CLIENTE: MODELO: SERIE: BH8000

MANUAL DE OPERACIN DE LA MQUINA TRANSFORMADOR ACME MOTOR PRINCIPAL BALDOR SENSORES OPTICOS BANER UNIDAD DE LUBRICACIN DE AIRE SMC TANQUE DE GOMA NORDSON CONTADOR RED LION SENSOR DE REGISTRO NT6 SICK BOMBA DE VACI SPENCER CONTROL DE TENSIN DE ETIQUETA WARNER ELECTRIC NIVELADOR DE ETIQUETA ERHARDT & LEIMER CONTROLADOR DE TEMPERATURA WATLOW PARTES Y DIAGRAMAS DE LA MQUINA PANTALLA DE MENSAJES ALLEN BRADLEY SERVO SISTEMA ORMEC PLC MITSUBISHI

MANUAL
BH - 8000
VERSION EN ESPANOL

INDICE
1. Introduccin 2. Descripcin y especificaciones de las mquinas 2.1 Descripcin general de las mquinas. 2.2 Manejo de los envases 2.3 Manejo del rollo de etiquetas. 2.4 Especificaciones tcnicas 3. Instrucciones de Instalacin 3.1 Embarque y manejo. 3.2 Requerimientos de Alimentacin. 3.3 Intrucciones de ensamble 4. Procedimiento de alistamiento. 4.1 Introduccin a los requerimientos de alistamiento. 4.2 Alistamiento de las partes de manejo de etiqueta. 4.2.1 Cuchilla. 4.2.2 Tambor de Vaco. 4.2.3 Alimentacin y registro de etiquetas. 4.2.4 Mesa Soporte de rollo y guas. 4.2.5 Aplicacin de adhesivo. 4.3 Alistamiento de las partes de manejo del envase. 4.3.1 Estrella Principal 4.3.2 Guas del envase. 4.3.3 Estrella de Transferencia. 4.3.4 Estrella de Sincronizacin. 4.3.5 Guas de respaldo (Solo para la 8000 y 8000S) 4.3.6 Tornillo de alimentacin (Solo para la 8000S y 8000U). 4.3.7 Almohadilla de Rodamiento Primaria. 4.3.8 Almohadilla de rodamiento secundaria. 4.4 Temporizacin de la mquina. 4.4.1 Alimentacin de etiquetas-Sensor Detector de envases. 4.4.2 Rodillo Engomador - Sincronizacin 4.4.3 Compuerta - Sincronizacin. 4.4.4 Sensores de lnea- Sincronizacin 5. Sistema Elctrico 5.1 Descripcin de los componentes. 5.2 Localizacin de fusibles y elementos de desconeccin. 5.3 Descripcin y localizacin de sensores y suiches de posicin. 5.4 Sistema de mensajes de falla. 5.5 Descripcin de la lgica de la mquina. 5.6 Control de temperatura del adhesivo. 5.7 Control de tensin del rollo.

6.

Mantenimiento. 6.1 Requerimientos generales. 6.2 Partes mecnicas. 6.3 Lubricacin 6.4 Partes Elctricas.

1.

Introduccin.

Las mquinas de la serie 8000 utilizan el concepto de etiquetado de Alimentacin por rollo (roll-fed) inventado por B&H, el cual ha llegado a ser el sistema ampliamente aceptado por su alta velocidad y economa, en aplicaciones de etiquetas plsticas delgadas. Las etiquetas se suministran en forma de rollos continuos, los cuales, son cortados por nuestro Sistema de Registro Computarizado (CRS), en etiquetas individuales en preciso registro con el diseo grfico. Las etiquetas son colocadas en los envases en un movimiento rectilneo continuo. Este concepto, junto con el diseo geomtrico especial de las partes de manejo del envase, permite aplicaciones de etiquetas sin imperfecciones, desde baja hasta muy alta velocidad. En comparacin con otras mquinas que utilizan principios de alimentacin similares, las mquinas de la serie BH8000, por su diseo y alta calidad de manufactura, son capaces de alcanzar ms consistente calidad de produccin a altas velocidades, con mnimo mantenimiento. La operacin de la mquina es altamente automatizada y su versatilidad de posibles opciones, hacen que su operacin sea menos exigente para los operarios. Debido a que la lgica de la mquina est integrada en el PLC, stas pueden ser fcilmente adaptadas a las lneas de produccin. Existen un sinnmero de opciones para satisfacer las necesidades de produccin. Las mquinas de la serie BH-8000 son la nueva respuesta a un viejo problema, de decoracin de envases, en forma rpida, de alta calidad y economa, en un ambiente amigable.

2. Descripcin y especificaciones de la mquina.

En los siguientes captulos, describiremos sus componentes o ensambles principales para establecer un lenguaje comn, asi como para familiarizar a usted con el diseo de la mquina. Para una fcil orientacin, los tpicos son mostrados acompaados de su ilustracin.

2.1

Descripcin general de las mquinas.

La BH-8000 es es el modelo bsico de la serie 8000. Esta mquina no tiene sin fin de alimentacin y en su lugar utiliza un diseo especial de estrella que al mismo tiempo desempea las funciones de sin fin de alimentacin y de Estrella Principal, para el manejo de envases a la entrada. Los envases entran en la mquina por la izquierda y salen por la derecha de la posicin del operario. La BH-8000S es un segundo modelo de la serie. Los envases entran en la mquina por la izquierda y salen por la derecha, como en el caso anterior. La mquina viene con Tornillo Alimentador, Estrella Principal y Estrella de Transferencia para la entrada. La BH-8000U es el tercer modelo de la serie 8000. Los envases entran en la mquina por el lado derecho y salen regresando por el mismo lado derecho. Esta mquina viene con Sin fin de alimentacin y Estrella Principal para la entrada. Debido a su diseo geomtrico, la mquina viene con dos transportadores de banda. Todos los modelos estn equipados con el mismo ensamble bsico as como tambien en sus sistemas elctricos. El armazn y engranajes es universal pudindose tericamente hacer la conversion de un modelo a otro. Las partes de cambio de manejo de envases son diferentes y por lo tanto, no son intercambiables. Las partes de cambio de manejo de etiqueta (Cuchilla, Tambor de Vaco y Rodillo Engomador), tienen el mismo diseo en todos los modelos como tambien las partes que asisten en el etiquetado (Almohadilla de Rodamiento Primaria, Almohadilla de

Rodamiento Secundaria, y Banda de Rodamiento), y por lo tanto, son intercambiables.Todos los modelos utilizan la configuracin #3 de desenrollado igual que todas la otras mquinas de B&H. Para orientacin, los tres modelos de la serie 8000 se ilustran en las proximas pginas.

2.2

Manejo de los envases

El adecuado manejo de los envases es muy importante para una aplicacin correcta de las etiquetas a cualquier velocidad. Las partes de asistencia son diseadas con la geometra apropiada para llevar a cabo dicha tarea. Los envases deben moverse a travs de la mquina, suavemente, sin vibraciones o cualquier otra clase de movimientos errticos. Todos las partes de manejo de envases que mencionaremos mas adelante deben ser ajustadas de tal manera que siempre haya una tolerancia de trabajo entre ellas y el envase. Esta tolerancia debe ser entre 1 y 2 mms aproximadamente. Al mismo tiempo stas partes deben ser ajustadas de tal manera que mantengan el envase en posicin vertical con respecto a la superficie que est en contacto con la base (ya sea transportador o platinas fijas). Si sta condicin no se cumple, van a resultar varios defectos de etiquetado. Como el manejo de envases es diferente para cada uno de los tres modelos, los describiremos separadamente.

BH-8000
Los envases son separados por la Estrella Primaria (Timing Starwheel). Guas de respaldo asisten a la Estrella Primaria posicionando los envases tangentes al Tambor de Vaco. La Estrella Principal controla la posicin de los envases y los entrega con el espaciamiento apropiado y en fase con el Tambor de Vaco. Las guas son necesarias para un alneamiento apropiado de los envases con el Tambor de Vaco. Los envases posteriormente ruedan alrededor del Tambor de Vaco para enrollarse sus propias etiquetas y son descargados en la Banda de Rodamiento secundaria. El propsito de sta banda es el de estabilizar los envases y descargarlos sin girar y con el debido espaciamiento sobre el transportador. El ordenamiento de la descarga es comn para todas las mquinas.

BH-8000S
Esta mquina ha sido diseada para muy altas velocidades, por lo tanto, se ha prestado especial atencin a la separacin de los envases. Esta labor es hecha por el Tornillo o Sin Fin Alimentador (Feed Screw) el cual los separa gradualmente a la distancia correcta requerida por el diseo de la mquina y a su vez absorbe la presin de la lnea de envases. Opuesto a ste est la Gua del Sin Fin de Alimentacin (Feed Screw Guide) y la Compuerta de Entrada. Saliendo del Sin Fin de alimentacin los envases son tomados por la Estrella de Transferencia (Transfer Starwheel) cuyo nico propsito es el de cambiar la direccin de movimiento de los envases y entregarlos a la Estrella Principal (Main Starwheel). Tal como en el caso anterior, sta est asistida por las Guas de Respaldo. El progreso posterior de los envases es idntico a la BH-8000 descrita previamente.

BH-8000U
El manejo de envases en sta mquina es similar a la BH-8000S. Este modelo no utiliza la Estrella Primaria (Timing Starwheel), ni sus Guas de Respaldo (Back-up Guides). Las Guas de Envase (Container Guides) son elaboradas en dos secciones para permitir una instalacin mas fcil. La funcin de la Estrella Principal (Main Starwheel) y partes subsecuentes es la misma que la descrita para la BH-8000.

2.3

Manejo del Rollo de Etiquetas.

El manejo de etiquetas es igual en todos los modelos. Las partes y subensambles son diseados para permitir el uso del ms amplio rango de materiales sin que sea necesario hacer cambios. El rollo de etiquetas, es colocado sobre el Plato Porta-Rollo (Label Roll Stand) despues la cinta de etiquetas es guiada a travs del primer set de guas, pasa alrededor del rodillo del Brazo Danzante (Dancing Arm), luego a travs del Segundo Set de Guas o del Mecanismo opcional de control de nivel (Web Tracking Device) si lo tiene, del Rodillo de Etiquetas (Label Roller), alrededor de Rodillo del Sensor de Registro (Registration Sensor Roller) y es entregada a la cuchilla mediante el Rodillo Alimentador (Feed Roller). Un Rodillo de Presin es utilizado para asegurar que la etiqueta no se deslice. Despues de dejar la Unidad Cortadora (Cutting Head) hay un elaborado sistema de presin y vaco que las coloca sobre el Tambor de Vaco (Vacuum Drum). El tambor de Vaco transfiere la etiqueta al Rodillo Engomador (Glue Roller), el cual le aplica una fina capa de adhesivo en ciertas partes seleccionadas de la etiqueta y continua siendo transportada hasta que su borde delantero entra en contacto con el envase que se la envolver mientras rota sobre el Tambor de Vaco. La etiqueta se adhiere y envuelve al envase hasta que el borde trasero entre en contacto con l, terminando la aplicacin. Se requiere un ajuste apropiado de la Almohadilla de Primaria para una buena aplicacin de etiquetas.

Specificationes Tcnicas
Modelo Mquina
Peso (approx.) Ancho Total Longitud Total Dimetro Min. Del envase Dimetro Max.. Del envase Longitud Min. de etiqueta Longitud Max. de etiqueta Ancho Max. de etiqueta en libras en kilogramos en pulgadas en mm en pulgadas en mm en pulgadas en mm en pulgadas en mm en pulgadas en mm en pulgadas en mm en pulgadas en mm

2.4
8000U

8000

8000S

6000 6000 6000 2700 2700 2700 65.5 65.5 70.25 1664 1664 1784 200.0 200.0 173.5 5080 5080 4407 1.50 1.50 1.5 38 38 38 6.12 5.75 5.75 155 146 146 1 1 1 25 25 25 18.5 18.5 18.5 470 470 470 7.25 7.25 7.25 184 184 184 Etiquetas mas anchas bajo pedido especial. 440 VAC-15 Amp or 220 VAC-30 Amps 3 phases, 60 Hz, 12 Kw otros voltajes and frecuencias disponibles. 8 CFM a 80 PSI o 0.2 metros cubicos/min. at 55O kPa

Requerimientos Elctricos

Consumo de Aire

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3.

Instrucciones de Instalacin 3.1 Embarque y manejo.

La mquina es despachada fija a la estiba de embalaje por medio de pernos, con todas las partes mviles fijadas y aseguradas con el objeto de prevenir cualquier dao. Si la mquina es despachada por va martima es tratada previamente contra la corrosin. Mientras la mquina est en su estiba de embalaje el manejo de ella es por debajo, ya sea por intermedio de un montacargas o puede ser deslizado sobre tierra firme empujando contra sus vigas principales. No permita que sea expuesta a sol y agua para evitar una severa corrosin. Si ella es desempacada, se puede mover por medio de un montacargas o de una grua, levantndola de la base. Bajo ninguna circunstancia, use los ensambles de la mquina para levantarla o moverla, por ejemplo agarrandola del transportador o de la cuchilla.

3.2

Requerimientos de Alimentacin

La mquina debe ser alimentada con una acometida trifsica de acuerdo a las especificaciones elctricas de fbrica. Para prevenir cualquier dao, verifique la documentacin y tambien el transformador antes de conectarla. Si hay alguna discrepancia o duda, por favor, llame al departamento de servicio de B&H. Debido a que la mquina contiene computadores y otros componentes electrnicos hay necesidad de suministrarle un aterrizaje apropiado. El aire suministrado al conjunto filtro/regulador/lubricador debe estar libre de aceite y agua. El filtro debe ser vaciado regularmente para evitar malfuncionamiento. Aceite o agua en el sistema de aire de la mquina pueden afectar severamente su comportamiento.

3.3

Instrucciones de Ensamble.

La mquina se despacha totalmente ensamblada y probada. Algunas partes mviles son aseguradas para evitar daos y deben ser posteriormente liberadas. Si fu tratada contra corrosin en el trayecto martimo, debe ser limpiada y relubricada. La instalacin y puesta a punto debe ser supervisada por personal de B&H con el objeto de lograr un arranque rpido y libre de inconvenientes. No le haga ninguna alteracin para evitar cualquier posible dao y/o prdida de la garanta.

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4.

Procedimiento de Alistamiento 4.1 Introduccin a los requerimientos de Alistamiento.

Para tener un etiquetado fcil, rpido y libre de inconvenientes, debe llevarse a cabo la secuencia de puesta-a-punto y de chequeos descritos a continuacin. Algunos pasos pueden pasarse por alto dado el caso que las partes o ensambles involucrados no hayan cambiado o no se requieran ajustes. Si se encuentra algn problema con la calidad del etiquetado, la mejor forma de rectificar sta situacin es una rpida verificacin de la puesta-a-punto en la misma secuencia original. La parte crucial de la mquina es la unidad cortadora, puesto que ella efecta una funcin crtica (separacin de las etiquetas). La cuchilla rotatoria es el reloj o puntero alrededor de la cual es temporizada la totalidad de la mquina. Esta funcin es hecha con la ayuda del Codificador Maestro (Master Encoder), directamente acoplado a su eje, de tal forma que todas las partes mecnicas deben estar sincronizadas de acuerdo a la posicin de la cuchilla rotatoria. Por lo tanto, la puesta a punto empieza desde la cuchilla y va progresando a partir de ella en ambas direcciones, la primera desde la cuchilla en direccin hacia los Platos Porta-Rollos y la segunda en direccin hacia la entrada de envases.

4.2

Alistamiento de las partes de manejo de etiqueta

Primero se pone a punto las partes de manejo de etiqueta, seguido por las partes de manejo de envase. Como se menciona anteriormente, seguir la secuencia de puesta-a-punto facilitar la tarea. El orden recomendado es el siguiente: Partes de manejo de etiqueta: 1. Posicin de corte y corte correcto. 2. Rodillo de Presin y alimentacinde etiqueta (CRS). 3. Posicin vertical de la etiqueta Plato Porta-Rollo - Guas de la cinta o Control de nivel. 4. Control de Tensin. 5. Sincronizacin del Tambor de Vaco y transferencia de etiqueta desde el cortador. 6. Rodillo Engomador, patrn de aplicacin de adhesivo y temporizacin con respecto al Tambor de Vaco.

4.2.1 Unidad Cortadora

El diseo del cortador es el resultado de muchos aos de experiencia de B&H en etiquetado a partir de rollo. Es importante un funcionamiento correcto para la buena operacin de la mquina. Su fuerte armazn , su montaje en rodamientos sobredimensionados autoajustables, nos aseguran un buen funcionamiento una vez se haya puesto a punto. Las caractersticas refinadas de manejo de etiquetas permiten el corte de pelculas hechas de diversos materiales sin necesidad de hacer ajustes posteriores. Para un correcto alistamiento tres operaciones importantes deben hacerse a la unidad cortadora que se describen a continuacin: a) - Corte de etiquetas ........ ajuste y reemplazo de cuchillas. b) - Transferencia de etiquetas al Tambor de Vaco ....... Configuracin del rodillo cortador (taponamiento estratgico de los huecos) c) - Control del descuadre.

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a)

Reemplazo de cuchillas

El reemplazo de las cuchillas el la operacin mas crtica de la mquina. El tiempo de reemplazo, dependiendo de la experiencia, puede tomar entre 10 y 30 minutos y debe tenerse mucho cuidado de no daarlas. En produccin normal siempre que se sospeche de problemas de corte, deben mirarse primero otras posibles causas, antes de que, como ltimo recurso, se toque la cuchilla estacionaria. Para reemplazar tanto la cuchilla rotatoria como la estacionaria refirase al procedimiento que sigue: 1. Remueva la cuchilla estacionaria soltando los tres pernos de cabeza hexagonal (3/8-24 UNF x 2 Lg - Grado 8) y la platina de presin. 2. Afloje los tres tornillos allen de ajuste (1/4-28 UNC x 3/4 Lg) al menos 3 vueltas completas. 3. Remueva la Cuchilla Rotativa soltando los siete tornillos allen (1/4-28 UNC x 5/8 Lg) empezando por el del medio y progresando hacia ambos extremos de la cuchilla. 4. Limpie los asientos y superficies de contacto de materias extraas. 5. Inserte la nueva cuchilla rotativa y apriete todos los pernos empezando por el de la mitad, progresiva y alternadamente hacia los extremos. Re-apriete los pernos en la misma secuencia. Si utiliza torqumetro, recomendamos un torque de 10 libras-pie 6. Manualmente accione la cuchilla estacionaria usando el selector de la cuchilla localizado en el panel de control del operador. Alinie la barra horizontal que sirve de soporte del pistn (perpendicular hacia usted), de tal manera que quede paralela a la superficie de la pared lateral de la base. El espaciamiento debe ser de 9 a 10 mms aproximadamente (3/8). Por medio del pulsador Jog, lleve la cuchilla rotatoria hasta una posicin cercana a corte de etiqueta. Inserte la nueva cuchilla estacionaria y apriete ligeramente los tres pernos de cabeza hexagonal, aliniela paralela a la rotativa por medio de los tres tornillos allen de alneamiento. La cuchilla estacionaria ser movida por stos hasta que su filo est lo mas cerca posible pero sin tocar a la cuchilla rotatoria. 7. Apriete los tres pernos (3/8-24 UNF x 2 Lg) con un torquimetro hasta 10 lb-ft (13.6 Nm) o bien, hasta que la arandela de presin quede plana. Desenganche y enganche la cuchilla otra vez. Pulse la mquina con Jog ligeramente y verifique de que las cuchillas no se estn interfiriendo. 8. Prenda la mquina presinando el pulsador RUN. Manteniendo una hoja de papel entre la cuchillas, con mucho cuidado empiece moviendo la cuchilla estacionaria gradualmente hacia la rotativa por medio de los tornillos allen de ajuste superior e inferior ( no tocar el central) hasta que las cuchillas esten cortando papel de arriba a abajo. Pare la mquina y ajuste los tres pernos de cabeza hexagonal hasta un torque de 40 lbs-pie (54 Nm). Tambin, coloque en posicin el tornillo prisionero allen de ajuste central. Retire la cuchilla estacionaria un poco hacia afuera, rotando el perno de ajuste (aquel con el resorte) 1/4 de vuelta en el sentido de las manecillas del reloj. Prenda la mquina y verifique el corte trayendo nuevamente la cuchilla estacionaria levemente hacia adentro y observando otra vez como corta el papel. 9. Contine los ajustes usando ahora el plstico de las etiquetas. Como ahora el ajuste es muy fino, cada vez que la cuchilla estacionaria es movida mediante los tornillos allen de alineamiento, la mquina debe permanecer parada y la primera vuelta de la cuchilla rotativa debe hacerse con pequeos pulsos con JOG hasta que sta pase frente a la estacionaria sin tocarse. Si se tocasen, traiga la cuchilla estacionaria hacia atrs nuevamente. Esto se hace con el objeto de prevenir que las cuchillas se bloqueen.

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Gradualmente traiga la cuchillas otra vez a posicin de corte mediante el mismo tornillo (se supone que la mquina est rotando ahora a baja velocidad) y contine de sta manera hasta que las cuchillas esten cortando perfectamente desde abajo hasta arriba. 10. Verifique que el torque en los pernos de cabeza hexagonal de la cuchilla estacionaria es el apropiado, 40 lb-ft (54 Nm). Una vez que todos los pernos y tornillos allen estn ajustados, no los vuelva a mover pues va a perder el ajuste. Prenda la mquina presinando el pulsador RUN y engrane manualmente las cuchillas. Lleve la mquina hasta 400 CPM presinando y sosteniendo el pulsador HIGH SPEED. Vuelva a baja velocidad y verifique el corte otra vez. Si se sostiene el corte perfecto, termine el procedimiento. En caso contrario vuelva al punto (9). 11. Es posible que despues de algunas horas de trabajo se requiera de un ajuste muy fino nuevamente. En tal caso se hace un pequeo ajuste en el tornillo allen superior o inferior de alineamiento sin aflojar ninguno de los pernos que aseguran la cuchilla estacionaria.

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(b)

Transferencia de etiquetas.

