featuring a corresponding
class of protection may be operated.
S Do not operate the unit in an explosive environment.
S Keep parts of the body or clothing away from rotating parts. Do not
wear loose articles of clothing when operating or servicing units with
rotating parts. Take off wrist watches, rings, necklaces, or similar
pieces of jewelry and pin up or cover long hair before performing any
work on or with the unit.
S To carry out measurements on work pieces, switch off the unit and
wait until it comes to a standstill.
S Never point hand guns or applicator nozzles at yourself or other
persons.
Less-obvious Dangers
WARNING: An operator or service technician working with the
unit should be aware of less-obvious dangers that often cannot
be completely minimized at production sites:
S Exposed surfaces of the unit which cannot be practically
safeguarded. They may be hot and take time to cool after the unit
has been operating.
S The possibility that electrical potentials may remain in the unit after
the unit was de-energized
S Hot melt material and vapors
S Hydraulically or pneumatically operated parts of the unit
S Parts winding something up or down which are not covered
Action in the Event of Unit
Malfunction
If the unit malfunctions, switch it off immediately.
S Turn the circuit breaker or main power switch OFF.
S Have the unit repaired by qualified personnel only.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
1-6
Safety
Danger of Burns
Contact with hot melt materials or hot areas of the unit may produce a
severe skin burn.
WARNING: Hot! Risk of burns. Wear heat-protective clothing,
safety goggles, and/or heat-protective gloves depending on the
symbols shown.
S Be extremely careful when using hot melt material. Even solidified
material may still be very hot.
S Always wear protective clothing which safely covers all exposed parts
of the body.
In case of burns:
S Immediately cool affected skin areas using cold, clean water.
S Do not forcefully remove hot melt material from the skin.
S Immediately seek medical attention.
7. Maintenance/Repair
Allow only qualified personnel to perform the procedures described in this
document. When performing such tasks, wear protective clothing, and
equipment.
WARNING: Even when the circuit breaker or main power
switch is OFF, the unit is still electrically energized. Complete
the following steps prior to maintenance or repair:
S Disconnect, lock out, and tag external power supply.
S To ensure the external power supply is disconnected, attempt to
operate the unit. If the unit does not energize, proceed with
maintenance or repair work.
S If the unit energizes, repeat the disconnect, lock out, and tag
procedure. Re-test the unit.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Safety
7. Maintenance/Repair
(contd.)
1-7
S Follow the specific instructions provided in this manual to relieve the
system pressure in the entire unit.
S Secure pneumatically- or hydraulically-operated equipment against
uncontrolled movement.
S Only use parts which do not compromise the safety of the unit. Only
use genuine Nordson parts.
S Always use tools with insulated handles when removing or installing
components.
8. Cleaning
NOTE: Always refer to the material manufacturer’s Material Safety Data
Sheet (MSDS) or material information sheet before working with any
material.
WARNING: Never clean any aluminum part or flush any
system using halogenated hydrocarbon fluids. Examples of
common halogenated hydrocarbons are: dichloromethylene,
1,1,1-trichloroethylene, and perchloroethylene. Halogenated
hydrocarbons may react violently with aluminum parts.
WARNING: Fire, open flame, and smoking are prohibited when
cleaning fluids are used. Observe all explosion prevention
regulations. Cleaning fluids may only be heated using
temperature-controlled and explosion-protected heaters.
S Never use an open flame to clean the unit or components of the unit.
S Use only cleaning fluids designed or intended to be used with the hot
melt material being used in the unit. Never use paint fluids under any
circumstances.
S Note the flash point of the cleaning fluid used. Only use a controlled
heating method to heat fluids.
S Ensure sufficient room ventilation to draw off generated vapors.
Avoid prolonged breathing of vapors.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
1-8
Safety
9. Thermoplastic Hot Melt
Material
NOTE: Always refer to the material manufacturer’s Material Safety Data
Sheet (MSDS) or material information sheet before working with any hot
melt material.
S Ensure the work area is adequately ventilated.
S Do not exceed recommended processing temperatures. Doing so
creates a danger to personnel due to decomposition of the material.
10. Equipment and Material
Disposal
Manual 66--PC50--MA--01 (formerly 57--30)
Dispose of equipment and materials used in operation and cleaning
according to local regulations.
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Section 2
Description
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
2-0
Description
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Description
2-1
Section 2
Description
1. Introduction
This section contains a description of controller capabilities that must be
understood before programming.
NOTE: Output Groups and Operating Modes, Offset, and Gun
Compensation are discussed in this section to allow operators to
determine controller set up and programming that is best suited for their
application. These topics should be thoroughly read and completely
understood prior to any programming attempts.
PC50 controllers use a resolver (Figure 2-1) to indicate machine position.
Resolvers use fixed and rotating wire coils to generate an electronic
signal that represents shaft position. The resolver is usually coupled to a
machine shaft at a 1:1 ratio so that one resolver shaft rotation
corresponds to one machine cycle. Resolvers have no brushes,
contacts, or any frictional moving parts to wear out.
Based on the resolver signal, PC50 Series Pattern Controllers turn
electrical circuits, or “outputs,” on and off.
5940300
Fig. 2-1
Resolver
Because the combination PC50 Series Pattern Controllers/resolver
system is completely electronic and has no frictional parts, it offers
several advantages:
S Long service life with no parts to wear out
S “On” and “off” points can be adjusted instantly from the keypad
S Adjustment is possible with the machine running or stopped
S Programmable logic allows complex switching functions that are
impossible with typical pattern controllers
S Operation at speeds up to 3000 RPM
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
2-2
Description
2. PC50 Series Pattern
Controller Components
Controller and Keypad
PC50 Series controllers consist of two main components, the controller
and the keypad/display, both housed within a cabinet. The controller
contains the microprocessor, associated circuitry, and all of the I/O
circuits.
5
1
6
2
3
4
5
5940394
Fig. 2-2
PC50 Series Controller
1. Cabinet
2. Keypad/Display
3. On/Off Switch
4. Stick-On Program Menu and
Program List
5. Mounting Flange (Top and Bottom)
6. Access to Cabinet Interior
The keypad/display provides a complete user interface from which every
aspect of the controller’s operation can be monitored and programmed.
On PC55 controllers, an additional optional keypad, remotely mounted
from the main controller cabinet, can be attached to the system. A clear
silicon rubber boot assembly is available to provide protection for
installations where caustic washdown chemicals are used.
When interfaced to a PLC or IBM compatible computer, through
Nordson’s optional communication package, controller programming can
be stored on disk. If programming in a controller is lost, the controller can
be completely reprogrammed from the computer without using the
keypad/display. See Nordson Communication Software in Section 8,
Options.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Description
2-3
PC50 Series controllers are available in two models, the PC54 and the
PC55. See Section 7, Specifications for a listing of each controller’s
capabilities.
1
2
3
5
4
5940282
Fig. 2-3
Controller Keypad and Display and Program Menu Tree and Program Listing
1. Display
2. Keypad
E 1996 Nordson Corporation
All rights reserved
3. Power ON/OFF and FAULT
indicators
4. Program Menu Tree
107 126B
Issued 01/96
5. Operator Created Program Listing
Manual 66--PC50--MA--01 (formerly 57--30)
2-4
Description
3. Keypad Description
Display Screen
S Shows Active Program, RPM, Position, and Group number, if
applicable.
S See Main Screen in this section for a description of screen readouts.
5940297
Fig. 2-4
S Press SEL key when cursor is on “MENU” to enter Menu Tree and
initiate programming. See Figure 4-1.
Display Screen
Cursor Keys
Use to:
S Scroll through Menu Tree. (See Figure 4-1)
S Move around within a screen
S Scroll through setpoints
5940293
Fig. 2-5
Cursor Keys
ESC, SEL, HLP Keys
SEL
ESC
S ESC exits from current menu level to previous menu, or aborts
numeric entry.
HLP
S SEL enters a new menu level; toggles a value; and selects an output
group if multiple groups with different offsets are used.
S HLP shows help regarding menu selection and what keys to press.
5940294
Fig. 2-6
Use this key if unsure what to do.
ESC, SEL and HLP Keys
INC, DEC Keys
INC
S Increment or Decrement (increase or decrease) a value within a field.
S Hold for rapid scrolling of value.
DEC
5940295
Fig. 2-7
INC and DEC Keys
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Description
2-5
3. Keypad Description
(contd.)
Numeric Keys
S Input numeric values within a field.
S ENT must be pressed to enter the value; entry will flash until ENT is
pressed.
S CLR will backspace within an entry prior to pressing ENT.
S converts a positive number to a negative number, or vice versa.
5940296
Fig. 2-8
Numeric Keys
4. Basic Terminology
The following terms, used throughout this manual, are defined to provide
understanding of PC50 Series controller installation, programming and
operation:
Channels
Each Channel (CHN) in a PC50 Series controller contains “on” and “off”
setpoints for one 360 revolution of the resolver shaft. There are two
types of channels:
Output Channels -- Output module(s) are used to turn an external
circuit on or off. The number of output channels depends on the
number of output modules provided in the controller. One or two Run
Up modules, depending on the controller type, may be used to
generate a control signal proportional to parent machine rpm.
NOTE: PC54 controllers can have 1 optional Run Up module. PC55
controllers can provide up to 2 optional Run Up modules.
Group Channels -- control the interaction between groups of outputs
and an input received from a sensor or other controlling device. See
Output Groups and Operating Modes in this section for details on
Group Channels.
Setpoints
“Setpoints” are the points within one rotation of the resolver at which a
channel turns on or off. Setpoints are programmed into a channel
through the keypad/display. PC50 Series controllers can turn any given
channel on and off multiple times within one rotation.
NOTE: With the optional communication package, setpoints can be
downloaded from a computer or PLC through serial communications.
Duration
E 1996 Nordson Corporation
All rights reserved
A “duration” is the “on” period between the time a channel is turned on
and off. The “on” setpoint is the leading edge of the duration, and the
“off” setpoint is the trailing edge. Adhesive is applied to the substrate
during the duration. When multiple pairs of setpoints are programmed
into one channel, the channel is said to have multiple durations.
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
2-6
Description
4. Basic Terminology
(contd.)
Stitch
Stitch is a type of adhesive application with a duration consisting of a
repeating pattern of short adhesive beads (stitch lengths) with uniform
spaces (stitch gaps) between them.
Programs
A program is combination of channels (output and group) with defined
setpoints that perform a specific operation. The settings are stored as a
program. For example:
S Output channels on the controller are programmed with setpoints
S
S
to apply a specific adhesive pattern to the leading and trailing flap
of a certain size carton. These settings are stored as a “program.”
The output channels can then be reprogrammed with different
setpoints for a different size carton. This second set of setpoints
is then stored as a program.
An operator activates the program corresponding to the carton
size being run and the program of setpoints takes effect.
The active program is selected through the keypad/display or the optional
communication package.
S PC54 controllers can store 16 programs.
S PC55 controllers can store 64 programs.
Inputs
In addition to accepting a signal from the resolver, PC50 Series
controllers can accept input signals from mechanical switches, relay
contacts, DC two- or three-wire sensors, solid state DC output modules,
or PLC DC outputs.
PC50 Series controller hardware inputs are dedicated to specific
functions involving program selection, and controlling output channels
based on sensor signals.
NOTE: The PC54 can have up to 8 inputs; the PC55 can have up to 16
inputs.
Output Groups and Operating
Modes
Output channels can be combined into “Output Groups”, and each Output
Group can be associated with an input terminal in different “Operating
Modes”.
S PC54 controllers have three different Operating Modes.
S PC55 controllers have six different Operating Modes.
See Output Groups and Operating Modes in this section.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Description
2-7
5. Standard Features
Scale Factor
Users can program the number of increments per revolution, or “Scale
Factor”.
S PC54 controllers have a resolution of 2-1024 increments per
S
revolution.
PC55 controllers have a resolution of 2-4096 increments per
revolution.
Examples of possible linear distance applications include:
-
the scale factor may be set to define increments in terms of linear
distance, such as one increment equals 0.1I of travel
for an application (with the PC55 controller only) in which one
revolution of the resolver equals 24I of linear travel, a scale factor
of 2400 results in increments equal to 0.01I of travel
Examples of having the controller display position in degrees include:
-
the scale factor may be set at 360 (for both the PC54 and the
PC55) allowing programming in 1 degree increments
the scale factor may be set at 3600 (PC55 only) allowing
programming in 0.1 degree increments
Programming Access
Two levels of programming access are provided: Operator and Master.
Each level is assigned a password which must be entered, to allow
programming at that level. Careful use of programming access levels
provides key personnel with required flexibility in controller programming,
while protecting settings against accidental/unauthorized changes. The
Operator and Master levels can be activated on an individual keypad
through hardware terminals on the back.
Speed Enable/Disable
Minimum/maximum speed ranges can be programmed into the controller.
Each power output module can be linked, (through ANDing, see CHN
ANDing Menu) with the minimum or maximum speed range.
Min Speed ANDing
The Min Speed ANDing selection is used to link (AND) programmed
outputs to either of two speed ranges programmed into the controller.
Typically, outputs are ANDed with either speed range such that the
output is disabled unless the machine speed is within the range.
Timed Outputs
Timed outputs, like standard outputs, are programmed to turn on and off
at specific points during resolver rotation. Once a timed output is on, it
remains on for a specified time period regardless of RPM. However, if
the programmed off position is reached before the the time period
passes, the output turns off. Timed outputs can be used to provide a
constant volume of adhesive over a wide range of machine speed.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
2-8
Description
5. Standard Features
(contd.)
Gun Compensation
Gun Compensation advances the setpoints for gun output as machine
speed increases, providing greater accuracy, higher production speeds,
and reduced downtime for machine adjustment.
Pull In/Drop Out
The PC50 Series controller’s pull-in/drop-out gun compensation
programming factors in the response time for gun actuators. This feature
is used for devices whose “on” and “off” response times may be different.
See Gun Compensation later in this section.
Run Up
Optional Run Up output modules produce output signals linearly
proportional to parent machine rpm. The Run Up signal levels at zero
rpm, as well as the rpm that corresponds to maximum signal (maximum
line speed), can be programmed. Measuring equipment and calibration
is not required for set up and operation.
Typical use for this Run Up output is to control adhesive output by
varying applicator motor speed and pressure control (by signaling the
applicator) as parent machine speeds change.
S PC54 controllers - one (1) optional output module
S PC55 controllers - two (2) optional output modules
6. Optional Features
Manual 66--PC50--MA--01 (formerly 57--30)
See Section 8, Options for a description of options available on PC50
Series controllers. Insert instruction sheets for any purchased options in
the Options section of this manual for future reference.
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Description
7. System Configuration
and Preprogramming
Considerations
Output Groups and
Operating Modes
2-9
NOTE: Output Groups, Operating Modes, Offset, and Gun
Compensation are discussed in this section to provide operators with
PC50 Series controller set up and programming considerations. These
topics should be thoroughly read and completely understood prior to any
programming attempts.
Controller Input Signals
In many industrial applications, the action of a machine component such
as an adhesive gun pneumatic solenoid, electric adhesive gun driver or
parent machine pneumatic cylinder is related to an input signal from a
limit switch, sensor, or controller such as a PLC. Typically, input signals
are used in two ways:
Conditional Operation
S The device being controlled is allowed to function only if an input
signal occurs. In adhesive application, photoeyes are used to
sense the presence of a product immediately before adhesive
application occurs. If the product is not present, the gun is not
enabled to turn on at its programmed setpoints.
Phase Adjustment
S The device being controlled must maintain a certain relationship
to other devices on the machine. For example, web converting
lines such as disposable diaper machines usually have several
machine sections, each performing a different operation on a
continuous web of material. As line speed increases, the phase
relationships between different machine sections adjust,
compensating for stretching of the web material. To keep a
device synchronized within its machine section, a sensor is used
to detect a registration mark on a component such as shaft or
disk. The sensor signal “resets” the position of the device each
revolution, ensuring that the device operates at the correct
position on the web of moving material.
PC50 Series controller programming links input signals from sensors or
other devices to the controller’s output channels. The controller’s output
channels can remain separate or they can be combined together into
groups. Each Output Group can then be assigned to an Operating Mode.
The Operating Mode controls the interaction between the output group
channel, its input terminal and its output channel(s).
NOTE: PC54 controllers have two inputs which can be associated with
two Output Groups. PC55 controllers have six inputs, allowing output
channels to be divided into as many as six group channels.
NOTE: PC54 controllers have Operating Modes 2, 3, and 5 available.
PC55 controllers have Operating Modes 0-5 available.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
2-10
Description
Output Groups and
Operating Modes (contd.)
Output Group Programming
PC50 Series controller output channels can be combined into Output
Groups through OUTPUT GROUP programming. The number of
available Output Groups depends on the controller type.
NOTE: On PC54 controllers, each Output Group is automatically
associated with one of the input terminals on TB 1, (See Figure 3-11) as
well as a special “Group Channel” ranging from Channel 91 to 92.
NOTE: On PC55 controllers, each Output Group is automatically
associated with one of the input terminals on TB 1, (See Figure 3-12) as
well as a special “Group Channel” ranging from Channel 91 to 96.
The relationship between Output Groups, input terminals, and group
channels is summarized in Table 2-1 and Table 2-2.
Table 2-1 PC54 Controller
Output Groups, Input Terminals, and Group Channels
Output
Group
Group Input
Terminal
TB 1, (Figure 3-13)
Group
Channel
1
1
91
2
2
92
Table 2-2 PC55 Controller
Output Groups, Input Terminals, and Group Channels
Manual 66--PC50--MA--01 (formerly 57--30)
Output
Group
Group Input
Terminal
TB1, (Figure 3-14)
Group
Channel
1
9
91
2
10
92
3
11
93
4
12
94
5
13
95
6
14
96
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Description
2-11
Output Group Programming (contd.)
When combining output channels into Output Groups, specific rules must
be followed:
S Output channels are assigned to Output Groups sequentially.
S
S
S
Output Group 1 begins with output channel 1 and includes the
specified number of output channels; Output Group 2 begins with
the next output channel and continues sequentially for its
specified number of output channels; and so on. The last Output
Group automatically includes all remaining output channels.
With the PC55, six Output Groups or as few as one Output Group,
can be established.
With the PC54, two Output Groups or as few as one Output
Group, can be established.
More than one Output Group can be assigned to the same
Operating Mode.
Table 2-3 Output Group Example 1 (PC54)
All Outputs in One Group
Output
Group
Includes
Output
Channels
Group Input
Terminal
TB 1, Figure 3-13
Group
Channel
*Mode
1
1 thru 8
1
91
2, 3, or 5
All Outputs in Two Groups
Output
Group
Includes
Output
Channels
Group Input
Terminal
TB 1, Figure 3-13
Group
Channel
*Mode
1
1 thru 4
1
91
2, 3, or 5
2
5 thru 8
2
92
2, 3, or 5
*NOTE: PC54 controllers have Operating Modes 2, 3, and 5 available.
PC55 controllers have Operating Modes 0-5 available.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
2-12
Description
Output Group Programming (contd.)
Table 2-4 Output Group Example 2 (PC55)
All Outputs in One Output Group
Output
Group
Includes
Output
Channels
Group Input
Terminal
TB 1
(Figure 3-14)
Group
Channel
1
1 thru 25
9
91
Output
Group
Includes
Output
Channels
Group Input
Terminal
TB 1
(Figure 3-14)
Group
Channel
1
1 thru 4
9
91
0,1, 2, 3, 4
or 5
2
5 thru 25
10
92
0,1, 2, 3, 4
or 5
Output
Group
Includes
Output
Channels
Group Input
Terminal
TB 1
(Figure 3-14)
Group
Channel
1
1&2
9
91
0,1, 2, 3, 4
or 5
2
3&4
10
92
0,1, 2, 3, 4
or 5
3
5 thru 25
11
93
0,1, 2, 3, 4
or 5
*Mode
0,1, 2, 3, 4
or 5
All Outputs in Two Output Groups
*Mode
All Outputs in Three Output Groups
*Mode
Output Group Assignment to Operating Modes
During OUTPUT GROUP programming, each Output Group is assigned
an Operating Mode that controls the interaction between the Output
Group, its input terminal, and its group channel.
*NOTE: PC54 controllers have Operating Modes 2, 3, and 5 available.
PC55 controllers have Operating Modes 0-5 available.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Description
Output Groups and
Operating Modes (contd.)
2-13
Operating Modes
Operating Mode 0
NOTE: Mode 0 is available only on the PC55 controller.
NOTE: Mode 0 can be simulated on a PC54 controller by using Mode 3,
and hardwiring the group’s input permanently “on”.
Output channels in a group assigned to Operating Mode 0 energize at
programmed setpoints and are not affected by the corresponding input
terminal or group channel. For example, adhesive guns fire at the
programmed setpoints regardless of trigger input. (A trigger has no effect
on any output group operating in Mode 0.
S MIN SPEED ANDing and REM ENAB ANDing can be used with
outputs in an Operating Mode 0 group.
S The machine position for an Operating Mode 0 group can be set
through OFFSET programming. See Section 4, Programming.
Programming
During OUTPUT GROUP programming, group together output channels
that should remain unaffected by Operating Modes, and assign them to
Operating Mode 0.
Operating Mode 1
1
2
3
Fig. 2-9
5940332
NOTE: Mode 1 is available only on the PC55.
Output Groups assigned to Operating Mode 1 are always enabled to turn
on at their programmed setpoints. However, when the corresponding
input terminal is energized, the machine position for the group
immediately resets to the “Preset” value programmed through the
OFFSET function, (See Section 4, Programming.)
Once the position is reset, the input terminal has no effect until it is turned
off and the resolver reaches the leading edge of a duration programmed
into the corresponding group channel. See Table 2-1 and Table 2-2 for
input terminal and group channel assignments.
Operating Mode 1 - Typical
Setup
1. Group Channel Duration
2. Input Signal
3. Output Channel Duration
NOTE: Operating Mode 1 can be used to automatically adjust phase
relationships between machine sections. Another use is in applications
where some machine sections run multiple cycles per resolver revolution.
S The group position resets at the leading edge of the input terminal
S
S
E 1996 Nordson Corporation
All rights reserved
signal, regardless of how long the terminal is on (item 2, Figure
2-9).
Output channel setpoints are always enabled (item 3, Figure 2-9).
Duration (item 1, Figure 2-9) in Group Channel re-arms the
terminal .
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
2-14
Description
Operating Mode 1 (contd.)
Possible Applications:
S Machines with Multiple Cycle Ratios - Some machines have different
S
1
sections that run at different cycle ratios per overall machine cycle.
For example, one portion of a machine may complete several cycles
while another section makes only one cycle. By using Mode 1 or 2, it
is possible for some output groups to cycle multiple times while others
cycle once.
Web Converting Machines - Disposable diapers, medical pads, office
folders, and similar products. Mode 1 can automatically change the
timing of individual machine sections to compensate for changes in
phase relationships between sections.
4
1
2
5
8
6
5
3
7
5
3
2
9
5940311
Fig. 2-10 Operating Mode 1 Example Application
1. Machine Sections 1, 2, and 3
2. Ratio 1:1
3. Resolver
4. Sensor Group 1
5. Registration Marks
6. Sensor Group 2
7. Sensor Group 3
8. Adjustable Differential
9. Machine Shaft
Three sections of an adjustable phase converting machine are controlled
by a single controller and resolver. Groups 1, 2 and 3 all operate in Mode
1. The position of each group is reset to the “preset” value when the
group’s sensor detects the registration mark on the shaft for the
corresponding machine section. This keeps the electrical control signals
properly synchronized to the mechanical devices in each section when
phase adjustments are made.
One resolver provides the position information needed for all sections of
the machine, regardless of their phase relationship.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Description
2-15
Operating Mode 1 (contd.)
Application Specifics
S The group position resets at the leading edge of the input terminal
signal, regardless of how long the terminal is on.
S Once a reset occurs, the input terminal has no effect until it is
S
S
S
S
S
de-energized and the leading edge of a duration in the
corresponding group channel re-arms the terminal.
When the position of a group resets, the position of the
corresponding group channel also resets.