El propsito de la multitud de huecos roscados en el rodillo de la unidad cortadora es el de ayudar en en el manejo de la cinta de etiquetas y asistir en la transferencia del borde delantero de la etiqueta al Tambor de Vaco. Hoy en da, con el uso de materiales ms y ms delgados, los ajustes de vaco, presin de soplado y posicin de corte son de suma importancia. Para configurar el cortador a cada longitud de etiqueta utilizado, siga el siguiente procedimiento. 1. En el CRS desabilite el registro (REGISTRATION OFF) e introduzca la longitud nominal de la etiqueta que va a cortar. 2. Presine al mismo tiempo LABEL FEED y JOG y alimente al menos dos etiquetas. Cuando la siguiente etiqueta se est aproximando, y empieza ya a transferirse al Tambor de Vaco, pare la mquina y con un marcador seale la posicin del borde delantero de la etiqueta sobre el rodillo cortador. Hay dos posiciones posibles del borde de la etiqueta en relacin con el patrn de huecos roscados. Tapone con tornillos prisioneros (#6-32 UNF x 1/8 Lg) las lneas verticalmente como se muestra en la figura (ver pgina siguiente). 3. Repita el mismo procedimiento para todas las etiquetas a utilizar. 4. Rote la Placa-Vlvula de la unidad cortadora de tal manera que la direccin de soplado es como se muestra en el esquema de la pgina siguiente y asegrela en sta posicin. 5. Verifique y ajuste si es necesario la posicin del Tambor de Vaco con respecto a la cuchilla, de tal forma que el espacio entre los dos sea de 1 a 1.5 mms medido sobre la parte resaltada del caucho del Tambor de Vaco. Ver figura en pgina 18 6. Ajuste el volumen de aire que sopla la etiqueta contra el Tambor de Vaco (manguera azul) a un valor de 2 aproximadamente en la escala del medidor de flujo o verifique que haya una transferencia suave de la etiqueta, sin sobresaltos a cualquier velocidad. 7. Ajuste el volumen de aire que ayuda a la transferencia de la etiqueta desde la barra de soplado secundaria (manguera amarilla) a un valor entre 1 y 1.5 en la escala del medidor de flujo o tan bajo como sea necesario para que las etiquetas no tengan arrugas sobre el Tambor de Vaco. Un nivel muy alto de soplado puede ocasionar una mala colocacin del borde trasero de la etiqueta sobre el Tambor de Vaco u otros problemas.

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(c)

Control de descuadre de la etiqueta

Como se describir en los siguientes apartes de ste manual, una vez la etiqueta es colocada ajustada y sin arrugas sobre el envase, si ocurre algn descuadre de la etiqueta (el final de la etiqueta est mas alta o baja que el principio), ste puede ser ajustado inclinando levemente toda la unidad cortadora. Al hacer esto la etiqueta es colocada con un pequeo ngulo en el Tambor de Vaco. Esto significa que la etiqueta no tiene necesariamente que estar exactamente paralela a los bordes del Tambor de Vaco. El perno de ajuste de la inclinacin (3/8-24 UNF) se muestra en la ilustracin que sigue. Una vuelta entera (360 grados) en el sentido de las manecillas del reloj mover el borde trasero de una etiqueta de 14 pulgadas de largo en 0.8 mms (1/32) hacia arriba y contrareloj lo mover hacia abajo en el mismo valor. Este ajuste es muy fino y es posible que tenga que repetirse si las condiciones de etiquetado cambian. Puede efectuarse ste ajuste con la mquina en movimiento. Si el descuadre es mayor de 1 mm se recomienda corregirlo girando la estrella superior con respecto a la inferior.

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4.2.2 Tambor de Vaco

El Tambor de Vaco es una de las partes de los formatos de cambio. Se disea para cada etiqueta de determinada longitud, ancho, altura y colocacin sobre el envase. El Tambor de Vaco est hecho de pasadizos complejos para manejar mediante vaco el transporte de la etiqueta. Vaco y aire a presin son distribuidos por intermedio de la Placa Vlvula Dual (Dual Vacuum Port Valve), la cual es mantenida en posicin apropiada por medio de brazo tope de vlvula montado sobre el poste del Rodillo Engomador. El Tambor de Vaco y la Placa Vlvula Dual deben ser colocados apropiadamente en tiempo con respecto a la geometria de la mquina tal como se muestra en la ilustracin de la pgina siguiente. Para poner en tiempo el Tambor de Vaco, gire la cuchilla rotatoria hasta que est mas o menos en la lnea imaginaria que une los centros del Tambor de Vaco y el Rodillo de la Cuchilla. Afloje los 3 tornillos de cabeza hexagonal (3/8-16 UNC x 1 Largo) colocados en el anillo temporizador debajo del Tambor de Vaco y adems el perno grande en la parte superior que fija el Tambor de Vaco a la mquina y gire ste de tal forma que la parte resaltada del Tambor de Vaco correspondiente a la parte trasera de la etiqueta, tenga un espacio de 1 a 2 mms adelantada con respecto a la cuchilla. Apriete nuevamente el perno superior y verifique la colocacinde las etiquetas en su parte trasera, alimentando algunas. Si la posicin es correcta, apriete los otros tornillos de cabeza hexagonal debajo del Tambor de Vaco. Para colocar en tiempo la placa vlvula, afloje el tornillo de rosca izquierda (3/4-10 UNC) y gire la placa vlvula a la posicin mostrada en la figura siguiente (La toma de aire debe estar centrada con respecto al Rodillo Engomador). Apriete nuevamente el tornillo. Para ajustar el vaco , cierre la vlvula hasta lograr que con el mnimo vaco se garantice una transferencia confiable de las etiquetas desde el cortador. En la mayora de los casos, ste valor estar entre 5 y 7 de la escala. La presin de aire a la placa vlvula (manguera roja) debe estar cerrada en operacin normal y solo se usa durante el alistamiento y pruebas de la mquina o en algunos envases especiales.

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TEMPORIZACION DEL TAMBOR DE VACIO

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4.2.3 Alimentacin y registro de etiquetas.

Las mquinas del la serie 8000 estan equipadas con el Sistema de Registro por Computador (en ingles Computer Registration System o abreviado CRS, trmino que seguiremos usando en adelante) el cual alimenta la cinta de etiquetas a la cuchilla de tal forma que sea cortada en longitud y posicin correcta con respecto a la impresin. El mantenimiento de sta posicin es siempre referida como el registro. El sistema consiste de las siguientes partes: Un rodillo alimentador el cual es conducido por intermedio de una banda dentada por el Servo Motor (montado debajo). Un Servo Motor que tiene su propio codificador y que enva informacin sobre la posicin de su eje al computador de registro GEN III. Un Codificador Maestro (Master Encoder), acoplado directamente a la cuchilla, que enva informacin al Computador sobre la posicin de sta. Un Sensor de Registro, montado frente al rodillo alimentador de etiquetas, que enva tambien un pulso cada vez que detecta una marca de registro en la cinta de etiquetas. Un pantalla de operador (Operator Interface ITM 270), montado en el panel de control frente a la mquina, que habilita al operador para introducir la longitud deseada de etiqueta, la posicin de corte (mediante el CUTOFF) y otras variables. Este monitor tambien es utilizado para darle los tiempos a la mquina como explicaremos en su debido momento. Una descripcin detallada del CRS asi como del procedimiento de puesta a punto se encuentran en el Addendum #1 de ste manual. El CRS es capaz de alimentar en registro etiquetas desde 25 hasta 610 mms (1 a 24 pulgadas) a velocidades de hasta 1200 etiquetas por minuto (sin exceder la velocidad de la cinta de 10000 pulgadas por minuto), manteniendo la posicin de corte (Registro) dentro de 1/16", siempre y cuando el sistema est correctamente ajustado y el material de la etiqueta sea de buena calidad.

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A continuacin daremos una descripcin de procedimiento bsico de alimentacin y registro de etiquetas. (una explicacin mas detallada la encuentra en el Adendum #1 de manual del CRS). Si el CRS est ya configurado y no se han hecho cambios mecnicos en el tren de conduccin de la mquina, la mayoria de los pasos que se van a detallar, pueden pasarse por alto. Esto hace que el cambio de una etiqueta a otra sea muy simple, puesto que solamente tiene que introducirse la nueva longitud de etiqueta y mover el Sensor hacia arriba o hacia abajo de tal forma que detecte la mueva marca de registro. En el caso de que el CRS no haya sido configurado o se hayan hecho cambios en el tren de engranajes que den como resultado la necesidad de puesta a punto, debe seguirse la siguiente secuencia: 1. Establecimiento de la Referencia del Codificador Maestro. El objeto de ste procedimiento es el de encontrar la diferencia entre el llamado punto cero del codificador y la posicin de las cuchillas, cuando stas se encuentran enfrentadas. Esta diferencia es expresada en pulsos del Codificador Maestro, cada revolucion (360) equivale a 10.000 pulsos. Lleve la cinta a travs de la mquina y asegrela entre el rodillo alimentador y el rodillo de presin. Verifique que tiene la suficiente presin, simplemente tratando de halar la cinta a travs de stos rodillos de tal forma que no se deslice. Si es necesario aplique mas presin con el perno inferior del rodillo de presin. Introduzca la longitud de etiqueta deseada SET LABEL, en el pantalla del operador ITM-270, desabilite el registro (REGISTRATION OFF) y manualmente pulse al mismo tiempo JOG y MANUAL FEED para alimentar algunas etiquetas. Si el CRS no ha sido configurado la primera y ultima etiquetas probablemente sern diferentes. Presine JOG por al menos 2 revoluciones completas de la cuchilla y enfrente las cuchillas (actue el swiche MANUAL CUTTER IN para actuar la cuchilla estacionaria y asi alnearlas hasta que estn 1 mm una de la otra) . Entre el pasabordo en la pantalla del operador ITM-270 ("1" de fabrica), pulse la tecla COMMAND para entrar al menu de temporizaciones (ver la organizacin del ITM-270 en la seccin 4.4 de ste manual). El mensaje STORE CUT POSITION aparecer en el monitor. Vaya al monitor ITM-270 y presione EXECUTE para que ste almacene la posicin de la cuchilla estableciendo lo que se llama el EDRREF (Referencia del Codificador Maestro). Puede leerse el nuevo valor de EDRREF si presiona COMMAND y con NEXT va hasta EDRREF. Para verificar de que la posicin alcanzada es la correcta, alimente manualmente varias etiquetas y compare su longitud. Si estan dentro de 1.5 mms o mejor, no se requiere de mas ajustes. Si es mayor la diferencia hay necesidad de variar manualmente el EDRREF sencillamente variando ligeramente el valor que aparece en el monitor (Refierase al manual CRS).

2. Puesta a punto del Sensor de Registro

Las mquinas se suministran con el sensor marca SICK modelo NT-6. Siga exactamente las instrucciones del manual SICK para su ajuste pues es de extrema importancia para el correcto funcionamiento del CRS. Mueva el sensor hasta que lea la marca de registro seleccionada. Este sensor nos da la posibilidad de escoger entre 2 colores de luz, rojo o verde ya que algunas combinaciones de colores son muy dificiles sino imposibles de registrar por una u otra fuente de luz. En produccin normal no olvide de limpiar de polvo, de cuando en cuando, el lente del sensor.

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Marca Clara

J J

Control de Sensibilidad

1. Seleccione el color de luz que va a utilizar (verde o roja, escogiendo la que se comporte mejor) y coloque el suiche selector en marca clara por ahora. 2. Posicione el color mas claro (fondo o marca) bajo el punto focal. 3. Coloque el suiche selector en J. Ahora el sensor registra en memoria ste color. 4. Mueva la etiqueta de tal forma que el color ms oscuro (ya sea el fondo o la marca de registro) est en el punto focal. 5. A - Si la luz indicadora esta encendida, gire el control de sensibilidad en sentido a reloj hasta que se apague. B - Si la luz indicadora no est encendida, gire el control de sensibilidad en sentido contrareloj hasta que encienda, entonces gire a reloj hasta que apague. 6. Coloque finalmente el suiche selector en la posicin de marca clara u oscura, como usted lo desee.

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3.

Puesta a punto del Registro

Si los pasos anteriores se han completado, el paso siguiente es el de encontrar la distancia entre el Sensor de Registro y el punto de corte, el cual se llama CUT-SNSE. La mejor manera de medir sta distancia es como sigue: Marque con un lpiz, el lugar donde est la luz del sensor sobre la cinta de etiquetas, accione el interruptor CUTTER IN y rote la cuchilla una vuelta hasta que corte el pedazo de etiqueta que sobresale de entre las dos cuchillas (OVERHANG), remueva la cinta de etiquetas y mida la distancia entre la marca hecha con lapiz y el final de la cinta (en pulgadas). Vaya a la pantalla del operador ITM-270 y pulse NEXT hasta llegar al mensaje CUT-SNSE; presione la tecla CHANGE, introduzca el valor ledo en pulgadas y presione ENTER. La nueva distancia aparecer ahora en pantalla.

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Para continuar con el alistamiento del registro siga el siguiente procedimiento: Verifique que el parmetro REGISTRATION est en ON Introducir la distancia deseada entre la marca de registro y el punto de corte de la etiqueta en el parmetro CUTOFF (normalmente se introduce el valor 0.100 y se presiona ENTER). Arranque la mquina presionando RUN y avance o retarde la cinta de etiquetas presionando los botones ADVANCE o RETARD. (Asegrese de que el suiche de la cuchilla est apagado. En esta posicin la cuchilla engrana o desengrana conforme lo vaya necesitando el CRS). Corte una o dos etiquetas (presionando el boton MANUAL LABEL) y verifique que la marca de registro est en la posicin deseada (por ejemplo a 0.100 como lo dijimos antes). Si no fuera as, avance o retarde hasta lograr que corte en la posicin correcta. Cuando las etiquetas son cortadas en la posicin correcta (1/8), alimente varias etiquetas retirndolas del Tambor de Vaco. Asegrese que el LED del panel principal marcado como PICK-UP est parpadeando (las marcas de registro estn siendo registradas por el CRS). Si todo est funcionando correctamente, el LED de color verde REGISTRATON IN LOCK nos va a anunciar que el registro se esta sosteniendo. Mida en la etiqueta la distancia entre la marca de registro y el borde delantero de la etiqueta. Es posible que sta distancia no sea exactamente (debera estar dentro de 1/32) la que introdujimos en el CUTOFF. La razn es que puede haber estiramiento en la etiqueta o imprecisin en la medida. Calibre entonces el sistema. Calcule entonces la diferencia entre la distancia real medida y el valor del CUTOFF introducido, por ejemplo si el valor ledo es 0.250 y el valor introducido es 0.100 la diferencia ser (0.250-0.100=+0.150), vuelva al mensaje CUTSNSE, y sustraiga ste valor del valor mostrado en pantalla e introdzcalo nuevamente en el CUTSNSE. Si por ejemplo el valor inicial era 19.56 sustraiga 0.15 e introduzca el valor resultante 19.41). Nuevamente alimente algunas etiquetas y verifique la posicin de la marca de registro despues de que el LED de REGISTRATION LOCK nos anuncie que el registro se mantiene. Si fuese necesario corrija el CUTSNSE otra vez.

4. Verificacin rpida del registro con la mquina en produccin

En produccin normal, con todos los sistemas ajustados apropiadamente, para una rpida verificacin o rectificacin de problemas menores, siga la siguiente secuencia: Si la marca de registro no est en la posicin deseada, sta puede ser movida con la mquina an en movimiento presionando el boton de ADVANCE o RETARD. La marca de registro se mover aproximadamente 0.250 mms en una u otra direccin por cada segundo que se mantiene pulsado el botn. En produccin normal el LED verde (REGISTRATION LOCK) debe permanecer encendido mientras que el amarillo (PICK-UP) debe titilar en sincronizacin con la cuchilla. Si ste no fuera el caso, verifique el Sensor de Registro as como tambin la posicin vertical de la cinta de etiquetas, por si acaso se ha movido hacia arriba o hacia abajo debido a falta de traccin, haciendo que el sensor pierda la marca de registro por estar fuera de posicin. Si el registro est cambiando de baja a alta velocidad, verifique el vaco en la cuchilla y la cuchilla misma por cualquier contaminacin de producto o de adhesivo en ella. Limpie la cuchilla y ajuste el vaco en ella al mnimo, observando la cinta de etiquetas en el espacio entre el rodillo alimentador y el rodillo cortador. Si el vaco es muy bajo, la cinta va a pulsar en alta

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velocidad y esto va a afectar el registro. Aumente el vaco hasta que la cinta deje de vibrar y se mueva en lnea. Si ocurre una falla de registro presione el botn de RESET para desbloquearla. Si la pantalla del operador ITM-270 muestra alguna falla en presione el botn EXECUTE para resetearla. Las fallas ms comunes son: MISSED MARKS (Perdida de la marca de registro) para lo cual debe verificar el Sensor de Registro y AXIS FAULT, botella faltando a alta velocidad o adhesivo en el Tambor de Vaco. Cuando se cambia a una nueva etiqueta pero no todas las partes mecnicas han de ser cambiadas asegrese de que los siguientes items de registro son correctos: Verifique la sensibilidad del Sensor de Registro Reajuste la posicin vertical del Sensor de Registro Introduzca la nueva longitud de la etiqueta. Introduzca el nuevo CUTOFF si es necesario. Entonces manualmente coloque la cinta en posicin correcta de corte, para iniciar con el nuevo producto.

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4.2.4 Mesa Soporte de Rollo y Guas

La mquina est equipada con dos bases porta-rollos para permitir que el operador prepare un nuevo rollo de etiquetas mientras el otro est operando. El dimetro mximo de rollo es 24 (mayores dimetros pueden usarse si se solicita). Este es colocado y centrado en el plato mediante la placa de inserto central y la pieza de ajuste. Para que el Sistema de Control de Tensin trabaje apropiadamente, el rollo debe asegurarse firmemente en el Plato, previniendo que gire libremente sobre l. La elevacin del plato puede cambiarse en +/- por medio del sin fin y la manija colocada en la parte inferior. Si se desea cambiar an ms la elevacin, el mecanismo asegurador de la base sobre el sin fin puede aflojarse y reposicionarse el plato hasta lograr la altura deseada. Asegrese de que los discos estn libres colocando el plato en la mitad de los pines. Los discos deben moverse libremente hacia arriba o hacia abajo para que el control de tensin funcione apropiadamente. Lleve la cinta a travs del primer set de Guas (ver figura en la pagina siguiente) y hlela hasta que adquiera la altura deseada. Si el mecanismo de traccin (Web Tracker Control) es usado, coloque el control de ste en la posicin central o sea deshabilitado. Si la elevacin de la etiqueta es correcta (cuando la etiqueta cortada se posiciona centrada en el Tambor de Vaco.), coloque las guas de la cinta cercanas al rollo de tal forma que quede una tolerancia de 1/8 en ambos lados de la etiqueta. Las guas mas cercanas a la cuchilla deben ajustar la etiqueta en ambos extremos y ms an pellizcando un poco. Esto ayudar para un buen alneamiento y corregir los defectos de devanado de los rollos. Si la etiquetadora no est equipada con el mecanismo de traccin (Web Tracking Control), ajuste las segundas guas igual que las primeras. El Brazo Danzante es parte de los Platos Porta-Rollos y est conectado electrnicamente al sistema de control mediante un potencimetro acoplado a su eje. El Control de Tensin recibe el voltaje del potencimetro, el cual le indica la posicin del brazo danzante proporcionando un control PID anlogo, sobre el freno localizado debajo de los Platos Porta-rollos. Al cambiar de posicin cambia tambien el voltaje aplicado al freno, manteniendo la posicin del brazo danzante en la mitad de su arco y asegurando una alimentacin suave de etiquetas durante la aceleracin y desaceleracin de la mquina. La tensin en la cinta se mantendr asi constante siempre.

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Ilustracin: Diagrama de colocacin de la cinta de etiquetas

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4.2.5

Aplicacin de Adhesivo

Todas las mquinas de la serie 8000 vienen equipadas con el sistema de adhesivo caliente (Hot Melt) diseado para aplicacin de diversos tipos de adhesivos en el rango de temperaturas entre 200 a 280 grados F (93 a 137 grados Centigrados). El sistema aplica un patrn preciso de adhesivo en las reas requeridas de la etiqueta an a altas velocidades. El sistema consiste (ver ilustracin) de lo siguiente: Tanque con una bomba que entrega el adhesivo caliente a travs de una manguera tambien caliente, a la Barra de Adhesivo. La Barra de Adhesivo, la cual recibe el adhesivo y lo distribuye a lo largo del rodillo aplicador. La Placa Raspadora (Doctor Blade), la cual barre el exceso de adhesivo, creando un patrn preciso de adhesivo, correspondiente al moleteado del rodillo aplicador, sobre las partes resaltadas del Tambor de Vaco, que en operacin normal deben estar cubiertas por la etiqueta. El Rodillo Engomador el cual es calentado por medio de una resistencia en forma de espiral localizada dentro del cilindro. El RTD el cual est en contacto con el Rodillo Engomador en la parte de atrs justo frente a la Barra de Adhesivo y sensa la temperatura de Este. Tangente al plano entre el Rodillo Engomador y el Tambor de Vaco estan los alambres que previenen el que eventualmente alguna etiqueta se envuelvan al Rodillo Engomador y se atasque dentro de la Barra de Adhesivo. El Watlow localizado en el poste que soporta el Rodillo Engomador, controla la temperatura en l. Para ajustar los parmetros, siga su manual o introduzca los parmetros que listamos ms adelante. La Manguera de Retorno, la cual devuelve por gravedad el exceso de adhesivo al tanque. El Rodillo Engomador entra en contacto con el Tambor de Vaco por intermedio de un pistn. La electrovlvula que lo acta, recibe la seal del PLC, sincronizada con la posicin de la cuchilla, de acuerdo a la lgica programada. El Rodillo Engomador solo accionar si el Sensor Detector de Etiquetas detecta la presencia de una de ellas sobre el Tambor de Vaco. As se previene que ste se unte de adhesivo. Mediante el Tornillo de Ajuste (3/8-24 UNF) localizado frente al poste de soporte se aplica la presin requerida entre el Rodillo Engomador y el Tambor de Vaco, el cual est pre-tensinado por un fuerte resorte para mantener la misma posicin todo el tiempo. El paralelismo entre el Rodillo Engomador y el Tambor de Vaco tambien es ajustable mediante los dos pernos laterales que actuan desplazando rodamiento superior del eje central, variando as lvemente el ngulo entre las dos superficies cilndricas: Rodillo Engomador y Tambor de Vaco.

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Ajuste del Patrn de Adhesivo

Si la mquina est funcionamiento correctamente, una apropiada aplicacin de adhesivo es de la mayor importancia. Las mquinas de la serie 8000 aplican adhesivo sobre la etiqueta a temperaturas en el rango de 220 a 280 grados F (105 a 140 grados centgrados). El sistema encolador est diseado para manejar una amplia variedad de adhesivos. Para asegurarnos una aplicacin correcta y confiable, todos los componentes que contribuyen a la calidad del patrn de adhesivo deben ajustarse correctamente. Los ajustes y las partes necesarias para llevar a cabo sto, seran listadas a continuacin: Ajuste del paralelismo entre el Rodillo Engomador y el Tambor de Vaco Ajuste de la placa raspadora (Doctor Blade). Ajuste de la Barra de Adhesivo. El control de Temperatura. Reemplazo de la Barra de Adhesivo. Reemplazo o limpieza del Rodillo Engomador.

Ajuste del paralelismo

El Rodillo Engomador y el Tambor de Vaco deben estar paralelos con el objeto de obtener un patrn de adhesivo parejo a todo lo ancho de la etiqueta. Engome algunas etiquetas de prueba disminuyendo la presin del Rodillo Engomador sobre el Tambor de Vaco, (apretando el tornillo de ajuste) hasta que el adhesivo empiece a desaparecer. Si el patrn est parejo cuando ya empiece a desaparecer, es porque el Rodillo Engomador est paralelo y no requiere de ajuste. Si hubiere ms adhesivo en la parte inferior que en la superior, entonces la parte superior debe ser ajustada para aproximarse ms al Tambor de Vaco y viceversa. Para llevar a cabo sta tarea, afloje las contratuercas de ambos pernos laterales, las cuales aseguran la posicin del rodamiento superior y afloje aquel perno que nos permita, mientras apretamos el otro, mover el rodillo en el sentido que deseamos. Esta labor se efecta sin tener que aflojar los pernos que fijan el rodamiento a su base. Despues de cada ajuste, pruebe nuevamente el patrn de adhesivo aplicado y repita el procedimiento hasta que logre una aplicacin sea pareja. Apriete nuevamente los pernos y asegure finalmente las contratuercas.

Ajuste de la Cuchilla Raspadora (Doctor Blade)

Solo se obtiene una aplicacin correcta de adhesivo cuando la cuchilla raspadora (Doctor Blade) est limpiando la superficie del rodillo de tal forma que solamente el adhesivo contenido en el moleteado pueda pasar a travs de ella. La cuchilla raspadora debe estar en contacto a todo lo largo del Rodillo Engomador y debe estar colocada con el ngulo correcto con respecto a ste. La tensin en el resorte debe estar graduado para aplicar la cantidad de adhesivo deseado (Ver la figura siguiente). Para asegurar la propia tensin en el resorte, ajuste a mano o con una llave hasta que sienta tensin en el resorte y luego dle una o dos vueltas adicionales. Como algn desperdicio se acumula en la cuchilla raspadora durante la operacin normal, sta debe limpiarse a intervalos entre 120 a 200 horas de trabajo. Para ello afloje el tornillo de presin hasta que la cuchilla raspadora pueda girar libremente; lmpiela de desperdicio y aprete el tornillo nuevamente.

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La cuchilla raspadora se gasta en operacin normal hasta el punto en que no es posible ajustarla correctamente. En tal caso, reemplcela con una nueva.

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Ajuste de la Barra de Adhesivo

La funcin de la Barra de Adhesivo es la de efectuar una distribucin pareja de adhesivo a lo largo del rodillo. Para obtener esto, la Barra de Adhesivo debe permanecer limpia de desperdicio, asentada a la superficie del rodillo segn se explicar en la prxima seccin y con sus alambres limpiadores insertados dentro de las ranuras del Rodillo Engomador. Para ajustar la distancia apropiada entre la Barra y el Rodillo Engomador, afloje las tuercas marcadas con (N) en la figura siguiente. Los resortes mantendran en contacto las dos piezas. Si los alambres de cobre no estan alineados con las ranuras, puede hacerlo aflojando los tornillos marcados (B). Luego apriete a mano las tuercas (N) y posteriormente con una llave dles de vuelta ms. Aprete las contratuercas para asegurar sta posicin. Los tornillos allen que aseguran la barra a su base deben estar ajustados solo hasta permitir un ligero juego lateral como para que la barra se deslize sobre sus ranuras. Para ajustar el flujo de adhesivo apropiado, necesario no solo para cubrir el rodillo de adhesivo sino tambien para limpiar los pasajes con adhesivo fresco, afloje el tornillo tapn marcado (S) en la figura, aproximadamente 3 a 4 vueltas desde la posicin de cerrado totalmente. Debe verse emerger adhesivo por ste hueco en forma permanente. Para ajustar los alambres limpiadores, sencillamente empjelos contra el Rodillo Engomador hasta asegurarse que entren en sus respectivas ranuras y que las mantienen limpias cuando ste permanece rotando.

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El Control de Temperatura
El Rodillo Engomador contiene internamente una resistencia en forma de espiral cuya temperatura es controlada por medio de un control PID llamado el Watlow insertado en el poste de soporte del Rodillo Engomador. La temperatura del rodillo es registrada por medio del elemento sensor RTD (similar a una termocupla), fijo a una placa metlica y en contacto con el rodillo en la parte inferior lisa. Si el RTD no est en contacto seguro con el rodillo, ste puede recalentarse severamente. Nunca posicione el RTD en contacto con la superficie moleteada del rodillo, ya que aquel est hecho de un acero relativamente suave y puede daar su superficie. Dentro de la Bandeja de Adhesivo (debajo del Rodillo Engomador) est insertada una resistencia calefactora , la cual mantiene caliente la bandeja para que el adhesivo no utilizado retorne fcilmente. El poste soporte de los alambres contiene tambien una resistencia cuyo propsito es el de mantener calientes los alambres y as tambien mantener lquido el adhesivo que se acumule en ellos. Si la temperatura en el Rodillo Engomador excede de los 130 C (270 F), en algunos casos, podemos daar la etiqueta al quemarla cuando pasa por l. La temperatura en la manguera de entrada debe ser unos 5 C (10 F) por encima del Rodillo Engomador y la temperatura del tanque de adhesivo debe ser unos 10 C (20 F) tambin encima de dicho valor. Para proteger el tambor de contaminacin por adhesivo carbonizado, debe mantenerse la mquina rotando con la bomba encendida, auncuando no se est etiquetando. Si la mquina no se va a usar por un perodo de tiempo prolongado, digamos por encima de media hora, desconecte la resistencia del Rodillo Engomador, mediante el suiche localizado en el panel del operador, pero debe tambin tener en cuenta de desconectar la bomba de adhesivo. Asimismo, nunca debe conectarse la Bomba de Adhesivo, hasta tanto el Rodillo Engomador no haya alcanzado la temperatura correcta. La bomba debe entregar la suficiente cantidad de adhesivo de tal forma que, en alta velocidad se pueda ver exceso de adhesivo siendo barrido por la cuchilla raspadora. Si esto no se logra, vamos a ver una aplicacin irregular en alta velocidad. Es importante tener en cuenta que el filtro de la unidad encoladora a menudo se tapa por residuos de etiquetas o por residuos de adhesivo quemado depositados en l y es preciso limpiarlo peridicamente.

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Reemplazo de la Barra de Adhesivo

La Barra de Adhesivo se gasta con el tiempo, especialmente cuando roza contra el Rodillo Engomador por un mal ajuste. Cuando una barra nueva se va a instalar debe ser asentada para que se conforme exactamente a la circunferencia del Rodillo Engomador (similar a como se asientan las escobillas de un motor). Esto se hace de la siguiente forma: Remueva el pin de plstico encima del Rodillo Engomador. Remueva la Barra de Adhesivo que va a ser reemplazada. Limpie el rodillo con solvente para eliminar el adhesivo adherido a l e inserte la nueva barra. Inserte entre la barra y el Rodillo Engomador una hoja de papel de lija # 180 de tamao 8x11 y fjela al rodillo mediante cinta adhesiva. Aplicando presin ya sea a mano o mediante los resortes de presin que ella tiene, rote manualmente el rodillo en el sentido de rotacinde la mquina hasta que las marcas originales del maquinado desaparezcan. Repita el procedimiento anterior con lija # 400. Limpie todos los elementos de las impurezas que hayan quedado e instale la barra de acuerdo al procedimiento descrito anteriormente. Si ste procedimiento no se hace correctamente, la aplicacin de adhesivo ser dispareja especialmente en alta velocidad y puede contaminarse el Tambor de Vaco o las guas.

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Reemplazo del Rodillo Engomador

Algunas veces el Rodillo Engomador est tan contaminado de adhesivo quemado, hasta el punto tal que el carbon ha llenado el moleteado; se hace necesario entonces removerlo y limpiarlo afuera. Cuando sta operacin se hace no retire el rodillo de su soporte pues puede perder el ajuste de excentricidad, sino que remueva el ensamble rodillo-soporte-pin retirando los 4 tornillos de cabeza allen que mantienen fijo todo el conjunto al poste soporte, cuidando eso si de no daar la resistencia en espiral que hay dentro de l, tal como de muestra en la figura. Cuando el Rodillo Engomador ha sido retirado de su placa soporte para reemplazarlo por uno nuevo, se requiere verificar con un comparador la excentricidad, pues un mal montaje puede daar los rodamientos superiores al tener que aplicar mucha presin para obtener adhesivo en todos los puntos requeridos de la etiqueta.

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4.3

Alistamiento de las partes de manejo del envase

Para un etiquetado correcto y de calidad consistente, todas las partes que tienen que ver con el manejo de los envases deben ser ajustados apropiadamente. En la siguiente ilustracin podemos ver los nmeros que indican el numeral en el manual donde aparece la descripcin de los ajustes con el objeto de encontrarlos ms fcilmente.

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4.3.1 Estrella Principal

Este subensamble consta de la estrella superior e inferior separados por el anillo central de separacin. La estrella superior es desplazable con respecto a la inferior (en algunos pocos casos es la estrella inferior la desplazable). La base en que apoya la Estrella Principal, tiene unas ranuras de temporizacin cuyo objeto es el de poder rotar el conjunto y temporizarlo de tal forma que el envase reciba la etiqueta en el momento apropiado. Hay tres ajustes ha efectuar en la puesta a punto de la Estrella Principal.

41

1. Para ajustar la perpendicularidad del envase con el el transportador y al mismo tiempo el paralelismo con el Tambor de Vaco, coloque el envase sobre el transportador (asegurndose de antemano que no haga contacto con la almohadilla principal) y ajuste las dos estrellas de tal forma que cuando la base del envase est 100% apoyada sobre el transportador, las dos estrellas estan haciendo contacto con l. Si el envase de prueba sale con la etiqueta muy floja en la parte superior entonces mueva ligeramente (menos de 1 mm) la estrella superior en sentido a reloj y repita la prueba. Si el envase de prueba sale con la etiqueta muy floja en la parte inferior entonces mueva ligeramente (menos de 1 mm) la estrella superior en sentido contrareloj y repita la prueba. 2. La Estrella Principal debe posicionarse a una distancia entre centros con respecto al Tambor de Vaco de tal forma que al colocar un envase entre los dos (como se muestra en la ilustracin siguiente) haya un espacio de 1 a 2 mms. El envase debe estar tocando la parte resaltada de Tambor de Vaco mientras la almohadilla de presin no debe ejercer presin alguna.

3. Para temporizar la Estrella Principal con respecto al Tambor de Vaco debe tenerse en cuenta
que cuando el envase haga contacto con el Tambor de Vaco, debe estar ligeramente adelantado con respecto a la etiqueta. Por otra parte debe tenerse en cuenta que el envase debe envolverse su propia etiqueta antes de abandonar la parte circular de la almohadilla principal. Si se logran estas condiciones no se requieren ajustes posteriores.

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43

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4.3.2 Guas del envase.

El propsito de las guas es el de llevar el envase hasta el Tambor de Vaco y colocarlo tangencialmente a ste, de tal forma que la pared de aquel sea paralela con la del Tambor de Vaco en el momento de hacer contacto. Este punto de contacto es crtico pues una vez el envase toca el Tambor de Vaco, ya nada se puede hacer para mejorar la calidad del etiquetado. La tolerancia entre las guas y la Estrella Principal debe ser de 1 a 2 mms (sin que la almohadilla principal haga presin). Las guas deben ajustarse despues de que se haya logrado la distancia correcta entre la Estrella Principal y el Tambor de Vaco como se muestra en la seccin anterior.

45

Para ajustar las guas siga el siguiente procedimiento: Retire la almohadilla principal y coloque envases sobre la Estrella Principal como se muestra. Ajuste la gua inferior de tal forma que sta coloque la botella tangente al Tambor de Vaco en una zona de transferencia de unos 12 mms adelante de la lnea de centros entre la Estrella Principal y el Tambor de Vaco, tal como se ilustra en la figura anterior. Cuando el envase llega a ste punto debe empujarse contra la gua con la mano, imitando la funcin de la almohadilla principal. Una vez logrado sto, retire la Estrella Principal y lleve con la mano un envase ajustado a las guas, tal como lo hara la Estrella Principal, hasta el punto de contacto. Observe y ajuste la posicin de la gua superior de tal forma que cuando la pared del envase toque el Tambor de Vaco, est perfectamente paralela a l. Si no se logra un perfecto paralelismo entre la superficie del envase y la pared del Tambor de Vaco, se presentan inevitablemente defectos de aplicacin de etiqueta.

4.3.3

Estrella de Transferencia

Solo el modelo de mquina BH-8000S tiene Estrella de Transferencia. Su funcin es la de transferir los envases suavemente desde el sin fin de alimentacin hasta la Estrella Principal. Para temporizar la Estrella de Transferencia, rote la mquina hasta una posicin en que el envase debera estar en la lnea de centros de las estrellas, afloje los pernos inferiores de la Estrella de Transferencia y el que sujeta la estrella misma y rtela hasta lograr que el envase est posicionado como se indic, o bien como ilustra la figura y apriete de nuevo los pernos. Verifique la tolerancia. Si es necesario mueva todo el ensamble de la Estrella Principal hacia atrs si fuera necesario.

46

4.3.4

Estrella de Sincronizacin

En el modelo 8000 que no tiene Tornillo de Alimentacin sta estrella adems de tomar la presin de la lnea, separa los envases y los entrega suavemente a la Estrella Principal. Su ajuste se hace igual a como se explic en el paragrafo anterior para la Estrella de Transferencia.

4.3.5

Gua de respaldo

La gua de respaldo es utilizada en las mquinas modelo BH-8000 y BH-8000S solamente. El proposito es el de ayudar a guiar el envase en cercanas a la Estrella Principal. Estas deben colocarse a una altura apropiada y mantener una tolerancia de 2 a 3 mms con respecto al envase. Ver la figura anterior.

4.3.6

El Tornillo de Alimentacin

El Sin Fin o Tornillo de Alimentacion es usado en las mquinas BH-8000S y BH-8000U. Su propsito es el de aliviar la presin de la lnea, separar gradualmente los envases y entregarlos a la Estrella de Transferencia en el caso de la BH-8000S o a la Estrella Principal en el caso de la BH-8000U. El ensamble del Sin Fin puede moverse hacia arriba o hacia abajo y el Sin Fin mismo horizontalmente hacia el centro o afuera del transportador. Su ajuste debe ser tal que vaya insertando gradualmente el envase en el bolsillo de la Estrella.

47

48

Para ajustar el Sin Fin, empiece por ajustarlo primero con respecto a la Estrella Principal (Ver la figura siguiente); luego ajuste la elevacin si acaso fuere necesario y finalmente su posicin horizontal. La tolerancia entre el Sin Fin y el envase debe mantenerse entre 1 y 2 mms. Para temporizar el Sin Fin con respecto a la Estrella Principal, afloje el buje de entrabamiento localizado en la parte baja de la caja de la polea conductora. Coloque un envase en el bolsillo de la estrella en la posicin que se muestra en la figura siguiente. Con la mano rote el Sin Fin hasta obtener igual tolerancia entre todas las partes. Apriete el buje de entrabamiento y verifique la tolerancia pasando algunos envases. La transferencia debe ser suave, sin sobresaltos y sin inclinar los envases. Ajuste la gua del Sin Fin tanto como sea necesario. La gua debe estar centrada verticalmente en el Sin Fin y debe permitir a su vez una tolerancia razonable. (ver ilustracin en las pginas anteriores). Si la gua del Sin Fin est muy ajustada, los envases se inclinaran al pasar por l. Si la gua del Sin Fin est muy alejada los envases vibraran y/o se inclinaran al pasar por l.

49

Para remover el Sin Fin siga la ilustracin anterior si el modelo es BH-8000S o siga la siguiente ilustracin si el modelo es BH-8000U. El eje estriado del Sin Fin tiene una cua pinada a ste y puede deslizarse hacia afuera para liberarlo. El eje conductor estriado es asegurado en su buje estriado mediante un tornillo prisionero interno especialmente maquinado. Este prisionero es accesible a travs de un hueco o abertura situada en la tapa que cubre la caja del eje y para ser removido se requiere una llave allen de 3/8. Cuando se instala un nuevo Sin Fin, el eje estriado est engranado con su cua en el buje del Sin Fin. No apriete el tornillo prisionero mucho pues puede sobrecargar rodamiento trasero.

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4.3.7

Almohadilla de Rodamiento Primaria

La almodilla primaria es una parte de suma importancia para una buena aplicacin de la etiqueta. Su ajuste es determinante en la calidad del etiquetado. Esta es una de las piezas del formato de cambio y se disea para cada envase en particular. Con el uso regular, la almohadilla se va desgastando y su superficie va mostrando seas. Cuando ste desgaste es apreciable debe ser reemplazada por otra original. La geometra de esta pieza es el fruto de muchos aos de experiencia, si se sustituye por una copia puede afectar negativamente la calidad del etiquetado. Para ajustar la almohadilla primaria, hgalo verticalmente primero, de tal forma que quede centrada con respecto al Tambor de Vaco. Coloque tres envases alrededor de ste sin tocar los resaltos, como se muestra en la siguiente ilustracin. Afloje parcialmente el perno de prensado y mueva la almohadilla primaria hasta que entre suavemente en contacto con los envases mediante los pernos de ajuste. Note que en la superficie superior del soporte de la almohadilla hay una lnea mda. Esta lnea debe estar alineada con la correspondiente lnea en el yugo. Si todo estuviera correcto el radio de la almohadilla estar centrado con el centro del Tambor de Vaco. Ahora ajuste an ms los pernos de ajuste en 1 vuelta completa para envases vacios o en 2 a 3 vueltas para envases llenos. Si la etiqueta est floja en toda la circunferencia del envase entonces es porque la almohadilla esta o muy floja o muy apretada contra los envases. Corregir en el caso que fuere necesario. La mayora de las veces el etiquetado defectuoso es producto de mucha presin de la almohadilla particularmente en envases vacos. Si nota algn cambio en la calidad del etiquetado, ajuste nuevamente la almohadilla primaria.

4.3.8

La Almohadilla de Rodamiento Secundaria

La Almohadilla de Rodamiento Secundaria junto con la Banda de Rodamiento Secundaria han sido diseadas para estabilizar el envase despues que han pasado por el Tambor de Vaco. Para ajustar ambas, cntrelas verticalmente tal como se hizo con la almohadilla primaria. Coloque algunos envases entre la almohadilla y la banda y ajuste la posicin horizontal por medio de los pernos de ajuste (igual que en la almohadilla primaria). El envase mas cercano a la

51

almohadilla primaria debe estar sujetado firmemente. El envase que est a unos 3 a 5 cms de la salida debe ya tener alguna tolerancia entre ambas, almohadilla y banda, con el objeto de que vaya liberando el envase gradualmente y no tenga vibracion o giro.

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4.4

Temporizacin de la mquina

Las mquinas de la serie 8000 vienen con temporizacin computarizada tanto en el CRS como en y su PLC. En los pargrafos anteriores hemos descrito la temporizacin de las partes mecnicas que manejan tanto los envases como las etiquetas. Existe una secuencia lgica en el programa del PLC el cual controla el inicio y final de cada una de las funciones que se describen a continuacin. La programacin esta contenida en el men de temporizacin del ITM-270 (ver pagina siguiente) a) Alimentacin de etiqueta - Arranque y parada

Esta funcin se ejecuta automticamente en tiempo y posicin con referencia a la cuchilla y al Tambor de Vaco, por medio del CRS al recibir la seal del PLC de HABILITAR ETIQUETA. Si el CRS est configurado apropiadamente, no se requiere de ms ajustes. El Sensor Detector de Envase (PE2 en la figura) debe estar viendo un envase en posicin apropiada tal como se describe en la seccin 4.4.1 para que se ejecute la alimentacin. b) El Rodillo Engomador Entrada y salida

El Rodillo Engomador engancha y desengancha por medio de un cilindro de aire que recibe presin de una vlvula neumtica localizada en el espacio inferior del tren de engranajes, la cual a su vez es actuada por un solenoide que recibe la seal del PLC. El Sensor Detector de Etiqueta (PE1 en la figura) debe estar viendo una etiqueta para que el PLC ejecute la seal. El Rodillo Engomador debe entrar cuando el Tambor de Vaco est en cierta posicin pues de otra forma el tambor se contaminara de adhesivo. Por lo tanto se requiere una temporizacin adecuada tal como se describe en la seccin 4.4.2 . c) La Compuerta - Apertura y cierre

El propsito de la compuerta es iniciar y detener el flujo de envases a la mquina. La compuerta es operada por un cilindro de aire que recibe presin de una vlvula neumtica localizada en la parte inferior del tren de engranajes, la cual a su vez recibe la seal del PLC. Para que el PLC abra la compuerta el Sensor de Entrada de Compuerta (PE5 en la figura) debe estar viendo un envase y a su vez el Sensor de Salida de Compuerta (PE6 en la figura) no debe estar viendo un envase. El flujo de los envases debe comenzar en fase con la posicin de la mquina de tal forma que el primer envase alcance suavemente el inicio del Sin Fin. Tambien la compuerta debe cerrar sin causar dao a los envases. La temporizacin adecuada de la compuerta se describe en la seccin 4.4.3 .

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IDLE MODE

Organizacin de las funciones de la pantalla ITM-270

para entrar al menu de datos presione

DATA SET LBL Previous RUN LBL CUTOFF ##.### ##.### ##.### Previous

REGISTR ON/OFF SPEED RPM COUNT

Para entrar al men de alistamiento entre el pasabordo y presione ENTER

Nota: 1. Los recuadros sombreados corresponden a mensajes disponibles solamente en el programa CRSG. 2. Los menus de alistamiento y de temporizacion no estan disponibles cuando la mquina est alimentando etiqueta.

### ######

COUNT x 1000 ###### CONTAINER # LOAD # Next

ENTER PASSWORD ENTER LEADING TRAILING EDR REF Men de alistamiento CUTSENS OVERHANG MISS MARK FEED DIA PASSWORD MAXSPEED PRINTER #.### #.### #### ### #.### ### #.### ###### ### ON/OFF ### ### ### ### ### ### ### Next Previous

Men de tiempos

para entrar al menu de tiempos presione COMMAND

STORE CUT POS Para retornar al men de alistamiento presione DATA en cualquier momento GLUE OFF GLUE ON FLOW OFF FLOW ON PRINT OFF PRINT ON ### ### ### ### ### ###

EXECUTE

MACHINE POS GLUE OFF GLUE ON FLOW OFF Next FLOW ON PRINT OFF PRINT ON

Para temporizar cada funcion: Rote la maquina con "JOG" hasta la posicin deseada y presione
EXECUTE EXECUTE EXECUTE EXECUTE EXECUTE EXECUTE

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4.4.1 Alimentacion de etiquetas Sensor Detector de Envases.