On start-up, the input terminal is armed and the group position is
the same as the value programmed in SHAFT POSITION, Section
4, Programming. When powered down, the group’s current
position setting is lost.
Either edge of a duration in the group channel can re-arm the
input terminal. If the resolver shaft is rotating in the forward
direction (position is increasing as shaft rotates) the “on” edge of
the duration re-arms the terminal. If the shaft is rotating in the
reverse direction (position decreasing as shaft rotates), the “off”
edge of the duration re-arms the terminal.
Each program in the controller can have different setpoints for
output channels and the corresponding group channel.
MIN SPEED ANDing and REM ENAB ANDing can be used with
outputs in an Operating Mode 1 group.
Programming
See Tables 2-1 and 2-2 for input terminal and group channel assignments
while reviewing programming steps.
1. Follow the programming steps in OUTPUT GROUPS, in Section 4,
Programming to establish Output Groups and Operating Modes.
2. Program the “Preset” value for each Operating Mode 1 group
following the steps in OFFSET, in Section 4. Programming.
3. Jog the machine to the point where the group input terminal
energizes. Using this point as a reference, program setpoints into the
output channels in the group.
4. Program a duration in the group channel to disable the output
channels and re-arm the input terminal. This duration must be after
all of the output channels have completed their functions, but before
the input terminal is energized.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
2-16
Description
Operating Mode 2
NOTE: Mode 2 is available on both the PC54 and PC55 controllers.
2
1
3
Operating Mode 2 Output Groups are disabled until the corresponding
input terminal is energized. The input terminal resets the group position
and enables the output channel. Once the input terminal energizes,
outputs then turn on at their programmed setpoints, and the group
position immediately resets to the value programmed through the
OFFSET function. (See Section 4, Programming.)
The leading edge of a duration in the corresponding group channel
disables the group’s outputs and re-arms the input terminal.
5940334
Fig. 2-11
Operating Mode 2 - Typical
Set-Up
1. Group Channel Duration
2. Input Signal
3. Output Channel Duration
NOTE: Operating Mode 2 is used where products may not be evenly
spaced and when the Output Groups should cycle only if product has
been sensed.
Application Specifics
S Outputs are enabled and the group position resets at the leading
S
S
S
S
S
S
Manual 66--PC50--MA--01 (formerly 57--30)
edge of the input terminal signal, regardless of how long the
terminal is on.
Once a reset occurs, the input terminal has no effect until it
de-energizes and the leading edge of a duration in the
corresponding group channel re-arms the terminal.
When the position of a group resets, the position of the
corresponding group channel also resets.
On power up, outputs are disabled, the input terminal is armed,
and the group position is the same as the value programmed in
SHAFT POSITION, Section 4, Programming.
Either edge of a duration in the group channel can re-arm the
input terminal. If the resolver shaft is rotating in the forward
direction (position is increasing as shaft rotates) the “on” edge of
the duration re-arms the terminal. If the shaft is rotating in the
reverse direction (position decreasing as shaft rotates), the “off”
edge of the duration re-arms the terminal.
Each program in the controller can have different setpoints for
output channels and the corresponding group channel.
MIN SPEED ANDing and REM ENAB ANDing can be used with
outputs in a Operating Mode 2 group.
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
2-17
Description
Operating Mode 2 (contd.)
2
3
4
1
5
6
7
5940272
Fig. 2-12 Operating Mode 2 Example Application
1. Conveyor Direction
2. Group 1 Sensor
3. Group 1 Adhesive Gun
4. Group 2 Sensor
5. Group 2 Adhesive Gun
6. Adhesive Pattern
7. One Resolver Provides Info for Both
Guns
Application Example
Refer to Figure 2-12 while reviewing the application example.
S Two adhesive guns at different locations on the conveyor are
S
S
controlled independently by a single controller and resolver.
Product spacing is random.
The sensors are connected to the input terminals for the
corresponding groups. When a sensor detects a product, it resets
the corresponding group position to the “preset” values and
enables the group outputs to turn on the guns at the correct
setpoints.
When parts are not present, the outputs are inactive.
Programming
See Tables 2-1 and 2-2 for input terminal and group channel assignments
while reviewing programming steps.
1. Program OUTPUT GROUPS to establish groups and modes.
2. Use OFFSET to program the “Preset” value for any Operating Mode 2
Output Groups.
3. Jog the machine to the point where the group input terminal will
energize. Using this point as a reference, program setpoints into the
output channels in the group.
4. Program a duration in the group channel to disable the output
channels and re-arm the input terminal. This duration must be after
all of the output channels have completed their functions, but before
the input terminal is energized.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
2-18
Description
Operating Mode 3
NOTE: Mode 3 is available on both the PC54 and PC55 controllers.
Description
1
Output Groups assigned to Operating Mode 3 are on only while their
programmed setpoints are on and while the corresponding input terminal
is energized. If the input terminal is off, all outputs are off, regardless of
setpoint programming.
NOTE: Use Operating Mode 3 where outputs should be active only while
a sensor or limit switch is on.
2
5940274
Fig. 2-13 Operating Mode 3 - Typical
Set-Up
1. Input Signal
2. Output Channel Duration
Application Specifics
S The group channel for a group operating in Mode 3 has no effect.
S Each program in the controller can have different setpoints for
S
S
output channels in the group.
MIN SPEED ANDing and REM ENAB ANDing can be used with
outputs in a Mode 3 group.
The machine position for a Mode 3 group can be set through
OFFSET programming.
Programming
See Tables 2-1 and 2-2 for input terminal assignments.
1. Program OUTPUT GROUPS to establish Output Groups and
Operating Modes.
2. Use OFFSET to program the absolute offset value for any Operating
Mode 3 groups.
3. Program setpoints into the output channels in the group.
NOTE: Output channels in Operating Mode 3 are enabled only while a
signal is applied to the group terminal.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Description
2-19
Operating Mode 3 (contd.)
2
1
3
4
5
5940273
Fig. 2-14 Operating Mode 3 Application Example
1. Adhesive Application Stops When
Sensor Turns Off Due to Carton
Crushing
2. Adhesive Gun
3. Sensor
4. Conveyor Direction
5. Resolver Linked to Conveyor
Application Example
Refer to Figure 2-14 while reviewing the application example.
Adhesive application occurs only while the photo-eye sees the top edge
of a carton. Adhesive application stops when crushed or improperly
erected cartons cause the photoeye to lose sight of the carton’s top edge.
Operating Mode 3 eliminates the need to hardwire photoeyes and other
sensors in series with the corresponding controller outputs. Instead, the
sensor is “ANDed” with the output through Operating Mode 3
programming.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
2-20
Description
Operating Mode 4
NOTE: Mode 4 is only available on the PC55 controller.
Refer to Figure 2-15 while reading the Operating Mode 4 description.
1
2
3
Output Groups in Operating Mode 4, are enabled to turn on at their
programmed setpoints for one machine cycle if the corresponding input
terminal (item 1), turns on within a duration programmed into the group
channel (item 2). The output channel (item 3) is disabled at the start of
the next duration in the group channel.
NOTE: Use Operating Mode 4 to check the presence and correct
positioning of a product before enabling the outputs for this machine
cycle. Operating Mode 4 operation is appropriate for flight bar
conveyors, rotary index tables, and similar types of machinery where
product position is consistent from cycle to cycle.
5940275
Fig. 2-15 Operating Mode 4 - Typical
Setup
1. Input Signal
2. Group Channel Duration
3. Output Channel Duration
Application Specifics
S The leading edge of the signal from the input terminal must occur
S
S
S
S
Manual 66--PC50--MA--01 (formerly 57--30)
during the duration in the group channel. If the leading edge
occurs before the duration, the outputs are not enabled.
Each program in the controller can have different setpoints for
output channels and the corresponding group channel.
Either edge of a duration in the group channel can disable the
outputs. If the resolver shaft is rotating in the forward direction
(position is increasing as shaft rotates) the “on” edge of the
duration disables the outputs. If the shaft is rotating in the reverse
direction (position decreasing as shaft rotates), the “off” edge of
the duration disables the outputs.
MIN SPEED ANDing and REM ENAB ANDing can be used with
outputs in an Operating Mode 4 group.
Machine position for an Operating Mode 4 group can be set
through OFFSET programming.
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Description
2-21
Operating Mode 4 (contd.)
Programming
See Tables 2-1 and 2-2 for input terminal and group channel
assignments.
1. Program OUTPUT GROUPS to establish Output Groups and
Operating Modes.
2. Use OFFSET to program the absolute offset value for any Operating
Mode 4 Output Groups.
3. Jog the machine to the point where the group input terminal
energizes. Program a duration in the group channel that turns on a
little earlier than this point, and off a little later. The shorter the
duration, the narrower the portion of the machine cycle in which the
input signal enables the outputs.
4. Program setpoints into the output channels in the group.
NOTE: The leading edge of the duration in the group channel disables
the output channels in the group.
Application Example
3
2
1
4
5
5940276
Fig. 2-16 Operating Mode 4 - Application Example
1. Empty Flight Bar
2. Sensor
3. Adhesive Gun
4. Conveyor Direction
5. Carton Positioned Ahead of Flight
Bar is Skipped
Refer to Figure 2-16 while reviewing the application example.
The adhesive gun is enabled for one machine cycle only if the sensor
detects the leading edge of a carton during the duration programmed in
the group channel. If a carton is missing (item 1) or incorrectly
positioned, (item 5) the gun does not activate.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
2-22
Description
Operating Mode 5
NOTE: Mode 5 is available on both the PC54 and PC55 controllers.
Mode 5 operation is similar to Mode 4 operation, with the following
differences:
S In Mode 5, the Group Outputs are enabled if any portion of the
1
S
S
3
2
5940277
input signal occurs within the duration programmed into the group
channel. (In Mode 4, the input terminal signal leading edge must
occur within the duration.)
If the machine stops, the group outputs are disabled immediately.
This prevents adhesive application from continuing if the machine
stops.
If the machine is stopped and the group’s input terminal is “on”,
energizing the First Cycle Enable (terminal #7 on TB 1 for the
PC54; terminal #15 on TB 1 for the PC 55) re-enables the
outputs. The discontinued operation can be completed on the
product in process when the machine stopped.
Fig. 2-17 Operating Mode 5 - Typical
Set-Up
1. Input Terminal Within Duration
Enables Outputs
2. Duration of Group Channel
3. Output Channel Duration
Application Specifics
S Regardless of its programmed “off” point, the duration in the group
channel ends as soon as any of the outputs in the group turn on.
S Each program in the controller can have different setpoints for
S
S
Manual 66--PC50--MA--01 (formerly 57--30)
output channels and the corresponding group channel.
MIN SPEED ANDing and REM ENAB ANDing can be used with
outputs in an Operating Mode 5 group. Use MIN SPEED ANDing
to prevent the First Cycle Enable terminal from re-activating the
outputs while the machine is stopped.
The machine position for an Operating Mode 5 group can be set
through OFFSET programming.
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Description
2-23
Operating Mode 5 (contd.)
Programming
See Tables 2-1 and 2-2 for input terminal and group channel
assignments.
1. Program OUTPUT GROUPS to establish Output Groups and
Operating Modes.
2. Use OFFSET to program the absolute offset value for any Operating
Mode 5 Output Groups.
3. Jog the machine to the point where the group input terminal
energizes. Program a duration in the group channel that will be on
during any portion of the input terminal signal. The smaller the
overlap between the input signal and the group channel duration, the
narrower the portion of the machine cycle in which the input signal
enables the outputs.
4. Using the start of the overlap from Step 3 as a reference point,
program setpoints into the group output channels.
NOTE: Do not overlap setpoints programmed in Step 4 with the group
channel duration programmed in Step 3.
Application Example
3
2
1
4
5
5940338
Fig. 2-18 Operating Mode 5 - Application Example
1. Empty Flight Bar is Skipped
2. Sensor
3. Adhesive Gun
4. Pushbutton to Finish Cycle
5. Conveyor Direction
The adhesive gun (item 3) is enabled for one machine cycle if the sensor
(item 2) detects a carton during the duration programmed in the group
channel. If a carton is missing (item 1) the gun does not activate.
If the line stops, the gun is disabled immediately. The gun is re-enabled
on the same machine cycle by depressing the pushbutton (item 4) while
the product sensor is ‘on’.
NOTE: On the PC54, the pushbutton is wired to Terminal 7 of TB 1; on
the PC55, Terminal 15 of TB 1.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
2-24
Description
Offset
Menu Path
At the MAIN SCREEN:
-
Press SEL
Scroll down to SETUP MENU. Press SEL.
Scroll down to OFFSET. Press SEL.
Since PC50 Series Controllers are programmable, they can be set to
display a “zero” position at any point in the machine cycle. Usually, a
machine is jogged to the beginning of a cycle, and the SHAFT POSITION
function is set to zero at this point.
Each Output Group operating in Mode 0, 3, 4, or 5 (where applicable,
depending on controller model) can be individually “offset” from this
SHAFT POSITION through OFFSET programming. This allows the
output channels in a group to be set to “zero” at a different machine
position than the one that corresponds to “zero” in SHAFT POSITION.
1
2
1. Output Group
2. Group Position = Shaft Position + ABS
Offset
3. Absolute Offset Value for This Group
3
5940339
Fig. 2-19 Offset Screen - Group Mode 0, 3, 4 or 5
Setting an Output Group to its own zero position simplifies setpoint
programming for output channels by clarifying the relationship between
the setpoints and the machine component controlled by the group.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Description
2-25
Offset (contd.)
EXAMPLE:
Assume that an Output Group controls a gun on a cartoning
machine and that the scale factor is 360_ (1 increment equals 1
degree). When jogging the machine and viewing POS on the
controller display, it is evident that the gun opens at 347 and closes
at 22 when using the position set through SHAFT POSITION.
Since other output channels correlate well with SHAFT POSITION,
it is not desirable to change the SHAFT POSITION setting.
By using the OFFSET function for this group, and adding 13 to the
shaft position, the gun opens at a group position of 0 and closes at
35. Although the group position has been “offset” by 13, the gun
still opens at 347 and closes at 22, in terms of shaft position.
For Output Groups operating in Mode 1 or 2, (where applicable,
depending on controller model) the group position is reset to a “preset”
value whenever the group’s input terminal is energized. This preset is
defined through OFFSET programming. Because the reset can occur at
any resolver position, the relationship between the position of a group
operating in Mode 1 or 2 and the SHAFT POSITION varies.
1
2
1. Output Group
2. Group Position = PRE + Change Since
Last Reset
3. Group Preset Value (If Group is
Mode 1 or 2)
3
5940340
Fig. 2-20 Offset Screen -Group Mode 1 or 2
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
2-26
Description
8. Gun Compensation and
Operating Modes
“Gun compensation” is the controller’s ability to automatically advance or
retard setpoints in any output channel depending on the speed of the
machine. Gun compensation allows devices with fixed response times,
such as solenoids or electric gun drivers, to perform accurately over a
wide range of machine speeds. Without gun compensation, the adhesive
pattern “drifts” out of position as parent machine speed increases.
Programming gun compensation for the gun output channel, maintains
the adhesive pattern position precisely throughout the complete range of
machine speeds.
Gun compensation affects individual channels in an Output Group as
programmed through GUN COMP. However, gun compensation will not
affect the group channels, 91 through 96.
Gun Compensation Guidelines
Device Placement
For gun compensation to work most effectively, the device being
controlled by the output channel should be located on the machine in a
position where the product moves past the device at a constant speed.
(Figure 2-21) In the case of a gun, if the gun is ON when the speed is
changing, adhesive distribution may be inconsistent from carton to carton
at varying machine speeds.
1
2
3
5940341
Fig. 2-21 Constant Product Speed
Past Gun
1. Gun Placement at Line Steady
Speed Location
2. Product Speed
3. One Machine Cycle
Gun Compensation and Operating Modes
When using Operating Modes, be aware that gun compensation affects
the relationship between the setpoints, the Group Input signal, and the
duration programmed into the Group Channel.
When using gun compensation and Operating Modes together:
S Gun compensation may shift an output channel’s setpoints into a
duration programmed in the group channel
S Gun compensation may shift an output channel’s setpoints into
the position in which an input signal occurs
NOTE: Depending on the Operating Mode selection and the setpoint
arrangement, gun compensation may produce unexpected results.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Description
Pull In/Drop Out Gun
Compensation
2-27
Gun pull in/drop out allows assigning different adhesive gun
compensation values for the leading and trailing edges of the adhesive
application duration. Consequently, machine operators can precisely
define, within a targeted area, how close to the front and back edges
(leading/trailing edges) adhesive is applied.
Setting Pull In/Drop Out Gun Compensation
1. If the gun’s ON and OFF response times are known, jog the parent
machine line to determine ON and OFF setpoints at zero line speed.
2. Enter the gun compensation values through GUN COMP
programming.
NOTE: When setting gun compensation on a system where zero speed
setpoints are established, always adjust the gun compensation value. Do
not adjust the individual output setpoints!
Compensation setting where system response time is not known:
1. Jog the line to determine ON and OFF setpoints at zero speed.
2. Estimate gun response times for ON and OFF and enter them
through the GUN COMP function. The ON timing value controls Pull
In, while the the OFF timing value controls Drop Out.
3. Start the parent machine and run product through the adhesive
station at a fixed speed. Adjust each gun compensation value as
required for proper application. This can be done while the line is in
motion.
4. Once the ON and OFF setpoints are programmed, vary the line
speed to confirm proper operation at all speeds. Fine tune the GUN
COMP values if necessary.
Compensation setting where parent machine can’t be jogged:
NOTE: GUN COMP must be set to zero, for both Pull In and Drop Out,
while establishing the setpoints.
1. Run the line at a fixed speed, setting the gun ON and OFF operating
setpoints as required. Write down the programmed ON and OFF
setpoints.
2. Increase the line speed, adjusting the gun ON and OFF operating
setpoints to restore proper application.
NOTE: Do not adjust gun compensation values when adjusting ON and
OFF setpoints. The first setpoints were adjusted at fixed speed with zero
compensation. Changing the GUN COMP value now will upset the first
pair of setpoints.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
2-28
Description
Pull In/Drop Out Gun
Compensation (contd.)
3. Establish the second pair of setpoints.
4. Establish separate Pull In and Drop Out GUN COMP values as
calculated in the example in Table 2-5.
Table 2-5 Example for Calculating Pull In and Drop Out
RPM
Pull In
(Glue On)
Drop Out
(Glue Off)
Difference
1st Line Speed:
200
73_
156_
83_
2nd
680
49_
144_
95_
Line Speed:
NOTE: The length of the duration is 83_ at 200 RPM, and 95_ at 680 RPM.
This means that the leading and trailing edges require different speed
compensation values.
Leading Edge (Pull In)
Difference in Position: 73_ -- 49_ = 24_
Difference in Speed:
680 RPM -- 200 RPM = 480 RPM
Speed Compensation Value: Divide difference in position by difference in speed:
24_/480 RPM = 0.05_ per 1 RPM
Since a shaft at 1 RPM rotates 0.006_/ms, this shaft requires (0.05/0.006), or 8.3 ms
to rotate 0.05_. This speed compensation value is 8.3.
Trailing Edge (Drop Out)
Difference in Position: 156_ --1 44_ = 12_
Difference in Speed:
680 RPM -- 200 RPM = 480 RPM
Speed Compensation Value: Divide difference in position by difference in speed:
12_/480 RPM = 0.025_/ 1 RPM
Since a shaft at 1 RPM rotates 0.006_/ms, this shaft requires (0.025/0.006), or 4.2
ms to rotate 0.05_. This speed compensation value is 4.2.
5. Gun compensation settings programmed in Step 4 affect the ON and
OFF setpoints programmed in Step 1. Restart the parent machine
line, running it at a constant speed, adjusting the ON and OFF
setpoints, as required, for proper adhesive application.
6. Once new ON and OFF setpoints are programmed for the line
running at constant speed, vary the line speed, confirming proper
adhesive application at all speed ranges.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Description
Negative Gun Compensation
2-29
Normal gun compensation advances an output channel’s setpoints,
compensating for a fixed response time in the device being controlled.
Some applications require negative gun compensation to retard the
setpoints in an output channel.
Negative gun compensation is usually found in two situations:
Wrap Up - As some machines increase in speed, the drive train at
some point between the resolver and the product “wraps-up,” or shifts
with respect to the resolver. If the wrap-up is proportional to machine
speed, negative gun compensation can be used to retard an output
channel’s setpoints from the true resolver position, thus maintaining
output accuracy.
Sensor Lag - While output channels are usually used to switch
devices on and off, another use is to “gate” a sensor into the
controller or other computer.
Figure 2-22 illustrates a basic sensor gating scheme, in which the signal
from the sensor reaches the controller only when the output channel from
the controller is turned on.
1
3
2
1. PC50 Series Controller
2. PC50 Series Controller Output
Channel
3. Sensor
5940342
Fig. 2-22 Simple Sensor Gating Scheme
Most sensing devices have very fast response times. However, if a
sensor’s response time is slow, its signal appears later and later in the
machine cycle as the machine speeds up. Eventually, sensor to resolver
lag is so great that the sensor signal fails to appear during the window
programmed into the controller’s output channel.
Negative gun compensation corrects this problem by causing the output
channel to lag its programmed machine position by a specified number of
milliseconds. Negative gun compensation is calculated using the same
method as standard gun compensation. See GUN COMP in Section 4,
Programming for details on programming negative gun compensation.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
2-30
Description
9. Controller Initial
Programming
While performing initial programming refer to Figure 4-1, Program Menu
Tree. The tree shows the path to each major program grouping and
selections available within each group.
Practice scrolling through the menu selections to become familiar with
the screens prior to attempting initial programming.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Section 3
Installation
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
3-0
Installation
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Installation
3-1
Section 3
Installation
WARNING: Allow only qualified personnel to perform the
following tasks. Observe and follow the safety instructions in
this document and all other related documentation.
1. Introduction
This section provides unpacking, safety, and installation information
necessary for installing the Nordson PC50 Series controller.
Unpacking
Exercise normal care to prevent equipment damage during unpacking.
Inspection
The PC50 Series controller is shipped preassembled.
After unpacking the controller, make the following inspections:
S Check the cabinet surfaces for evidence of shipping damage.
S Open the front panel and check for loose electrical connections to the
power supply, the controller and the keypad/display. Tighten any
loose fasteners and connections.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
3-2
Installation
2. Installation
The resolver must be mounted to the parent machine and then wired to
the controller. Various other wiring connections may be required,
depending on the required number of inputs and outputs to the controller.
Resolver Installation
Choose a mounting location for the resolver that allows convenient
mechanical connection of the resolver shaft to the machine. The resolver
is normally driven at a 1:1 ratio to machine cycles, but this is not true in
all applications. Commonly used methods for driving the resolver shaft
include timing pulley and belt, chains and sprockets or direct in-line
shaft-to-shaft coupling.
NOTE: If a shaft-to-shaft coupling is used, using a flexible coupling is
recommended. Call Nordson for information on suitable flexible
couplings.
5940300
Fig. 3-1
Resolver
CAUTION: Using a solid coupling with shaft misalignment
greater than 0.005⟩ (T.I.R.) may damage the resolver. Because
of tolerance stackups shimming a resolver to its mounting
surface may be required for proper alignment.
No provision need be made for physically rotating the resolver shaft with
respect to the machine shaft. PC50 Series controllers are easily
programmed to set any resolver position as the 0 position.
If possible, select a location that shelters the resolver from accidental
mechanical abuse, lubricants, washdown chemicals or any other liquids.
Most resolvers have a NEMA 4 rating or better, but avoiding
contaminants maximizes service and reliability.
Figures 3-2, 3-3 and 3-4 provide dimensional information for the three
most commonly used resolvers.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
3-3
Installation
Resolver Installation (contd.)
5.00 in.
(127.0 mm)
4.50 in.
(114.3 mm)
0.749 in.
0.747 in.
(19.02 mm)
(18.97 mm)
1.00 in.
(25.4 mm)
0.50 in.
(12.7 mm)
2.00 in.
(50.8 mm)
1.38 in.
(35.1 mm)
2.00 in. sq.