El sensor detector de envase debe ver con confiabilidad cada envase para que la mquina funcione apropiadamente. Si un envase no es detectado en baja velocidad (abajo de 110 EPM), cesar la alimentacin de etiqueta y el envase no sera etiquetado. Si un envase no es detectado en alta velocidad (encima de 110 EPM), de acuerdo con el programa del PLC, se asumir que el envase no est efectivamente presente y ejecutar la Parada de Emergencia. Para un funcionamiento apropiado el envase debe detectarse cuando la mquina esta en la posicin 9030. (La posicin de la mquina puede verse en la pantalla del operador ITM-270). Lleve la mquina pulsando JOG hasta una posicin intermedia entre 60 y 120 (preferiblemente 90). Coloque un envase en el tornillo Sin Fin o si no tiene ste en la Estrella Principal 3 posiciones adelante del que estara haciendo contacto con el Tambor de Vaco. Mueva el sensor hasta que detecte el envase. Es mas confiable que lo coloque leyendo la tapa. Ajuste la sensibilidad si fuera necesario. Mantenga la distancia del sensor al envase al menos en 5 cms para protegerlo de contaminacin de producto o de agua.

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4.4.2 Rodillo Engomador.

Una vez temporizada la mquina mecnicamente con respecto a la cuchilla tal como se ha descrito anteriormente, no hay necesidad de temporizar nuevamente el Rodillo Engomador a menos que se hayan hecho algunos cambios en el tren de engranajes o cadenas. Para temporizar el Rodillo Engomador lleve la mquina pulsando JOG hasta que el final de resalto trasero del Tambor de Vaco est frente al Rodillo Engomador o un poco pasado (no mas de 1 cm). Vaya a la Pantalla del Operador ITM-270 y a travs del men hasta encontrar el parmetro ENTER PASSWORD. Digite la clave para entrar (de fbrica vienen con la clave 1) y presione ENTER. Para acceder al menu de temporizacion presione COMMAND. Vaya hasta el mensaje GLUE OFF presionando NEXT. Presione EXECUTE. All la posicin de la mquina para GLUE OFF es almacenada en la memoria. Mueva la mquina con JOG unos 10 mms adelante (Sin que la parte resaltada de la siguiente etiqueta en el Tambor de Vaco, llegue a estar al frente del Rodillo Engomador), presione NEXT en menu de temporizacin hasta GLUE ON. Presione EXECUTE y ya entonces la posicin GLUE ON del Rodillo Engomador queda almacenada. Para verificar las posiciones programadas vaya al menu de puesta a punto del ITM-270, presione DATA y vaya hasta GLUE OFF ###. El nmero mostrado es la posicin programada en grados. Cercirese tambin de que la posicin GLUE ON est tambin cercana, como unos 10 de diferencia. La posicin programada puede cambiarse manualmente presionando CHANGE , introduciendo el valor deseado y presionando finalmente ENTER. Para temporizar el Sensor Detector de Etiqueta (marcado como PE1 en los esquemas elctricos) , una vez que la mquina est alimentando la etiqueta con longitud correcta, vaya al men de alistamiento hasta MACHINE POS ### y lleve la mquina pulsando JOG hasta una posicin igual o no menor de 15 de la posicin programada para GLUE OFF. En sta posicin el sensor debe ver la etiqueta. Mueva el sensor y notar que los mejores resultados se obtienen cuando el sensor no esta viendo exactamente perpendicular al Tambor de Vaco sino con unos 10 o 15 grados de inclinacin. (ver la prxima ilustracin). Si se usa un sensor de ngulo de visin amplio (Ref. Banner 312WQD, requerido cuando se usan etiquetas transparentes), la distancia del Tambor de Vaco debe ser de 2.5 cms aproximadamente. Ajuste la sensibilidad del sensor para que no detecte el tambor y si detecte con seguridad la etiqueta. Rote la mquina para asegurarse que el sensor actua as.

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4.4.3 Sincronizacin de la Compuerta.

La temporizacin de la Compuerta es el ltimo paso. Debe ser hecha tambin cuando hay cambio de envase pues sta no solo depende de la cuchilla sino tambin del tamao del envase, asi que para cada envase habra una temporizacin diferente. Si la mquina est usando el programa CRSG, todas las variables estarn contenidas en el programa del parmetro CONTAINER # y al llamarlo va a cargar automticamente stas. Para temporizar FLOW ON posicione la mquina hasta que el Sin Fin est en posicin de recibir el primer envase. (ver la ilustracin). En la pantalla ITM-270 vaya hasta ENTER PASSWORD y digtelo. Presione ENTER y luego COMMAND para entrar al menu de temporizacin. Vaya hasta el mensaje FLOW ON presionando repetidamente NEXT. Presione EXECUTE para que almacene en memoria la posicin de la mquina. Debido a la inercia mecnica del cilindro en cortar el flujo, generalmente sta posicin es un poco retardada. Puede cambiarlo manualmente adelantandolo unos 30 grados aproximadamente. Si presiona DATA , entra al men de temporizacin y va hasta FLOW ON ### donde se muestra la posicin programada, se puede hacer el cambio presionando CHANGE y entrando la nueva posicin. Por ejemplo si la posicin programada es de 120, la nueva posicin sera 90 (120-30), presione finalmente ENTER. Para verificar que la posicin seleccionada es la correcta, rote la mquina y abra la compuerta (no olvide de actuar el interruptor Logic Bypass previamente). Cierre la compuerta en cualquier instante y observe si la compuerta esta abriendo muy temprano o muy tarde y corrija como se indica en el pargrafo anterior. Note que cualquier cambio en la presin de aire, o cualquier cambio en los controles de velocidad del cilindro de la vlvula solenoide afectan el tiempo de respuesta de la compuerta. Para temporizar FLOW OFF rote la mquina hasta un punto tal que la compuerta quede justamente entre dos envases tal como se ilustra en la pgina siguiente. En la pantalla ITM-270 vaya hasta ENTER PASSWORD y digtelo. Presione ENTER y luego COMMAND para entrar al menu de temporizacin. Vaya hasta el mensaje FLOW OFF presionando repetidamente NEXT. Presione EXECUTE para que almacene en memoria la posicin de la mquina. Debido a la inercia mecnica del cilindro en cortar el flujo, generalmente sta posicin es un poco retardada. Puede cambiarla manualmente adelantndolo unos 60 grados aproximadamente. Si presiona DATA y entra al men de temporizacin y va hasta FLOW OFF ### donde se muestra la posicin programada, se puede hacer el cambio presionando CHANGE y entrando la nueva posicin. Por ejemplo si la posicin programada es de 250, la nueva posicin sera 190 (250-60), presione finalmente ENTER. Para verificar que la posicin seleccionada es la correcta, rote la mquina y abra la compuerta (no olvide de actuar el interruptor Logic Bypass previamente). Cierre la compuerta en cualquier instante y observe si la compuerta esta cerrando en tiempo y corrija como se indica en el pargrafo anterior si fuese necesario. Note que cualquier cambio en la presin de aire, o cualquier cambio en los controles de velocidad del cilindro de la vlvula solenoide afectan el tiempo de respuesta de la compuerta.

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Temporizacin de la Compuerta

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4.4.4 Temporizacion de los Sensores de Lnea

Las mquinas han sido diseadas para operar automticamente en la lnea de produccin. Para cumplir con esta tarea el PLC recibe las seales de 2 sensores a la entrada y 2 sensores a la salida de la mquina que le informan sobre la carga de envases en la lnea en todo instante. La mquina entonces abrir o cerrar la compuerta o pasar a alta o baja velocidad de acuerdo con la carga. Para asegurar que la mquina sea una unidad flexible dentro de la lnea de produccin, los sensores deben estar apropiadamente localizados y sus tiempos de retardo para ON y para OFF debidamente ajustados. Las mquinas de la serie 8000 estn programadas para lgica positiva lo cual significa:

Si la seal es ON, la mquina ejecuta la funcin

El Sensor de Entrada de la Compuerta (PE5 en los planos elctricos) y el Sensor de Descarga de la Compuerta (PE6 en los planos elctricos) controlan la apertura y cierre de la misma. Para que el Sensor de Entrada abra la compuerta debe existir una acumulacin de envases a la entrada y stos entren confiablemente en el Sin Fin. Se recomienda entre 15 a 20 envases los cuales a su vez determinan la posicin del Sensor de Entrada. La mnima distancia recomendada es de 1 metro medido desde la compuerta misma. El Sensor de Descarga debe estar ubicado a tal distancia de la Banda de Rodamiento secundaria que cuando la compuerta se cierra, el ltimo envase etiquetado debe terminar a unos 10 cms afuera de la Banda de Rodamiento secundaria si hay acumulacin de envase a la salida. En las mquinas dotadas de Sin Fin de Alimentacin ste sensor debe estar ubicado a una distancia equivalente a 12 envases (cuando se trata de una mquina de 2 estaciones) de la Banda de Rodamiento secundaria. La mnima distancia recomendada es de 1.20 metros. El sensor normalmente utilizado es retroreflexivo con el espejo montado en el otro lado de la lnea. Se recomienda que el sensor y el espejo no sean perpendiculares con el objeto de que el sensor no vea entre envases cuando stos se encuentren acumulados. El ngulo recomendado entre espejo y sensor es de 15. Cuando el Sensor de Entrada est ON, es porque el haz de luz est interrumpido por acumulacin de envase (Sensor en modo DARK) y viceversa en OFF, porque no est interrumpido. Al contrario, cuando el Sensor de Descarga est en ON, es porque el haz de luz no est interrumpido porque no hay acumulacin de envase (Sensor en modo LIGHT) y viceversa en OFF, porque est interrumpido. Ajuste los retardos para ON y para OFF en stos sensores de acuerdo a la siguiente tabla:

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Sensor
Sensor de Entrada de Compuerta PE5 Sensor de Descarga de Compuerta PE6 Sensor de Alta de Entrada PE3 Sensor de Alta de descarga PE4

Modo
DARK LIGHT DARK LIGHT

Retardo de seal ON OFF

3a5 3a5 3a5 3a5 2a3 2a3 1a2 1a2

Los sensores de Alta Velocidad de Entrada (PE3 en los planos elctricos) y de Alta Velocidad de la Descarga (PE4 en los planos elctricos) controlan la mquina para pasar de baja a alta velocidad o viceversa. Deben haber siempre suficientes envases a la entrada, entre los sensores de Entrada de Compuerta y de Alta Velocidad, pues la mquina toma al menos 15 segundos (se recomienda entre 18 y 20 segundos) para bajar la velocidad sin que pierda el registro. Por la misma razn debe haber suficiente espacio entre los sensores de descarga de Compuerta y de Alta Velocidad para que los envases se acumulen durante el perodo de desaceleracin. En el caso de lnea con una sola fila de envases en el transportador de salida, recomendamos una distancia entre stos sensores de 6 a 7 metros, para una velocidad en alta de 400 EPM. Para determinar la mnima distancia necesaria siga la la grfica de la pgina siguiente. Esta grfica ha sido diseada para lneas de transportadores de una sola fila. La distancia de los sensores depende de la mxima velocidad, dimetro del envase y del nmero de estaciones de la mquina. Si el espacio recomendado no esta disponible, consulte a B&H para la recomendacin de nuestro departamento de ingeniera.

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5. Sistema elctrico
Los ensambles elctricos estan contenidos en la cabina elctrica principal la cual es parte del cuerpo principal de la mquina. Mnimas conexiones son hechas en el panel de botones de comando colocado a la derecha del operador. Este panel contiene tambien el mdulo del control de tensin de la etiqueta y el control remoto del Web Tracking (opcional). La mquina es movida por un motor trifsico de 5 HP controlado por medio de un variador de frecuencia montado en la cabina principal. Dentro del marco principal de la mquina est montado el ServoMotor y Codificador Principal los cuales forman parte del CRS. La lgica de la mquina es programada en el PLC, el cual usa las seales del computador para ejecutar las funciones de la mquina. Los componentes que controlan la temperatura en el Rodillo Engomador estan alojadas en el Poste Soporte del Rodillo Engomador. Todas las conexiones de la mquina son hechas por cables de varios hilos, ningun alambre individual es usado fuera de las cabinas.

5.1
PE1 PE2 PE3 PE4 PE5 PE6 PE9

Descripcin de los sensores y de los interruptores de posicin.

es el Sensor Detector de Etiqueta el cual detecta la presencia de una etiqueta en el Tambor de Vaco y enva una seal al PLC para actuar el Rodillo Engomador. es el Sensor Detector de Envase el cual detecta la presencia de un envase y enva la seal al PLC para iniciar la alimentacin de etiqueta. es el Sensor de Alta Velocidad a la Entrada el cual detecta si la cantidad de envases a la entrada es suficiente para operar en alta velocidad. es el Sensor de Alta Velocidad a la Salida el cual detecta si hay espacio suficiente a la salidad para operar en alta velocidad. es el Sensor de Compuerta a la Entrada el cual detecta si hay suficiente acumulacin de envases a la entrada para abrir la compuerta e iniciar alimentacin de envases. es el Sensor de Compuerta a la Salida es cual detecta si hay suficiente espacio a la salida para abrir la compuerta e iniciar alimentacin de envases. es el Sensor de Seguridad de Alimentacin el cual detecta la presencia de la cinta de etiquetas deslizandose sobre los rodillos. Si no detecta la cinta la mquina parar inmediatamente.

PE10 es el Sensor de Seguridad del Tambor de Vaco el cual detecta si hay una etiqueta sobre el Tambor de Vaco que no se aplic sobre su respectivo envase. En tal caso la mquina parar inmediatamente. PE11 es el Sensor de Final de Bobina No 1 el cual detecta si el diametro de la bobina No 1 es muy pequeo. Entoces envia una seal al PLC para pasar a baja velocidad. Tambien la luz azul indicadora de alarma se activar.

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PE12 es el Sensor de Final de Bobina No 2 que hace la misma funcin que el sensor PE11 en la la mesa porta bobina nmero 2. PE14 es el Sensor de Registro el cual detecta la presencia de una marca de registro y la enva al computador. El Interruptor de Bajo Nivel de Adhesivo es un termstato que cuando no hace contacto con el adhesivo caliente enva una seal y activa la luz amarilla de alarma. Esta luz tambien va permanecer activada cuando la adhesivo est fro. El Interruptor de Seguridad del Motor Principal detecta cuando el embrague de seguridad del motor principal ha sido desenganchado y detiene la mquina inmediatamente. El Interruptor Seguridad de la Estrella Principal detecta cuando el embrague de seguridad de la Estrella Principal ha sido desenganchado y detiene la mquina inmediatamente. El Interruptor de Seguridad de la Estrella Secundaria detecta cuando el embrague de seguridad de la estrella secundaria ha sido desenganchado y detiene la mquina inmediatamente. El Interruptor de Baja Presion de Aire contenido dentro de un presstato detecta cuando la presin de aire est por debajo del lmite establecido y detendr la mquina.

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5.4

MENSAJES DE FALLAS DEL SISTEMA

Las mquinas BH8000 son equipadas con un display Allen Bradley modelo DL5 el cual almacena mensajes en su memoria. Los mensajes almacenados son mostrados cuando se recibe una seal de comando del PLC. Los mensajes son mostrados en dos partes y su significado se explica a continuacin: GLUE ROLLER TEMP. TOO HIGH OR LOW CHECK TEMP. AND SENSOR. TEMPERATURA DEL RODILLO ENGOMADOR MUY ALTA O MUY BAJA. VERIFIQUE LA TEMPERATURA Y EL SENSOR. El sensor de temperatura del Rodillo Engomador detect una temperatura fuera de los lmites (ALO y AHI). LOW AIR PRESSURE CHECK AIR LINE PRESION DE AIRE BAJA VERIFIQUE LA PRESION EN LA LINEA La presin de aire en la mquina est por debajo del lmite fijado en el presstato. MAIN CLUTCH IS DISENGAGED CHECK GEAR ARRANGEMENT EL EMBRAGUE ESTA DESENGANCHADO - VERIFIQUE EL TREN DE ENGRANAJES. El interruptor lmite esta activado porque el embrague principal de seguridad esta desenganchado o no esta ajustado apropiadamente. VACUUM DRUM SAFETY SENSOR - REMOVE LABEL CHECK SENSOR

SENSOR DE SEGURIDAD DEL TAMBOR DE VACO REMUEVA LA ETIQUETA DEL TAMBOR

El sensor del Tambor de Vaco ha detectado una etiqueta..

CONTAINER NOT DETECTED AT HIGH SPEED ENVASE NO DETECTADO A ALTA VELOCIDAD

El Sensor Detector de Envase a la entrada no detect una botella en el ltimo ciclo. La mquina detiene porque sobra una etiqueta que al final va a terminar en la parte trasera de la cuchilla con adhesivo aplicado.

LABEL WEB BROKEN CHECK LABEL WEB OR SENSOR

CINTA DE ETIQUETA ROTA REVISE EL SENSOR DE LA CINTA DE ETIQUETAS El Sensor de la Cinta de Etiqueta detect que se acabo el rollo de etiquetas. INFEED STARWHEEL IS DISENGAGED CHECK INFEED STARWHEEL ESTRELLA DE ENTRADA DESENGANCHADA REVISE LA ESTRELLA DE ENTRADA. El interruptor lmite de la Estrella de Entrada (estrella pequea) ha detectado que el embrague de seguridad esta desenganchado. La mquina se detiene y solo puede ser operada con JOG. MAIN STARWHEEL IS DISENGAGED CHECK MAIN STARWHEEL ESTRELLA PRINCIPAL DESENGANCHADA REVISE LA ESTRELLA PRINCIPAL El interruptor lmite ha detectado que el embrague de seguridad esta desenganchado. La mquina se detiene y solo puede ser operada con JOG.

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LABEL WRAPPED AROUND FDRLR OR NO LABEL FEED ETIQUETA ENROLLADA EN EL RODILLO ALIMENTADOR O NO HAY ALIMENTACION DE ETIQUETA. El Sensor Detector de Etiqueta, no detect etiqueta cuando el rodillo alimentador estaba accionado y la mquina estaba en modo RUN (alimentando etiqueta). La mquina se detiene para proteger el Tambor de Vaco. Esta proteccin no funciona cuando la mquina es operada mediante el botn JOG. OUT OF REGISTRATION RESET REGISTRATION FUERA DE REGISTRO RESTABLECER EL REGISTRO El computador indica que est fuera de registro. La mquina se detiene y al menos 1 etiqueta debe ser alimentada en JOG para eliminar esta falta. FLOW GATE CLOSED INFEED SENSOR OUT OF CONTAINERS COMPUERTA CERRADA POR EL SENSOR DE ENTRADA FALTAN ENVASES El Sensor de Entrada no detecta envases y entonces el PLC ha cerrado la compuerta. Esta orden se puede pasar por alto actuando el suiche Logic Bypass. FLOW GATE CLOSED DISCHARGE SENSOR CONTAINERS ARE BACKED-UP COMPUERTA CERRADA POR EL SENSOR DE SALIDA SALIDA LLENA DE BOTELLAS. El Sensor de Salida ha detectado la lnea llena de envases y entonces el PLC ha cerrado la compuerta. Al igual que en el mensaje anterior esta orden puede pasarse por alto actuando el suiche Logic Bypass LOW REEL SAFETY REPLACE ROLL SE ACABA LA BOBINA REEMPLACE LA BOBINA Uno de los sensores debajo de la mesa portaetiquetas no detecta la bobina o la mesa. La luz azul empieza a parpadear y la mquina pasa a baja velocidad. Esta orden puede pasarse por alto manteniendo presionado el boton Hi speed para volver a alta velocidad. AT LOW SPEED INFEED SENSOR WAITING FOR CONTAINERS A BAJA VELOCIDAD SENSOR DE ENTRADA ESPERANDO POR BOTELLAS El Sensor de Entrada de Alta velocidad ha detectado que no hay suficientes envases para rodar a alta velocidad y el PLC desacelera la mquina hasta baja velocidad. Si esta condicin cambia, la mquina nuevamente acelera hasta alta velocidad. AT LOW SPEED DISCHARGE SENSOR WAITING TO CLEAR CONTAINERS A BAJA VELOCIDAD SENSOR DE SALIDA ESPERANDO QUE SE DESPEJE DE ENVASES El sensor de alta a la salida ha detectado acumulacin de envases y el PLC desacelera la mquina hasta baja velocidad. Si esta condicin cambia la mquina nuevamente acelera hasta alta velocidad. B & H MANUFACTURING MADE IN U.S.A. Este mensaje informa que la mquina esta OK y lista para etiquetar a alta velocidad.

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5.5

Descripcin de la lgica de la mquina

La lgica de la mquina tal como est programada en el PLC habilita el operador a usarla en tres modos diferentes. An ms, la lgica est diseada para proveer mxima proteccin tanto al operador como a la mquina misma, manteniendo la mxima eficiencia. Cuando detecta las fallas responde apropiadamente para mantener tanto la calidad del etiquetado como para proteger todo el sistema. La situacin del proceso es comunicada al operador por varios medios: Por intermedio del la Pantalla del Operador ITM-270. Por intermedio del las luces del Panel del Operador Por intermedio de las luces Beacon de alarma Por intermedio de los varios LEDS distribuidos en ella. Los modos de operacin de la mquina son: JOG Este modo es usado para el alistamiento o tambien para limpiar algunas de las fallas que puedan ocurrir en operacin como por ejemplo cuando hay adhesivo en el Tambor de Vaco, fuera de registro, etc., algunas de las protecciones de la mquina en otros modos, son inoperantes en ste. Cuando el botn de JOG es liberado la operacin cesa inmediatamente. JOG pasa por alto todas las seguridades excepto EMERGENCY STOP, LOW AIR PRESSURE y LOW GLUE ROLLER TEMPERATURE (Parada de emergencia, bajo nivel de aire y baja temperatura del Rodillo Engomador).

RUN Este modo es usado para condiciones normales de operacin. Todas las seguridades y todas las conexiones lgicas son operables normalmente. Cada botn ON OFF es operado separadamente. Las funciones de la mquina pueden ser canceladas en cualquier momento siempre y cuando la velocidad de la mquina est por debajo de la velocidad programada para desenganche (high speed interlock), normalmente 120 CPM. AUTOMATIC Este modo es el ms avanzado y preferentemente debe usarse durante la operacin de rutina. Al presionar RUN y AUTOMATIC toda la mquina entra en ON en la medida en que se le requiere. La mquina acelera hasta alta velocidad, desacelera hasta la baja velocidad, abre y cierra la compuerta a medida que se vayan dando las condiciones, para una operacin totalmente automtica. Todas las protecciones estn activadas y no es posible evadirlas. Si todo el sistema es ajustado correctamente antes de arrancar la mquina no se requiere ms intervencin del operador para una operacin libre de fallas.

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5.6

Sistema de control de temperatura

El sistema de control de temperatura consiste del control Watlow serie 965. Este es un control basado en un microprocesador de entrada nica, salida controlada doble. La pantalla exhibe doble visor para suministrar informacin sobre la temperatura actual y la temperatura objetivo fijada. Tambin es usada para programarlo. El control recibe una seal de temperatura por medio de un sensor tipo RTD de 3 alambres (Un termistor) localizado en la base del Rodillo Engomador. El control enva la seal de salida a un rel de estado slido el cual conmuta los 220 Voltios AC para calentar la resistencia helicoidal alojada dentro del Rodillo Engomador. El Wattow de la serie 965 es programado de fbrica (B&H) con los siguientes valores: LOC=0; In=rtd; dEC=0; C-F=F; rL=40; rH=300; Ot1=ht; HSC=2; Ot2=PrA; HSA=3; LAt=nLA; SIL=OFF; rtd=din; rp=OFF; rt=100; PL=50; dSP=nor El men de operacin tambien es programado por B&H durante las pruebas finales con los siguientes parmetros: Pb1=50; rE1=0.2; rA1=1.5; Ct1=2.5; ALO=190; AHI=280 Refirase al manual del fabricante pginas numeros 18 a 20 para la explicacin de los parmetros. El control 965 tiene dos alarmas las cuales han sido incorporadas a la lgica de la mquina y son mostradas en la Pantalla del Operador ITM-270 cuando se activan. Nota: Cuatro barras, ---- en la pantalla del control de temperatura nos indica un error. Para corregirlo refirase al manual del fabricante.

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5.7

Sistema de control de tensin de la etiqueta.

El control de tensin de la cinta de etiquetas consiste del control MCS-203 marca Warner, del brazo danzante y del potencimetro del brazo danzante. El control recibe informacin sobre la posicin del brazo danzante mediante el potencimetro y suministra un voltaje variable a los frenos de las mesas portabobinas con el objeto mantener el brazo danzante en una posicin estable. El sistema de control trabajo en bucla cerrada. La puesta a punto es hecha en B&H en las pruebas finales de la mquina. El voltaje de operacin se selecciona entre 120 o 220/240 voltios. Este es un control PID el cual requiere ajuste en 3 potencimetros correspondientes a la parte proporcional, la parte integral y la parte diferencial. El control diferencial requiere el ajuste de 3 interruptores tipo DIP (marcados SW1 en los esquemas elctricos). El procedimiento de puesta a punto es como sigue: Ganancia del PID (R32) (PID gain) se rota el potencimetro totalmente en el sentido a reloj y luego se retrocede 90 grados. Ganancia del diferenciador (R16) se rota el potencimetro totalmente en el sentido a reloj y se retrocede 180 grados. Ganancia del integrador (R24) se rota totalmente el potencimetro en el sentido a reloj y luego se retrocede 90 grados. Respuesta del diferenciador (SW1) pngalo en medio 1=off, 2=on, 3=off. En el panel frontal del control ajuste la posicin del brazo danzante en la mitad aproximadamente y la ganancia en 3. Verifique el voltaje aplicado en los frenos cuando la posicin del brazo est en la posicin extrema en sentido contrareloj, sin etiquetas y con los contrapesos en posicin. Si los parmetros se han puesto de acuerdo a las indicaciones anteriores el voltaje debe estar entre 5 y 6 VDC., si no es as, entonces afloje los tornillos prisioneros allen del acople que conecta el potencimetro con el brazo danzante y rote aqul hasta que el voltaje sea se. Asegure el acople nuevamente. Coloque la cinta de etiquetas a travs de la mquina y verifique la posicin del brazo danzante. Debe parar en la mitad entre los dos topes. Aada o retire peso para mantener el brazo en esta posicin cuando la mquina est parada. Para el ajuste final del sistema en funcin dinmica la cinta de etiqueta debe estar debidamente colocada y la mquina debe estar etiquetando. Verifique que el brazo danzante se mantenga estable en la posicin central y sin oscilar. Si no fuera as, ajuste ligeramente la ganancia proporcional (R32) y la ganancia diferencial (R16). Note cual de los potencimetros requiere ajuste adicional con el objeto de estabilizar el brazo y tambien mantener su posicin.

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Mantenimiento preventivo

Las mquinas BH8000 son diseadas para operar con mnimo mantenimiento., pero an asi se requiere un mantenimiento diario y semanal. Mantenimiento no efectuado afecta la confiabilidad y eficiencia de la mquina. La mquina debe mantenerse limpia, cualquier trazo de adhesivo en las piezas debe limpiarse an cuando la mquina est trabajando satisfactoriamente. Recomendamos que durante el cambio de las debe hacerse un rpido chequeo visual y efectuar el mantenimiento que se requiera. Tambien durante los cambios de turnos o al menos al final del da un mantenimiento mnimo debe efectuarse para mantener la calidad y preservar la eficiencia al mximo. La mquina esta diseada para poderse lavar, todas las partes elctricas y mecnicas con excepcin del sistema de adhesivo son a prueba de agua. Las partes mecnicas estan hechas de acero inoxidable o bien resistentes a la corrosin para trabajar en condiciones de operacin adversas. El mantenimiento recomendado debe ser programado como sigue; a) Cada bobina de etiquetas o cada hora de produccin. b) Cada turno de produccin o una vez por da. c) Cada semana de produccin. d) Cada ao de produccin.

Mantenimiento Horario
Para mxima eficiencia de produccin y alta calidad de etiquetado debe hacerse un mantenimiento mnimo en todo momento disponible. Es una buena prctica efectuar una breve inspeccin y mantenimiento cada vez que la bobina de etiquetas es colocada o al menos cada una o dos horas. Esto puede tomarle tan poco como un minuto pero seguro mejorar el comportamiento de la mquina. Limpie el Tambor de Vaco de cualquier residuo de adhesivo (gotas, vapores o residuos de los alambres) si son observados. Limpie cualquier adhesivo depositado sobre el cuerpo de la mquina o sobre las guas de los envases. La mquina debe mantenerse meticulosamente limpia en todo momento. Chequee los alambres por depositos de adhesivo y lmpielos en caso de que tengan algo. Tambien haga chequeos rpidos de la tensin en los alambres. Observe la pantalla del computador para ver si la longitud de la etiqueta cambia en alta velocidad. Si la longitud cambia de baja a alta velocidad por ms de 0.03 ajuste el vaco en el tambor de la cuchilla (disminuya) para evitar el estiramiento de la etiqueta y prevenir problemas de registro. Limpie cualquier producto que se haya regado, como a menudo ocurre y limpie las lentes de los sensores pticos. Visualmente inspeccione la mquina por si hay alguna parte desgastada. Reemplcela inmediatamente ya que stas conducen a problemas ms serios.

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Mantenimiento Diario
Al final de cada turno o al menos cada tres turnos de produccin continua debe efecuarse un mantenimiento preventivo: Limpie las partes exteriores de la mquina de cualquier residuo de adhesivo o de producto. Chequee el Rodillo Engomador y el patrn aplicado sobre la etiqueta. Chequee el sensor de temperatura y asegrese de que est haciendo buen contacto con el Rodillo Engomador Remueva cualquier pedazo de etiqueta presente en el sistema de adhesivo y trate de determinar porqu estan all. Chequee las cuchillas y cercirese de que el corte es correcto. (Para hacer esto debe eliminar el vaco en el Rodillo de la Cuchilla). Ajuste si fuere necesario. Limpie las partes de cambio de residuos de adhesivo o de producto. Chequee y limpie las lentes de los sensores pticos de producto o de polvo. (use un trapo suave. No use solvente). Cada 16 horas de produccin (o cada 250000 etiquetas contadas en el contador de la pantalla del computador ITM-270 en el parmetro CNTx1000) lubrique la placa vlvula del Tambor de Vaco (aquella de plstico que se aloja en el Tambor de Vaco). Chequee todos los rodillos por cualquier contaminacin (esto termina en barrigas en los rodillos generando estiramiento en la cinta de etiquetas) y lmpielos. Chequee la presion de aire y la cantidad de aceite neumtico en el lubricador. Drene el agua.

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Mantenimiento Semanal
Semanalmente si consideramos dos turnos de produccin diaria a 400 BPM o cada dos semanas si consideramos velocidades mas bajas o bien un turno de produccin diaria debe efectuarse el siguiente mantenimiento preventivo (Tambien puede usar el contador de envases por millar cada cierto nmero de unidades. El mximo intervalo entre dos sesiones de mantenimiento preventivo no debe ser mayor de 2.5 millones de etiquetas):

Tren de Engranajes
Chequee todos las cadenas y correas conductoras y asegrese de que tienen la tensin apropiada. Si nota alguna cadena o correa con sntomas de dao o desgaste, cambielas inmediatamente. Para observar la cadenas debe limpiarlas de grasa. Chequee todos las lneas de grasa y asegrese de que no hay taponamientos u obstrucciones.

Sistema Servo
Chequee la correa del Servo Motor para ver si tiene la tensin apropiada. Chequee todos los tornillos tuercas o mecanismos de fijacin para asegurarse de que no se han aflojado. Limpie la grasa sobrante especialmente encima del Codificador (Encoder). Chequee todas las conecciones elctricas para ver si no se han aflojado (Con la mquina desconectada elctricamente, por supuesto).

Sistema de Encolado
Chequee la Barra de Adhesivo (remuvala y asegrese de que no hay materiales extraos) y ajuste nuevamente el espaciamiente con respecto al Rodillo Engomador. Chequee y reajuste los alambres limpiadores que se insertan en las ranuras. Chequee y limpie la cuchilla barredora de adhesivo (Doctor blade). Inspeccione el Tambor de Adhesivo por si hay adhesivo quemado en las ranuras grafiladas (Si se toma por costumbre desconectar la resitencia del Rodillo Engomador cuando la mquina no est en uso, ste mantenimiento es innecesario). Si el bombeo de adhesivo es irregular, retire y limpie el filtro de la unidad de adhesivo (Si hay muchos pedacitos de etiquetas dentro del filtro chequee las cuchillas y partes relacionadas para corregir la causa del problema). Limpie toda acumulacin o depsitos de adhesivo en el ensamble del Rodillo Engomador.

Sistema de Vaco
Remueva y limpie la placa vlvula del Tambor de Vaco. Use solvente pues los vapores del adhesivo pueden condensarse en sta placa y crear extensa friccin, vibraciones y otros problemas en el Tambor de Vaco. Inspecciones y limpie los pasajes de vaco del Tambor de Vaco. Inspeccione y limpie el filtro en la turbina de vaco. Si ocurre mucho derramamiento de producto, abra la turbina y limpie los labes de cualquier producto que se haya endurecido alli, pues esto puede daarlos.

Lubricacin
Lubrique todos los puntos de la mquina, cada uno con una sola carrera de la bomba de grasa. Limpie todo exceso de grasa y al mismo tiempo inspeccione la integridad de todos los sellos de aceite. Inspeccione el nivel de aceite en el reductor de velocidad principal as como tambien en la caja del Sinfin de alimentacin y rellenela si fuera necesario. Nota: Mantenga la grasa alejada del adhesivo pues puede producir fallas de adhesin del adhesivo. Asegrese de que no hay grasa o aceite encima del encoder pues esto puede producir fallas en el CRS.

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Mantenimiento Anual
Cada ao (para una lnea de produccin de 2 turnos), o despues de 100 millones de envases etiquetados (use el contador por mil del computador, parmetro CNTx1000), lo que sea primero, debe efectuarse un mayor mantenimiento preventivo. El tiempo estimado para ste trabajo es aproximadamente 40 horas o menos.

Tren de Engranajes.
Remueva todas las cadenas e inspeccinelas. Si las ve estiradas o con eslabones doblados reemplcelas. Inspecciones los piones de cadena y engranajes por cualquier dao. Inspeccione los rodamientos y cuando vea un gran juego o detecte sellos daados, reemplacelos. Chequee todos los conductos de lubricacin por obstrucciones o taponamientos (use la bomba de grasa en cada bico y verifique al otro extremo la salida de ella). Limpie todos los elementos, ajuste la tensin y relubrique la mquina. Reemplace el aceite en el reductor de velocidad principal y en la caja del Sinfin de Alimentacin. Chequee el juego de los piones de la caja del Sinfin de Alimentacin y ajstela si fuere necesario.

Unidad de Corte.
Remueva y limpie la placa-vlvula de la Unidad de Corte. Si hay desgaste excesivo (mas de 1.5 mms de desgaste en la cara) reemplacela por una original. Inspeccione las cuchillas. Si la cuchilla estacionaria tiene un desgaste de mas de 1.5 mms (1/16) reemplacela. Chequee el cilindro de aire y los pines del soporte. Chequee los rodamientos, no se exceda en la lubricacin. Limpie todas las partes de posible contaminacin. Desbarate la base ajustable, lmpiela y lubrquela.

Sistema de Vaco.
Limpie todas las partes del Tambor de Vaco, reemplace las mangueras de vaco. Si la turbina de vaco no ha sido limpiada durante el mantenimiento semanal, brala y lmpiela por dentro. Reemplace los filtros de la turbina de vaco. Limpie todos los pasajes internos del Tambor de Vaco. Inspeccione el Tambor de Vaco y hagalo reencauchar cada vez que fuese necesario.

Sistema de Encolado
Remueva el Rodillo Engomador y limpie todo carbon depositado. Bote toda el adhesivo del tanque y limpie todos los ensambles del tanque y de la bomba, tal como se recomienda en el manual del fabricante. Reemplace todas las partes daadas o inoperantes. Remueva y limpie la barrra de adhesivo, si muestra excesivo desgaste reemplcela por una nueva. Reemplace tambien la cuchilla barredora de adhesivo (doctor blade) si estuviese desgastada. Chequee la funcin elctrica de sensor de temperatura RTD y todas las resistencias.

Sistemas Elctricos
Visualmente inspeccione todas las partes elctricas en los dos paneles. Limpie todo el polvo y reajuste todos los terminales. Remueva todos los fusibles e inspecinelos por si acaso tienen seas de corrosin y reemplcelos si fuere necesario. Chequee todos los conectores y contactos por signos de corrosin. Inspeccione todos los botones de pulsacin y cambie los que estn daados. Chequee todos los sensores y reemplace los que estan malos (Especialmente inspeccione los pticos por signos de contaminacin por humedad). Reemplace el potencimetro del Brazo Danzante. Limpie los frenos de friccin de las mesas portabobinas (evite cualquier contaminacin de aquellos con grasa o aceite). Cambie los filtros de los paneles elctricos.

Partes de Recambio.
Revise todas la parte por desgaste y reemplace la malas. Chequee las almohadillas primaria y secundaria y si hay algun resquebrajamiento o endurecimiento de la esponja de caucho, o

75

delaminacin de la cubierta, reemplcelas con partes originales. Chequee los bolsillos de las estrellas por inperfecciones. Y reemplcelas si fuere necesario.

Materiales usados en Mantenimiento.

Los lubricantes recomendados son producidos por Mobil. Los sustitutos apropiados de otras marcas pueden ser usados Grasa Lubricante: Grasa Mobil HP El aceite para el reductor de velocidad principal debe ser sinttico. El aceite utilizado es: Aceite Mobil SHC 634 (ISO VG 460) Todos los demas reductores y conductores angulares utilizan el siguiente aceite: Aceite Mobil 600W Super Cylinder Oil Para la limpieza de las superficies de la mquina y partes contaminadas con adhesivo use el solvente Espritus Minerales (Mineral Spirits). No use solventes sintticos para pinturas ni solvente aromticos como acetona, xyleno, tolueno ,acetato de etilo o de butilo, ni solventes clorinados, tampoco use gasolina o benzina.

76

Sistema de Registro por Computador

CRS
CRS una obra de arte en cuanto se refiere a control de registro para una cinta de etiquetas basado en un servosistema comandado por un computador. CRS es superior a cualquier sistema electromecnico actualmente en el mercado. El comportamiento de cualquier mquina etiquetadora que usa CRS mejora notablemente ademas de proveer herramientas para el manejo de materiales difciles con la misma alta eficiencia. Este manual esta dividido en las siguientes secciones las cuales estan ordenadas de acuerdo a su importancia y son acompaadas por esquemas grficos con la explicacin de la terminologa usada. (A) Descripcin del sistema (B) Descripcin de la interface del operador (C) Puesta a punto y temporizacin (D) Puesta a punto del registro (E) Puesta a punto del sensor de registro (F) Correccin de fallas y errores (G) Especificaciones generales

77

PROGRAMA DEL COMPUTADOR CRS

CRS (Computer Registration System) funciona de acuerdo a un programa escrito (no accesible al usuario). Las variables del programa (longitud de etiqueta, posicin de corte, etc.) pueden ser cambiadas por intermedio de la pantalla montada en el panel principal, tiene 15 caracteres que le informan al operador acerca de los valores actuales de las variables, as como tambin del comportamiento del CRS. Para entender apropiadamente la terminologa usada para operar la mquina sin inconvenientes, explicamos a continuacin el significado de los trminos usados. El orden de los parmetros del programa es como aparece en la pagina 4 y la explicacin de cada uno es como sigue: IDLE MODE significa que todo esta OK. y el operador puede ver o cambiar cualquier parmetro en la pantalla. Si presiona DATA y el display muestra por ejemplo SET LABEL 14.000 (longitud de la etiqueta 14 pulgadas), lo cual significa que la mquina esta lista para alimentar etiquetas de esta longitud. Para cambiar este valor siga el siguiente procedimiento: Si presiona CHANGE, la pantalla va a mostrar inmediatamente:

SETLABEL 14.000?
Entre la longitud deseada (por ejemplo 12.230) Presione luego ENTER y el display cambiar a: SETLABEL 12.230 lo cual significa que la mquina est ahora lista para alimentar etiquetas de esta longitud. De esta misma forma el operador puede cambiar cualquier variable accesible a travz de la pantalla. Debe tenerse en cuenta que una vez la mquina entra a alimentar etiquetas, el operador no puede cambiar las variables hasta tanto el rodillo alimentador de etiqueta este parado y que la ltima etiqueta sea completamente alimentada. El mensaje WRITE PROTECTED aparece y cualquier entrada sera rechazada. El operador puede recorrer en sentido directo los parmetros presionando NEXT o al revs presionando PREVIOUS. RUN LABEL es un parmetro de lectura solamente y es la longitud de la etiqueta que est siendo alimentada, medida por el computador. El computador solamente leer la longitud cuando el parmetro REGISTRATION esta en ON. CUTOFF 1.000 Significa que la marca de registro sera posicionada a 1.000 pulgadas del borde delantero de la etiqueta. REGISTRATION ON Significa que el computador va a tomar en cuenta la seales que vienen del sensor de registro, en caso de que este parmetro este en OFF el computador va a alimentar etiquetas exactamente del mismo tamano especificado en SETLABEL. SPEED RPM 123 Es un parmetro de lectura solamente e informa al usuario la velocidad de la mquina. COUNT x 1000 123456 es un contador acumulativo que no es posible cambiar. Informa del gran total de etiquetas alimentadas por la mquina. Este parmetro debe usarse con el propsito de hacer mantenimiento preventivo.

78

CONTAINER 1 es el parmetro que nos indica que nmero de programa (o botella) est siendo usado en la mquina en ese instante. El operador tiene la alternativa de escoger programas de 1 hasta 9. Cuando una nueva botella va a ser etiquetada, cargue el programa que le corresponde y todos lo parmetros incluidos en dicho programa seran cargados. LOAD 1 es el parmetro que permite cargar un nuevo programa. Una vez el programa a sido cargado, cualquier parmetro puede ser cambiado y sera automaticamente almacedo para uso posterior. ENTER PASSWORD? Este mensaje indica que para tener acceso a los siguientes parmetros, usted debe introducir el cdigo secreto. Esto es para evitar que personal no autorizado pueda cambiar algunos parmetros que afectan drsticamente el comportamiento de la mquina. El cdigo puede ser un nmero de hasta 7 digitos. El cdigo de fabrica es 1. LEADING 0.4 es la distancia frente a la marca de registro (ventana frontal) en la cual el pulso del sensor de registro va a ser aceptado por el computador para retardar. El primer pulso del sensor dentro de esta ventana sera tenido en cuenta, los dems seran ignorados. TRAILING 0.4 Es la distancia posterior a la marca de registro (ventana trasera) en la cual el pulso del sensor de registro va a ser aceptado por el cumputador para adelantar. EDR REF 5000 es el desfase entre el cero del Encoder Maestro y la posicin de las cuchillas cuando estan enfrentadas y en posicin de corte. Puede ser cualquier nmero entre 0 y 9999 pues el encoder divide cada revolucin en 10.000 partes. A menos que la mquina se salga de sincronismo, el EDR REF no debe cambiarse cuando se va a utilizar una nueva etiqueta. Para sincronizar la cuchilla con el encoder siga el siguiente procedimiento: Coloque las cuchillas tocandose (en posicin de corte) . Presione COMMAND y luego EXECUTE. CUT-SNSE 22.000 es la distancia desde la cuchilla estacionaria cuando esta activada hasta el sensor de registro, medido en pulgadas a lo largo de la cinta de etiquetas. OVERHANG 1.000 es la distancia que hay desde el final de la cinta de etiqueta hasta la cuchilla estacionaria cuando esta se encuentra activada. MISS MARK 10 es el nmero de etiquetas que el computador puede alimentar sin recibir seal de marca de registro antes de enviar mensaje de alarma OUT OF REGISTRATION en el panel de comando. Tambien el mensaje MISSED REG MARKS se ver en la pantalla del computador. FEED DIA 3.375 Es el diametro actual del rodillo alimentador de etiquetas. Este parmetro no debe ser cambiado. PSWRD 1 Es el codigo secreto. Si desea cambiarlo presione CHANGE introduzca un nmero hasta de 7 digitos y presione luego ENTER. (ADVERTENCIA: Si cambia el pasabordo y luego se olvida, solamente puede ser recuperado por personal de B&H que tenga el Software apropiado para hacerlo).

79

MAXSPEED 600 Es la velocidad programada a la cual la seal anloga generada por el computador estar en su nivel maximo (10 VDC o 4 a 20 mA). Esta seal puede ser usada para sincronizacin de lnea con la etiquetadora. PRINTER ON/OFF Es el parmetro para habilitar o deshabilitar la entrada a una impresora. Como la impresora es una opcin, cuando la mquina no la trae mantengase en PRINTER ON. MACHINE POS 123 Es un parmetro de lectura solamente. Es la posicin de la cuchilla rotativa. El punto de partida es tal que cuando las dos cuchillas estan enfrentadas y tocandose (en posicin de corte), la posicin de la mquina es 0 GLUE OFF 115 Tambor de Vaco. Es la posicin de la mquina en que el Rodillo Engomador se retira del

GLUE ON 130 Es la posicin de la mquina cuando el Rodillo Engomador actua para entrar en contacto con el Tambor de Vaco. FLOW OFF 170 FLOW ON 200 Esta posicin de la mquina en la cual se abre la compuerta. Es La posicin de la mquina en que se cierra la compuerta.

PRINT OFF Es la posicin de la mquina en la que la impresora para de imprimir. (Nota: No se utiliza este parmetro ni el siguiente si la mquina no tiene impresora.) PRINT ON Es la posicin de la mquina en que la impresora inicia la impresion.

80

IDLE MODE

Organizacin de las funciones de la pantalla ITM-270

para entrar al menu de datos presione

DATA SET LBL Previous RUN LBL CUTOFF ##.### ##.### ##.### Previous

REGISTR ON/OFF SPEED RPM COUNT

Para entrar al men de alistamiento entre el pasabordo y presione ENTER

Nota: 1. Los recuadros sombreados corresponden a mensajes disponibles solamente en el programa CRSG. 2. Los menus de alistamiento y de temporizacion no estan disponibles cuando la mquina est alimentando etiqueta.