(50.8 mm)
1.00 in.
(25.4 mm)
1.00 in. x 0.19 in. Keyway
(25.4 mm x 4.7 mm)
2.07 in.
(52.6 mm)
Fig. 3-2
2.50 in. sq.
(63.5 mm)
1.50 in.
(38.1 mm)
0.44 in. Dia.
(11.2 mm)
1/4--20 Tap x
0.62 deep
(4 Places)
2.13 in.
(54.1 mm)
4.25 in.
(108.0 mm)
5.50 in.
(139.7 mm)
5940281
Foot Mount Resolver
2.65 in. sq.
(67.3 mm)
4.25 in.
(108.0 mm)
3.70 in.
(94.0 mm)
2.07 in. sq.
(52.6 mm)
1.03 in.
(26.2 mm)
0.28 in.
(7.1 mm)
0.375 in.
0.374 in.
(9.53 mm)
(9.50 mm)
0.30 in.
(7.6 mm)
0.90 in.
(22.9 mm)
Fig. 3-3
0.22 in. Dia.
(5.6 mm)
(4 Places)
1.03 in.
(26.2 mm)
5940283
Flange Mount Resolver
1.00” x 0.19” Keyway
25.4 x 4.7 mm
0.125” NPT Plug
(1 Each Side)
1.97 in.
(50.0 mm)
1.50 in.
(38.1 mm)
6.63 in.
(168.4 mm)
0.50 in.
(12.7 mm)
0.50 in. NPT
(12.7 mm)
0.625 in.
0.624 in.
(15.88 mm)
(15.85 mm)
2.07 in.
(52.6 mm)
1.50 in.
(38.1 mm)
Fig. 3-4
2.80 in.
(71.1 mm)
0.44 in. Dia.
(11.2 mm)
2.13 in.
(54.1 mm)
4.25 in.
(108.0 mm)
5.50 in.
(139.7 mm)
0.50 in. NPT
(12.7 mm)
5940284
Stainless Steel Resolver
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
3-4
Installation
Resolver Installation (contd.)
Ambient Temperature
Resolver operation requires an ambient temperature range of --40 _ to
+125 _C (--40 _ to +257 _F).
WARNING: Risk of electrical shock. Failure to observe may
result in personal injury, death, or equipment damage.
WARNING: Disconnect equipment from the line voltage.
Resolver Wiring
NOTE: Resolver cables supplied with the resolver are a special type,
consisting of three individually twisted/shielded pairs with a common
braid shield, insuring that reliable position information is being received
by the controller. See Figures 3-5 and 3-6. Using other cable types
could degrade the accuracy of the position signals, making them more
susceptible to electrical noise.
Cables for non-stainless resolvers are shipped with one end soldered to
the resolver connector and the other end screwed into the controller
connector. See Figure 3-5.
Remove the controller connector if routing the cable through areas where
the connector won’t fit. Run the cable from the resolver back to the
controller cabinet.
The shield is connected at both ends of the cable to prevent damage due
to electrostatic discharge. If electrical noise problems are suspected
when the control is in operation, call your Nordson Representative for
advice regarding shielding.
The cable used with the stainless steel resolvers does not have a
connector at the resolver end because screw terminals are used inside
that resolver. When routing this cable, start at the controller end and run
the plain end of the cable to the resolver. When properly connected, both
ends of the cable shield will be connected. If electrical noise problems
are suspected when the control is in operation, call your Nordson
Representative for advice regarding shielding.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
3-5
Installation
Resolver Wiring (contd.)
GR
BK
RD
BK
WT
BK
SH
Green
Black
Red
Black
White
Black
Pin B -- Green
Pin A -- Black
Pin D -- Red
Pin C -- Black
Pin F -- White
Pin E -- Black
Shield
FRONT VIEW
(pin out)
Shield
Not Used
Fig. 3-5
5940268
Resolver Cable with Cannon Connector
NOTE: The resolver cable illustrated in Figure 3-5 has a ring lug on a
green shield wire at the resolver end. Attach the ring lug to one of the
resolver connector strain relief screws as a protection against static
discharge through the resolver cable.
In some installations, it may be advisable to disconnect the ring lug to
prevent ground loops through the cable shield. Call your local Nordson
Representative if electrical noise problems are suspected.
GR
BK
RD
BK
WT
BK
SH
Green
Black
Red
Black
White
Black
White
Black
Black
Red
Black
Green
Shield
White
Black (P/W) WHITE
Black (P/W) RED
Red
Black (P/W) GREEN
Green
Shield
5940302
Fig. 3-6
Cable for Stainless Steel Resolver (with Terminal Strip Connections)
NOTE: The resolver cable illustrated in Figure 3-6 has a spade lug
connected to the shield at the resolver end. Attach the lug to the
grounding stud on the cover plate of the resolver.
In some installations, it may be advisable to disconnect the lug to prevent
ground loops through the cable shield. If electrical noise problems are
suspected when the controller is in operation, call your Nordson
Representative.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
3-6
Installation
Controller Installation
Mount the controller cabinet in a suitable location on the parent machine.
The cabinet flanges are pre-drilled for mounting on a panel. Leave
sufficient room on each side of the cabinet for wiring access. Resolver
and serial communication access is provided on the left side of the
cabinet. Input/ power cables are installed on the left hand side of the
cabinet. System power wiring and input/output wiring access is provided
by knockouts on both sides of the cabinet.
1
2
2
5
4
5940308
Fig. 3-7
Controller Cabinet
1. Knockout for AC Power or I/O
Access (Not Shown)
2. Resolver Cable Entrance w/ Nylon
Conduit Fitting
3. Knockout for AC Power or I/O
Access (Not Shown)
4. Communication Cable Connection
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
5. Knockout for I/O Access (Not
Shown)
E 1996 Nordson Corporation
All rights reserved
Installation
3-7
A phillips head screw holds each module in place. Individual modules
can be removed and installed without affecting the other modules on the
unit.
Module Mounting
WARNING: Risk of electrical shock. Failure to observe may
result in personal injury, death, or equipment damage.
WARNING: Disconnect equipment from the line voltage.
WARNING: Disconnect power to the controller before changing
modules.
2
3
1
1. Module
2. Phillips head screw
3. Module operating lamp
5940279
Fig. 3-8
Controller Module Removal/Replacement
DIP Switches
E 1996 Nordson Corporation
All rights reserved
NOTE: If installing a PC55 controller that is purchased separately (not in
a cabinet), set the DIP switches on the side of the controller and keypad
to their proper positions before mounting the units in a panel. See DIP
Switch Settings in this section for DIP switch information.
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
3-8
Installation
Controller Wiring Guidelines
WARNING: Disconnect equipment from the line voltage.
WARNING: Risk of electrical shock. Failure to observe may
result in personal injury, death, or equipment damage.
Controller Wiring, General
Follow normal wiring practices associated with installing electronic
controls. Guidelines include:
S Route input and output wiring away from high voltage, motor drive,
and other high level control signals.
S Use shielded cables for resolver, input, and communication circuits.
S
S
Shield module output circuits driving low current electronic input
circuits.
Ground shielded cables at the controller end only (except for resolver
cable). Use any of the screws on the controller back for grounding.
Use appropriate suppression devices where module outputs are
directly driving inductive loads.
Power Supply Wiring
NOTE: Nordson recommends installing a circuit breaker, with lockout
capability, at the external AC power supply.
NOTE: Figure 3-9 illustrates the general arrangement for installing
controller AC power. PC 50 Controllers are factory pre-wired for 240
VAC service.
2
When preparing to wire the input power supply terminal strip, verify that
the terminal strip is correctly wired for the required supply voltage.
1
5940393
Fig. 3-9
NOTE: Changing from 240 VAC to 120 VAC service requires installing
additional jumpers on the terminal strip per schematics and wiring
diagrams in Section 5, Troubleshooting and Repair and replacing fuses
F1 and F2 with customer supplied 2 amp Slo Blo fuses.
AC Power Connection to
Controller Power Supply
1. AC Power Supply In (w/Strain
Relief)
2. Input Power Wiring Terminal Strip
Electrical power is supplied to the controller as illustrated in the
schematics in Section 5, Troubleshooting and Repair.
Connect a 240 VAC or 120 VAC power cable to the controller’s terminal
strip as illustrated in Figure 3-9 and per the schematics and diagrams in
Section 5, Troubleshooting and Repair. Provide a strain relief for the
wires at the cabinet.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Installation
3-9
Power Supply Wiring (contd.)
WARNING: Disconnect equipment from the line voltage.
WARNING: Risk of electrical shock. Failure to observe may
result in personal injury, death, or equipment damage.
NOTE: To insure electrical noise immunity, connect a good electrical
ground to the ground terminal on the power supply terminal block.
NOTE: For controllers purchased as individual components and installed
in the customer’s main control panel, provide electrical power from a 20
to 30 VDC power supply. From the VDC power supply, run wires to TB 8
(Figure 3-10). Reversing the polarity blows the 1-1/4 amp power fuse.
The controller will not be damaged. Correct the polarity, then replace the
fuse.
2
1. TB 8 20-30 VDC connection from DC
power supply
2. Main Power Fuse (1 1/4 A Slo-Blo)
1
5940307
Fig. 3-10
Front View of Controller - Power Supply to Controller
Controller Input Wiring
Terminal Blocks
All terminal blocks can be unplugged from the controller. Each block is
keyed so it cannot be plugged into the wrong socket. All terminals are
labelled on each block. Controller general arrangement and location of
the terminal blocks are illustrated in Figure 3-11 (PC54) and Figure 3-12
(PC55).
Input Terminals
Hardware inputs can be used to select a program of setpoints or activate
groups of outputs based on sensor signals according to mode logic as
described in Section 4, Programming.
Depending on the controller model, inputs on PC50 Series controllers are
arranged on two terminal strips, TB 1 and TB 3, as shown in Figures 3-13
through 3-16. Inputs are optically isolated in groups of eight and can be
powered from an external DC power source or the auxiliary power
terminals located on TB 2.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
3-10
Installation
Controller Input Wiring (contd.)
1
5
4
6
2
8
7
3
9
12
13
11
10
14
15
5940343
Fig. 3-11
1.
2.
3.
4.
5.
PC54 Controller Components and Terminal Locations
Aux. Power Fuse (TB 2) & tester
Status LED (Yellow)
Power LED (Green)
AC/DC Modules (Outputs 1-8)
AC, DC, or Run Up Module
(Output 9)
Manual 66--PC50--MA--01 (formerly 57--30)
6.
7.
8.
9.
10.
TB 5 (Keypad)
DIP Switch
DB-9F (RS-232/485
Main Fuse, 1 1/4 A
TB 4 (Resolver)
107 126B
Issued 01/96
11.
12.
13.
14.
15.
TB 8 (VDC for Controller)
TB 7 (Outputs 1-4)
TB 6 (Outputs 5-9)
TB 2 (Power for Inputs)
TB 1 (Inputs 1-8)
E 1996 Nordson Corporation
All rights reserved
3-11
Installation
1
7
8
6
5
9
11
10
2
3
4
12
15
13
14
16
17
18
19
5940262
Fig. 3-12
1.
2.
3.
4.
5.
6.
PC55
Controller Components and Terminal Locations
Aux. Power Fuse (TB 2) & tester
AC/DC Modules - Outputs 1-8
Status LED (Yellow)
Power LED (Green)
AC/DC Modules (Outputs 9-15)
AC, DC, or Run Up Module Outputs
(16 and 17)
E 1996 Nordson Corporation
All rights reserved
7.
8.
9.
10.
11.
12.
TB 10 (Outputs 5-8)
TB 9 (Outputs 1-4)
TB 5 (Keypad)
DIP Switch
DB 9F (RS-232/485)
Main Fuse, 1 1/4 A
107 126B
Issued 01/96
13.
14.
15.
16.
17.
18.
19.
TB 4 (Resolver)
TB 8 (VDC for Controller)
TB 7 (Outputs 9-12)
TB 6 (Outputs 13-17)
TB 3 (Inputs 1-8)
TB 2 (Power for Inputs)
TB 1 (Inputs 9-16)
Manual 66--PC50--MA--01 (formerly 57--30)
3-12
Installation
Controller Input Wiring (contd.)
Sinking or Sourcing
NOTE: PC54 Controllers have one input terminal strip (TB 1). See
Figure 3-11. PC55 Controllers have two input terminal strips (TB 3 and
TB 1). See Figure 3-12.
Input terminal strip(s) can be wired to accept sinking or sourcing input
signals, but all eight inputs on that strip require the same type of signal.
Many types of hardware can drive these inputs, including mechanical
switches, relay contacts, DC 3-wire sensors, solid state DC output
modules, and PLC DC outputs.
NOTE: Two wire DC sensors can also be used, but may require a load
resistor in parallel with the input.
Figure 3-13 and Figure 3-14 illustrate current sourcing output, with
positive (+) VDC being switched. Figure 3-15 and Figure 3-16 illustrate
a current sinking output, with DC common being switched.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Installation
3-13
Controller Input Wiring (contd.)
1
2
+VDC
1. TB 1 (Inputs 1-8)
2. TB 2 (Aux Power for Inputs)
3. Switch or Relay Contact (Connect to
desired input 1-8)
4. Sourcing Module - (PLC or other
electronic output Connect to desired
input 1-8)
5. Three (3) wire DC Sensor with current
sourcing output (PNP)
3
DC COM
4
5
Fig. 3-13
Function
3-6
Program Select
1
Group 1 Input
2
Group 2 Input
7
First Cycle Enable
8
Remote Enable
5940345
PC54 Controller Input Wiring - Sourcing Devices
1
2
1. TB 3 (Inputs 1-8)
2. TB 2 (Aux Power for Inputs)
3. TB 1 (Inputs 9-16)
4. Switch or Relay Contact (Connect to
desired input 1-16)
5. Sourcing Module - (PLC or other
electronic output Connect to desired
input 1-16)
6. Three (3) wire DC Sensor with current
sourcing output (PNP)
3
+VDC
4
5
DC COM
6
Fig. 3-14
Terminal
Terminal
Function
1-8
Program Select
9
Group 1 Input
10
Group 2 Input
11
Group 3 Input
12
Group 4 Input
13
Group 5 Input
14
Group 6 Input
16
Remote Enable
15
First Cycle Enable
5940298
PC55 Controller Input Wiring - Sourcing Devices
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
3-14
Installation
Sinking or Sourcing (contd.)
2
1. TB 1 (Inputs 1-8)
2. TB 2 (Aux Power for Inputs)
3. Switch or Relay Contact. (Connect to
desired input 1-8)
4. Sinking Module - (PLC or other
electronic output. Connect to desired
input 1-8)
5. Three (3) wire DC Sensor with current
sinking output (NPN)
1
3
4
5
+VDC
Terminal
Function
3-6
Program Select
1
Group 1 Input
2
Group 2 Input
7
First Cycle Enable
8
Remote Enable
5940344
Fig. 3-15
PC54 Controller Input Wiring - Sinking Devices
1
2
1. TB 3 (Inputs 1-8)
2. TB 2 (Aux Power for Inputs)
3. TB 1 (Inputs 9-16)
4. Switch or Relay Contact. (Connect to
desired input 1-16)
5. Sinking Module - (PLC or other
electronic output. Connect to desired
input 1-16)
6. Three (3) wire DC Sensor with current
sinking output (NPN)
3
4
5
+VDC
6
Terminal
Function
1-8
Program Select
9
Group 1 Input
10
Group 2 Input
11
Group 3 Input
13
Group 5 Input
14
Group 6 Input
15
First Cycle Enable (Mode 5)
16
Remote Enable
5940299
Fig. 3-16
PC55 Controller Input Wiring - Sinking Devices
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Installation
3-15
Controller Input Wiring (contd.)
Input Wiring Guidelines
S Voltage from TB 2 is the same as the voltage supplied to the
controller
S Each input powered from TB 2 draws 11 mA at 24 VDC. TB 2 is
S
S
S
S
fused at 1/4 amp
Inputs operate with voltages from 10 to 30 VDC
An optional external power supply can be used instead of TB 2 to
power inputs
A combination of mechanical and solid state devices can be used
On PC55 Controllers, TB 1 can be wired for sourcing while TB 3 is
wired for sinking and vice versa
Input Terminal Function
The following are the input terminals and their corresponding functions:
Program Select (3-6 on PC54; 1-8 on PC55)
The on/off status of these terminals selects which program of setpoints is
controlling the outputs. Binary, BCD, or Gray Code formats can drive
these terminals as shown in Figure 3-18 and Figure 3-19.
NOTE: Nordson eight position Gray Code selector switches are
available as accessories for PC50 Series controllers. See Section 8,
Options for program select switch installation.
When all program select inputs are off, the “Default” program becomes
active as programmed through DEFAULT PROGRAM function.
Group Inputs (1 and 2 on PC54; 9-14 on PC55)
5940353
Fig. 3-17
These inputs work in conjunction with groups of outputs according to
mode logic as discussed in Section 4, Programming. Typically, photo
eyes and other sensors operate these inputs.
Program Select Switch
First Cycle Enable (7 on PC54; 15 on PC55)
Mode 5 uses this input to allow the machine to resume a cycle after being
stopped in mid-cycle. See Section 4, Programming for details.
Remote Enable (8 on PC54 and 16 on PC55)
Any output (except Run UP) can be ANDed with this input through
OUTPUT ENABLE ANDing. ANDed outputs operate only when this input
is on. This output can be used in conjunction with Speed Enable/Disable
and output modes.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
3-16
Installation
Controller Input Wiring (contd.)
PC54 Controller
BCD FORMAT
BINARY FORMAT
GRAY CODE FORMAT
Units
Input Terminal:
Value:
6
8
5 4 3
4 2 1
Program:Default
1
2
3
4
5
6
7
8
9
0
0
0
0
0
0
0
0
1
1
0
0
0
0
1
1
1
1
0
0
Fig. 3-18
0
0
1
1
0
0
1
1
0
0
0
1
0
1
0
1
0
1
0
1
Input Terminal:
Value:
6
8
5 4 3
4 2 1
Program:Default
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
Input Terminal: 6 5 4 3
Value:MSB
LSB
Program:Default
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
PC54 Program Select Terminals for Various Formats
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
3-17
Installation
PC55 Controller
BCD FORMAT
10’s
BINARY FORMAT
GRAY CODE FORMAT
Units
Input Terminal: 7 6 5 4 3 2 1
Value: 40 20 10 8 4 2 1
Input Terminal: 7 6 5 4 3 2 1
Value: 64 32 16 8 4 2 1
Program:Default 0 0 0 0 0 0 0
Program:Default 0 0 0 0 0 0 0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
Fig. 3-19
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
1
1
0
0
0
0
0
0
0
0
1
1
0
0
0
0
0
0
0
0
1
1
0
0
0
0
0
0
0
0
1
1
0
0
0
0
0
0
0
0
1
1
0
0
0
0
0
0
0
0
1
1
0
0
0
0
0
0
0
0
1
1
1
1
0
0
0
0
0
0
1
1
1
1
0
0
0
0
0
0
1
1
1
1
0
0
0
0
0
0
1
1
1
1
0
0
0
0
0
0
1
1
1
1
0
0
0
0
0
0
1
1
1
1
0
0
0
0
0
0
1
0
1
1
0
0
1
1
0
0
0
0
1
1
0
0
1
1
0
0
0
0
1
1
0
0
1
1
0
0
0
0
1
1
0
0
1
1
0
0
0
0
1
1
0
0
1
1
0
0
0
0
1
1
0
0
1
1
0
0
0
0
1
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
Input Terminal: 7 6 5 4 3 2 1
Value: MSB
LSB
Program:Default 0 0 0 0 0 0 0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
PC55 Program Select Terminals for Various Formats
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
3-18
Installation
Controller Input Wiring (contd.)
Program Notes
BCD Format
S For BCD, calculate the program selected by adding the values for
each of the inputs that are on. For example, if inputs 5, 3, and 1 are
On, Program 15 is active (10 + 4 + 1).
S Only three of the normal four BCD digits for 10’s are used.
S Nine (9) is the largest valid value for the units digit. A units digit
combination larger than 9 sets the units digit to 9.
Binary Format
S For Binary, calculate the program selected by adding the values for
each of the inputs that are on. For example, if inputs 5, 3, and 1 are
On, Program 21 is active (16 + 4 + 1).
Gray Code Format
NOTE: Nordson eight position Gray Code program enable and program
select switches are available as options for PC50 Series controllers. See
Section 8, Options for program enable and program select switch
installation instructions.
Notes Common to All Formats
Manual 66--PC50--MA--01 (formerly 57--30)
-
On PC54 controllers (16 programs available), any program select
value larger than 16 selects program number 16.
-
On PC55 controllers (64 programs available), any program select
value larger than 64 selects program number 64.
-
The Default Program is determined by programming the Default
Program function. See Section 4, Programming.
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Installation
3-19
Controller Output Wiring
Output Modules
Available outputs depend on the PC50 Series model:
Output Type
PC54
PC55
AC/DC/RR Modules Only
Outputs 1--8
Outputs 1--15
AC/DC/RR or *Run Up Modules
Output 9
Output 16 and/or 17
* Run Up modules are optional. The PC54 accepts 1 optional
module; the PC55 accepts 2 optional modules.
NOTE: The load device to be driven must match the output type.
Power Output Modules
Power output modules directly switch inductive loads and resistive loads.
Each output module has two dedicated terminals and therefore does not
share any common signal with the other modules. This allows AC and
DC modules to be mixed on the same controller.
DC modules can be wired to sink or source as shown in Figure 3-24.
NOTE: The modules do not supply the power for the load; they simply
switch it.
TB 6
5
6
7 8
9
AB A B A B AB AB
TB 6
9
8
7
6
5
4
3
2
1
Fig. 3-20
1
1. TB 6 (Outputs 5-9 with 9 being Run
Up, or AC/DC)
2. TB 7 (Outputs 1-4)
TB 7
1
2
3 4
AB A B A B AB
2
TB 7
5940326
PC54 Output Terminal Strips
TB 10
TB 6
8
7
6
5
AB A B A B AB
2
TB 10
TB 9
23
13 14 15 16 17
AB A B A B AB AB
8
7
6
5
4
3
2
1
TB 9
4
3
2
1
AB A B A B AB
17
16
15
14
13
12
11
10
9
1. TB 6 (Outputs 13-15 with 16 & 17
being Run Up, or AC/DC)
2. TB 10 (Outputs 5-8)
3. TB 9 (Outputs 1-4)
4. TB 7 (Outputs 9-12)
1
TB 6
TB 7
4
TB 7
9
10 11 12
AB A B A B AB
5940263
Fig. 3-21
PC55 Output Terminal Strips
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
3-20
Installation
Controller Output Wiring (contd.)
Run Up Output Modules
Run Up output modules, which generate signals proportional to the
resolver rpm, can be used only in the output positions shown Figure 3-21.
A 0-10 VDC or 4-20 mA Run Up module can be used in either module
position.
NOTE: RUN UP QTY must be programmed to indicate the number of
Run Up modules installed. An external power supply is not needed; Run
Up modules power is from the controller. The Run Up output signal is
completely isolated.
AC Output
2
4
L1
3
1
L2
5
6
5940287
Fig. 3-22
1. Neutral
2. Hot
3. Module Terminals
4. Varistor
5. Load
6. R-C Suppressor
AC Output
NOTE: Although most applications will not require the varistor or R-C
suppressor shown in Figure 3-22, when switching devices are in series or
parallel with the AC module, voltage spikes may damage the module.
Use one of the following two methods to suppress voltage spikes.
-
For infrequent switching, connect a varistor (item 4) across the
terminals.
For continuous switching, wire an R-C suppressor (item 6) in
parallel with the load.
Run Up Output
2
(+)
1
3
(--)
4
Fig. 3-23
1. Run Up Load Device
2. Run Up Positive Voltage
3. Module Terminals
4. Run Up Negative Voltage
5940289
Run Up Output
NOTE: Run Up output modules source the Run Up signal, no external
power supply is required and the Run Up output signals are isolated.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Installation
3-21
Controller Output Wiring (contd.)