### ######

COUNT x 1000 ###### CONTAINER # LOAD # Next

ENTER PASSWORD ENTER LEADING TRAILING EDR REF Men de alistamiento CUTSENS OVERHANG MISS MARK FEED DIA PASSWORD MAXSPEED PRINTER #.### #.### #### ### #.### ### #.### ###### ### ON/OFF ### ### ### ### ### ### ### Next Previous

Men de tiempos

para entrar al menu de tiempos presione COMMAND

STORE CUT POS Para retornar al men de alistamiento presione DATA en cualquier momento GLUE OFF GLUE ON FLOW OFF FLOW ON PRINT OFF PRINT ON ### ### ### ### ### ###

EXECUTE

MACHINE POS GLUE OFF GLUE ON FLOW OFF Next FLOW ON PRINT OFF PRINT ON

Para temporizar cada funcion: Rote la maquina con "JOG" hasta la posicin deseada y presione
EXECUTE EXECUTE EXECUTE EXECUTE EXECUTE EXECUTE

81 MENSAJES DE LA PANTALLA DEL PLC

Las mquinas BH8000 son equipadas con un display Allen Bradley modelo DL5 el cual almacena mensajes en su memoria. Los mensajes almacenados son mostrados cuando se recibe una seal de comando del PLC. Los mensajes son mostrados en dos partes y su significado se explica a continuacin: 1. GLUE ROLLER TEMP. TOO HIGH OR LOW CHECK TEMP. AND SENSOR. TEMPERATURA DEL RODILLO ENGOMADOR MUY ALTA O MUY BAJA. VERIFIQUE LA TEMPERATURA Y EL SENSOR. El sensor de temperatura del Rodillo Engomador detect una temperatura fuera de los lmites (ALO y AHI).
2. LOW AIR PRESSURE CHECK AIR LINE PRESION DE AIRE BAJA VERIFIQUE LA PRESION EN LA LINEA

La presin de aire en la mquina esta por debajo del lmite fijado en el presstato. 3. MAIN CLUTCH IS DISENGAGED CHECK GEAR ARRANGEMENT EL EMBRAGUE ESTA DESENGANCHADO - VERIFIQUE EL TREN DE ENGRANAJES. El interruptor lmite esta activado porque el embrague principal de seguridad esta desenganchado o no esta ajustado apropiadamente. 4. VACUUM DRUM SAFETY SENSOR - REMOVE LABEL CHECK SENSOR SENSOR DEL TAMBOR DE VACO REMUEVA LA ETIQUETA DEL TAMBOR El sensor del Tambor de Vaco ha detectado una etiqueta.. 5. CONTAINER NOT DETECTED AT HIGH SPEED BOTELLA NO DETECTADA A ALTA VELOCIDAD El sensor detector de botella a la entrada no detect una botella en el ltimo ciclo. La mquina para porque sobra una etiqueta que al final va a terminar en la parte trasera de la cuchilla con adhesivo aplicado. 6. LABEL WEB BROKEN CHECK LABEL WEB OR SENSOR CINTA DE ETIQUETA ROTA REVISE EL SENSOR DE LA CINTA DE ETIQUETAS El sensor de la cinta de etiqueta detect que se acabo el rollo de etiquetas. 7. INFEED STARWHEEL IS DISENGAGED CHECK INFEED STARWHEEL ESTRELLA DE ENTRADA ESTA DESENGANCHADA REVISE LA ESTRELLA DE ENTRADA. El suiche lmite de la estrella de entrada (estrella pequena) ha detectado que el embrague de seguridad esta desenganchado. La mquina para y solo puede ser operada con JOG. 8. MAIN STARWHEEL IS DISENGAGED CHECK MAIN STARWHEEL ESTRELLA PRINCIPAL DESENGANCHADA REVISE LA ESTRELLA PRINCIPAL El suiche lmite ha detectado que le embrague de seguridad esta desenganchado. La mquina para y solo puede ser operada con JOG.

82

LABEL WRAPPED AROUND FDRLR OR NO LABEL FEED ETIQUETA ENROLLADA EN EL RODILLO ALIMENTADOR O NO HAY ALIMENTACION DE ETIQUETA. El sensor detector de etiqueta, no detect etiqueta cuando el rodillo alimentador estaba accionado y la mquina estaba en modo RUN (alimentando etiqueta). La mquina para para proteger el Tambor de Vaco. Esta proteccin no funciona cuando la mquina es operada mediante el boton JOG. 9. OUT OF REGISTRATION RESET REGISTRATION FUERA DE REGISTRO RESTABLECER EL REGISTRO El computador indica que esta fuera de registro. La mquina para y al menos 1 etiqueta debe ser alimentada en JOG para eliminar esta falta. 10. FLOW GATE CLOSED INFEED SENSOR OUT OF CONTAINERS COMPUERTA CERRADA POR EL SENSOR DE ENTRADA FALTAN BOTELLAS El sensor de entrada no detecta envases y entonces el PLC ha cerrado la compuerta. Esta orden se puede pasar por alto actuando el suiche Logic Bypass. 11. FLOW GATE CLOSED DISCHARGE SENSOR CONTAINERS ARE BACKED-UP COMPUERTA CERRADA POR EL SENSOR DE SALIDA SALIDA LLENA DE BOTELLAS. El sensor de salida ha detectado la linea llena de envases y entonces el PLC ha cerrado la compuerta. Al igual que en el mensaje anterior esta orden puede pasarse por alto actuando el suiche Logic Bypass 12. LOW REEL SAFETY REPLACE ROLL SE ACABA LA BOBINA REEMPLACE LA BOBINA Uno de los sensores debajo de la mesa portaetiquetas no detecta la bobina o la mesa. La luz azul esta parpadeando y la mquina desacelera hasta baja velocidad. Esta orden puede pasarse por alto manteniendo presionado el boton Hi speed para volver a alta velocidad. 13. AT LOW SPEED INFEED SENSOR WAITING FOR CONTAINERS A BAJA VELOCIDAD SENSOR DE ENTRADA ESPERANDO POR BOTELLAS El sensor de entrada de alta velocidad ha detectado que no hay suficientes envases para rodar a alta velocidad y el PLC desacelera la mquina hasta baja velocidad. Si esta condicin cambia, la mquina nuevamente acelera hasta alta velocidad. 14. AT LOW SPEED DISCHARGE SENSOR WAITING TO CLEAR CONTAINERS A BAJA VELOCIDAD SENSOR DE SALIDA ESPERANDO QUE SE DESPEJE DE BOTELLAS El sensor de alta a la salida ha detectado acumulacin de envases y el PLC desacelera la mquina hasta baja velocidad. Si esta condicin cambia la mquina nuevamente acelera hasta alta velocidad. 15. B & H MANUFACTURING MADE IN U.S.A. Este mensaje informa que la mquina esta OK y lista para etiquetar a alta velocidad.

ACME ELECTRIC CORPORATION

4815 West Fifth Street Lumberton, NC 28358 (910) 738-1121 Inside NC (800) 334-5214 Outside NC (910) 739-0024 Fax www.acmepowerdist.com

PDPD-01

ATD-101-1001 Revised -02/ 06

Printed in USA

PDPD-01
REVISION 02/ 06

SECTION

STA

Selection Charts
SINGLE PHASE
GROUPI
240 X480 PRIMARY VOLTS -120/240 SECONDARY VDLTS - FDUR WINDlNG -10 , 60 Hz
KVA
, .05
(ti".lO

CATAlOGNO.
T-'53004 T,'53005

APPROX.OIMENSIONS Inclles (Cm.)

APflROX. SHIPWEIGHT

TYPEMTG. W-W.II
F-Floor

KNOCKOurS

" .15

0,25
" .50

ID .75

1.00 1.SO 2.00 '.00 '.00 5.00 5.00 7.SO

10.00 15.00 25.00 37.50

SOOO
75.00 100.00 167.00 250.00

T,'53006 T-2-53OO7-5 T253OO8-5 T-2-53009-5 T253010-5 T-2-53011-$ T-253012-$ T-2-53013-$ T-25301345 T-2-53014$ T253014-45 T253515-35 T2-5351635 T2-53517-3$ T2-53518-3S T-2-53019-35 H-53Q20-35 1-2-53021-35 T-2A530223S T-1-53023-35 T-1-53024-35

HEIGHT 6.41 (16.3) 7.16 (18.2) 7.16 (18.2) 8.68 (22.0) 9.06 (23.0) 9.68 (24.6) 10.50 (26.71 11.62 (29.5) 13.00 (33.0) 11.50 (29.2) 11.50 (29.2) 14.38 (38.5) 14.38 (36.5) 15.19 (38.6) 15.19 (38.6) 16.94 (43.0) 18.44 (46.8) 25.50 (64.8) 25.50 (64.8) 35.90 (91.2) 41.52{105.5) 42.00 (106.7) 60.00 (152.4)

WlDTH
3.14 (B.O)

DEPTH
3.05 (7.7) 3.67 (9.3)
3.67 (9.3)

Lbe.(Kg.)

lnehee (Cm.)
0.875 (2.2) 0.875 (2.2) 0.875 (2.2) 0.50-0.75 (1.3-1.9) 0.50-0.75 (1.3-1.9) 0.50-0.75 (1.3-1.9) 0.50-0,75 (1.3-1.9) 0.50-0.75 (1.3-1.9) 0.50-0.75 (1.3-1.9) 0.75-1.25 (1.9-3.2) 0.75-1.25 (1.9-3.2) 0.75-1.25 (1.9-3.2) 0.75-1.25 (1.9-3.2) 0.75-1.25 (1.9-3.2) 0.75-1.25 (1.9-3.2) 1.00-1.50 (2,53.8) 1.00-1.50 (2.53.8)

WEATHER Eleetrlcal Connecllons and Deslgn Figures SHIELD Begin on Page 44 'IN

3.89 (9.9) 3.89 (9.9)

4.06 (lOA)
4,37(11.1)

4 (1.8) 5 (2.3)
7 (3.2)
10(4.5)

3.88 (9.9) 4.20 (10.7)

4.50 (11.4)

w w w
W W W

15 (6.8)

4.75(12.1) 5.50 (14.0) 5.50 (14.0) 5.50 {14.0)

5.13 (13.0) 5.13 (13.0) 5.13 (13.0) 7.13 (18.1) 7.13(18.1) 7.13 (18.1) 7.13 (18.1) 10.84 (27,S) 10.54 (27.5) 11.59(29.4) 13.34 (33.9) 19.37 (49.2) 19.37 (49.2) 26.88 (68.3) 29.87 (75.9) 35.50 (90.2) 36.00(91.4)

19 (8.6) 24 (10.9) 30 (13.6) 38 (17.2) 55 (25.0) 55 (25.0) 75 (34.0) 75 (34.0) 115(52.2) 125 (56.7) 170 (77.1) 250 (113.0) 2fi5 (120.0) 325 (147.0) 440 (196.0) 700 (318.0) 750 (340.0) 1680 (762,0)

w
W

10.31 10.31 10.31 10.31

(26.2) (26.2) (26.2) (26.2)

w
W

13.50 (34.3) 1350 (34.3) 14.12 (35.9) 16.13 (41.0) 24.39 (61.9) 24.39 (61.9) 31.90(81.0) 32.90 {83,6) 40.00 (101.6) 41.00(104.1)

w w w
W W

w
F@ F' F F F F

NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA
W5A1 W5A-l W5A--3 W5A4 W$A-53 W5-B-l

1A 1A 1A 2-8 2-B 2-8 2-B 2-B 2-B 2-<: 3-<:

2-<:

3-<:
4-0

4-0
4-0

NA NA NA NA NA NA

4-0 5-E >-E

5-E 5-E 5-E 5-E

GROUP 11
NDNVENTlLATEO TRANSFORMER5-24O X480 PRIMARY VOLTS -120/240 SECONOARY VOLTS - FDUR WINOING -18,60 Hz
<VA
37.5 50.0 75.0 100.0 CATAlOG NO. TE25301935 TE-2-53020-35 TE2A-53021-35 TE-'-53022-3S APPROX. OlMENSIONS Inches (Cm.) HEIGHT WIOTH DEPTH 31.90 (81.0) 26.90 (68.3) 35.40 (90.0) 35.40 (90.0) 31.90 (Bl.0) 26.90 (68.3) 35.40 (90.0) 31.90 (Bl.0) 26.90 (68.3) APPROX. SttIPWEIGHT lbs. (Kg.) 450 (204.0) 450 (204.0) 700 (318.0)

TYPE MTG. W-Wall F-ROO!' F' F@ F F

KNOCKOUTS

WEATHER Electrlcal COI1J'1eC1ions SHIElD and Design Figures Begin 011 Paga 44 'IN

42.00 (l06.n

40.00 (101.6)

30.00 r6.2)

m 1352 O)

NA NA NA NA

NA NA NA NA

5--!<

>-H >-H >-H

mI!IEI VDLTS -120/240 SECDNDARY VDLTS 120 X240 PRIMARY

KVA 1.0 1.5 2.0 '.0 5.0 7.5
10.0 15.0 25.0
,
Su~able

FOUR WINDING -18 , 60 Hz

TYPEMTG. W-WaU F-ROO!' KNOCKOUTS Inches (Cm.) 0.50-0.75 (1.3-1.9) 0.50-0.75 (1.3-1.9) 0.50-0.75 (1.3-1.9) 0.75-1.25 (1.9-3.2) 0.75-1.25 (1.93.2) 0.75-1.25 (1.93.2) 0.751.25 (1.93.2) 1.00-1.50 (2.5-3.8) 1.00-1.50 (2.5-3.8) WEATHER Electrlcal ConJ'leC1ions SHIELO &nd Oesigll Figures ,IN Begin on Page 44

CATAlOG NO. T-3-530408 f.3-53041-5 T353042-5 T-3530435 T3-53044-5 T3-53545-5 T--3-53546-5 T-3-53547-$ f.3-53548-S
lor 50160 Hz.

APPROX.DIMENSIONS Inches (Cm.) HEIGHT WIDTH DEPTH 10.50 (26.7) 5.50 (14.0) 5.13(13.0) 11.62 (29.5) 5.50 (14.0) 5.13(13.0) 13.00 (33.0) 5.50 (14.0) 5.13(13.0) 11 ,SO (29.2) 10.31 (26.2) 7.13(18.1) 14.38 (36.5) 10.31 (26.2) 7.13(18.1) 15.19(38.6) 13.50 (34.3) 10.84 (27.5) 15,19(38.6) 13.50 (34.3) 1084 (27.5) 16.94 (43,0) 14,12 (35.9) 11,59 (29.4) 18.44 {46.8) 16.13 (41.0) 13.34 (33.9)

APPROX. SHIPWEIGHT lbl.(Kg.) 24 (10.9)

30 (13.6)
38 (17.2) 55 (24.9) 75 (34.0) 115(52.2) 125 (56.7) 170 (n.l) 250(113.0)

W W W

w
W W W W W

NA NA NA NA NA NA NA NA NA

'3-B
'>-8

13-B 13-<: .3-<: l3-0 '3-D '3-D 13-D

9

'Wall mounllng brackets are aWllable lar these Slzes. reler lo page 53.

SECTION

UL3R Enclosures
SINGLE PHASE,.05 150 KVA
Features
UL listed. e i\ certified and Ul.r3R enclosure mecls Of cxceeds alllisting (.';\(~ria indudiuJ{
Complclcly cllc10sed UL-3R cllclosure for indoor/outdoor service. Ruggt:d non-ventil.1ted construction.

NEMA. ANSI and OSHA standard:>. Eas)' and cOlwcnicnt instaJiatioll lo meel your requiremcnts. thc transfonner can be mounled in an)'
position. Long Life ULdass 13O'C insulation

Plcnty of knockouts for multidircctional entry. AII copper lcad ",re t.cnninatiolls. Ground studs for use with

non-metallic l"Onduit.

system. TransfomlCrscan lxbanked for three phasc :serv1ce.

large ",inng comparlmcnt no conduit or pull boxcs required. Frool access for ....,ring case. Wiring l.."Omparlrncnl rcmaios rool.

SINGLE PHASE, .250 25 KVA Features

VI. listed, CSA ccrtified ami
UI.r3H: cnclosurcs 1ll(:ctS or excccds 0111 listillj! oileria includillj.{

NEMA. ANSI amI OSIIA standards.

Shicldcd for c1cancr pOWCf.

Inst<llIatioll keyhole mounting slots for mounling bolts prior lo installalion. Mounting slols are acccssiblc from U1C front. jftjng cttrs are inc1udcd on3 to 25 KVA units. Wiring ncxible copper lcadwire Icrminations rOl' casy conne<::tions

outside tite front access wirin,g cOml)artmcnt. Dual sizc knockouts in bolh sidcs amllhc bottom of lhe wiring compartmcnt rOl' .,rreatcf wiring COllvcnicncc ami nexibility.

Enc<lpsulillcd ami completely

cndoscd dcsign c1cclric'll j.{radc

sili\..- and rcsilll"OlIIpounds C0111-

plctcly cndoSl' ll\(: (;Ore amI coil lo seal out aH moislurc alld airo ULTYI.Ie:m cl1c1osure for indoor or uutdoor scrvke. Encilllsulatioll eliminales corrosion ami insulatioll delerioratioll.
Quict olJemtion with sound levels Wf'1I bt.'low NEMA standard!>. LonJ! life Utdass 155 e insulation system. 115" C riS(! thru .750 KVA; I8<rC insulalion syslem. 115 e rise. 1 KVA ami above.

!.L

-;r

~
"

Underwritcr~' l.lboralories. Inc. is an indcpClldclll nol for profi organiwtiotl whidl tests products for safety. Acrnc's lrans(ormers are desiglle<1 and manufacture<lto comply with UL Slmulard S06, 1561. 1012, or 1062 and carry the applicable UL 1Jsting Label. Bccause of lhe conlinuous product evo-lulions al Acme. il is besl Ihal YOll conlact

Ihe factor)' fol' Ihe current file and ,"ruide numbers associaled with Ihe listings. 111e Canadian Standards A~socialion is Ihe Canadian counlel'part lO UndcrWlilCrs' Laboralones. Acmc's transformcrs are also construclcd and mled lo comply wilh CSA Slandards C22.2-47 and C22.2-66 and carry Ihe eSA Certitkatioll IA1beL

AH of Acme's Irans(ormers are mallt! faclured lO meel National Eledlical eode requiremenls. Other Agencies ane! Standards: National EI('cLlicllI Manu(aclurers Assoeiatioll (NEMA) Sr.20 19lJ (RI978) American Nalionlll Slandnl~ Instilule (ANSI)
OSHA

IEEE

@Listed

How to overcurrent pratect (OCP) 600 valt class trans10rmers and associated wiring
. in accordance with the '90 National Electric Code (Ar1icles 450-3(b) and 240-3 (i Primary Case Type 01 Suppty Voltage Maln Phase Number 01 Wires on Secondary 2 More Ihan 2 Not Applicabte 2 More lhan 2 Not Applicable Protection Required Primary Only Primary Secondary

~'"

Certified

OC,
Location

Current (AMPS)

OC,
(% 01 ratlng) 125 ' 167 max. 3OOmax. 125!J 167 max. 3OOmax.

Current (AMPS)

OC,
(% 01 rating)

1
2

10 10
30

A A& B

29

<:9.<:2
<2 <9. ;a <2

NOl ReqUlred

29

Main Feeder C,rcuit wllh OCP Feeder Circuit withOCP

&
Secondary IV

;;
<9

125 ' 167 mal(.

3
4

10 10 30

Non'
on
Eilher Secondary Only@

NOl Required

NOl ReqUlred

NOl Required

29
<9

125(!l 167 mal(.

Acme Transformer Products vs. U/L Insulation Systems & U/L Standards
Acme Construction SlVIe Enclosad Acme Catalog Product Name General Purpose and BuckBooSl General Purpose Buck-Boosl & OIT Panel Tran Swim Pool & S a Hardwired CVR Portable PLC Induslrial Conlrol General Purpose OptiMise~ & Oll Alr Condillonmg and Retngerallon Appliance

UIL
Standard

UIL
Cate 10ry XPTQ XPTO YEFR HOGV

UIL
File Number E79947Vl E79947V1 E56936Vl E111069V1 E86492V1 E86492V1 E79947Vl E12547V3

UIL
Listed Control'

UIL
lnsulation Number B3223 X3221 H3221 H3180 H3221 H3180 83223 X3221

lnsulation

proe~~ct

Sy~~.m Tem lC
130 155 1&0 160 160 160 130 155 130 130 220 130

KVA
Single Phase .050-.150 .255.0 7.5-25.0

KVA
Three Phase

506 506 1062 379

1012 1012

5088 5088 NIA NlA 6881 6081

50B8

NIA
3.06.0 7.575.0

~om~tnd F~~d Enea ulaled

5.0
7.525.0 0.10-.30 .253.0 5.015.0 .252.0 .050'5.0 37.5250.0

NIA
9.0-30.0

OOFU
QQFU XPTQ XQNX

63223
B3223 C3222

n Gore & Coil AirCooled Venlilatad & Non Ventilaled Enclosad

506
1561

NIA NlA NlA NlA NlA

251000

5428

NONE

NONE

NONE

NlA

NONE

.0852.0

NIA

, o, ot raled currenl (01 neld hlgher slandard rallOg) In cases where \he secendary is overcurrenl prOlecled. !he pnmary overcurrent protecl,en rallng can be no more !han 250"'0 (2.5 times) lull k>ad amps (shown en aboVe ;hart). For example. ,f a 10 KVA. Single phase lransformer has a 480V plimary and a 1201240 secondary. anc.l \he secondary lS ovel"ClJrrenl prolecled. mIDClmum pnmaty O' ;urrenl prolecllOfl rallOg lS 20.8 amps (tullload currenl) x 2.5 (250%) = 52. TherelOle, use a standard 50 amp luse or breaker selecled Irom NEC Secllen 240-6 (be!ow). Se!:lion 240-6 01 the 1993 Nalional Ele;trl;al Codeo The Slandard ampere rallngs lor luses and Inverse lime ;11;Ull breakers shall be conSldered 15.20.25. 30,35.40, 45.50.60.70.80.90. lOO. 110. 125 150. 175,200.225.250.300.350.400.450.500.600.700.800. 1000. 1200. 1600.2000.2500.3000.4000. SOCO and 6000 amperes El(cepllen; AddlllOrnll slandald ratlngs lar luses shall be conSldered 1. 3. 6. 10. IInd 601 '"EXlraded by permlssion Irom ANSVNFPA 70-1993. Natlonal ElectriClI1 Ceme-, Copyrighf'.1992, National Fire Protedion Associalion, Boslon. MA.'" Acme Eleelr,;-Power Olslribulion P,oducts Oivision has never used polychlorinated biphenyls (PCBs) in lhe manulacture 01 our qllality producls.