DC Output - Sourcing and Sinking
6
3
+
4
5
1
Fig. 3-24
2
(--)
5940288
DC Output - Sinking
3
+
6
5
4
1
2
(--)
5940346
Fig. 3-25
1. DC Common
2. Load
3. Positive VDC
4. Module Terminals
5. Zener Diode
6. Reverse Bias Diode
1. DC Common
2. Load
3. Positive VDC
4. Module Terminals
5. Zener Diode
6. Reverse Bias Diode
DC Output - Sourcing
NOTE: Diodes are not required in most applications, however, highly
inductive DC loads may damage modules by generating voltage spikes
when switched off. Suppress voltages spikes using one of the following
two methods: See Figures 3-24 and 3-25.
E 1996 Nordson Corporation
All rights reserved
-
Connect a Zener diode (item 5) across the terminals. This does
not significantly increase the load turn off time. The voltage rating
of the diode must be greater than the normal circuit voltage.
-
Connect a reverse-biased diode (item 6) across the load. This
may increase load turn off time.
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
3-22
Installation
3. Keypad Wiring
One or two keypads may be connected to a PC54 controller as shown in
Figure 3-26.
Number of Keypads
Figures 3-31, 3-32, and 3-33 illustrate possible keyboard configurations
and how they are linked together.
2
1
X
W
Z
Y
+
3
--
12
S
4
E1 E2 C
6
5
S
-- +
11
W X
Y
Z
E1 E2 C
9
8
7
S
-- +
W X
Y
Z
10
10
Bk Wh Bk Gn Rd Bk
Bk Rd Wh Bk Gn Bk
Bk Rd Wh Bk Gn Bk
5940264
Fig. 3-26
1.
2.
3.
4.
Keypad Wiring
RS-485 to Keypad
RS-485 from Keypad
Positive (+) 20-30 VDC Out
Positive (+) 20-30 VDC In
Manual 66--PC50--MA--01 (formerly 57--30)
5.
6.
7.
8.
RS-485 from Host
RS-485 to Host
Positive (+) 20-30 VDC In
RS-485 from Host
107 126B
Issued 01/96
9.
10.
11.
12.
RS-485 to Host
Shield
Keypad Terminal Block
Controller Terminal Block (TB 5)
E 1996 Nordson Corporation
All rights reserved
Installation
3-23
The terminal block on the back of each keypad includes terminals to
select Master or Operator level programming access for that keypad.
These terminals can be temporarily jumpered during set-up to allow entry
of programming access codes, or they can be switched with a variety of
devices including mechanical switches, relay contacts, and PLC DC
outputs. See PASSWORDS in the programming section for details on
programming access.
Programming Enable
If a solid state device will activate the Programming Enable terminals,
that device is the determining factor in whether sourcing or sinking wiring
is used.
For mechanical devices such as jumpers or key switches, either sourcing
or sinking wiring may be used. Figures 3-27 and 3-28 illustrate keypad
terminal block sinking and sourcing wiring for programming enable.
3
2
1
E1
E2
C
S
--
+
W
X
Y
1. Master Program Enable
2. Operator Program Enable
3. Enable Common
4. Switch (To E1 or E2)
5. Sourcing Device (To E1 or E2)
Z
4
5
5940291
Fig. 3-27
Program Enable, - Sourcing
3
2
1
E1 E2
C
S
--
+
W
X
Y
1. Master Program Enable
2. Operator Program Enable
3. Enable Common
4. Switch (To E1 or E2)
5. Sinking Device (To E1 or E2)
Z
4
5
5940292
Fig. 3-28
Program Enable, - Sinking
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
3-24
Installation
4. Controller/Keypad DIP
Switch Configurations
DIP Switches
Each keypad and controller has a DIP switch as shown in Figures 3-29
and 3-30.
Controller Settings
The address settings on the controller DIP switch apply to a network
connecting the controller to a PLC or other system host. When the DIP
switch is set to zero, the default address programmed through the
COMMUNICATIONS function takes effect. Whereas the DIP switches
can set a maximum address of ‘7’, the COMMUNICATIONS function can
establish much higher address numbers. These settings are not related
to communications with the keypads.
Two sets of termination switches are included on the controller. One set
establishes the termination value for an RS-485 network connecting the
controller to a PLC or other system host. It does not apply to an RS-232
network. The other termination switches apply to the keypad network.
See Figures 3-31, 3-32 and 3-33 for guidelines and sample settings.
2
1
3
B0 B1 B2 4 5 6 7
4
1
0
Off
On
6
5
8
7
9
11
10
PLC or
SYSTEM
HOST
5940347
Fig. 3-29
1.
2.
3.
4.
Controller DIP Switch Identification
1’s Digit
2’s Digit
4’s Digit
For Address Settings
Manual 66--PC50--MA--01 (formerly 57--30)
5. For Termination Settings
6. Address for System
Communications (B0, B1, and B2)
7. Termination for System
Communications (RS-485 Only) (4
and 5)
107 126B
Issued 01/96
8. Termination for Keypad
Communications (6 and 7)
9. RS-232 or RS-485 System
Communications
10. Controller
11. Keypads
E 1996 Nordson Corporation
All rights reserved
3-25
Installation
Keypad Settings
The address and termination settings on the keypad DIP switch apply to
the RS-485 network that connects it to the controller. See Figures 3-31,
3-32 and 3-33 for guidelines and sample settings.
1
0 1
2
B0
B1
B2
B3
6
3
4
5
On Off
7
8
9
11
12
10
PLC or
SYSTEM
HOST
5940265
Fig. 3-30
1.
2.
3.
4.
Keypad DIP Switch Identification
0’s and 1’s for Address Settings
1’s Digit
2’s Digit
4’s Digit
DIP Switch Guidelines
5. 8’s Digit
6. Address for Keypad Communication
(B0 thru B3)
7. Termination for Keypad
Communication
8. ON/OFF for Termination Settings
9. RS-232 or RS-485 System
Communications
10. For RS-485 Keypad/Controller
Communications
11. Controller
12. Keypad
Termination:
-
Termination must be “on” for devices on each end of the chain.
Termination must be “off” for devices in the middle of the chain.
Both termination switches in a pair must be in the same position.
Address:
-
E 1996 Nordson Corporation
All rights reserved
Keypad addresses must be assigned starting with ‘0’ and
increasing sequentially.
The physical location of a keypad in the chain has no relationship
to its address.
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
3-26
Installation
DIP Switch Guidelines (contd.)
-
During initial programming, the KEYBOARD QTY function must
be used to enter the number of keypads in the chain.
KEYBOARD QTY can be accessed only through the keypad
whose address is ‘0’.
1
2
1 2 3 4 56
1 2 3 4 5 6 7
Fig. 3-31
5940266
DIP Switch Settings - One Keypad
1. Keypad DIP Switches
Termination: ON and Address: 0
2. Controller Keypad DIP Switches
Termination: ON (Switches 6 & 7)
1
3
2
1 23 456
1 2 3 456
1 2 3 4 5 6 7
5940286
Fig. 3-32
DIP Switch Settings - Two Keypads with Controller in Middle
1. Keypad DIP Switches
Termination: ON and Address: 0
2. Controller Keypad DIP Switches
Termination: OFF (Switches 6 & 7)
1
2
3. Keypad DIP Switches
Termination ON and Address: 1
3
1 2 3 4 56
1 2 3 4 56
1 2 3 4 5 6 7
5940285
Fig. 3-33
DIP Switch Settings - Two Keypads with Controller on End
1. Keypad DIP Switches
Termination: ON and Address: 1
Manual 66--PC50--MA--01 (formerly 57--30)
2. Keypad DIP Switches
Termination Off and Address: 0
107 126B
Issued 01/96
3. Controller Keypad DIP Switches
Termination: ON (Switches 6 & 7)
E 1996 Nordson Corporation
All rights reserved
Installation
5. Communications Wiring
3-27
If the optional communications package is purchased, follow the
communications wiring steps detailed here.
NOTE: All communication set up and operation procedures are detailed
in the instruction sheet provided with communication system software.
DB- 9F Port
Serial communication to a PLC or other system host is provided through
a DB-9 female connector. See Figures 3-11 and 3-12 for location. This
connector can be wired for RS-232 or RS-485 communications.
RS-232/485 Selection
Use the COMMUNICATIONS function to select RS-232 or RS-485
communications.
RS-232
RS-232 can connect only a single PC50 Series controller to a system
host.
1
1. Data Terminal Ready (Not Used)
2. Transmit Data to Host
3. Receive Data From Host
4. Clear to Send (Not Used)
5. Signal Common
2
3
4
5
Fig. 3-34
5940348
DB-9 Female Connector on Controller - RS-232 Signals
Receive Data
Transmit Data
Transmit Data
Receive Data
Signal Common
Signal Common
Clear to Send
Data Terminal Set Ready
Data Terminal Ready
Fig. 3-35
5940349
RS-232 Cable Wiring -- DB-25 (Host) to DB-9F (Controller)
Receive Data
Transmit Data
Transmit Data
Receive Data
Signal Common
Signal Common
Data Terminal Ready
Data Set Ready
Clear to Send
Fig. 3-36
5940350
RS-232 Cable Wiring -- DB-9 (Host) to DB-9F (Controller)
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
3-28
Installation
5. Communications Wiring
(contd.)
RS-485 can be used for “multi-drop” networks where more than one
controller could be connected to the system host.
RS-485
1
1. Receive Data From Host (--)
2. Transmit Data to Host (--)
3. Transmit Data to Host (+)
4. Receive Data From Host (+)
5. Signal Common
2
3
4
5
5940351
Fig. 3-37
DB-9 Female Connector on Controller - RS-485 Signals
6. Initial Programming
Bench Test
Test the PC50 Series controller, prior to installation, following the steps
below:
1. Verify that output modules are plugged into the controller beginning
with Position 1. See Figures 3-20 and-21.
2. Verify resolver connection. See Figure 3-5 and Figure 3-6.
3. Verify keypad/display wiring connection to the controller. See Figures
3-11 and 3-12.
4. Set the controller DIP switches 6 and 7 to “ON,” as shown in Figure
3-29.
5. Set the keypad DIP switch to address ‘0’ and termination “ON,” as
shown in Figure 3-30.
6. Use two jumper wires to enable Master Level programming as shown
in Figure 3-27 (for sourcing) and Figure 3-28 (for sinking). These
jumpers permit access to the entire menu tree. The menu tree is
illustrated in Figure 4-1.
7. Verify DC input power. See Figure 3-10.
NOTE: Factory default for the PC54 is for all outputs to be in Mode 2.
NOTE: Supply a trigger for the PC54 input terminals 1 and/or 2. See
Table 2-1. Since only 2, 3, and 5 Operating Modes are available on the
PC54, an input signal is required to test the controller.
When experimenting with the controller, note that the LED on an output
module lights when that output channel is turned on. By hand-turning the
resolver shaft and watching the module LED’s, you can observe the
effects of programming setpoint values.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Installation
6.
3-29
Initial Programming
(contd.)
Machine Setup
After installing the unit, program the following set up information into the
controller before attempting any other programming:
Information
Menu Selection
Direction of Rotation
INCREASING DIR
Scale Factor
SCALE FACTOR
Shaft Position
SHAFT POSITION
No. of Keypads
KEYBOARD QTY
No. of Run Up Outputs
RUN UP QTY
No. of Output Groups
OUTPUT GROUPS
Modes for Output
Groups
OUTPUT GROUPS
Group Display Mode
GRP POS DISP
Group Offsets
OFFSET
Once this information is entered, setpoints can be established and
modified in the groups and output channels.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
3-30
Installation
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Section 4
Programming
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-0
Programming
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-1
Section 4
Programming
1. Introduction
This section provides the basic steps required for programming PC50
Series controllers. Explanations for controller functions and capabilities
are provided in Section 3, Description. PC50 Series controller installation
and initial testing is provided in Section 3, Installation.
Review the menu tree prior to programming the controller. Programming
steps have a menu path description, but following the menu tree
illustration is helpful while scrolling to the programming selection.
Although sample screens are provided with many of the programming
steps, sample screens are not provided for each step. Typically, those
functions requiring only one screen for data display or data entry do not
have a screen illustration.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-2
Programming
ESC SEL
Password
Setpoints
Gun Compensation
Timed Outputs (PC 55 only)
Offsets
Speed Enable/Disable
Run Up
Stitch
Channel Copy
Program Copy
Default Program
Setup Menu
ESC SEL
(If Outputs are
divided into Groups)
Output Status
I/O Status Menu
Input Status
ESC SEL
Setpoint Use
Software Version
Model and Options
System Info Menu
ESC SEL
Config Menu
Hardware Menu
Keyboard Quantity (PC 55 only)
Increasing Direction
Scale Factor
Shaft Position
Run Up Quantity (PC 55 only)
Pgm Sel Mode
Display Menu
Rate Setup
Toggle RPM
ESC SEL
Grp Pos Disp
Enable Codes
ESC SEL
Channel ANDing Menu
ESC SEL
Min Speed ANDing
Rem Enab AND
Output Groups
Communications Menu
Test Menu
Memory Tests
ESC SEL
5940352
Fig. 4-1
PC50 Series Controller Program Menu Tree
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-3
Specific set up information, generally related to controller firmware and
system interface physical characteristics must be initially programmed
into the controller before other system configuration information can be
entered.
2. Initial Programming
(contd.)
Follow the Menu Tree while performing programming functions. Initial
programming dictates starting at the main screen, scrolling down to the
CONFIGURATION (CONFIG) MENU, then selecting the HARDWARE
MENU. Selections in the HARDWARE MENU provide the basis for
system set up.
NOTE: Not all programming and/or operator interface screens are
illustrated. Only multi-step screens or multiple screens within a
procedure are presented.
On power-up, or after five minutes of keypad inactivity, the controller
displays one of two main screens. The screen that is displayed depends
on whether one, or multiple, output groups are programmed and whether
each output group has its own position in the machine cycle or if all
groups share one position in the machine cycle.
Main Screens
NOTE: Group Position Display (GRP POS DISP) programming
determines the main screen that is displayed.
S One Output Group, and GRP POS DISP set to “One” or “Each”
S Multiple Output Groups, and GRP POS DISP set to “One”
1
2
1. Active Program
2. Machine Speed
3. Machine Position
3
5940354
Fig. 4-2
NOTE: Machine position, (item 3 in Figure 4-2), is equal to the machine
shaft position plus the Group Offset.
S Multiple Output Groups and GRP POS set to “Each”
1
3
1. Group Position
2. Group Selection
3. Menu Tree Entry
2
5940355
Fig. 4-3
NOTE: For Operating Modes 1 or 2, position (item 1 in Figure 4-3), is
equal to the Preset plus the change since last reset. For Operating
Modes 0, 3, 4, or 5, position (item 1, Figure 4-3), is equal to the shaft
position plus the Group Offset.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-4
Programming
Main Screen (contd.)
Active Program
The PC54 controller can store 16 programs in its memory. The PC55 is
capable of storing 64 programs in its memory. The “active program”
(item 1, Figure 4-2) is the program currently controlling the output
channels.
If hardware inputs, such as Nordson’s program enable and program
select switches, are being used to select the Active Program, the display
indicates the program selected by the inputs. If all hardware inputs are
off, the active program is the DEFAULT PROGRAM specified through the
DEFAULT PROGRAM function.
NOTE: Controller Input Wiring in Section 3, Installation provides
information on using hardware inputs to select the Active Program.
Section 8, Options provides instructions for installing Nordson’s program
enable and program select switches.
If hardware inputs are not used, the Active Program is the program
specified through the DEFAULT PROGRAM function.
Machine Speed
When the machine is moving, Machine Speed (item 2, Figure 4-2) is
displayed in user selectable units of RPM (revolutions per minute), BPM
(bags per minute), or CPM (cartons per minute). Machine Speed is
displayed as a value which is 1X, 2X, or 3X the resolver RPM. See
RATE SETUP for details.
Toggle RPM
Machine or Group Position is displayed only when the resolver speed is
below the TOGGLE RPM speed. At higher speeds Machine Position will
be blank. See TOGGLE RPM for programming details.
Entering Menu Tree
Enter the Menu Tree from the Main Screen by moving the cursor to
“MENU”, then pressing the SEL key.
See also DEFAULT PROGRAM, RATE SETUP, TOGGLE RPM,
OFFSETS and GRP POS DISP
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-5
Password
Menu Path
At the MAIN SCREEN:
-
Press SEL.
Scroll down to PASSWORD. Press SEL.
The screen displays the current programming access level and provides
an area to enter a password. Press SEL to toggle between the access
levels. Use the numeric keys, followed by ENT, to enter the password
number code. Programming levels are activated (or “enabled”) by
entering the password or by activating Terminals E1 and E2 on the back
of the keypad. (See Figures 3-26, 3-27, and 3-28).
Figure 4-34 provides a summary of programming functions available to
the different levels. Codes corresponding to each level are established in
the ENABLE CODES screen.
Entering a Password
Enter a password through the numeric keypad, followed by ENT. As the
number keys are pressed, dashes replace the asterisks. If a mistake is
made, pressing CLR erases the last key pushed.
If a password is entered that has been programmed through ENABLE
CODES, the keypad functions at the corresponding programming level.
If either of the programming enable terminals on the back of the keypad
is active when a password is entered, the programming level will be
which ever is greater.
Clearing a Password
When programming operations are completed, enter a password value of
‘0’, then ENT to clear the enable level.
A keypad left unattended with an active password automatically clears
the access code after five minutes of keypad inactivity. The keypad
reverts to the “Normal Display” mode shown in Figure 4-34.
See also CONFIGURATION MENU and ENABLE CODES later in this
section for Password set up information.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-6
Programming
Hardware Menu
Initial programming of the controller begins with selections in this menu.
Upon completion, other items are programmed through the
CONFIGURATION MENU. PASSWORDS and SETPOINTS are other
programmed selections, but are selections off the main menu tree.
Keyboard Quantity
The KEYBOARD QTY screen shows the number of keypads with which
the controller will communicate.
NOTE: The P55 controller can be provided with an additional keyboard,
the PC54 controller cannot.
Menu Path
At the MAIN SCREEN:
-
Press SEL.
Scroll down to CONFIG MENU. Press SEL.
Scroll down to HARDWARE MENU. Press SEL.
Scroll down to KEYBOARD QTY. Press SEL.
The controller attempts to establish communication with as many
keypads as are programmed through this screen. Keypads are assumed
to be addressed sequentially, starting at address ‘0’ as shown in
Figures 3-31, 3-32, and 3-33.
NOTE: Changing the number of keypads shown in KEYBOARD QTY
can only be done from the keypad whose address is ‘0’.
NOTE: If KEYBOARD QTY is set to ‘2’, but only one keypad is physically
connected, Menu Tree operation will be very slow. Change KEYBOARD
QTY to ‘1’ to restore normal Menu Tree speed.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-7
Hardware Menu (contd.)
Increasing Dir
Menu Path
At the MAIN SCREEN:
-
Press SEL.
Scroll down to CONFIG MENU. Press SEL.
Scroll down to HARDWARE. Press SEL.
Scroll down to INCREASING DIR. Press SEL.
The Increasing Direction screen displays the direction of resolver
rotation, clockwise (CW) or counter-clockwise (CCW), as viewed from the
shaft end, that causes the position display to increase in value.
Whether CW or CCW, the position value should increase as the machine
turns in its forward direction.
Changing Direction
Pressing SEL toggles the value of increasing direction. The new value
begins flashing. Pressing the ENT key confirms the selection.
Scale Factor
Menu Path
At the MAIN SCREEN:
-
Press SEL.
Scroll down to CONFIG MENU. Press SEL.
Scroll down to HARDWARE MENU. Press SEL.
Scroll down to SCALE FACTOR. Press SEL.
This function controls the number of increments into which one resolver
revolution is divided. A scale factor of 360 (0 to 359) allows the controller
to operate in degrees. A scale factor of 1024 (0 to 1023) allows positions
to be programmed more accurately. In some applications, the scale
factor can be set so each increment equals a unit of linear travel.
NOTE: The scale factor on PC54 controllers ranges from 2-1024. PC55
controllers have a scale factor ranging from 2-4096.
NOTE: When the scale factor is changed, all programmed setpoints are
recalculated, converting them to the new scale factor. The
keypad/display is inoperative until the calculations are complete.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-8
Programming
Hardware Menu (contd.)
Shaft Position
Menu Path
At the MAIN SCREEN:
-
Press SEL.
Scroll down to CONFIG MENU. Press SEL.
Scroll down to HARDWARE MENU. Press SEL.
Scroll down to SHAFT POSITION. Press SEL.
Because PC50 Series controllers are programmable devices, they can be
set to display a position of “zero” at any point in the machine cycle.
Usually, the machine is jogged to the beginning of a cycle, and SHAFT
POSITION is set to zero at this point. This function eliminates the need
to adjust the physical coupling between the machine and resolver in
order to change the displayed machine position.
Programming
Use the INC/DEC keys or the numeric keys, followed by ENT to change
shaft position.
NOTE: Set SHAFT POSITION before doing any SETPOINT or OFFSET
programming.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-9
Hardware Menu (contd.)
Run Up Qty
NOTE: PC54 controllers can have 0, or 1 optional Run Up module.
PC55 controllers can have 0, 1, or 2 optional Run Up modules.
Menu Path
At the MAIN SCREEN:
-
Press SEL
Scroll down to CONFIG MENU. Press SEL.
Scroll down to HARDWARE MENU. Press SEL.
Scroll down to RUN UP QTY. Press SEL.
This screen displays the number of RUN UP outputs being programmed
into the controller.
Programming
Use the numeric keys to enter ‘0’, ‘1,’ or ‘2’ for the number of modules
installed in the controller. Run Up output module(s) are required to
generate the Run Up output signal(s).
Each output can be offset and scaled by different values. See RUN UP
OUTPUT for details.
See also RUN UP OUTPUT and OUTPUT STATUS
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-10
Programming
Hardware Menu (contd.)
Pgm Sel Mode
Menu Path
At the MAIN SCREEN:
-
Scroll down to CONFIG MENU. Press SEL.
Scroll down to HARDWARE. Press SEL.
Scroll down to PGM SEL MODE. Press SEL.
This screen allows you to specify the format for the hardware Program
Select inputs on:
1
Fig. 4-4
5940356
-
PC55 - Terminals 1 through 8 of Terminal Block 3 (TB3).
-
PC54 - Terminals 3 through 6 of Terminal Block 1 (TB1).
Program Select Screen
1. Format Selection
See Figures 3-13 through 3-16.
The Program Select inputs can operate in Binary, BCD or Gray Code
formats as shown in Figures 3-18 and 3-19.
Use the SEL key to toggle the input format.
WARNING: If the input signals controlling program selection
are lost due to a malfunction, the DEFAULT PROGRAM
activates. To prevent sudden changes in machinery operation
that may damage equipment or injure personnel, program the
DEFAULT PROGRAM with settings that will not cause harm in
the event of sudden activation.
See also DEFAULT PROGRAM
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-11
Setpoints
Menu Path
1
At the MAIN SCREEN:
-
Press SEL
Scroll down to SETPOINTS. Press SEL.
When SETPOINTS is selected, a preliminary screen specifies which
program’s setpoints will be programmed.
5940357
Fig. 4-5
Setpoints Preliminary
Screen
1. Program to View/Modify
2
1
5
3
Although the active program is displayed, any other program can be
specified by using the numeric keys or INC and DEC to choose a
program, then pressing SEL to move to setpoint programming.
4
5940358
Fig. 4-6
Active Program Display
1. <--P--> for Multiple Pulses ( Blank
if Only 1 Pulse in Display)
2. Channel
3. Pulse Mode
4. OFF Setpoint
5. ON Setpoint
Channel to Edit
Use the numeric keypad and ENT to select the channel to program.
NOTE: PC54 controllers have 1-9 channels available; PC55 controllers
have 1-17 channels available.
Setpoint Values
Use the left and right arrow keys to move between the ON and OFF
setpoints.
S If a channel has more than one duration, you may view the other
S
1
5940359
S
Fig. 4-7
durations by pressing the right cursor key when viewing the OFF
setpoint, or by pressing the left cursor key when viewing the ON
setpoint.
If a channel contains no durations, the ON and OFF setpoints are
‘0’. (item 1)
If a channel is always on, both the ON and OFF setpoints are ‘1’.
Channel Display
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-12
Programming
Setpoints (contd.)
Adding a Duration
You may add a new duration to a channel by pressing the SEL key when
the cursor points to either the ON or the OFF setpoint.
1
2
Fig. 4-8
The display changes to show blank ON and OFF (item 1) setpoints; the
cursor (item 2) will point to the ON setpoint. Enter the ON setpoint
through the numeric keypad, then press the ENT key or the right cursor
to move to the OFF setpoint. Enter the OFF setpoint through the numeric
keypad, then press the ENT key.
5940360
Adding Durations
Adding Multiple Durations
If ON and OFF setpoints for a duration are visible on the screen and SEL
is pressed to program a new duration, the original duration remains in the
output channel. If the ON or OFF setpoints being entered overlap an
existing duration in the channel, “Error: Duration Overlap” is displayed on
the screen.
S To abort entering a duration at any time, press ESC.
Changing Setpoints
Change a setpoint value by entering a new value using the numeric keys,
followed by ENT, or increase/decrease the setpoint value with the INC
and DEC keys.
Duration Modes
The Duration Mode controls how the INC and DEC keys modify
setpoints. There are three modes; EDG (edge), DUR (duration), and
CHN (channel.)
Change the Duration Mode by pressing the SEL key when the cursor
points to the Duration Mode.
S In EDG mode, the INC and DEC keys affect the selected ON or
OFF setpoint only.
S In DUR mode, both ON and OFF setpoints are incremented or
decremented simultaneously.
S In CHN mode, all ON and OFF setpoints for all durations in the
channel are incremented or decremented simultaneously.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-13
Setpoints (contd.)
Deleting a duration - Delete a duration by making ON equal to
OFF, or vice versa.
S If there is more than one duration in the channel, the next duration
appears in the ON/OFF setpoint area.
S If the channel has no more durations, the ON and OFF setpoints
are both zero.
Clearing a Channel - Clear a channel of all durations by entering a
new duration with ON and OFF setpoints of ‘0’.
Channel Always ON - A channel may be programmed to be on for
a full revolution (always on) by entering a new duration with both ON
and OFF values equal to ‘1’.
Record Setpoints - Record setpoints as they are established for
each program.
NOTE: For most installations, before programming setpoints, it is best to
set SHAFT POSITION to zero at the start of a machine cycle. This
allows jogging the machine to various points in the machine cycle where
output channels must turn on or off. The operator then notes these
machine positions on the controller display and enters the positions into
setpoint programming. Setpoints programmed in this manner relate
directly to the machine position. If setpoints are programmed before
SHAFT POSITION is set, and SHAFT POSITION subsequently changes,
the setpoints no longer correlate with the machine’s zero position.
The same logic applies if OFFSET is used for individual output groups.
Program the offsets before establishing setpoints for the channels in the
groups.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-14
Programming
2. Set -Up Menu
Gun Compensation
Menu Path
At the MAIN SCREEN:
-
Press SEL
Scroll down to SETUP MENU. Press SEL.
Scroll down to GUN COMP. Press SEL.
Adhesive application peripheral devices, such as pneumatic gun
solenoids and electric gun drivers, require a fixed amount of time to
perform their function. As a parent machine speeds up, these devices
require earlier actuation in the cycle in order to perform at the required
time. Gun compensation automatically advances the On/Off setpoints of
specified output channel(s) as the parent machine speeds up,
maintaining proper synchronization at all speeds.
PC50 Series controllers can be programmed with pull in/drop out
compensation, so that the ON and OFF edges in a channel can have
different gun compensation values.
When GUN COMP MODE is selected, the data entry screen illustrated in
Figure 4-9 appears.
1
2
1. Output Channel
2. Pull in (10.5 ms shown)
3. Drop out (20 ms shown)
3
5940361
Fig. 4-9
Pull in/Drop out Gun Compensation Screen
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-15
Gun Compensation (contd.)
Gun Comp Units
Gun compensation is programmed by entering the on/off response times
of the output device in milliseconds (0.001 Sec). The output turns on the
assigned number of milliseconds before the programmed ON position is
reached, and turns off the assigned number of milliseconds before the
programmed OFF position is reached. As parent machine production
speed increases, the number of degrees of advance automatically
increases, maintaining the number of milliseconds of advance.
Programming
To change output channels, move the cursor to the channel number and
enter a new channel number or use the INC or DEC keys.
To change gun comp values, use the numeric keys or INC and DEC. To
enter tenths of milliseconds, use the decimal point. When entering even
milliseconds, the decimal point is not needed. (For example, when “12”
is entered and ENT pressed, the resulting value is 12.0.)
Negative Speed Comp
Negative values of gun compensation cause an output channel to lag its
programmed machine position by the specified number of milliseconds.
(See Gun Compensation in Section 2, Description for a detailed
discussion on applying negative speed compensation.)
To program negative gun comp, press the +/ -- key after entering a
number, but before pressing ENT. You may also decrement (decrease) a
value below zero.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-16
Programming
Timed Outputs (PC55 Only)
Menu Path
At the MAIN SCREEN:
-
Press SEL
Scroll down to SETUP MENU. Press SEL.
Scroll down to TIMED OUTPUTS. Press SEL.
Any four outputs can be programmed to time out rather than remain on
until an OFF setpoint is reached. This makes the output duration
constant regardless of machine speed. If the OFF setpoint is reached
before the specified time has elapsed, the timing will be aborted and the
output will turn off immediately.
1. Channel
2. Time Duration
1
2
5940362
Fig. 4-10
Timed Output Screen
Once an output times out, it will not turn on until the next output pulse is
reached. Each timed output can have a unique time delay length.
Outputs are timed in 1 millisecond (ms) increments up to a maximum of
9999 ms (9.999 seconds).
A timed output must be programmed with ON and OFF position setpoints
in order for output timing to take effect.
NOTE: If the parent machine is rotating in the reverse direction, timed
outputs energize when the OFF edge of the duration occurs.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-17
Offsets
NOTE: Group Position Display (GRP POS DISP) must be set to “EACH”
to assign different offset groups through OFFSET programming.
Menu Path
At the MAIN SCREEN:
-
Press SEL
Scroll down to SETUP MENU. Press SEL.
Scroll down to OFFSET. Press SEL.
NOTE: PC54 controllers have Operating Modes 2, 3, and 5 available.
PC55 controllers have Operating Modes 0-5 available.
Offset Programming
To change the offset for an Output Group in Operating Mode 0, 3, 4, or 5,
first select the group by moving the cursor to GRP. Use INC or DEC, or
the numeric keypad and ENT to select the Output Group.
Screens
1
2
1. Output Group
2. Group Position = Shaft Position + ABS
Offset
3. Absolute Offset Value for This Group
3
5940363
Fig. 4-11
Offset Screen - Operating Mode 0, 3, 4 or 5
1
2
1. Output Group
2. Group Position = PRE + Change
Since Last Reset
3. Group Preset Value (If Group is in
Operating Mode 1 or 2)
3
5940364
Fig. 4-12
Offset Screen -Operating Mode 1 or 2
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-18
Programming
Offset Programming (contd.)
Offset can be programmed in two ways:
S Direct Entry - Enter the offset directly by moving the cursor to ABS
and entering the offset value on the numeric keypad, followed by
ENT.
S Group Position - Jog the machine to a position corresponding to the
desired group position, move the cursor to POS, and enter the group
position using the numeric keypad, followed by ENT.
For example:
Jog the machine to a point where the group position should be
zero, then press ‘0’ ENT while the cursor is at POS.
S The ABS value directly shows the relationship between the group
position and machine 0 (shaft position) in scale factor increments.
For example:
Suppose that SHAFT POSITION is set to machine 0 and SCALE
FACTOR is set to 360. If the ABS of a group is 20, its position will
always be 20 degrees ahead of the machine position.
S If groups have been programmed with their own offsets, changing
SHAFT POSITION changes all of the group positions at once. It is
usually best to set SHAFT POSITION to the desired zero position in
the machine cycle before programming individual group offsets.
S If groups have been programmed with their own offsets, changing
GRP POS DISP to “ONE” immediately changes ABS for all groups to
the value programmed for Group 1.
Programming Preset
To change the preset for an Output Group in Operating Mode 1 or 2, first
select the group by moving the cursor to GRP. Use INC or DEC, or the
numeric keypad and ENT to select the group. Move the cursor to PRE
and enter the preset value, followed by ENT. Preset is programmed in
scale factor units.
NOTE: The preset value is stored in the controller on power down.
However, the last group position is not. On power up, the group position
will be the same as SHAFT POSITION. When the group’s input terminal
is energized, then the group position resets to the preset value.
See also SHAFT POSITION, GRP POS DISP, OUTPUT GROUPS
See Output Groups and Operating Modes in Section 2, Description.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-19
Speed Enable/Disable
Menu Path
At the MAIN SCREEN:
-
Press SEL
Scroll down to SETUP MENU. Press SEL.
Scroll down to SPEED ENABLE/DISABLE. Press SEL.
SPEED ENABLE/DISABLE establishes one or two speed ranges, with
low and high RPM values. The two ranges are independent of each
other.
Each output channel can be ANDed with either SPEED
ENABLE/DISABLE level. ANDed outputs are enabled only when the
resolver speed is within the specified speed range. Output channels that
are not ANDed are “on” whenever the machine position is within their
programmed setpoints, regardless of machine speed.
One use of SPEED ENABLE/DISABLE and MIN SPEED ANDing is to
turn off devices such as glue guns if the parent machine stops or jams.
The SPEED ENABLE/DISABLE function is used to establish one or two
speed levels. Once the speed levels are programmed, use MIN SPEED
ANDing to tie individual output channels to a SPEED ENABLE/DISABLE
level.
The SPEED ENABLE/DISABLE screen displays the SPEED LEVEL, the
LOW RPM, and the HIGH RPM.
Programming
Use the numeric keys and ENT to change values for SPEED LEVEL,
LOW RPM, and HIGH RPM.
See MIN SPEED ANDing
Using Channels as Motion Detectors
An output channel can be used as a motion detector by programming it to
be on at ‘1’ and off at ‘1’, and then ANDing it with the desired Speed
Enable/Disable level. This turns the output “on” constantly, as long as
the machine speed is within the specified Speed Enable/Disable range.
See also MIN SPEED ANDing
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-20
Programming
Run Up
Menu Path
At the MAIN SCREEN:
Press SEL
Scroll down to SETUP MENU, press SEL
Scroll down to RUN UP OUTPUT, press SEL
1
1. Run Up Module Number
2. Run Up High RPM
3. Run Up Offset
2
3
Fig. 4-13
5940365
Run-Up Module Screen
RUN UP output signals are linearly proportional to the resolver RPM.
Two types of Run Up output modules are available: 0-10 VDC and
4-20 mA.
This function assigns OFFSET and HIGH RPM values to output positions
for Run Up modules.
Module Number
The following table shows the relationship between the Run Up module
number on the screen and the module position on the controller back.
See Figures 3-20 and 3-21 for an illustration of Run Up module
positions.
Model
Module #1
On Screen
PC54
Output #9
PC55
Output #17
Module #2
On Screen
N/A
Output #16
NOTE: RUN UP characteristics can be programmed for Modules #1 and
#2 even if no Run Up modules are physically mounted on the controller.
Programming can be done first, and the modules mounted later.
NOTE: To program OFFSET and HIGH RPM for Module #2 on PC55
controllers, be sure the RUN UP QTY function is set to ‘2’. If RUN UP
QTY is set to ‘1’, programming for Module #2 is not available.
NOTE: When two Run Up outputs are used, the two outputs can have
different values for OFFSET and HIGH RPM.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-21
Run Up (contd.)
Module Number (contd.)
RUN UP OUTPUT
1. Max Output
2. Offset
3. High RPM
1
2
3
RPM
5940366
Fig. 4-14
To program Module Number, move the cursor to “RUN UP MODULE”,
then use the numeric keys to enter the number of modules, then
press ENT.
High RPM
Run Up High RPM is the resolver speed at which full scale output occurs.
High RPM is programmed in whole RPM. When this speed is reached,
the Run Up output signal level is at full scale (10 VDC or 20 mA).
Increasing speed beyond the High RPM will not increase the RUN UP
output beyond full scale.
To program High RPM, move the cursor to “Hi” and enter the number
using the numeric keys, then press ENT.
Offset
Run Up Offset is the signal level output when the resolver is at zero
RPM. This allows the minimum signal to be greater than zero volts or
4 mA.
NOTE: PC50 Series controllers have 4096 increments of Run Up signal
level available.
The offset is specified as the number of signal increments that should be
output at zero RPM.
Calculate Run Up Offset values as follows:
For 0--10 VDC: (Minimum Signal/10) x 4096
Example: For a 2 VDC minimum signal; Offset = (2/10) x 4096 = 819
For 4--20 mA: ((Minimum Signal -- 4)/16) x 4096
Example: For a 5 mA minimum signal; Offset = ((5--4)/16) x 4096 = 256
To program RUN UP Offset, move the cursor to “Of”, use the numeric
keys to enter the calculated Offset value, then press ENT.
See OUTPUT STATUS
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-22
Programming
Stitch
Menu Path
At the MAIN SCREEN:
-
Press SEL
Scroll down to SETUP MENU. Press SEL.
Scroll down to STITCH. Press SEL.
Stitch allows programming a series of durations into a channel without
having to enter On and Off setpoints for each duration. The Stitch
function prompts for the beginning and ending setpoints for the durations
(individual stitches within the pattern); the number of durations per stitch
pattern; and the length of time for each duration. Stitch then divides the
designated portion of the resolver cycle into the specified number of
stitch durations, evenly dividing the unused portion of the segment
between the durations.
Programming
Example -- Generate a stitch pattern as follows:
DURATION
ON
OFF
1
0
50
2
100
150
3
200
250
4
300
350
5
400
450
6
500
550
7
600
650
8
700
750
9
800
850
10
900
950
Each duration is 50 increments wide, separated from the next duration by
50 increments.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-23
Programming (contd.)
The STITCH function requires navigating through eight screens. Figure
4-15 illustrates the screens and the captions explain each step.
1
1. Program to Add Stitch Pattern to:
Enter Number, Then SEL to Go to Next
Screen
2. Channel to Add Stitch Pattern to:
Enter Number, Then SEL to Go to Next
Screen
3. “On” Time of Leading Edge of First
Duration:
Enter Number, Then ENT and SEL to
Go to Next Number
4. OFF Time of Trailing Edge of Last
Duration:
Enter Number, Then ENT and SEL to
Go to Next Screen
5. Total Number of Durations to be
Added:
Enter Number, Then ENT and SEL to
Go to Next Screen
6. Length of Each Duration to be Added:
Enter Number, Then ENT and SEL to
Go to Next Screen
7. Move Cursor to EXECUTE, Then
Press SEL to Generate Stitch Pattern.
To Review Values Before Executing,
Move Cursor to Top Row and Press
SEL as Needed.
8. COMPLETE Indicates Stitch Pattern
Has Been Generated.
2
3
4
5
6
7
8
5940367
Fig. 4-15
1
2
After completing the programming, go to SETPOINTS to confirm the
Stitch pattern.
5940368
Fig. 4-16
Stitch Verification
1. <--P--> Indicates Multiple Durations
in Channel
2. Move Cursor to OF and Use Arrow
Keys to Review Duration
Setpoints.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-24
Programming
Channel Copy
Menu Path
At the MAIN SCREEN:
-
Press SEL
Scroll down to SETUP MENU. Press SEL.
Scroll down to CHANNEL COPY. Press SEL.
Channel Copy allows copying all of the durations from one channel to
another in the same program.
This function is especially useful for cartoning or other applications where
complex patterns must be applied to parallel flaps as cartons travel past
the guns.
The Channel Copy function consists of five screens:
1
1. Program Containing Channel to Copy.
Enter Number, Press ENT, then SEL
5940433
Fig. 4-17
1
1. Channel Being Copied From. Enter
Number, Press ENT, then SEL
5940434
Fig. 4-18
1
1. Destination Channel Being Copied to.
Enter Number, Press ENT, then SEL
5940435
Fig. 4-19
1
5940436
1. Move Cursor to Execute, then Press
SEL
Fig. 4-20
1. COMPLETE indicates Channel
Information Successfully Copied
1
5940437
Fig. 4-21
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-25
Program Copy
Menu Path
At the MAIN SCREEN:
-
Press SEL
Scroll down to SETUP MENU. Press SEL.
Scroll down to PGM COPY. Press SEL.
Program Copy allows copying all of the channels and setpoints from one
program to another. It is often easier to copy an existing program, and
then modify it, than to enter new programs from scratch.
The Program Copy function consists of four screens:
1
1. Program to be Copied From
5940369
Fig. 4-22
1
1. Destination Program to be Copied to
5940370
Fig. 4-23
1
1. Move cursor to Execute, then press
SEL to copy program
5940371
Fig. 4-24
1. Complete indicates Program
successfully copied
1
5940372
Fig. 4-25
Programming
Use the numeric keys and SEL to enter program numbers.
During programming, the cursor keys allow movement between the
Source and Destination screens and allow value changes before
selecting EXECUTE.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-26
Programming
Default Program
Menu Path
At the MAIN SCREEN:
-
Press SEL
Scroll to SETUP MENU. Press SEL.
Scroll to DEFAULT PROGRAM. Press SEL.
The Default Program is the program that controls the output channels
when terminals 3-6 of TB 1 on the PC54 or terminals 1-8 of TB 3 on the
PC55 (Program Select terminals) are “off”. See Figures 3-13 and 3-14.
NOTE: The PC54 controller can store 16 programs in its memory. The
PC55 is capable of storing 64 programs in its memory.
The Active Program is the program number currently controlling the
output channels. If there are program select inputs on TB 1 or TB 3,
those inputs determine the Active Program, and the Default Program is
ignored. If no hardware inputs are “on”, the Default Program becomes
the Active Program.
For installations where the program select inputs on TB 1 or TB 3 are not
used, the Default Program is always the Active Program.
Programming
Use the numeric keys to enter the number of the program designated as
the Default program, then press ENT.
WARNING: If hardware input signals are used to select the
Active Program, and those signals are lost due to a malfunction,
the Default Program activates. To prevent sudden changes in
machinery operation that may damage equipment or injure
personnel, program the Default Program with settings that will
not cause harm in the event of sudden activation.
See also PGM SEL MODE
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-27
3. Input /Output Status
Menu
Output Status
Menu Path
At the MAIN SCREEN:
- Press SEL
- Scroll down to I/O STATUS MENU. Press SEL.
- Scroll down to OUTPUT STATUS. Press SEL.
The screen(s) display the On/Off state of the output channels. The 0
indicates Off; the 1 indicates On.
1
2
5940373
Fig. 4-26
PC 54 Output Status
Screen (1 Screen)
1. Output On/Off Status Line
2. Output Numbers 1-9
Change the set of outputs displayed by pressing the SEL key.
NOTE: If any output positions have been programmed as Run-Up
outputs, the On/Off status shows ‘R’ instead of ‘0’ or ‘1’.
1
3
Fig. 4-27
2
NOTE: Output numbers 9-17 are outputs for the PC55 controller, and
are not available on the PC54 controller.
4
5940374
PC55 Output Status
Screens (2 Screens)
1. Output On/Off Status Line
2. Output Numbers 1-8
3. Output Numbers 9-17
Forcing Outputs
Forcing outputs allows forcing an output on or off for diagnostic purposes.
NOTE: When leaving the Output Status screen, remember that any
forced outputs return to their original programmed state.
Programming
Press the left arrow to access Output 1, causing the ‘0’ to blink. Press
SEL to turn this output on. The ‘0’ changes to a ‘1’. Select other desired
outputs by pressing the left or right arrows. If the output is already on, a
‘1’ is displayed instead of a ‘0’. The ‘1’ changes to a ‘0’ when the output
is forced.
Press ESC to return to output number selection. Outputs remain forced
until you leave the Output Status screen. Press SEL to access Outputs
9-17 on the PC55.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-28
Programming
3. Input/Output Status
Menu (contd.)
Input Status
Menu Path
At the MAIN SCREEN
-
Press SEL
Scroll down to I/O STATUS MENU. Press SEL.
Scroll down to INPUT STATUS. Press SEL.
The input status screen displays the On/Off status of the DC inputs on
Terminal Blocks TB 1 and TB 3 (for PC55 controllers only), (see Figure
3-13 and Figure 3-16).
1
2
Inputs are numbered 1 through 16, but only 8 inputs are shown at one
time. The On/Off status is shown under the input number. The 0
indicates Off; the 1 indicates On.
Selecting Inputs
3
Fig. 4-28
5940375
View inputs 1-8 (for PC54 and PC55 controllers).
Input Status Screens
1. Input On/Off Status Line
2. Input Numbers 1-8
3. Input Numbers 9-16 (PC55 only)
NOTE: On PC55 controllers only, inputs 9-16 may be viewed by
pressing the SEL key to toggle between the two groups of inputs.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-29
4. System Info Menu
Setpoint Use
Menu Path
At the MAIN SCREEN:
-
Press SEL
Scroll down to SYSTEM INFO MENU. Press SEL.
Scroll down to SETPOINT USE. Press SEL.
The Setpoint Use screen displays:
-
the total number of setpoint On/Off pairs, or “durations” available
for programming
the number of durations that have been programmed
The number of setpoints shown as “Used” is the sum of all durations that
are programmed into all channels of all programs. The “Total” value is
the number of durations that can be stored in non-volatile EEPROM
memory. The difference between the two numbers is the number of
durations available for programming.
NOTE: The number of durations programmed into all channels of all
programs cannot exceed the value displayed as Total.
Values cannot be changed in this screen.
Firmware Version
Menu Path
At the MAIN SCREEN:
-
Press SEL
Scroll down to SYSTEM INFO MENU. Press SEL.
Scroll down to FIRMWARE VERSION. Press SEL.
The Firmware Version screen displays the revision number of the
firmware contained within the controller. This information may be useful if
the unit needs to be returned for service.
Values cannot be changed in this screen.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-30
Programming
5. Config Menu
Sub-menus falling under the CONFIG MENU include: HARDWARE
MENU, DISPLAY MENU, ENABLE CODES, CHN ANDing MENU,
OUTPUT GROUPS and COMMUNICATIONS MENU. Many of these
sub-menus require access only during original controller programming.
Hardware Menu
Selections within the HARDWARE MENU were provided earlier in this
section under Initial Programming
Display Menu
RATE SET UP
Menu Path
At the MAIN SCREEN:
-
Press SEL
Scroll down to CONFIG MENU. Press SEL.
Scroll down to DISPLAY MENU. Press SEL.
Scroll down to RATE SETUP. Press SEL.
The Rate Setup function allows you to configure the RPM display on the
Main Screen. Three parameters can be programmed:
S Rate—The ratio of displayed RPM to actual resolver RPM. This
S
2
1
S
4
Fig. 4-29
3
ratio is a fraction consisting of a multiplier (MPY) (item 1, Figure
4-29) over a divider (DIV) (item 4, Figure 4-29).
Units— (item 3, Figure 4-29) The Main Screen can label the
resolver speed as Revolutions Per Minute (RPM), Bags Per
Minute (BPM), Cartons Per Minute (CPM), or Inches Per Minute
(IPM).
Decimal Points—The controller divides the Rate by 1, 10, 100, or
1000 to display 0, 1, 2, or 3 decimal places, respectively (item 2,
Figure 4-29).
5940376
Rate Setup Screen
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-31
Display Menu (contd.)
RATE SET UP (contd.)
Following are a few examples of the relationships between multiplier
(MPY), divider (DIV), decimal points (DP), actual resolver speed, and
displayed resolver speed:
If
MPY
Is ...
And
DIV
Is ...
And
DP
Is ...
Then
MPY/DIV
Is ...
And a
Resolver
Speed Of ...
Is
Displayed
As ...