130

GENERAL

ACME TRANSFORMER WIRING DIAGRAMS

Wiring Diagrams
Sections I, II, III & IV
1
PRIMARY: 240 X 480 SECONDARY: 120/240 TAPS: None
H1 H3 H2 H4

PRIMARY: 240 X 480 SECONDARY: 120/240 TAPS: None

H1 H3 H2 H4

PRIMARY: 240 X 480 SECONDARY: 120/240 TAPS: 2, 2 1/2 % ANFC, 2, 2 1/2 % BNFC
H1 H2 H3 H4 H5 H6 H7 H8

X2 X4

X3 X1 X4

X2

X3 X1 X4

X2

X3 X1

Primary Volts 480

Connect Primary Lines To H1-H4 H1-H3 & 240 H2-H4 Secondary Volts 240 120/240 120

InterConnect H2 to H3

Connect Secondary Lines To

Primary Volts 480

X2 to X3 X2 to X3 X1 to X3 X2 to X4

X1-X4 X1-X2-X4 X1-X4

Connect Primary Lines To H1-H4 H1-H3 & 240 H2-H4 Secondary Volts 240 120/240 120

InterConnect H2 to H3

Connect Secondary Lines To

Primary Volts 252 240

Connect Primary Lines To H1-H8 H1-H7 H1-H6

X2 to X3 X2 to X3 X1 to X3 X2 to X4

X1-X4 X1-X2-X4 X1-X4

228

PRIMARY: 240 X 480 SECONDARY: 120/240 2, 2 1/2 % ANFC, 2, 2 1/2 % BNFC

H1 H2 H3 H4 H5 H6 H7 H8 H9 H10

PRIMARY: 240 X 480 SECONDARY: 120/240 TAPS: 2, 2 1/2 % ANFC, 2, 2 1/2 % BNFC
H3 H1 1 2 3 4 5 6 7 8 H2 H4

504 H1-H8 492 H1-H8 480 H1-H7 468 H1-H7 456 H1-H6 Secondary Volts 240 120/240 120

InterConnect H1 to H5 H4 to H8 H1 to H5 H3 to H7 H1 to H5 H2 to H6 H4 to H5 H3 to H5 H3 to H5 H2 to H5 H2 to H5 X2 to X3 X2 to X3 X1 to X3 X2 to X4

Connect Secondary Lines To

X1-X4 X1-X2-X4 X1-X4

X2 X4

X3 X1 X4

X2

X3 X1

PRIMARY: 208 SECONDARY: 120/240 TAPS: 2, 5% BNFC

H1 H2 H3 H4

Primary Volts 216 228 240 252

Connect Primary Lines To H1-H10 H1-H10 H1-H10 H1-H10

432 H1-H10 444 H1-H10 456 H1-H10 468 H1-H10 480 H1-H10 492 H1-H10 504 H1-H10 Secondary Volts 240 120/240 120

InterConnect H1 to H9 H10 to H2 H1 to H8 H10 to H3 H1 to H7 H10 to H4 H1 to H6 H10 to H5 H2 to H9 H3 to H9 H3 to H8 H4 to H8 H4 to H7 H5 to H7 H5 to H6 X2 to X3 X2 to X3 X1 to X3 X2 to X4

Connect Secondary Lines To

Primary Volts 216 228 240 252

Connect Primary Lines To H1-H4 H1-H4 H1-H4 H1-H4

X1-X4 X1-X3-X4 X1-X4

432 H1-H4 444 H1-H4 456 H1-H4 468 H1-H4 480 H1-H4 492 H1-H4 504 H1-H4 Secondary Volts 240 120/240 120

Connect InterSecondary Connect Lines To H1, H3, 8 & H2, H4, 1 H1, H3, 7 & H2, H4, 2 H1, H3, 6 & H2, H4, 3 H1, H3, 5 & H2, H4, 4 H2, 1 & H3, 8 H2, 2 & H3, 8 H2, 2 & H3, 7 H2, 3 & H3, 7 H2, 3 & H3, 6 H2, 4 & H3, 6 H2, 4 & H3, 5 X2 to X3 X2 to X3 X1 to X3 X2 to X4 X1-X4 X1-X2-X4 X1-X4

X2 X4

X3 X1

Connect Primary Primary Volts Lines To 208 H1 & H4 198 H1 & H3 187 H1 & H2 Secondary Volts 240 120/240 120

InterConnect

Connect Secondary Lines To

X2 to X3 X2 to X3 X1 to X3 X2 to X4

X1-X4 X1-X2-X4 X1-X4

ACME ELECTRIC, POWER DISTRIBUTION PRODUCTS DIVISION LUMBERTON, NC 800-334-5214 www.acmepowerdist.com

147

GENERAL

ACME TRANSFORMER WIRING DIAGRAMS

PRIMARY: 277 SECONDARY: 120/240 TAPS: 2, 5% BNFC

H1 H2 H3 H4

PRIMARY: 600 SECONDARY: 120/240 TAPS: None

H1 H2

PRIMARY: 600 SECONDARY: 120/240 TAPS: None

H1 H2

X2 X4

X3 X1 X4

X2

X3 X1

X2

X3 X1

X4

Connect Primary Primary Volts Lines To 277 H1 & H4 263 H1 & H3 250 H1 & H2 Secondary Volts 240 120/240 120

InterConnect

Connect Secondary Lines To

Connect Primary Primary Volts Lines To 600 H1-H2 Secondary Volts 240 120/240 120

InterConnect

Connect Secondary Lines To

X2 to X3 X2 to X3 X1 to X3 X2 to X4

X1-X4 X1-X2-X4 X1-X4

X2 to X3 X2 to X3 X1 to X3 X2 to X4

X1-X4 X1-X2-X4 X1-X4

Connect Primary Primary Volts Lines To 600 H1-H2 Secondary Volts 240 120/240 120

InterConnect

Connect Secondary Lines To

X2 to X3 X2 to X3 X1 to X3 X2 to X4

X1-X4 X1-X2-X4 X1-X4

12 11
PRIMARY: 600 SECONDARY: 120/240 TAPS: 2, 2 1/2 % ANFC, 4, 2 1/2 % BNFC
H1 1 2 3 4 5 6 H2

PRIMARY: 240 SECONDARY: 120/240 TAPS: None

1 3

10

PRIMARY: 600 SECONDARY: 120/240 TAPS: 2, 5% BNFC

H1 H2 H3 H4

2 1 3

X2 X4

X3 X4 X1

X2

X3 X1

Connect Primary Primary Volts Lines To 600 H1-H4 570 H1-H3 540 H1-H2 Secondary Volts 240 120/240 120

InterConnect

Connect Secondary Lines To

X2 to X3 X2 to X3 X1 to X3 X2 to X4

X1-X4 X1-X2-X4 X1-X4

13

PRIMARY: 120 x 240 SECONDARY: 120/240 TAPS: None

H1 H3 H2 H4

Connect Primary Primary Volts Lines To 540 H1-H2 555 H1-H2 570 H1-H2 585 H1-H2 600 H1-H2 615 H1-H2 635 H1-H2 Secondary Volts 240 120/240 120

InterConnect 1-6 1-5 2-6 2-5 3-5 2-4 3-4 X2 to X3 X2 to X3 X1 to X3 X2 to X4

Connect Secondary Lines To

Connect Primary Primary Volts Lines To 240 1-3 Secondary Volts 240 120 120/240

InterConnect

Connect Secondary Lines To

1-3 1-2 or 2-3 1-2-3

14

EXPORT MODEL PRIMARY: 190-220 x 380-440 SECONDARY: 120/240

H1 H5 H6 H2 H3 H4 H7 H8 H9 H10

X1-X4 X1-X2-X4 X1-X4 Primary Volts 190 200

X2 X4

X3 X1

Connect Primary Lines To H1 & H7 H1 & H8 H1 & H9 H1 & H10

X2 X4

X3 X1

208 Connect Secondary Lines To 220

Connect Primary Primary Volts Lines To 240 H1-H4 H1-H3 & 120 H2-H4 Secondary Volts 240 120/240 120

InterConnect H2 to H3

X2 to X3 X2 to X3 X1 to X3 X2 to X4

X1-X4 X1-X2-X4 X1-X4

380 H1 & H7 400 H1 & H8 416 H1 & H9 440 H1 & H10 Secondary Volts 240 120/240 120

InterConnect H1 to H6 H2 to H7 H1 to H6 H3 to H8 H1 to H6 H4 to H9 H1 to H6 H5 to H10 H2 & H6 H3 & H6 H4 & H6 H5 & H6 X2 to X3 X2 to X3 X1 to X3 X2 to X4

Connect Secondary Lines To

X1-X4 X1-X2-X4 X1-X4

148

ACME ELECTRIC, POWER DISTRIBUTION PRODUCTS DIVISION LUMBERTON, NC 800-334-5214 www.acmepowerdist.com

GENERAL

ACME TRANSFORMER WIRING DIAGRAMS

15

EXPORT MODEL PRIMARY: 190-220 x 380-440 SECONDARY:120/240

H3 H1 1 2 3 4 5 6 7 8 H2 H4

16

POWER LINE CONDITIONER

INPUT LINE A B C D E 1 2 3 4 5 6 7 8 11 12 13 14

17
F G H

PRIMARY: 208 Volts SECONDARY: 120/240 Volts TAPS:

H1 1 2 3 H2 4 5 6

X2 X4

X3 X1

X4

X2

X3

X1

Primary Volts 190 200 208 220

Connect Primary Lines To H1 & H4 H1 & H4 H1 & H4 H1 & H4

380 H1 & H4 400 H1 & H4 416 H1 & H4 440 H1 & H4 Secondary Volts 240 120/240 120

InterConnect H1, H3, 8 & H2, H4, 1 H1, H3, 7 & H2, H4, 2 H1, H3, 6 & H2, H4, 3 H1, H3, 5 & H2, H4, 4 H2, H3, 1, 8 H2, H3, 2, 7 H2, H3, 3, 6 H2, H3, 4, 5 X2 to X3 X2 to X3 X1 to X3 X2 to X4

Connect Secondary Lines To Volts

9 10

Input ConnectionsInsulate Connect 1, 3, 6, 8 to A 120 2, 5, 7, 10 to B 1, 6 to A 4, 9 to B 208 2, 3 to C 7, 8 to D 1, 6 to A 5, 10 to B 240 2, 3 to C 7, 8 to D 1 to A 10 to B 480 2, 3 to C 5, 6 to D 7, 8 to E Output Connections Connect 11 to F 12 to G 14 to H 11 to F 12 to G 14 to H 11 to F 12 to G 13 to H 11 to F 12 to G 14 to H & Isolate 4, 9

5, 10

4, 9

Connect Primary Primary Volts Lines To 218 H1 & H2 213 H1 & H2 208 H1 & H2 203 H1 & H2 198 H1 & H2 192 H1 & H2 187 H1 & H2 Secondary Volts 240 120/240 120

InterConnect 3 to 4 2 to 4 3 to 5 2 to 5 1 to 5 2 to 6 1 to 6 X2 to X3 X2 to X3 X1 to X3 X2 to X4

Connect Secondary Lines To

X1-X4 X1-X2-X4 X1-X4

4, 9

X1-X4 X1-X2-X4 X1-X4

Volts 120

Output Lines To F, G

20

PRIMARY: 380 Volts Delta SECONDARY: 220Y/127 Volts TAPS: 2, 2 1/2 % ANFC, 4, 2 1/2 % BNFC
H1 H2
76 5 4 3 21

18

PRIMARY: 240 Volts Delta SECONDARY: 208Y/120 Volts TAPS: 2, 5% BNFC

H1 H2 H3

H3
76 5 4 3 21

120/240

F, G, H

76 5 4 3 21

208

F, H

X0

X1

X2

X3

3 2 1

3 2 1

3 2 1

240
X0 X1 X2 X3

F, H

Connect Primary Primary Volts Lines To 240 H1, H2, H3 228 H1, H2, H3 216 H1, H2, H3 Secondary Volts 208 120 1 phase

InterConnect 1 2 3

Connect Secondary Lines To

NOTE: To prevent externally shorting, all leads marked INSULATE must be individually capped with wire nuts or equivalent. Insulate leads individually!

19
X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

PRIMARY: 240 Volts Delta SECONDARY: 208Y/120 Volts TAPS: 2, 2 1/2 % ANFC, 2, 2 1/2 % BNFC
H1 H2 H3

5 4 3 2 1

5 4 3 2 1

5 4 3 2 1

Connect Primary Primary Volts Lines To 399 H1, H2, H3 390 H1, H2, H3 380 H1, H2, H3 371 H1, H2, H3 361 H1, H2, H3 352 H1, H2, H3 342 H1, H2, H3 Secondary Volts 220 127 1 phase

InterConnect 1 2 3 4 5 6 7

Connect Secondary Lines To

X0

X1

X2

X3

Connect Primary Primary Volts Lines To 252 H1, H2, H3 246 H1, H2, H3 240 H1, H2, H3 234 H1, H2, H3 228 H1, H2, H3 Secondary Volts 208 120 1 phase

InterConnect 1 2 3 4 5

Connect Secondary Lines To

X1, X2,X3 X1 to X0 X2 to X0 X3 to X0

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

ACME ELECTRIC, POWER DISTRIBUTION PRODUCTS DIVISION LUMBERTON, NC 800-334-5214 www.acmepowerdist.com

149

GENERAL

ACME TRANSFORMER WIRING DIAGRAMS

21

PRIMARY: 480 Volts Delta SECONDARY: 208Y/120 Volts TAPS: 2, 5% BNFC

H1 H2 H3

22

PRIMARY: 480 Volts Delta SECONDARY: 208Y/120 Volts TAPS: 2, 2 1/2 % ANFC, 4, 2 1/2 % BNFC
H1 H2 H3

23

PRIMARY: 120/208/240/277 Volts SECONDARY: 120/240 Volts

H1 H2 H3 H4 H5

3 2 1

3 2 1

3 2 1

7 6 5 4 3 2 1

7 6 5 4 3 2 1

7 6 5 4 3 2 1

X4
X0 X1 X2 X3 X0 X1 X2 X3

X3

X2

X1

Connect Primary Primary Volts Lines To 480 H1, H2, H3 456 H1, H2, H3 432 H1, H2, H3 Secondary Volts 208 120 1 phase

InterConnect 1 2 3

Connect Secondary Lines To

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

24

PRIMARY: 380 Volts Delta SECONDARY: 220Y/127 Volts TAPS: 2, 5% BNFC

H1 321 H2 321 H3 321

Connect Primary Primary Volts Lines To 504 H1, H2, H3 492 H1, H2, H3 480 H1, H2, H3 468 H1, H2, H3 456 H1, H2, H3 444 H1, H2, H3 432 H1, H2, H3 Secondary Volts 208 120 1 phase

InterConnect 1 2 3 4 5 6 7

Connect Secondary Lines To

Connect Primary Primary Volts Lines To 277 H1, H5 240 H1, H4 208 H1, H3 120 H1, H2 Secondary Volts 120 120/240 240

InterConnect

Connect Secondary Lines To

X1 to X3 X2 to X4 X2 to X3 X2 to X3

X1-X4 X1-X2-X4 X1-X4

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

26

PRIMARY: 480 Volts Delta SECONDARY: 240 Volts Delta/120 Volts TAPS: 2, 2 1/2 % ANFC, 4, 2 1/2 % BNFC
H1 H2 H3 7 6 5 4 3 2 1 7 6 5 4 3 2 1 7 6 5 4 3 2 1

25

PRIMARY: 480 Volts Delta SECONDARY: 240 Volts Delta/120 Volts TAPS: 2, 5% BNFC
H1 H2 H3

X1

X4

X2

X3

X0

X1

X2

X3

Connect Primary Primary Volts Lines To 380 H1, H2, H3 361 H1, H2, H3 342 H1, H2, H3 Secondary Volts 220 127 1 phase

InterConnect 1 2 3

Connect Secondary Lines To

3 2 1

3 2 1

3 2 1

X1

X4

X2

X3

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

27

PRIMARY: 480 Volts Delta SECONDARY: 240 Volts Delta/120 Volts TAPS: 2, 2 1/2 % ANFC, 4, 2 1/2 % BNFC
H1 H2 H3

Connect Primary Primary Volts Lines To 480 H1, H2, H3 456 H1, H2, H3 432 H1, H2, H3 Secondary Volts 240 120

InterConnect 1 2 3

Connect Secondary Lines To

Connect Primary Primary Volts Lines To 504 H1, H2, H3 492 H1, H2, H3 480 H1, H2, H3 468 H1, H2, H3 456 H1, H2, H3 444 H1, H2, H3 432 H1, H2, H3 Secondary Volts 240 120

InterConnect 1 2 3 4 5 6 7

Connect Secondary Lines To

X1, X2, X3 X1, X4 or X2, X4

X1, X2, X3 X1, X4 or X2, X4

29

5 3 1

2 4 6

5 3 1

2 4 6

5 3 1

2 4 6

28

PRIMARY: 600 Volts Delta SECONDARY: 208Y/120 Volts TAPS: 2, 5% BNFC

H1 H2 H3

PRIMARY: 600 Volts Delta SECONDARY: 208Y/120 Volts TAPS: 2, 2 1/2 % ANFC, 4, 2 1/2 % BNFC
H1 H2 H3 7 6 5 4 3 2 1 7 6 5 4 3 2 1 7 6 5 4 3 2 1

X1

X4

X2

X3 3 2 1 3 2 1 3 2 1

X0

X1

X2

X3

Connect Primary Primary Volts Lines To 504 H1, H2, H3 492 H1, H2, H3 480 H1, H2, H3 468 H1, H2, H3 456 H1, H2, H3 444 H1, H2, H3 432 H1, H2, H3 Secondary Volts 240 120

InterConnect 1 to 2 2 to 3 1 to 4 3 to 4 1 to 6 3 to 6 5 to 6

Connect Secondary Lines To

X0 X1 X2 X3

Connect Primary Primary Volts Lines To 600 H1, H2, H3 570 H1, H2, H3 540 H1, H2, H3 Secondary Volts 208 X1, X2, X3 X1, X4 or X2, X4 120 1 phase

InterConnect 1 2 3

Connect Secondary Lines To

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

Connect Primary Primary Volts Lines To 630 H1, H2, H3 615 H1, H2, H3 600 H1, H2, H3 585 H1, H2, H3 570 H1, H2, H3 555 H1, H2, H3 540 H1, H2, H3 Secondary Volts 208 120 1 phase

InterConnect 1 2 3 4 5 6 7

Connect Secondary Lines To

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

150

ACME ELECTRIC, POWER DISTRIBUTION PRODUCTS DIVISION LUMBERTON, NC 800-334-5214 www.acmepowerdist.com

GENERAL

ACME TRANSFORMER WIRING DIAGRAMS

30

PRIMARY: 600 Volts Delta SECONDARY: 208Y/120 Volts TAPS: 2, 2 1/2 % ANFC, 4, 2 1/2 % BNFC
H1 H2 H3

31

PRIMARY: 480 Volts Delta SECONDARY: 480Y/277 Volts TAPS: 2, 2 1/2 % ANFC, 4, 2 1/2 % BNFC
H1 H2 H3

32

PRIMARY: 480 Volts Delta SECONDARY: 480Y/277 Volts TAPS: 2, 2 1/2 % ANFC, 4, 2 1/2 % BNFC
H1 H2 H3 5 3 1 2 4 6 5 3 1 2 4 6 5 3 1 2 4 6

5 3 1

2 4 6

5 3 1

2 4 6

5 3 1

2 4 6

7 6 5 4 3 2 1

7 6 5 4 3 2 1

7 6 5 4 3 2 1

X0

X1

X2

X3

X0

X1

X2

X3

X0

X1

X2

X3

Connect Primary Primary Volts Lines To 630 H1, H2, H3 615 H1, H2, H3 600 H1, H2, H3 585 H1, H2, H3 570 H1, H2, H3 555 H1, H2, H3 540 H1, H2, H3 Secondary Volts 208 120 1 phase

InterConnect 1 to 2 2 to 3 1 to 4 3 to 4 1 to 6 3 to 6 5 to 6

Connect Secondary Lines To

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

Connect Primary Primary Volts Lines To 504 H1, H2, H3 492 H1, H2, H3 480 H1, H2, H3 468 H1, H2, H3 456 H1, H2, H3 444 H1, H2, H3 432 H1, H2, H3 Secondary Volts 480 277 1 phase

InterConnect 1 2 3 4 5 6 7

Connect Secondary Lines To

Connect Primary Primary Volts Lines To 504 H1, H2, H3 492 H1, H2, H3 480 H1, H2, H3 468 H1, H2, H3 456 H1, H2, H3 444 H1, H2, H3 432 H1, H2, H3 Secondary Volts 480 277 1 phase

InterConnect 1 to 2 2 to 3 1 to 4 3 to 4 1 to 6 3 to 6 5 to 6

Connect Secondary Lines To

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

33

PRIMARY: 380 Volts Delta SECONDARY: 208/120 Volts TAPS: 2-2 1/2 % ANFC and BNFC
H1
5 4 3 21

34
H3
5 4 3 21

PRIMARY: 460 Volts Delta SECONDARY: 460Y/266 Volts TAPS: 1-5% ANFC and BNFC
H1 H2 H3

35

PRIMARY: 460 Volts Delta SECONDARY: 460Y/266 Volts TAPS: 2-2 1/2 % ANFC and BNFC
H1 H2 H3

H2
5 4 3 21

5 4 3 2 1 3 2 1 3 2 1 3 2 1

5 4 3 2 1

5 4 3 2 1

X0

X1

X2

X3

X0 X0 X1 X2 X3

X1

X2

X3

Connect Primary Primary Volts Lines To 399 H1, H2, H3 390 H1, H2, H3 380 H1, H2, H3 371 H1, H2, H3 361 H1, H2, H3 Secondary Volts 208 120 1 phase

InterConnect 1 2 3 4 5

Connect Secondary Lines To

Primary Volts 483 460 437 Secondary Volts 460 266 1 phase

% 105 100 95

Connect Leads to Tap No. 1 2 3 X1, X2, X3 X1 & X0 X2 & X0 X3 & X0

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

Primary Volts 483 472 460 449 437 Secondary Volts 460 266 1 phase

% 105 102.5 100 97.5 95

Connect Leads to Tap No. 1 2 3 4 5 X1, X2, X3 X1 & X0 X2 & X0 X3 & X0

36

PRIMARY: 460 Volts Delta SECONDARY: 460Y/266 Volts TAPS: 2-2 1/2 % ANFC and BNFC
H1 H2 H3

37
2 4 6

PRIMARY: 460 Volts Delta SECONDARY: 230Y/133 Volts TAPS: 1-5% ANFC and BNFC
H1 H2 H3

38

PRIMARY: 460 Volts Delta SECONDARY: 230Y/133 Volts TAPS: 2-2 1/2 % ANFC and BNFC
H1 H2 H3