1
2
0
0.5
100 RPM
50 RPM
1
2
1
0.5
100 RPM
5.0 RPM
1
2
2
0.5
100 RPM
0.50 RPM
1
2
3
0.5
100 RPM
0.050 RPM
1
1
0
1.0
100 RPM
100 RPM
1
1
1
1.0
100 RPM
10.0 RPM
1
1
2
1.0
100 RPM
1.00 RPM
1
1
3
1.0
100 RPM
0.100 RPM
2
1
0
2.0
100 RPM
200 RPM
2
1
1
2.0
100 RPM
20.0 RPM
2
1
2
2.0
100 RPM
2.00 RPM
2
1
3
2.0
100 RPM
0.200 RPM
Programming
S Units-Move the cursor to the “Units” field and use SEL to toggle
S
S
E 1996 Nordson Corporation
All rights reserved
between values.
MPY & DIV-Move the cursor to MPY or DIV and use the numeric
keys followed by ENT to enter a value.
DP-Move the cursor to DP and use SEL to toggle between values.
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-32
Programming
Display Menu (contd.)
TOGGLE RPM
Menu Path
At the MAIN SCREEN:
-
1
Fig. 4-30
5940377
Press SEL
Scroll down to CONFIG MENU. Press SEL.
Scroll down to DISPLAY MENU. Press SEL.
Scroll down to TOGGLE RPM. Press SEL.
After a certain speed the Position digits scroll too fast to read. Toggle
RPM allows setting the resolver rpm at which the Position display on the
Main Screen disappears. At speeds below the Toggle RPM setting, the
Position display is visible; at speeds above the Toggle RPM setting, the
Position does not display.
Toggle RPM Screen
1. Toggle RPM (resolver RPM)
Programming
Use the numeric keys and ENT to enter an RPM setting at which Position
display will blank out. Use INC and DEC to change an existing value.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-33
Display Menu (contd.)
GROUP POSITION DISPLAY
Menu Path
At the MAIN SCREEN:
-
Press SEL
Scroll down to CONFIG MENU. Press SEL.
Scroll down to DISPLAY MENU. Press SEL.
Scroll down to GRP POS DISP. Press SEL.
The Group Position Display determines whether each output group can
have its own position in the machine cycle, or if all groups share one
position. Because the position of a group in Operating Mode 1 or 2
changes each time the group’s input terminal is energized, GRP POS
DISP must be set to EACH if any groups are assigned to Operating Mode
1 or Mode 2.
Screen
In the Group Position Display Mode:
S EACH = Each Output Group has its own offset value.
S ONE = One value of Offset is shared by all Output Groups.
1
5940378
Fig. 4-31
Group Position Display
Screen
1. Group Position Display Mode
The value selected in the Group Position screen (illustrated in
Figure 4-31) determines the appearance of the main screen illustrated in
Figure 4-32 and described in the illustration captions.
S One Output Group, and GRP POS DISP set to “One” or
“Each”
S Multiple Output Groups, and GRP POS DISP set to “One”
1
4
2
3
5940379
1. Active Program
2. Machine Speed
3. Machine Position =
Shaft Position + Offset
4. To enter Menu Tree, press SEL when
cursor is here
Fig. 4-32
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-34
Programming
Display Menu (contd.)
GROUP POSITION DISPLAY (contd.)
S Multiple Output Groups, and GRP POS DISP set to “Each”
1
For item 1 in Figure 4-33, in Operating Mode 1 or 2, Position equals:
Preset + change since last reset
In Operating Mode 0, 3, 4, or 5, Position equals:
3
2
5940380
Shaft Position + Group Offset
Fig. 4-33
Item 2 in Figure 4-33, is the Group number. To change the Group
number, put the cursor in that location and press SEL.
To enter the Menu Tree (item 3, Figure 4-33) put the cursor at MENU and
press SEL.
Programming
Enter the GRP POS DISP function and press SEL to toggle between
“ONE” and “EACH”.
NOTE: GRP POS DISP must be set to “EACH” to assign different offsets
to groups through OFFSET programming.
NOTE: If groups have been assigned different offsets through OFFSET
programming, setting GRP POS DISP to “ONE” immediately changes the
individual group offsets to the value of Group 1.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-35
Enable Codes
Menu Path
At the MAIN SCREEN:
-
Press SEL. Scroll down to CONFIG MENU. Press SEL.
Scroll down to ENABLE CODES. Press SEL.
PC50 Series controllers have two levels of programming access:
OPERATOR and MASTER, in order of increasing capabilities.
Programming levels can be activated or enabled by entering a password
on the keypad or by activating Terminals E1 or E2 on the back of the
keypad as illustrated in Figures 3-27 and 3-28. The chart in Figure 4-34
indicates what items can be accessed or viewed from the Operator level
and the Master level.
Programming
The screen is used to establish the numbers that will be used as
passwords to enable the Operator and Master levels.
S Use the SEL key to toggle between enable levels
S Use the numeric keys, followed by ENT to assign codes
Each programming level can have only one password. That password is
stored in the controller and applies to all keypads connected to that
controller.
If a password is entered into a keypad that has a programming terminal
energized, the access level will be the higher of the two.
If one keypad in a two keypad system is enabled, the other keypad will
continue to operate in the “Normal Display” mode.
If both keypads in a two keypad system are enabled, each keypad will
operate at the programming level enabled on it. One keypad may be
Operator enabled, while the other keypad may be Master enabled.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-36
Programming
Programming Access Levels for Various Menu Items
Programming Level
Normal
Display
Operator
Master
-----------
Yes (E 2)
Yes
Yes (E1)
Yes
Can Be Enabled By . . .
Keypad Terminal
Password
Menu Item Access
Password
Enter
Enter
Enter
Setpoints
View
Program
Program
Gun Comp
View
Program
Program
Timed Outputs (PC55 Only)
View
Program
Program
Offsets
View
Program
Program
Speed Enable/Disable
View
Program
Program
Run-Up
View
Program
Program
Stitch
------
------
Program
Channel Copy
------
------
Program
Program Copy
------
------
Program
Default Program
View
Program
Program
Input Status
View
View
View
Output Status
View
View
View
Setpoint Use
View
View
View
Firmware Version
View
View
View
Model & Options
View
View
View
Keyboard Qty (PC55 Only)
------
------
Program 1
Increasing Dir
------
------
Program
Scale Factor
------
------
Program
Shaft Position
------
------
Program
Run-Up Qty
------
------
Program
Pgm Sel Mode
------
------
Program
Rate Setup
------
------
Program
Toggle RPM
------
------
Program
Grp Pos Disp
------
------
Program
Min Speed ANDing
------
------
Program
Rem Enab AND
------
------
Program
Output Groups
Communications Menu
------
------
Program
Memory Tests
------
------
Run
Setup Menu
I/O Status Menu
System Info Menu
Config Menu
Hardware Menu
Display Menu
Enable Codes
Chn ANDing Menu
Program
Test Menu
NOTES: 1 KEYBOARD QTY can be programmed only through the keypad whose address
is ‘0’.
Fig. 4-34
Programming Access Levels for Menu Items
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-37
Chn ANDing Menu
MIN SPEED ANDing
Menu Path
At the MAIN SCREEN:
-
Press SEL
Scroll down to CONFIG MENU. Press SEL.
Scroll down to CHN ANDING MENU. Press SEL.
Scroll down to MIN SPEED ANDing. Press SEL.
This function links the operation of output channels to the SPEED
ENABLE/DISABLE levels programmed through SPEED
ENABLE/DISABLE. Each output channel may be ANDed (linked) with
either SPEED ENABLE/DISABLE level.
If an output is MIN SPEED ANDed, it turns on only when:
S the resolver RPM is in the range specified for that SPEED
ENABLE/DISABLE level
And
S the setpoints programmed for the ANDed channel are “on”.
NOTE: Outputs that must always operate, regardless of machine speed,
should not be ANDed with a SPEED ENABLE/DISABLE level.
This screen displays the channel number and the SPEED
ENABLE/DISABLE level for MIN SPEED ANDing: L1, L2, or OFF. The
channel will not be MIN SPEED ANDed if the enable is OFF.
Programming
Select a new channel by pressing the INC/DEC keys, or through direct
numeric entry followed by ENT.
Press the SEL key to toggle the ANDing to L1, L2, or OFF.
Operation
S Any number of output channels can be ANDed to a single SPEED
ENABLE/DISABLE level.
S MIN SPEED ANDing and REMOTE ENABLE ANDing can be
S
combined for any given output channel.
When MIN SPEED ANDing is activated for a channel, it applies to
that channel in all programs.
Using Channels as Motion Detectors
Change any output channel to a Motion Detector channel by
programming it to be on at ‘1’ and off at ‘1’, and then ANDing it with the
desired SPEED ENABLE/DISABLE level. Output is then “on” constantly
as long as the machine speed is within the specified SPEED
ENABLE/DISABLE range.
See also SPEED ENABLE/DISABLE
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-38
Programming
Remote Enable ANDing
Menu Path
At the MAIN SCREEN:
-
Press SEL
Scroll down to CONFIG MENU. Press SEL.
Scroll down to CHN ANDing MENU. Press SEL.
Scroll down to REMOTE ENABLE ANDing. Press SEL.
REMOTE ENABLE ANDing allows ANDing (linking) any output channels
with input terminal #8 on PC54 controllers, or input terminal #16 on PC55
controllers. (See Figures 3-13 and 3-16). An output channel’s
programmed setpoints ANDed with input terminal #8 (PC54) or
#16 (PC55) are enabled only while the terminal is energized.
Programming
Select a new channel by pressing INC/DEC, or using the numeric keys
followed by ENT.
Use the SEL key to toggle ANDing on and off.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-39
Output Groups
Menu Path
At the MAIN SCREEN:
-
Press SEL
Scroll down to CONFIG MENU. Press SEL.
Scroll down to OUTPUT GROUPS. Press SEL.
This function allows division of output channels into groups, and then
assigning Operating Modes to the Output Groups.
Operating modes provide a powerful tool for relating output channel
operation to sensor signals or other inputs. Incorporating modes into a
control system can greatly improve line efficiency, reduce scrap, and
improve high speed control accuracy between machine sections.
1
4
Fig. 4-35
1. Selected Output Group
2. Number of Output Groups
3. Mode of Selected Output Group
4. Number of Channels in Selected
Output Group
2
3
5940381
Offset Screen -Group Mode 1 or 2
A complete explanation of the uses and applications of Output Groups
and Operating Modes is provided in Section 2, Description.
Establishing Groups
When dividing outputs into groups, several rules must be followed:
S Output channels are assigned to Output Groups sequentially. Group
1 begins with Output 1 and includes the specified number of outputs;
Group 2 begins with the next output and continues sequentially for its
specified number of outputs; and so on. The last group automatically
includes all remaining outputs.
S With the PC54 controller, 1 or 2 groups can be established. With the
PC55 controller, as many as six groups or as few as one group can
be established.
S More than one group can be assigned to the same mode.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-40
Programming
Establishing Groups (contd.)
PC54 Grouping Examples
Table 4-1 Grouping Example 1 -- All Outputs in One Group
Output Group
Includes Outputs
Mode
1
1 thru 8
3
Table 4-2 Grouping Example 2 -- Two Groups
Output Group
Includes Outputs
Mode
1
1 thru 4
2
2
4 thru 8
0
PC55 Grouping Examples
Table 4-3 Grouping Example 1 -- All Outputs in One Group
Output Group
Includes Outputs
Mode
1
1 thru 16
3
Table 4-4 Grouping Example 2 -- Two Groups
Output Group
Includes Outputs
Mode
1
1 thru 4
2
2
5 thru 16
0
Table 4-5 Grouping Example 3 -- Three Groups
Manual 66--PC50--MA--01 (formerly 57--30)
Output Group
Includes Outputs
Mode
1
1&2
0
2
3&4
4
3
5 thru 16
0
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-41
Establishing Groups (contd.)
Programming
Begin by moving the cursor to GRP QTY, then entering the number of
Output Groups desired, followed by ENT.
Next, move the cursor to GRP and enter ‘1’ followed by ENT.
Move the cursor to CHNS and enter the number of output channels to be
included in Group 1, followed by ENT.
Move the cursor to MODE and enter the operating mode for the Output
Group from zero to five, followed by ENT.
Move the cursor back to GRP and repeat the steps for each group being
programmed.
NOTE: When output channels are divided into Output Groups, the
appearance of the Main Screen changes slightly. See MAIN SCREEN for
details.
See also MAIN SCREEN, OFFSET, GRP POS DISP
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-42
Programming
Communications
Communications programming allows configuring a RS-232/485 serial
port (See Figures 3-11 and 3-12) to match the requirements of the host
PC or PLC.
Serial communications can be used in two ways:
S To exchange operating data and parameters with a host computer
S
using standard ModBus ASCII protocol (available on the PC55
controller only)
To upload/download PC50 Series controller programs using
Nordson’s optional Communications Software (available for PC54
and PC55 controllers)
NOTE: Initial communications programming is required only if an
optional communications package is being installed.
NOTE: These communications programming instructions must be used
in conjunction with installation instructions and operating procedures
found in the instruction sheet provided with the Nordson Communication
Software package.
Menu Path
From the MAIN SCREEN:
-
Press SEL
Scroll down to CONFIG MENU. Press SEL
Scroll down to COMMUNICATIONS. Press SEL
Purpose
This function sets the communications type, controller address, and baud
rate for communicating with a host computer.
Type
Use SEL to toggle between RS-232 and RS-485 communications.
Address
The address must be unique for each controller installed on a network.
This address is used by a host computer to identify and send information
to a particular controller. The controllers ignore incoming information if
the address field of the communication packet does not match the
address of the controller.
The address set through COMMUNICATIONS programming takes effect
only when the DIP switches, see Figure 3-29 and Figure 3-30, are set to
an address value of zero. Whereas the DIP switch can set a maximum
address of ‘7’, the COMMUNICATIONS function can set addresses
ranging from 0-255.
Use the numeric keys to enter the Address, then press ENT.
Baud Rate
Manual 66--PC50--MA--01 (formerly 57--30)
Use SEL to toggle between the available baud rates. The baud rate must
match that of the host computer. Available baud rates are 4,800, 9,600,
19,200 and 38,400.
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Programming
4-43
6. Test Menu
Memory Tests
Menu Path
At the MAIN SCREEN:
-
Press SEL
Scroll down to TEST MENU. Press SEL.
Scroll down to MEMORY TESTS. Press SEL.
This menu selection provides three functions allowing the clearing of
programmed values from the controller. A function test of the controller’s
watchdog timer is available as well.
Programming
Perform one of the memory test functions by using the numeric keys to
enter a function number, then pressing SEL.
Test Functions
Function 7000
Clears all setpoints and configuration settings from the controller’s EEPROM.
After clearing the settings, the controller reloads the factory default settings.
Function 7001
Clears all configuration settings from the controller’s EEPROM, including all
programming performed through the SETUP Menu and CONFIG Menu on the
Menu Tree. When finished, the controller reloads the factory default settings.
Function 7002
Clears all setpoints from the controller’s EEPROM, including any ON/OFF
setpoints programmed through SETPOINTS. All other settings are preserved.
Function 7998
The Watchdog Timer monitors controller microprocessor operation, shutting the
controller down if any internal malfunction is detected. The controller may
continue if the Watchdog Timer fails, but subsequent malfunctions or irregularities
may go undetected.
Function 7998 tests the Watchdog Timer. When operating properly, the controller
resets. If the controller does not reset, failure has occurred and the controller
must be replaced.
CAUTION: If a controller fails the Watchdog Timer test, do not
continue operating the controller. The controller may appear to
be functioning normally, but any internal malfunction may cause
erratic operation, possibly activating outputs at the wrong point
in the machine cycle. Such erratic operation may damage
products and machinery, and injure machinery operators.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
4-44
Programming
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Section 5
Troubleshooting and Repair
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
5-0
Troubleshooting and Repair
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Troubleshooting and Repair
5-1
Section 5
Troubleshooting and Repair
WARNING: Allow only qualified personnel to perform the
following tasks. Observe and follow the safety instructions in
this document and all other related documentation.
1. Controller Diagnostics
PC 50 Series controllers are not field repairable and must be returned to
Nordson for replacement. Do not disassemble failed units.
The yellow Status LED on the controller (Figure 5-1) blinks in various
patterns, indicating the controller status.
Status LED
1. Yellow Status LED
2. Green Power LED
1
Fig. 5-1
2
5940382
PC 50 Series Controller Status Indicators
Normal Operation
The Status LED blinks on and off rapidly.
Keypad Not Connected
If the controller is powered without a keypad connected, the LED blinking
pattern will be “off” for one second, followed by four quick “on” blinks.
Internal Errors
If the LED blinking pattern is “on” for a second, followed by one or more
quick blinks “off,” the controller is experiencing internal errors. The
specific error is indicated by the number of “off” blinks:
One “Off” Blink—Corrupt RAM
Two “Off” Blinks—Checksum error indicating EPROM corruption.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
5-2
Troubleshooting and Repair
Status LED (contd.)
Three “Off” Blinks—System error.
Four “Off” Blinks—System error.
If any of the above four patterns occur, power cycle the controller. If the
pattern occurs again, remove the controller from service and return it to
Nordson.
Five “Off” Blinks—Internal error; possibly noise problems.
Six “Off” Blinks—Internal error; possibly noise problems.
If either of these two patterns occur, check for loose connections and fix
any obvious noise problems. If the problem persists, remove the
controller from service and return it to Nordson.
2. Keypad Diagnostics
WARNING: The keypad cannot be repaired in the field. If a
unit fails, do not disassemble it. Return it to Nordson for
replacement.
If the Fault LED on the keypad lights, turn the controller off, then back on.
If the keypad Fault LED does not go off, the keypad microprocessor has
malfunctioned. Return the keypad to the factory.
Keypad Fault LED
1. Power Indicator
2. Fault Indicator
1
2
Fig. 5-2
5940383
Keypad Status Lights
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Troubleshooting and Repair
5-3
The Keypad includes a series of diagnostics that show the status of
various keypad functions.
Keypad Diagnostics
To start the diagnostics, turn the controller off, then restart the controller
while pressing any key on the keypad.
NOTE: After each display, press the down arrow, then press SEL. A
new screen appears. Press the up or down arrows to return to the menu.
1. The first screen displays a unique key ID number, the firmware
revision number, the keypad firmware revision date and the keypad
checksum.
5940384
Fig. 5-3
2. The Fault LED blinks on, then off, at one second intervals.
5940385
Fig. 5-4
3. The ‘1’ displayed indicates for keypad terminal block sinking or
sourcing wiring that E1 is jumpered; 2 indicates E2 is jumpered. (See
Figures 3-27 and 3-28.)
5940386
Fig. 5-5
4. The Address Switches screen displays the keypad dipswitch address
setting. (See Figure 3-30)
5940387
Fig. 5-6
5. The Comm Port tests communications. Figure 5-10 illustrates how
jumpers are placed in the keypad terminal block for testing.
5940388
Fig. 5-7
6. A complete character set scrolls across both lines. Press the up or
down arrows to return to the Menu.
5940389
Fig. 5-8
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
5-4
Troubleshooting and Repair
Keypad Diagnostics (contd.)
7. The screen displays a unique key number for each key pressed.
Press the ‘hidden key’ on the keypad face, just below HLP to exit.
5940390
Fig. 5-9
Keypad Communications Port
Test Set Up
E1
E2
C
S
--
1
Fig. 5-10
+
W
2
X
Y
Z
When the Comm Port diagnostic is run, with keypad terminals W, X, Y,
and Z jumpered as illustrated in Figure 5-10, a string of “plus” signs
scrolls across the display. When either jumper is removed, the scrolling
stops.
5940391
Keypad Terminal Block
+ 20-30
VDC In
1.
2. Jumpers for Test
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Troubleshooting and Repair
5-5
3. Resolver
Troubleshooting
Mechanical Problems
If the resolver is generating erratic RPM or position readings, or the
position appears to be shifting periodically with respect to the machine
cycle, check the mechanical coupling between the resolver and the
machine.
If the coupling is not slipping, loosen the coupling and rotate the resolver
shaft in both directions with sudden, jerky motions. If the controller
displays unusual position or RPM readings, the resolver may be need to
be replaced.
NOTE: Resolvers cannot be repaired in the field. If a unit fails, it must be
replaced. Contact your local Nordson representative.
Electrical Problems
Section 2, Installation provides installation procedures for the resolver
and cables. If any wire in one of the three individually shielded pairs
becomes disconnected, “ERROR: Resolver Not Connected” is displayed
on the keypad screen.
The output channels will immediately be disabled until the resolver is
re-connected. Pressing ESC clears the error message.
NOTE: ESC clears the message and restores access to keypad
programming even if the resolver has not been reconnected.
Follow this procedure to troubleshoot electrical problems:
WARNING: Risk of electrical shock. Failure to observe may
result in personal injury, death, or equipment damage.
1. Verify that the electrical connections at each end of the resolver cable
are secure.
2. Disconnect the cable at the controller. Measure the resistances
between all wires on the resolver cable terminal block. The paired
wires should have the resistances shown in Table 5-1, while the
resistance between every other combination of wires should be
infinite. If the resistances are correct, the controller may need to be
replaced.
3. If the resistances in Step 2 are incorrect, the problem may be in the
cable or in the resolver. Disconnect the cable at the resolver and
measure the resistances at the resolver pins. If the resistances are
correct, the cable is bad. If the resistances are wrong, the resolver
should be replaced.
Table 5-1. Resolver Wire Resistance
E 1996 Nordson Corporation
All rights reserved
Wire Pair
Resistance
White/Black
15 to 25 Ohms
Red/Black
20 to 40 Ohms
Green/Black
20 to 40 Ohms
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
5-6
Troubleshooting and Repair
4. General Troubleshooting
NOTE: Controllers and keypad/displays cannot be repaired in the field.
If a unit fails, do not disassemble it. Return the defective unit to Nordson
for replacement.
WARNING: Risk of electrical shock. Failure to observe may
result in personal injury, death, or equipment damage.
NOTE: See Figures 5-12 and 5-13 for the PC 50 Series controller
cabinet general arrangement and the cabinet wiring diagram.
Table 5-2. Troubleshooting Table
Problem
Possible Cause
Corrective Action
Main fuse blown.
Check main fuse.
Defective power supply to
controller.
Check controller power supply.
Keypad dead, but controller LED’s
are on.
Incorrect wiring between keypad
and controller.
Check wiring between keypad and
controller.
Keypad Fault LED “On”.
Keypad microprocessor has
malfunctioned.
Turn the controller off and back on.
If the keypad Fault LED does not
go off, return the keypad to the
factory.
Menu operation slow on keypad
display.
KEYBOARD QTY programming
incorrect.
Check KEYBOARD QTY
programming. If it is set for two
keypads, but only one is
connected, menu operation will be
very slow.
COMM FAILURE--HOST TO
KEYBOARD message
This message may flash briefly on
power-up under normal conditions.
If the message flashes after power
up, defective keypad wiring
connection may exist.
Check keypad wiring connections
at keypad and controller.
Incorrect DIP switch settings.
Check DIP switch settings.
Controller & keypad dead
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Troubleshooting and Repair
5-7
4. General Troubleshooting
(contd.)
Problem
Possible Cause
Corrective Action
This is a non-fatal error, indicating
the controller’s internal analog chip
is not working. A bad or missing
RUN UP module will not cause this
message.
Replace the controller.
Performing processor-intensive
programming tasks?
When performing processor
intensive programming tasks, such
as recalculating many setpoints
due to a change in SCALE
FACTOR, or creating many
setpoints through STITCH, the
controller may briefly lose contact
with the keypad. Once the
calculations are complete, contact
will be re-established. Press ESC
to clear any remnants of the error
message.
ERROR: RESOLVER NOT
CONNECTED message.
Resolver or resolver cable failure.
See Resolver Troubleshooting in
this section.
POS (position) moves opposite to
machine direction.
INCREASING DIR programmed
incorrectly for the correct direction
of rotation.
Check INCREASING DIR for the
correct direction of rotation.
ERROR: Analog Malfunction.
Check resolver wiring.
POS (position) does not match
machine position.
Serial communications not
working
E 1996 Nordson Corporation
All rights reserved
Incorrect OFFSET. Once set, the
offset value should not change.
Verify that OFFSET is correct.
Resolver coupling not tight.
Verify that the resolver coupling is
tight. Tighten if loose. See
Resolver Troubleshooting in this
section.
Type, baud rate, and address
incorrectly set in Communication
programming.
Check communication
programming to be sure type,
baud rate, and address are
correctly set.
DIP switches for the
controller-to-host communications
are set incorrectly.
Be sure the DIP switches for the
controller-to-host communications
are set correctly.
Defective communication cable
wiring.
Check communication cable
wiring.
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
5-8
Troubleshooting and Repair
4. General Troubleshooting
(contd.)
Problem
Outputs cycling regularly at
incorrect machine positions.
Erratic Operation
RUN UP output not working.
Possible Cause
Corrective Action
Incorrect program number is active.
Check that the correct program
number is active.
Incorrect setpoints of the output(s)
in question.
Check the setpoints of the
output(s) in question.
Incorrect SPEED COMP settings.
Check SPEED COMP settings.
Incorrect OFFSET settings.
Verify that OFFSET is correct.
Watchdog Timer test described
under Memory Tests in Section 4,
Programming.
Run the Watchdog Timer test
described under Memory Tests in
Section 4, Programming.
Resolver problem.
See Resolver Troubleshooting, in
this section.
RUN UP QTY and RUN UP Output
are programmed incorrectly.
Check that RUN UP QTY and
RUN UP Output are programmed
correctly.
Check that RUN UP output
module is located in the correct
module position. See Section 2,
Installation.
Check that RUN UP output wiring
is correct.
Verify that RUN UP load device is
within specifications for the Run
Up module.
Try a different RUN UP output
module.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Troubleshooting and Repair
5-9
4. General Troubleshooting
(contd.)
AC/DC module not working.
Incorrect program number is active.
Check that correct program
number is active.
Controller activating the output(s) at
the correct position in the resolver
revolution?
Use OUTPUT STATUS to see if
the controller is activating the
output(s) at the correct position in
the resolver revolution.
If not, verify that the Setpoints are
correctly programmed.
Programming that may prevent an
output from energizing includes
TIMED OUTPUTS (PC55 only),
REM ENABLE ANDING and MIN
SPEED ANDING.
Too small a value in Timed Output.
Too small a value will not turn on
output module.
Defective module.
If OUTPUT STATUS shows the
output is on, but the LED on top of
the module does not light, try
replacing the module.
Defective module fuse.
If the LED on the module lights but
the output terminal does not
energize, check the fuse built into
the top of the module. Use the
fuse tester built into the controller.
Defective wiring or no power in
circuit.
Check that load power is present
in the circuit and correctly wired.
Remember that modules do not
supply power to loads; they simply
switch the load circuit on and off.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
5-10
Troubleshooting and Repair
5. Controller Fuse Tester &
Fuse Replacement
Figure 5-11 shows location of the fuse test socket and LED used to test
TR5 style fuses. PC 50 Series controllers are shipped with a spare 4A
fuse mounted in the test socket.
Fuse Tester
2
1
1. 250 mA TR 5 for power to Inputs TB 2
2. LED Lights if Fuse in Test Socket
Good
3. Test Socket w/Spare 4 A TR 5 Fuse
3
5940269
Fig. 5-11
Fuse Tester Location
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Troubleshooting and Repair
5-11
6. Electrical Schematics
and Wiring Diagrams
WARNING: Disconnect equipment from the line voltage.
WARNING: Risk of electrical shock. Failure to observe may
result in personal injury, death, or equipment damage.
2
4
3
10
9
5
6
1
11
7
12
8
5940439
Fig. 5-12
1.
2.
3.
4.
Controller Cabinet Component General Arrangement
Left Side Exterior View
Front Interior View
Right Side Exterior View
24 VDC Power Supply
E 1996 Nordson Corporation
All rights reserved
5.
6.
7.
8.
PC 50 Series Pattern Controller
TB 8 Terminal Block
Input Power Terminal Strip
Input Power Conduit Entrance
107 126B
Issued 01/96
9. Input/ Output Wiring Conduit
Entrance
10. Resolver Wiring Conduit Entrance
w/ Nylon Fitting
11. Input/Output Wiring Conduit
Entrance
12. Communications Cable Fitting
Manual 66--PC50--MA--01 (formerly 57--30)
5-12
Troubleshooting and Repair
NOTE: Controllers are shipped configured for 240 VAC service.
7. Electrical Schematics
and Wiring Diagrams
WARNING: Disconnect equipment from the line voltage.
WARNING: Risk of electrical shock. Failure to observe may
result in personal injury, death, or equipment damage.
PC 50 Series Controllers with
240 VAC Service
Install 240 VAC input power to the terminal strip as illustrated in Figure
5-13.
+24V
24 VDC
POWER
SUPPLY
24V
COM
1
L1
2
L2
240 VAC
GND
3
F1
4
-- OUT
+ OUT
A
J1
B
F2
--
+
G
PATTERN CONTROLLER
CHASSIS GROUND
Fig. 5-13
5940438
Input Power Wiring Diagram (240 VAC)
NOTE: Fuses F1 and F2 are 1 amp Slo Blo for 240 VAC service.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
5-13
Troubleshooting and Repair
NOTE: Controllers are shipped configured for 240 VAC service.
PC 50 Series Controllers with
120 VAC Service
WARNING: Disconnect equipment from the line voltage.
WARNING: Risk of electrical shock. Failure to observe may
result in personal injury, death, or equipment damage.
To reconfigure for 120 VAC service, remove J1 (see Figure 5-13) from
terminals A and B, then install J2 from F1 to terminal B and J3 from F2 to
terminal A as shown in Figure 5-14. Route the 120 VAC service to the
terminal strip as illustrated in Figure 5-14.
NOTE: Replace fuses F1 and F2 with customer supplied 2 amp Slo Blo
for 120 VAC service.
+24V
24 VDC
POWER
SUPPLY
24V
COM
1
L1
2
L2
120 VAC
GND
3
F1
4
-- OUT
J2
+ OUT
A
B
J3
F2
--
+
G
PATTERN CONTROLLER
CHASSIS GROUND
Fig. 5-14
5940310
Input Power Wiring Diagram (120 V AC)
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
5-14
Troubleshooting and Repair
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Section 6
Parts
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
6-0
Parts
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
6-1
Parts
Section 6
Parts
1. Introduction
To order parts, call the Nordson Customer Service Center at
800-241-8777 or your local Nordson representative. Use this five-column
parts list, and the accompanying illustration, to describe and locate parts
correctly.
Using the Illustrated Parts List
Numbers in the Item column correspond to numbers that identify parts in
illustrations following each parts list. The code NS (not shown) indicates
that a listed part is not illustrated. A dash (--) is used when the part
number applies to all parts in the illustration.
The six-digit number in the Part column is the Nordson Corporation part
number. A series of dashes in this column (- - - - - -) means the part
cannot be ordered separately.
The Description column gives the part name, as well as its dimensions
and other characteristics when appropriate. Indentions show the
relationships between assemblies, subassemblies, and parts.
Item
Part
--
000 000
Assembly
1
1
000 000
S Subassembly
2
2
000 000
S S Part
1
Description
Quantity
Note
A
S If you order the assembly, items 1 and 2 will be included.
S If you order item 1, item 2 will be included.
S If you order item 2, you will receive item 2 only.
The number in the Quantity column is the quantity required per unit,
assembly, or subassembly. The code AR (As Required) is used if the
part number is a bulk item ordered in quantities or if the quantity per
assembly depends on the product version or model.
Letters in the Note column refer to notes at the end of each parts list.
Notes contain important information about usage and ordering. Special
attention should be given to notes.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
6-2
Parts
2. PC50 Series Controller
Parts Lists
PC50 Systems
Item
Part
Description
Quantity
-
188 096
PC54 Pattern Controller System
-
-
188 097
PC55 Pattern Controller System
-
-
188 063
Controller Unit, PC54
-
-
188 064
Controller Unit, PC55
-
Note
Controller Output Modules
Item
Part
Description
Quantity
Note
OUTPUT MODULES
-
188 087
0-60 VDC, 0-3 Amp DC Output
-
-
188 088
0-200 VDC, 0-1 Amp DC Output
-
-
188 089
24-280 VAC, 3 Amp
-
-
188 090
Output Reed Relay
-
RUN UP MODULES
-
188 091
0-10 VDC Run-Up Output Module
-
-
188 092
4-20 mAmp Run-Up Output Module
-
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Parts
6-3
Resolvers and Resolver Cables
Item
Part
Description
Quantity
Note
ENCODER, PC, RESOLVERS
-
188 065
Encoder, PC Resolvers, 3/4 FT, RC,
-
-
188 066
Encoder, PC Resolvers, 3/4 FT, SC,
-
-
188 067
Encoder, PC Resolvers, 3/8 FL, RC,
-
3/
8
-
188 068
Encoder, PC Resolvers,
FL, SC,
-
-
188 069
Encoder, PC Resolvers, 5/8 FT, RT,
-
-
188 070
Encoder, PC Resolvers,
5/
8
FT, LT,
-
ENCODER, PC, RESOLVER CABLES
-
188 071
Resolver, Cable
10 ft
-
188 072
Resolver, Cable
30 ft.
-
188 073
Resolver, Cable
50 ft.
-
188 074
Resolver, Cable
100 ft.
-
188 075
Resolver, Cable
150 ft.
-
188 076
Cable, for Resolver, Stainless Steel
10 ft.
-
188 077
Cable, for Resolver, Stainless Steel
30 ft.
-
188 078
Cable, for Resolver, Stainless Steel
50 ft.
-
188 079
Cable, for Resolver, Stainless Steel
100 ft.
-
188 080
Cable, for Resolver, Stainless Steel
150 ft.
Power Supply
Item
Part
-
188 099
E 1996 Nordson Corporation
All rights reserved
Description
Power Supply, PC, 24 VDC, 3 Amp
107 126B
Issued 01/96
Quantity
Note
-
Manual 66--PC50--MA--01 (formerly 57--30)
6-4
Parts
Keypad/Display and
Keypad /Display Cables
Item
Part
Description
Quantity
-
188 098
PC50 Pattern Controller System
-
-
188 093
Keypad/Display
-
Note
KEYPAD/DISPLAY CABLES
-
188 125
Cable, PC, Keypad/Display
2 ft.
-
188 081
Cable, PC, Keypad/Display
5 ft.
-
188 082
Cable, PC, Keypad/Display
10 ft.
-
188 083
Cable, PC, Keypad/Display
30 ft.
-
188 084
Cable, PC, Keypad/Display
50 ft.
-
188 085
Cable, PC, Keypad/Display
100 ft.
Terminal Blocks
Item
Part
Description
Quantity
Note
TERMINAL BLOCKS
-
188 112
Terminal Block, PC Resolver Cable
1
-
188 113
Terminal Block, PC Input Power
1
-
188 114
Terminal Block, PC Input 1-8
1
A
-
188 122
Terminal Block, PC Input 9-16
1
A
-
188 115
Terminal Block, PC 20-30 VDC Input
1
-
188 116
Terminal Block, PC Keypad/Display
1
-
188 120
Terminal Block, PC Output 9-12
1
A
-
188 121
Terminal Block, PC Output 13-17
1
A
-
188 117
Terminal Block, PC Output 1-4
1
A
-
188 119
Terminal Block, PC Output 5-8
1
A
-
188 118
Terminal Block, PC Output 5-9
1
B
-
188 123
Terminal Block, PC Output 1-4
1
B
-
188 124
Terminal Block, PC, Input 1-8
1
B
NOTE A: For PC55 only
B: For PC54 only
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
6-5
Parts
Spare Parts
Item
Part
Description
Quantity
-
188 101
Fuse, PC, Output Module, 4 Amp
Pkg of 5
-
188 102
Fuse, PC, PC 54/55 Control,1.25 Amp
Pkg of 5
-
188 103
Fuse, PC, PC, Accessory Power, 0.25 Amp
Pkg of 5
-
188 104
Strain Relief, PC, Cable
-
188 111
Connector, PC, Resolver Cable
-
-
Fuse, 1 Amp, Sol Blo (Controllers w/240 VAC input
power to Terminal Strip)
-
-
-
Fuse, 2 Amp, Sol Blo (Controllers w/120 VAC input
power to Terminal Strip)
-
Note
A
NOTE A: 2 amp Slo Blo fuses are customer supplied items.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
6-6
Parts
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Section 7
Specifications
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
7-0
Specifications
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Specifications
7-1
Section 7
Specifications
Electrical
Input Power:
20--30 VDC Keypad/display is powered from
controller.
Input Current:
PC54 System -- 400 mA max. @ 20 VDC
(includes controller, 1 keypad, resolver, 8 power
modules, 1 Run Up module and 8 inputs, all ON.
Current less at higher voltage500 mA maximum
(control only).
PC55 System -- 650 mA max. @ 20 VDC
(includes controller, 2 keypads, resolver, 15
power modules, 2 Run Up modules and 16
inputs, all ON. Current less at higher voltage.
Environment
Physical
PC50 Series Controller Cabinet
Mounting
Permanent Memory:
EEPROM (no battery required)
Operating Temp:
32_ to 131 _F (0_ to +55 _C)
Storage Temp:
--40_ to 160 _F (--40_ to +70 _C)
Humidity:
95% maximum relative non-condensing
NEMA Rating:
Keypad/display: NEMA 4X (NEMA 1, 4, 4X
and 12)
Overall Dimensions:
See Section 2, Description
Weight:
Controller: 3.5 lbs. (1.6 kg).
Keypad/Display: 0.5 lbs. (0.2 kg)
Wall or machine mounting by bolts through cabinet flanges.
Optional auxiliary keypad (PC55 only) may be
mounted up to 1000 feet from controller cabinet.
Controller unit, if ordered as individual unit not mounted in cabinet,
provided with EN-50035 (“G” profile) or EN-50022 (“Top Hat” profile).
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
7-2
Specifications
Inputs
DC Inputs:
PC54 - 8 DC inputs configurable as sinking or
sourcing as a group of 8. Optically isolated as a
group of 8.
PC55 - 16 DC inputs, configurable as sinking or
sourcing in groups of 8. Optically isolated in
groups of 8.
Input ON
State Voltage:
10-30 VDC
Input Current:
11 mA @ 24 VDC
Program Select
Response:
Response of All Other
Inputs:
100 ms typical (may be longer with large number
of setpoints)
1 -- 2 scans
Outputs
DC Outputs
60 VDC
Output Voltage: 0-60 VDC
Output Current: 3 amps DC @/ below
35 _C (95 _F) Above 35 _C derate 35.7 mA/_C
(19.8 mA/_F)
Turn On/Off Time: Each, 50 microseconds
200 VDC
Output Voltage: 0-200 VDC
Output Current: 1 amp DC @/ below
45 _C (113 _F) Above 45 _C derate 18 mA/_C
(10 mA/_F)
Turn On/Off Time: Each, 50 microseconds
Run Up Outputs
Manual 66--PC50--MA--01 (formerly 57--30)
0-10 VDC
Output Voltage: 0-10 VDC, proportional to RPM
Output Current: 10 mA maximum
Resolution: 12 bits (4096 increments)
Load Resistance 1 K Ohm minimum
4-20 VDC
Output Current: 4-20 mA
Resolution: 12 bits (4096 increments)
Load Resistance 450 Ohm maximum
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Specifications
Operation
7-3
Scan Time:
300--500 ←sec typical (exact time determined by
programming)
Position Resolution:
PC54 -- 1024 increments
PC55 -- 4096 increments
Gun Compensation:
Programmed in 0.1 ms steps, Pull in/Drop out
times can be individually compensated.
Calculations every 10 ms.
PC54 -- All channels can be individually
compensated.
PC55 -- Up to 16 channels can be individually
compensated.
Number of Timed
Outputs:
Multiple Programs:
Total Duration Memory:
4 maximum (PC55 only)
PC54 - 16 programs standard
PC55 - 64 programs standard
1258 durations
Durations per Program: 512 maximum
Durations per Output:
RS-232 Serial Communication
E 1996 Nordson Corporation
All rights reserved
512 maximum
Maximum Speed:
3000 RPM
Baud Rates:
4800, 9600, 19.2K, 38.4K
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
7-4
Specifications
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Section 8
Options
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
8-0
Options
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Options
8-1
Section 8
Options
1. Washdown Boot
Description
The washdown boot, (P/N 188 105) a clear silicon rubber boot fitting over
and around the keyboard area, protects the keyboard during caustic
chemical washdown. The transparent and pliable boot, allows the
keyboard to be viewed and operated through it. In addition to preventing
contamination from harsh chemicals, the boot protects the keyboard from
grease, oil, dirt, and normal wear that could otherwise shorten keyboard
life.
The boot is available separately and can be installed on existing controls
in the field.
Installing the Washdown Boot
1. Remove the nuts and regular black rubber gasket from the keyboard.
2. Carefully slip the silicone rubber boot over the keyboard. Slowly work
it over the mounting studs, being careful not to cause any tears in the
boot.
NOTE: Silicone rubber is very notch sensitive, tearing easily.
3. Smooth the boot into position so no stretching takes place. It should
be able to move into position easily.
4. Install the keyboard into the panel. The nut tightening sequence is
important. Start with a corner of the unit, holding the rubber boot
snugly to the edge of the keyboard while bringing the nut to a finger
tightness. Select the next nut, again tightening while holding the boot
snugly to the keyboard edge. When all the nuts are in place, tighten
each nut a little more, tightening one at a time. The silicone rubber
tends to extrude from under the keyboard if the bolts are not
tightened in an even sequence or if they are over torqued.
NOTE: Applying too much torque to the nuts does not improve
sealing. Damage to the silicone rubber seal may occur.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
8-2
Options
2. Program Enable and
Select Switches
Available as an option on PC50 Series controllers, program enable
(P/N 188 108) and program select (P/N 188 107) switches prevent
unauthorized programming changes to the controller and allow remote
selection of the Active Program.
Program Enable Switch
The switch is wired to the Master Program Enable terminal on the back of
the keyboard. A second switch may be wired to Operator Enable.
NOTE: See Keypad Wiring in Section 3, Installation for additional
information necessary to install the program enable switch.
The terminal block on the back of each keypad includes terminals to
select Master or Operator level programming access for that keypad.
See PASSWORDS in Section 4, Programming for details on
programming access.
For the program enable switch, either sourcing or sinking wiring may be
used. Figures 8-1 and 8-2 illustrate keypad terminal block sinking and
sourcing wiring for programming enable.
2
1
3
E1 E2 C
-- +
S
5
W X
Y
1. Master Program Enable
2. Operator Program Enable
3. Enable Common
4. Switch (To E1 or E2)
5. Terminal Block on Keypad
Z
4
Fig. 8-1
5940291
Program Enable - Sourcing
1
2
E1 E2 C
3
S
-- +
5
W X
Y
1. Master Program Enable
2. Operator Program Enable
3. Enable Common
4. Switch (To E1 or E2)
5. Terminal Block on Keypad
Z
4
5940292
Fig. 8-2
Program Enable - Sinking
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Options
The program select switch, which allows remote control of the Active
Program, allows the operator to change programs but does not allow
changing setpoints in the output channels. The switch provides access
to 8 programs in the active program bank.
Program Select Switch
8
7
6
5
4
3
2
1
9
10
8
7
6
5
4
3
2
1
C
1. Group 1 Input
2. Group 2 Input
3. Program Select 1
4. Program Select 2
5. Program Select 3
6. Program Select 4
7. First Cycle Enable
8. Remote Enable
9. Input Common
10. DC Power Out for Inputs
11. Chassis Ground
SINKING
TB1
GREEN
WHITE
RED
_
BLACK
+
TB2
11
8
7
6
5
4
3
2
1
9
10
8
7
6
5
4
3
2
1
C
SOURCING
TB1
GREEN
WHITE
RED
_
+
TB2
BLACK
11
Fig. 8-3
5940327
PC54 Program Select Switch Wiring
11
10
SINKING
_
9
TB2
1. Program Select 1
2. Program Select 2
3. Program Select 3
4. Program Select 4
5. Program Select 5
6. Program Select 6
7. Program Select 7
8. Program Select 8
9. Input Common
10. DC Power Out for Inputs
11. Chassis Ground
BLACK
+
8
7
6
5
4
3
2
1
C
8
7
6
5
4
3
2
1
11
10
TB3
GREEN
WHITE
RED
SOURCING
_
9
TB2
BLACK
+
8
7
6
5
4
3
2
1
Fig. 8-4
8-3
C
8
7
6
5
4
3
2
1
TB3
GREEN
WHITE
RED
5940392
PC55 Program Select Switch Wiring
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
8-4
Options
3. PC50 Series Controller
Communication
Software
Description
Communication software for PC50 Series controllers is available in two
forms:
Nordson Communication Software
Available as an option on both PC54 and PC55 controllers, Nordson’s
Communication Software is a DOS program that runs on most IBM-PC
compatible computers. When the serial port of the PC is connected to the
female DB-9 port on the PC50 Series controller, (See Figures 3-34, 3-35,
and 3-36), the software can transfer, in either direction, programming
values between the computer and the controller.
Insert the instruction sheet and diskette holder provided with the
communication package in Section 9, Communications for storage and
future reference.
Modbus Communication
Not available on PC54 controllers, Modbus communication capability is a
standard feature of PC55 controllers. Modbus communication provides
serial interface, using Modbus ASCII protocols, allowing interface with a
variety of compatible machine controllers.
See Section 9, Communications for a complete description of Modbus
communications and its use.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Section 9
Communications
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
9-0
Communications
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Communications
9-1
Section 9
Communications
1. Introduction
This section contains descriptions of and the operating requirements for
PC50 Series controller communications packages.
Nordson Communication
Software
If the optional Nordson Communication Software package is ordered,
insert the instruction sheet and diskette holder, with diskettes at the
indicated place at the end of this section.
Modbus Communication
Software
Modbus Communication software is a standard feature of PC55
controllers. Insert the diskette holders, with diskettes, at the end of the
Modbus software discussion.
NOTE: Modbus Communication is provided as a tool for customers
familiar with Modbus and experienced with computer programming and
developing control device interfaces. Modbus communications capability
on the PC55 provides a means for other control devices to interrogate the
PC55. This section provides the Discrete I/O elements and memory
register addresses. The two DOS utilities provided with the software
package enable PC55 connection with IBM compatible computers and
provide a means for mapping Data Display registers.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
9-2
Communications
2. Modbus
Communications
Introduction
Modbus communication provides serial interface, using Modbus ASCII
protocols, allowing interface with a variety of compatible machine
controllers. Compatible controllers can interrogate the PC55 for
configuration, or other operating data, and can change the data.
Due to the relatively slow speed of serial communication, applications are
usually limited to supervisory functions, such as selecting programs of
settings during a product changeover, rather than used to monitor real
time parameters such as machine position or rpm.
NOTE: Modbus protocol used in the PC55 is Modbus ASCII. Modbus
Plus or other variations will not work.
NOTE: When using serial communications, the host device must be set
for seven (7) data bits, two (2) stop bits and no parity.
Data Organization
The two types of data available through Modbus communications are
Discrete I/O and Registers.
S Discrete I/O - These elements represent input/output status. They
include coils which can be forced on or off. Forcing outputs is used
mainly for troubleshooting or diagnostic purposes.
S Registers - All controller data such as Duration setpoints, Gun
Compensation values and configuration settings are available through
registers. Values may be read from registers and changes in
controller configuration may be made by writing to registers.
Some data is represented by more than one register. ON and OFF
points, for example, for a particular Duration are referenced through five
separate registers: Program Index (40264), Channel Index (40265),
Duration Index (40266), Duration On (40267), and Duration Off (40268).
In order to read the On and Off setpoints for a Duration, data must first be
written to the three index registers to specify which Duration is to be read.
Data reading from the controller has been streamlined by providing,
special Data Display registers. By mapping a particular indexed element
to a Data Display register, the values for that element can be read without
always writing the appropriate index values.
EXAMPLE:
To map a specific Duration to a Data Display register:
1. Specify the Program, the Channel, and the Duration by writing to
Program Index (40264), Channel Index (40265) and Duration Index
(40266).
2. Using the Duration Mapping register, (40261), specify the Data
Display registers that reference this Duration.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Communications
9-3
Data Organization (contd.)
Once this Duration is mapped to these Data Display registers, reading
the registers returns the On and Off setpoints of the mapped Duration,
regardless of later changes to the values in the Index registers.
Careful use of the mapping registers allows a device to quickly read a
series of data from the PC55 without first having to specify the Index
registers for each element being read.
NOTE: Data Display registers will not accept mapping values until the
Map Limit register (40296) has been programmed with a value greater
than zero (0).
NOTE: When reading or writing to registers, no more than 32
consecutive registers may be referenced at one time.
DOS Utilities
On the diskette, furnished with the software package, are two (2) DOS
utilities for use with serial communications.
MODCMD. EXE
The MODCMD.EXE program allows an IBM compatible computer,
connected to a PC55 controller, to send and receive individual Modbus
commands for experimentation or manual programming. For each
command and response, the ASCII strings are displayed. This assists
the programmer in developing applications involving the PC55 controller.
The menu system is self-explanatory.
NOTE: When reading or writing to registers, use only the last three (3)
digits of the register.
S For example, to read or write to register 40305 (keyboard
quantity), type 305 when prompted. Do not enter 0305 or 40305.
NOTE: When using Mapping registers to specify a Data Display register,
do not add any leading zeroes (0) to the Data Display value.
S For example, to map an element to Data Display 40017, enter 17
when prompted by the program. Do not enter 017 or 40017.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
9-4
Communications
DOS Utilities (contd.)
MODMAP. EXE
Unlike Discrete I/O elements and registers which are dedicated to
specific parameters, the Data Display registers must be mapped for a
specific application in order to be useful. MODMAP. EXE is a utility
designed to simplify the programming and storage of Data Display
mapping.
MODMAP. EXE can be used to upload, from the PC55 controller to an
IBM compatible computer, the Data Display mappings that have been
established using MODCOM. EXE or another program. The mappings
can be saved as a text file, which can be reviewed, edited and then
downloaded to other PC55 controllers. The file can also be saved for
archival purposes.
Included with MODMAP. EXE is a text file called MAPPING. FMT which
can be opened in MODMAP and studied. This file explains the formats
used by MODMAP and includes a mapping example which can be
downloaded to a PC55 controller. The menus in MODMAP are
self-explanatory.
Modbus Register Map
This section provides a list of PC55 controller addresses for Discrete I/O
elements and memory registers.
Discrete I/O
Inputs
10001 -- 10016 DC Inputs
These points represent the status of the DC inputs.
Outputs
00001 -- 00100 Channel Outputs
These coils represent the status of the channel outputs. Forcing these
coils directly will set/clear the appropriate ORing and ANDing coils as
required.
The Channel Output Coil status before OR/ANDing is determined by
setpoints, group modes, speed compensation, motion ANDing, enable
input ANDing, timed outputs, and resolver fault status.
ORing and ANDing
00101 - 00200 Channel ORing Setting
Setting these coils to ‘1’ will force the corresponding channel Output Coil
ON.
00201 -- 00300 Channel ANDing
Setting these coils to ‘1’ will force the corresponding Channel Output Coil
OFF.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Communications
9-5
Discrete I/O (contd.)
Special Purpose (00301-00400)
301 Global Unforce
Clears all OR and AND coils when set from ‘0’ to ‘1’ (edge active).
302 Duration Register Enable
When ‘1’, this coil enables the creation of new Durations through writes to
the New Off Register. When this coil is ‘0’, writes to New Off Register do
not create a new Duration.
303 Create New Duration
Creates a new Duration defined by the New On and New Off registers
when set from ‘0’ to ‘1’ (edge active). This coil is ignored if coil 302 is ‘1’.
304 Move Both Edges of Duration
When ‘1’, this coil will cause both edges of a Duration to move when
either the leading or trailing edge is changed by ‘1’ (incremented or
decremented).
305 Move All Durations in Channel
When ‘1’, this coil will cause all edges of all Durations in a channel to
move when either the leading or trailing edge is changed by ‘1’
(incremented or decremented).
316 Auto Increment
When ‘1’, this coil enables the auto increment feature on index registers.
This feature allows sequential reading of indexed values without
changing the index register.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
9-6
Communications
Registers
Special Purpose and Data Display
40017 Data Display (240 registers)
These registers (017 -- 256) are used by the Mapping functions to display
individual instances of indexed data.
RPM
40257 RPM
Read only
Returns the current RPM.
Position
40258 Position Mapping
Read/write
Values: 17 -- 256
Specifies the general purpose register used to display the position for the
output group specified by the Group Index Register.
40259 Position Index
Read/write
Values: 1 -- 6
Specifies the output group whose position is displayed in the Position
Register.
40260 Position
Read only
Values: 0 -- (Scale Factor -- 1)
Returns the current position for the output group specified by the Group
Index Register.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Communications
9-7
Registers (contd.)
Duration Programming
40261 Mapping
Read/write
Values: 17 -- 255
General Purpose Register used for mapping the On and Off values for
the Duration specified by the index registers. Two registers will be used;
the first contains the On value, the second contains the Off value.
40262 Total Duration Count
Read/write
Values: 0 -- n
Returns the total number of Durations for all channels. Writing a value of
‘0’ to this register will erase all Durations. You can only write to this
register when the Stop register is ‘1’.
40263 Channel Duration Count
Read only
Values: 0 -- n
Returns the number of Durations in the channel defined by the index
registers below.
40264 Program Index
Read/write
Values: 0 -- Max Program Number
Contains the current program number for Duration access. Writing to this
register resets the Channel Index Register and the Duration Index
Register to ‘1’. When this register is ‘0’, the current active program is
used for setpoint access and for mapping (setpoints mapped with a
program index of ‘0’ will automatically change when the active program
changes).
40265 Channel Index
Read/write
Values: 1 -- Max Channel Number
Contains the current channel number for Duration access. Writing to this
register resets the Duration Index Register to ‘1’. This register is reset to
‘1’ when the Program Index Register is changed.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
9-8
Communications
Registers (contd.)
Duration Programming (contd.)
40266 Duration Index
Read/write
Values: 1 -- n
Contains the current Duration number for Duration access. This register
is reset to ‘1’ when the Program Index Register or Channel Index
Registers are changed.
40267 Duration On
Read/write
Values: 0 -- (Scale Factor -- 1)
Duration On Value.
40268 Duration Off
Read/write
Values: 0 -- (Scale Factor -- 1)
Duration Off Value.
40269 New On
Read/write
Values: 0 -- (Scale Factor -- 1)
New Duration On Value
Writing to this register loads the On setpoint of a new Duration for the
program and channel specified by the index registers above.
40270 New Off
Read/write
Values: 0 -- (Scale Factor -- 1)
New Duration Off Value.
Writing to this register loads the Off setpoint of a new Duration for the
program and channel specified by the index registers above. The
Duration is stored when the Off value is written if the Duration Register
Enable Coil is set to ‘1’; otherwise the Duration is stored when the Create
New Duration Coil is changed from ‘0’ to ‘1’ (edge active).
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Communications
9-9
Registers (contd.)
Default Program
40271 Default Program
Read/write
Values: 1 -- Max program number
Defines the active program if no hardware program select inputs are
active.
Gun Compensation
40272 Gun Comp Mapping
Read/write
Values: 17 -- 255
General purpose register used for mapping gun compensation values.
Two registers will be used; the first will contain the leading edge value,
the second will contain the trailing edge value.
40273 Channel Index
Read/write
Values: 1 -- Max Channel Number
Channel index for speed comp values.
40274 Leading Edge Comp
Read/write
Values: 0 -- n (.1mS)
Specifies the leading edge gun comp value.
40275 Trailing Edge Comp
Read/write
Values: 0 -- n (.1mS)
Specifies the trailing edge speed comp value.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
9-10
Communications
Registers (contd.)
Timed Outputs
40276 Timed Output Mapping
Read/write
Values: 17 -- 255
General purpose register used for mapping timed output values.
40277 Channel Index
Read/write
Values: 1 -- Max Channel Number
Channel index for time delay values.
40278 Time Delay
Read/write
Values: 0 -- n (1mS)
Specifies the maximum time in milliseconds that a channel may stay on
after it has been turned on.
Offset
40279 Offset Mapping
Read/write
Values: 17 -- 256
General purpose register used for mapping Group Offset values.
40280 Group Index
Read/write
Values: 1 -- 6
Group index for offset values.
40281 Group Offset
Read/write
Values: 0 -- (Scale Factor -- 1)
Offset value for the specified group.
NOTE: This value is a PRESET value for groups in Operating Modes 1
or 2.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Communications
9-11
Registers (contd.)
Speed Enable/Disable
40282 Speed Enable/Disable Mapping
Read/write
Values: 17 -- 255
General purpose register is used for mapping low and high motion
detection values. Two registers are used; the first contains the low
motion detection rpm value, the second contains the high motion
detection rpm value.
40283 Channel Index
Read/write
Values: 1, 2
Motion detection level index for high and low motion detection values.
40284 Min Speed Detection RPM
Read/write
Values: 0 -- n
Min Speed low limit for the level specified by the index register.
40285 -- Max Speed Detection RPM
Read/write
Values: 0 -- n
Max Speed high limit for the level specified by the index register.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
9-12
Communications
Registers (contd.)
Run Up Output
40286 Run Up Output Mapping
Read/write
Values: 17 -- 255
General purpose register used for mapping Run Up offset and high RPM
values. Two registers will be used; the first contains the Run Up offset
value, the second contains the high RPM value.
40287 Channel Index
Read/write
Values: 1, 2
Run Up channel index for Run Up offset and high RPM values.
40288 Run Up Offset
Read/write
Values: 0 -- 4095
Run Up output at 0 RPM.
40289 Run Up High RPM
Read/write
Values: 0 -- n
RPM at which Run Up output is 4095.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Communications
9-13
Registers (contd.)
Mapping Registers
40296 Map Limit
Read/write
Values: 0 -- 256
Sets the maximum number of data mappings.
40297 Map Quantity
Read/write
Values: 0 -- 256
Returns the number of data mappings active in the controller.
NOTE: Writing a ‘0’ to this register will delete all data mappings!
40298 Map Store
This register is only for use by utility programs.
40299 Map Recall
This register is only for use by utility programs.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
9-14
Communications
Registers (contd.)
Model Information
40300 Model
Read only
Returns the controller model number.
40301 Revision
Read only
Returns the major software revision.
40302 Output Quantity
Read only
Returns the number of output channels (8, 9, 16, 17, 25, etc.).
40303 Option Index
Read/write
Values: 1 -- n
Used as index for reading installed controller options through the Option
Register.
40304 Option
Read only
Values: 0 -- n
Returns installed controller options as specified through the Option Index
Register. A value of ‘0’ at index ‘1’ means no options are installed.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Communications
9-15
Registers (contd.)
Hardware Configuration
40305 Keyboard Quantity
Read/write
Values: 1, 2
Number of keyboards attached to the controller.
40306 Increasing Direction
Read/write
Values: 0 = CCW, 1 = CW
Specifies the resolver’s rotation direction (viewed from the shaft end) that
results in an increasing numerical display of position.
40307 Scale Factor
Read/write
Values: 2 -- 1024 (4096 with “--H” Option)
Scale factor used for Duration, position, and offset programming.
40308 Shaft Position
Read only
Values: 0 -- (Scale Factor -- 1)
Returns the current resolver shaft position, including the shaft offset.
40309 Shaft Offset
Read/write
Values: 0 -- (Scale Factor -- 1)
Offset that is added to raw resolver position to make Shaft Position.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
9-16
Communications
Registers (contd.)
Hardware Configuration
40310 Run Up Quantity
Read/write
Values: 0, 1, 2
Specifies the number of Run Up modules active.
40311 Resolver Type
Read/write
Values: 0 = Nordson, 1 = Other
Specifies type of resolver attached to controller.
40312 Program Select Module
Read/write
Values: 0 = Binary, 2 = BCD, 1 = Gray code
Specifies how the program select inputs determine the active program.
40316 Termination Resistor Two
Read/write
Values: 0 = Off, 1 = On
Termination resistor On/Off for RS-232/RS-485 communication port.
40318 Rate Multiplier
Read/write
Values: 1 -- 1091
RPM rate multiplier.
40319 Rate Divisor
Read/write
Values: 1 -- 63
RPM rate divisor.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Communications
9-17
Registers (contd.)
Display Configuration
40320 Rate Decimal Point Position
Read/write
Values: 0 -- 3
RPM decimal point position.
40321 Rate Units
Read/write
Values: 0 = RPM, 1 = BPM, 2 = CPM, 3 = IPM
RPM display units.
40322 Toggle RPM
Read/write
Values: 0 -- n
Specifies the RPM which causes the position display to blank.
40325 Group Position Display Mode
Read/write
Values: 0 = Each, 1 = One
Specifies whether the positions for output groups are individually
displayed, or if they are displayed as one value for all groups. Output
group positions can only be displayed as one if none are in mode 1 or
mode 2 (re-zero modes).
Password ID Numbers
40326 Operator ID
Read/write
Values: 0 -- n
Specifies the Operator ID number used to enable the Operator access
level for programming.
40328 Master ID
Read/write
Values: 0 -- n
Specifies the Master ID number used to enable the Master access level
for programming.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
9-18
Communications
Registers (contd.)
Min Speed ANDing
40332 Channel Index
Read/write
Values: 1 -- Max Channel Number
Channel index for the Min Speed Enable Level Register.
40333 Motion Enable Level
Read/write
Values: 0 = Off, n = Min Speed Level
Specifies the motion detection level used for a channel.
Rem Enable ANDing
40334 Output Enable Index
Read/write
Values: 1 -- Max Channel Number
Channel index for the Rem Enable register.
40335 Rem Enable
Read/write
Values: 0 = Channel not ANDed, 1 = Channel ANDed
Specifies whether a channel is ANDed with the Enable input.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Communications
9-19
Registers (contd.)
Group Programming
40336 Group Quantity
Read/write
Values: 1 -- 6
Specifies the number of output groups.
40337 Group Index
Read/write
Values 1--6
Group index for Channel Quantity and Group Mode Registers.
40338 Channel Quantity
Read/write
Values: 0 -- n
Defines the number of channels in the output group specified by the
Group Index Register.
40339 Group Mode
Read/write
Values: 0 -- 5
Defines the operating mode for the output group specified by the Group
Index Register.
NOTE: Groups in mode ‘0’ do not need (or have) an enable input.
E 1996 Nordson Corporation
All rights reserved
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
9-20
Communications
Registers (contd.)
Run Time Control
40340 Stop Control
Read/write
Values: 0 = Running, 1 = Stopped
When the PC55 controller is STOPPED, changes written to registers do
not update the checksum in EEPROM memory. Changes are faster
when unit is stopped, but you must read from the Checksum Register
when changes are complete to establish a valid checksum. Writing a ‘1’
value to this register will place the PC55 controller in STOPPED mode.
Writing a ‘0’ to this register will restart the PC55 controller via a watchdog
timer reset.
40341 EEPROM Checksum
Read only
Returns the current checksum of EEPROM memory. If computed
checksum of EEPROM memory does not match the current value (i.e. if
changes were made while unit STOPPED), a new value will be written to
EEPROM memory.
40342 EEPROM Changed
Read only
Values: 0 = no change, 1 = changed
A value of ‘1’ in this register means that the EEPROM has been changed
(through the keyboard) since the last time this register was read.
Reading this register sets it to ‘0’.
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Communications
3. Nordson Communication
Software
E 1996 Nordson Corporation
All rights reserved
9-21
Remove this page and insert the instruction sheet and diskette holder
provided with the optional Nordson Communication Software package.
107 126B
Issued 01/96
Manual 66--PC50--MA--01 (formerly 57--30)
9-22
Communications
Manual 66--PC50--MA--01 (formerly 57--30)
107 126B
Issued 01/96
E 1996 Nordson Corporation
All rights reserved
Index
i-1
Index
E
C
Channels, description, 2-5
Cleaning, Safety instructions, 1-7
Communication
baud rates, 7-3
Modbus communication, 9-2
programming, 4-42
software, 8-4
software descriptions, 8-4
wiring, 3-27
Controller
bench test, 3-28
cabinet installation, 3-6
communication wiring, 3-27
DIP switch settings, 3-24
dip switch settings, 3-7
initial programming, 3-28
input terminal functions, 3-15
input terminal wiring, 3-9
input wiring, 3-9
guidelines, 3-15
sinking or sourcing, 3-12
keypad/display description, 2-2
module installation, 3-7
output modules, 3-19
PC 54 terminal locations, 3-10
PC 55 terminal locations, 3-11
PC54 program select formats, 3-16
PC55 program select formats, 3-17
program menu tree, 4-2
status LEDs, 5-1
terminal blocks, 3-9
troubleshooting, 5-1
wiring, power supply, 3-8
wiring, guidelines, general, 3-8
D
Durations
adding durations, 4-12
adding multiple durations, 4-12
clearing a channel, 4-13
deleting durations, 4-13
description, 2-5
duration modes, 4-12
E 1995 Nordson Corporation
All rights reserved
Electrical
AC output, 3-20
cabinet general arrangement, 5-11
controller DIP switch settings, 3-24
controller fuse replacement, 5-10
controller outputs, 3-19
controller wiring, general, 3-8
controller/power supply wiring diagram, 5-12
input terminal function, 3-15
input terminals, 3-9
keypad/display DIP switch settings, 3-24
keypad/display wiring, 3-22
output wiring, 3-19
PC54 terminal locations, 3-10
PC55 terminal locations, 3-11
power supply wiring, general, 3-8
specifications, 7-1
terminal blocks, 3-9
G
Gun Compensation
affect on operating modes, 2-26
calculating pull-in/drop-out, 2-28
description, 2-8, 2-26
guidelines, 2-26
leading/trailing edges, 2-27
negative gun compensation, 2-29
setting pull-in/drop-out, 2-27
I
Inputs
description, 2-6
specifications, 7-2
terminals, wiring, 3-9
Installation
cabinet mounting, 3-6
communication software, 8-4
communication wiring, 3-27
controller bench test, 3-28
controller DIP switch settings, 3-24
controller input wiring, 3-9
controller output wiring, 3-19
controller power supply wiring, 3-8
initial controller programming, 3-28
keypad/display DIP switch settings, 3-24
107 126A
Issued 10/95
Manual 66-- PC50-- MA-- 01 (formerly 57-- 30)
i-2
Index
Index (contd.)
O (contd.)
I (contd.)
Installation (contd.)
keypad/display wiring, 3-22
module mounting, 3-7
program enable switch, 8-2
program select switch, 8-3
programming enable, 3-23
resolver, 3-2
washdown boot, 8-1
K
Keypad/Display
communications test set up, 5-4
description, 2-4, 2-5
diagnostics, 5-2
DIP switch settings, 3-24
parts list, 6-4
program enable, 3-23
wiring, 3-22
M
Operating Mode 2
application, 2-16
description, 2-16
programming, 2-17
Operating Mode 3
application, 2-18
description, 2-18
programming, 2-18
Operating Mode 4
application, 2-20
description, 2-20
programming, 2-21
Operating Mode 5
application, 2-22
programming, 2-22, 2-23
Operation, specifications, 7-3
Options
Nordson Communication Software description,
8-4
program enable switch, 8-2
program select switch, 8-3
washdown boot, 8-1
Modbus Communication
controller addresses, 9-4
data organization, 9-2
DOS utilities, 9-3
Output Groups
combining output channels into output groups,
2-11
establishing, 4-39
Modules
DC output, sourcing or sinking, 3-21
parts lists, 6-2
power output, 3-19
run up, 3-20
Output Groups and Operating Modes
controller input signals, 2-9
description, 2-6
output channels, 2-6, 2-10
output group assignment to operating modes,
2-12
output group programming, 2-10
Motion ANDing, description, 2-7
O
Outputs, specifications, 7-2
Offset, description, 2-24
Operating Mode
mode 0 description, 2-13
mode 1 description, 2-13
Operating Mode 0, programming, 2-13
Operating Mode 1
applications, 2-15
programming, 2-15
Manual 66-- PC50-- MA-- 01 (formerly 57-- 30)
P
Parts Lists
keypad/display, 6-4
keypad/display cables, 6-4
output modules, 6-2
PC50 systems, 6-2
power supply, 6-3
107 126A
Issued 10/95
E 1995 Nordson Corporation
All rights reserved
Index
i-3
Index (contd.)
P (contd.)
Parts Lists (contd.)
resolvers and resolver cables, 6-3
spare parts, 6-5
terminal blocks, 6-4
Passwords
enable codes programming, 4-35
program enable, 3-23
programming access, 2-7
Power Supply
installation, wiring, 3-8
parts list, 6-3
P (contd.)
Programming (contd.)
setpoints, 4-11
shaft position, 4-8
speed enable/disable, 4-19
stitch, 4-22
system testing, 4-43
timed outputs, 4-16
toggle rpm, 4-4, 4-32
Programs, description, 2-6
Pull-In/Drop-Out, description, 2-8
R
Program Enable Switch, installation, 8-2
Program Select Switch, installation, 8-3
Programming
active program, 4-4
channel copy, 4-24
communications, 4-42
default program, 4-26
enable codes, 4-35
entering menu tree, 4-4
establishing output groups, 4-39
firmware version, 4-29
group position display, 4-33
gun compensation, 4-14
hardware menu, 4-6
increasing direction, 4-7
input status, 4-28
keyboard quantity, 4-6
machine speed, 4-4
main screen description, 4-3
menu tree, 4-2
min speed ANDing, 4-37
offsets, 4-17
output groups, 4-39
output status, 4-27
password, 4-5
preprogramming considerations, 2-9
program copy, 4-25
program select mode, 4-10
rate set up, 4-30
remote enable ANDing, 4-38
run up, 4-20
run up quantity, 4-9
scale factor, 4-7
setpoint use, 4-29
E 1995 Nordson Corporation
All rights reserved
Resolver
description, 2-1
dimensional information, 3-3
installation, 3-2
parts list, 6-3
troubleshooting, 5-5
wiring, 3-4
Run Up, description, 2-8
S
Safety
Cleaning, 1-7
Installation and electrical connections, 1-4
Maintenance/Repair, 1-6
Operation, 1-4
Symbols, 1-2
Thermoplastic, 1-8
Scale Factor, description, 2-7
Setpoints
adding a duration, 4-12
adding multiple durations, 4-12
changing setpoints, 4-12
clearing a channel, 4-13
deleting a duration, 4-13
description, 2-5
duration modes, 4-12
Spare Parts, 6-5
Specifications
communication, 7-3
107 126A
Issued 10/95
Manual 66-- PC50-- MA-- 01 (formerly 57-- 30)
i-4
Index
Index (contd.)
S (contd.)
Specifications (contd.)
inputs, 7-2
operation, 7-3
outputs, 7-2
physical, 7-1
Speed Enable/Disable, description, 2-7
Stitch, description, 2-6
System Configuration
controller input signals, 2-9
output groups and operating modes, 2-9
set up considerations, 2-9
T
Terminal
blocks, controller, 3-9
input terminal function, 3-15
locations
PC54, 3-10
PC55, 3-11
PC54 input terminal program select formats,
3-16
PC55 input terminal program select formats,
3-17
Terminal Blocks, parts list, 6-4
Timed Outputs, description, 2-7
Troubleshooting
communications port, 5-4
controller cabinet general arrangement, 5-11
controller diagnostics, 5-1
controller fuse and fuse tester, 5-10
controller/power supply wiring diagram, 5-12
general, 5-6
keypad diagnostics, 5-2
resolver, 5-5
status LED, 5-1
table, 5-6
W
Washdown Boot, installation, 8-1
Manual 66-- PC50-- MA-- 01 (formerly 57-- 30)
107 126A
Issued 10/95
E 1995 Nordson Corporation
All rights reserved
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