5 3 1

2 4 6

5 3 1

2 4 6

5 3 1

5 4 3 2 1 3 2 1 3 2 1 3 2 1

5 4 3 2 1

5 4 3 2 1

X0

X1

X2

X3

X0 X0 X1 X2 X3

X1

X2

X3

Primary Volts 483 472 460 449 437 Secondary Volts 460 266 1 phase

% 105 102.5 100 97.5 95

Connect Leads to Tap No. 1 to 2 2 to 3 1 to 4 3 to 4 4 to 5 X1, X2, X3 X1 & X0 X2 & X0 X3 & X0

Primary Volts 483 460 437 Secondary Volts 230 133 1 phase

% 105 100 95

Connect Leads to Tap No. 1 2 3 X1, X2, X3 X1 & X0 X2 & X0 X3 & X0

Primary Volts 483 472 460 449 437 Secondary Volts 230 133 1 phase

% 105 102.5 100 97.5 95

Connect Leads to Tap No. 1 2 3 4 5 X1, X2, X3 X1 & X0 X2 & X0 X3 & X0

151

ACME ELECTRIC, POWER DISTRIBUTION PRODUCTS DIVISION LUMBERTON, NC 800-334-5214 www.acmepowerdist.com

GENERAL

ACME TRANSFORMER WIRING DIAGRAMS

39

PRIMARY: 460 Volts Delta SECONDARY: 230Y/133 Volts TAPS: 2-2 1/2 % ANFC and BNFC
H1 H2 H3

40
5 3 1 2 4 6

PRIMARY: 575 Volts Delta SECONDARY: 230Y/133 Volts TAPS: 1-5% ANFC and BNFC
H1 H2 H3

41

PRIMARY: 575 Volts Delta SECONDARY: 230Y/133 Volts TAPS: 2-2 1/2 % ANFC and BNFC
H1 H2 H3

5 3 1

2 4 6

5 3 1

2 4 6

3 2 1

3 2 1

3 2 1

5 4 3 2 1

5 4 3 2 1

5 4 3 2 1

X0

X1

X2

X3

X0

X1

X2

X3

X0

X1

X2

X3

Primary Volts 483 472 460 449 437 Secondary Volts 230 133 1 phase

% 105 102.5 100 97.5 95

Connect Leads to Tap No. 1 to 2 2 to 3 1 to 4 3 to 4 4 to 5 X1, X2, X3 X1 & X0 X2 & X0 X3 & X0

Primary Volts 604 575 546 Secondary Volts 230 133 1 phase

% 105 100 95

Connect Leads to Tap No. 1 2 3 X1, X2, X3 X1 & X0 X2 & X0 X3 & X0

Primary Volts 604 589 575 561 546 Secondary Volts 230 133 1 phase

% 105 102.5 100 97.5 95

Connect Leads to Tap No. 1 2 3 4 5 X1, X2, X3 X1 & X0 X2 & X0 X3 & X0

42

PRIMARY: 575 Volts Delta SECONDARY: 230Y/133 Volts TAPS: 2-2 1/2 % ANFC and BNFC
H1 H2 H3

43
5 3 1 2 4 6

PRIMARY: 575 Volts Delta SECONDARY: 460Y/266 Volts TAPS: 1-5% ANFC and BNFC
H1 H2 H3

44

PRIMARY: 575 Volts Delta SECONDARY: 460Y/266 Volts TAPS: 2-2 1/2 % ANFC and BNFC
H1 H2 H3

5 3 1

2 4 6

5 3 1

2 4 6

3 2 1

3 2 1

3 2 1

5 4 3 2 1

5 4 3 2 1

5 4 3 2 1

X0

X1

X2

X3

X0

X1

X2

X3

X0

X1

X2

X3

Primary Volts 604 589 575 561 546 Secondary Volts 230 133 1 phase

% 105 102.5 100 97.5 95

Connect Leads to Tap No. 1 to 2 2 to 3 1 to 4 3 to 4 4 to 5 X1, X2, X3 X1 & X0 X2 & X0 X3 & X0

Primary Volts 604 575 546 Secondary Volts 460 266 1 phase

% 105 100 95

Connect Leads to Tap No. 1 2 3 X1, X2, X3 X1 & X0 X2 & X0 X3 & X0

Primary Volts 604 589 575 561 546 Secondary Volts 460 266 1 phase

% 105 102.5 100 97.5 95

Connect Leads to Tap No. 1 2 3 4 5 X1, X2, X3 X1 & X0 X2 & X0 X3 & X0

45

PRIMARY: 575 Volts Delta SECONDARY: 460Y/266 Volts TAPS: 2-2 1/2 % ANFC and BNFC
H1 H2 H3

46
2 4 6

PRIMARY: 208 Volts Delta SECONDARY: 480Y/277 Volts TAPS: 2, 2 1/2 % ANFC, 2, 2 1/2 % BNFC
X1 X2 X3

47

PRIMARY: 416 Volts Delta SECONDARY: 208Y/120 Volts TAPS: 2, 2 1/2 % ANFC, 2, 2 1/2 % BNFC
H1 H2 H3

5 3 1

2 4 6

5 3 1

2 4 6

5 3 1

5 4 3 2 1

5 4 3 2 1

5 4 3 2 1

5 4 3 2 1

5 4 3 2 1

5 4 3 2 1

H0 X0 X1 X2 X3

H1

H2

H3

X0

X1

X2

X3

Primary Volts 604 589 575 561 546 Secondary Volts 460 266 1 phase

% 105 102.5 100 97.5 95

Connect Leads to Tap No. 1 to 2 2 to 3 1 to 4 3 to 4 4 to 5 X1, X2, X3 X1 & X0 X2 & X0 X3 & X0

Connect Primary Primary Volts Lines To 218 X1, X2, X3 213 X1, X2, X3 208 X1, X2, X3 203 X1, X2, X3 198 X1, X2, X3 Secondary Volts 480 277 1 phase

InterConnect 1 2 3 4 5

Connect Secondary Lines To

H1, H2, H3 H1 to H0 H2 to H0 H3 to H0

Connect Primary Primary Volts Lines To 437 H1, H2, H3 426 H1, H2, H3 416 H1, H2, H3 406 H1, H2, H3 395 H1, H2, H3 Secondary Volts 208 120 1 phase

InterConnect 1 2 3 4 5

Connect Secondary Lines To

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

152

ACME ELECTRIC, POWER DISTRIBUTION PRODUCTS DIVISION LUMBERTON, NC 800-334-5214 www.acmepowerdist.com

GENERAL

ACME TRANSFORMER WIRING DIAGRAMS

48

PRIMARY: 208 Volts Delta SECONDARY: 480Y/ 277 Volts TAPS: 2, 5% BNFC
X1 32 1 32 1 X2 X3

49

PRIMARY: 600 Volts Delta SECONDARY: 208Y/120 Volts TAPS: 2, 2 1/2 % ANFC, 2, 2 1/2 % BNFC
H1 H2 H3

50

PRIMARY: 600 Volts Delta SECONDARY: 380Y/220 Volts TAPS: 2, 2 1/2 % ANFC, 4, 2 1/2 % BNFC
H1 H2 H3

5 4 3 2 1

5 4 3 2 1

5 4 3 2 1

7 6 5 4 3 2 1

7 6 5 4 3 2 1

7 6 5 4 3 2 1

3 21

X0

X1

X2

X3

X0

X1

X2

X3

H0

H1

H2

H3

Connect Primary Primary Volts Lines To 208 X1, X2, X3 198 X1, X2, X3 187 X1, X2, X3 Secondary Volts 480 277 1 phase

InterConnect 1 2 3

Connect Secondary Lines To

H1, H2, H3 H1 to H0 H2 to H0 H3 to H0

Connect Primary Primary Volts Lines To 630 H1, H2, H3 615 H1, H2, H3 600 H1, H2, H3 585 H1, H2, H3 570 H1, H2, H3 Secondary Volts 208 120 1 phase

InterConnect 1 2 3 4 5

Connect Secondary Lines To

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

Connect Primary Primary Volts Lines To 630 H1, H2, H3 615 H1, H2, H3 600 H1, H2, H3 585 H1, H2, H3 570 H1, H2, H3 555 H1, H2, H3 540 H1, H2, H3 Secondary Volts 380 220 1 phase

InterConnect 1 2 3 4 5 6 7

Connect Secondary Lines To

51

PRIMARY: 600 Volts Delta SECONDARY: 480Y/277 Volts TAPS: 2, 2 1/2 % ANFC, 4, 2 1/2 % BNFC
H1 H2 H3

52

PRIMARY: 600 Volts Delta SECONDARY: 600Y/347 Volts TAPS: 2, 2 1/2 % ANFC, 4, 2 1/2 % BNFC
H1 H2 H3

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

7 6 5 4 3 2 1

7 6 5 4 3 2 1

7 6 5 4 3 2 1

7 6 5 4 3 2 1

7 6 5 4 3 2 1

7 6 5 4 3 2 1

53

PRIMARY: 600 Volts Delta SECONDARY: 380Y/220 Volts TAPS: 2, 5% BNFC

H1 H2 H3

X0

X1

X2

X3

X0

X1

X2

X3

Connect Primary Primary Volts Lines To 630 H1, H2, H3 615 H1, H2, H3 600 H1, H2, H3 585 H1, H2, H3 570 H1, H2, H3 555 H1, H2, H3 540 H1, H2, H3 Secondary Volts 480 277 1 phase

InterConnect 1 2 3 4 5 6 7

Connect Secondary Lines To

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

Connect Primary Primary Volts Lines To 630 H1, H2, H3 615 H1, H2, H3 600 H1, H2, H3 585 H1, H2, H3 570 H1, H2, H3 555 H1, H2, H3 540 H1, H2, H3 Secondary Volts 600 347 1 phase

InterConnect 1 2 3 4 5 6 7

Connect Secondary Lines To

X0

3 2 1

3 2 1

3 2 1

X1

X2

X3

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

Connect Primary Primary Volts Lines To 600 H1, H2, H3 570 H1, H2, H3 540 H1, H2, H3 Secondary Volts 380 220 1 phase

InterConnect 1 2 3

Connect Secondary Lines To

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

54

PRIMARY: 600 Volts Delta SECONDARY: 600Y/347 Volts TAPS: 2, 5% BNFC

H1 H2 H3

55

PRIMARY: 600 Volts Delta SECONDARY: 480Y/277 Volts TAPS: 2, 5% BNFC

H1 H2 H3

56
3 2 1

PRIMARY: 600 Volts SECONDARY: 480 Volts TAPS: 2, 5% BNFC

3 2 1

3 2 1

3 2 1

3 2 1

3 2 1

H1 H4 H7 X1

H2 H5 H8 X2

H3 H6 H9 X3

X0

X1

X2

X3

X0

X1

X2

X3

X0 H0

Connect Primary Primary Volts Lines To 600 H1, H2, H3 570 H1, H2, H3 540 H1, H2, H3 Secondary Volts 600 347 1 phase

InterConnect 1 2 3

Connect Secondary Lines To

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

Connect Primary Primary Volts Lines To 600 H1, H2, H3 570 H1, H2, H3 540 H1, H2, H3 Secondary Volts 480 277 1 phase

InterConnect 1 2 3

Connect Secondary Lines To

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

Connect Connect Primary Alt Primary Inter- Secondary Volts Rating Lines To Connect Lines To 600 480 H1, H2, H3 570 456 H4, H5, H6 540 432 H7, H8, H9 Secondary Volts 480 380 X1, X2, X3 X1 to X0 277 220 X2 to X0 1 phase 1 phase X3 to X0
153

ACME ELECTRIC, POWER DISTRIBUTION PRODUCTS DIVISION LUMBERTON, NC 800-334-5214 www.acmepowerdist.com

GENERAL
PRIMARY: 600 Volts SECONDARY: 480 Volts TAPS: 2, 5% BNFC

ACME TRANSFORMER WIRING DIAGRAMS

57

58
H3 1 2 3 X3

PRIMARY: 208 Volts SECONDARY: 120/240 Volts TAPS: 2, 5% BNFC

H1 1 2 3 H2 4 5 6

59

PRIMARY: 230 Volts Delta SECONDARY: 230Y/133 Volts TAPS: 2-2 1/2 % ANFC and 2-2 1/2 % BNFC
H1 H2 H3

H1 1 2 3 X1

H2 1 2 3 X2

5 4 3 2 1

5 4 3 2 1

5 4 3 2 1

X4
X0 H0

X2

X3

X1

Connect Connect Primary Alt Primary Inter- Secondary Volts Rating Lines To Connect Lines To 600 480 H1, H2, H3 1 570 456 H1, H2, H3 2 540 432 H1, H2, H3 3 Secondary Volts 480 380 X1, X2, X3 X1 to X0 277 220 X2 to X0 1 phase 1 phase X3 to X0

Connect Primary Primary Volts Lines To 208 H1 & H2 198 H1 & H2 187 H1 & H2 Secondary Volts 240 120/240 120

InterConnect 3 to 4 2 to 5 1 to 6 X2 to X3 X2 to X3 X1 to X3 X2 to X4

Connect Secondary Lines To

X0

X1

X2

X3

X1-X4 X1-X2-X4 X1-X4

Primary Volts 242 236 230 224 219 Secondary Volts 230 133 1 phase

% 105 102.5 100 97.5 95

Connect Leads to Tap No. 1 2 3 4 5 X1, X2, X3 X1 & X0 X2 & X0 X3 & X0

61

PRIMARY: 208 Volts Delta SECONDARY: 208Y/120 Volts TAPS: 2-2 1/2 % ANFC and 2-2 1/2 % BNFC
H1 H2 H3

60

PRIMARY: 208 Volts Delta SECONDARY: 208Y/120 Volts TAPS: 2-5% BNFC
H1 H2 H3 X0

62

5 4 3 2 1

5 4 3 2 1

5 4 3 2 1

PRIMARY: 230 Volts Delta SECONDARY: 230Y/133 Volts TAPS: 1-5% ANFC and 1-5% BNFC
H1 H2 H3

3 2 1 X1 X2 X3

3 2 1

3 2 1

3 2 1

3 2 1

3 2 1

X0

X1

X2

X3

Primary Volts 208 198 187 Secondary Volts 208 120 1 phase

% 100 95 90

Connect Leads to Tap No. 1 2 3 X1, X2, X3 X1 & X0 X2 & X0 X3 & X0

Primary Volts 218 213 208 203 198 Secondary Volts 208 120 1 phase

% 105 102.5 100 97.5 95

Connect Leads to Tap No. 1 2 3 4 5 X1, X2, X3 X1 & X0 X2 & X0 X3 & X0

X0

X1

X2

X3

Primary Volts 241 230 218 Secondary Volts 230 133 1 phase

% 105 100 95

Connect Leads to Tap No. 1 2 3 X1, X2, X3 X1 & X0 X2 & X0 X3 & X0

64
H1

PRIMARY: 190/208/220/240 x 380/440/480 Volts SECONDARY: 120/240 Volts

H3 H2 H4 H5 H6 H7 H8 H9 H10

65
H1

PRIMARY: 190/200/208/220 x 380/400/416/440 Volts SECONDARY: 110/220 Volts

H3 H2 H4 H5 H6 H7 H8 H9 H10

63

PRIMARY: 120/208/240/277 Volts SECONDARY: 120/240 Volts

H1 H4 H2 H3 H5 H8 H6 H7

X4

X3

X2

X1

X4

X3

X2

X1

Primary Volts 190

Connect Primary Lines To H1& H7 H1 & H8 H1 & H9 H1& H10

X4

X2

X3

X1

208 220 240

Primary Volts 120

Connect Primary Lines To H1 & H8

208 H1 & H8 240 H1 & H8 277 H1 & H8 Secondary Volts 240 120/240 120
154

InterConnect H1 to H6 H3 to H8 H2 to H7 H3 to H6 H4 to H5 X2 to X3 X2 to X3 X1 to X3 X2 to X4

Connect Secondary Lines To

X1 & X4 X1, X3, X4 X1 & X4

380 H1 & H7 416 H1 & H8 440 H1 & H9 480 H1 & H10 Secondary Volts 240 120/240 120

InterConnect H1 to H6 H2 to H7 H1 to H6 H3 to H8 H1 to H6 H4 to H9 H1 to H6 H5 to H10 H2 to H6 H3 to H6 H4 to H6 H5 to H6 X2 to X3 X2 to X3 X1 to X3 X2 to X4

Connect Secondary Lines To

Primary Volts 190 200 208 220

Connect Primary Lines To H1 & H7 H1 & H8 H1 & H9 H1 & H10

X1 - X4 X1- X2 - X4 X1 - X4

380 H1 & H7 400 H1 & H8 415 H1 & H9 440 H1 & H10 Secondary Volts 220 110/220 110

InterConnect H1 to H6 H2 to H7 H1 to H6 H3 to H8 H1 to H6 H4 to H9 H1 to H6 H5 to H10 H2 to H6 H3 to H6 H4 to H6 H5 to H6 X2 to X3 X2 to X3 X1 to X3 X2 to X4

Connect Secondary Lines To

X1-X4 X1-X2-X4 X1-X4

ACME ELECTRIC, POWER DISTRIBUTION PRODUCTS DIVISION LUMBERTON, NC 800-334-5214 www.acmepowerdist.com

GENERAL

ACME TRANSFORMER WIRING DIAGRAMS

66

PRIMARY: 416 Volts Delta SECONDARY: 208Y/120 Volts TAPS: 2, 5% BNFC

H1 32 1 32 1 H2 H3 3 21

67

PRIMARY: 480 Volts Delta SECONDARY: 208Y/120 Volts TAPS: 2-2 1/2 % ANFC, 4, 2 1/2 % BNFC
H1 H2 H3

68

PRIMARY: 480 Volts Delta SECONDARY: 240 Volts Delta/120 Volts TAPS: 2, 2 1/2 % ANFC, 4, 2 1/2 % BNFC
H1 H2 H3

7 6 5 4 3 2 1

7 6 5 4 3 2 1

7 6 5 4 3 2 1

7 6 5 4 3 2 1

7 6 5 4 3 2 1

7 6 5 4 3 2 1

X0

X1

X2

X3

Connect Primary Primary Volts Lines To 437 H1, H2, H3 416 H1, H2, H3 395 H1, H2, H3 Secondary Volts 208 120 1 phase

InterConnect 1 2 3

Connect Secondary Lines To

X0

X1

X2

X3

X1

X4

X2

X3

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

69

PRIMARY: 600 Volts Delta SECONDARY: 240 Delta/120 Volts TAPS: 2, 2 1/2 % ANFC, 4, 2 1/2 % BNFC
H1 H2 H3

Connect Primary Primary Volts Lines To 504 H1, H2, H3 492 H1, H2, H3 480 H1, H2, H3 468 H1, H2, H3 456 H1, H2, H3 444 H1, H2, H3 432 H1, H2, H3 Secondary Volts 208 120 1 phase

InterConnect 1 2 3 4 5 6 7

Connect Secondary Lines To

Primary Volts 504 492 480 468 456 444 432

Connect Primary Lines To H1, H2, H3 H1, H2, H3 H1, H2, H3 H1, H2, H3 H1, H2, H3 H1, H2, H3 H1, H2, H3

InterConnect 1 2 3 4 5 6 7

Connect Secondary Lines To

7 6 5 4 3 2 1

7 6 5 4 3 2 1

7 6 5 4 3 2 1

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

Secondary Volts 240 120

X1, X2, X4 X1, X4, or X2, X4

70
X1 X4 X2 X3

PRIMARY: 240 Volts Delta SECONDARY: 480Y/277 Volts TAPS: 2, 5% BNFC

H1 321 H2 321 H3 321

71

Primary Volts 630 615 600 585 570 555 540 Secondary Volts 240 120

% 105 102.5 100 97.5 95 92.5 90

Connect Leads to Tap No. 1 2 3 4 5 6 7 X1, X2, X3 X1, X4, or X2, X4

PRIMARY: 240 Volts Delta SECONDARY: 480Y/277 Volts TAPS: 2, 2 1/2 % ANFC & BNFC
X1 54 3 21 X2 54 321 X3 54 321

X0

X1

X2

X3

Primary Volts 240 228 216 Secondary Volts 480 277 1 phase

% 100 95 90

Connect Leads to Tap No. 1 2 3 X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

H0

H1

H2

H3

72

PRIMARY: 380 Volts Delta SECONDARY: 208Y/120 Volts TAPS: 2, 2 1/2 % ANFC, 4, 2 1/2 % BNFC
H1 H2 H3

73

PRIMARY: 440 Volts Delta SECONDARY: 220Y/127 Volts TAPS: 2, 5% ANFC & BNFC
H1 5 4 3 21 H2 5 4 3 21 H3 5 4 3 21

Connect Primary Primary Volts Lines To 252 X1, X2, X3 246 X1, X2, X3 240 X1, X2, X3 234 X1, X2, X3 228 X1, X2, X3 Secondary Volts 480 277 1 phase

InterConnect 1 2 3 4 5

Connect Secondary Lines To

7 6 5 4 3 2 1

7 6 5 4 3 2 1

7 6 5 4 3 2 1

H1, H2, H3 H1 to H0 H2 to H0 H3 to H0

X0

X1

X2

X3

Primary Volts 399 390 380 371 361 352 342 Secondary Volts 208 120 1 phase

% 105 102.5 100 97.5 95 92.5 90

Connect Leads to Tap No. 1 2 3 4 5 6 7 X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

X0

X1

X2

X3

Primary Volts 484 462 440 418 396 Secondary Volts 220 127 1 phase

% 110 105 100 95 90

Connect Leads to Tap No. 1 2 3 4 5 X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

155

ACME ELECTRIC, POWER DISTRIBUTION PRODUCTS DIVISION LUMBERTON, NC 800-334-5214 www.acmepowerdist.com

GENERAL

ACME TRANSFORMER WIRING DIAGRAMS

74

PRIMARY: 190/200/210/220/ 230/240 Volts Delta SECONDARY: 400Y/231 Volts

X1 6 5 4 3 2 1 6 5 4 3 2 1 X2 X3 6 5 4 3 2 1

75

PRIMARY: 190/200/210/220/ 230/240 Volts Delta SECONDARY: 400Y/231 Volts

H1 6 5 4 3 21 H2 6 5 4 3 21 H3 6 5 4 3 21

76

PRIMARY: 400 Volts Delta SECONDARY: 240 Volts Delta/120 Volts TAPS: 2, 5% BNFC
H1 321 H2 321 H3 321

H0

H1

H2

H3

X0

X1

X2

X3

X1

X4

X2

X3

Connect Primary Primary Volts Lines To 240 X1, X2, X3 230 X1, X2, X3 220 X1, X2, X3 210 X1, X2, X3 200 X1, X2, X3 190 X1, X2, X3 Secondary Volts 400 231 1 phase

InterConnect 1 2 3 4 5 6

Connect Secondary Lines To

H1, H2, H3 H1 to H0 H2 to H0 H3 to H0

Connect Primary Primary Volts Lines To 240 H1, H2, H3 230 H1, H2, H3 220 H1, H2, H3 210 H1, H2, H3 200 H1, H2, H3 190 H1, H2, H3 Secondary Volts 400 231 1 phase

InterConnect 1 2 3 4 5 6

Connect Secondary Lines To

Connect Primary Primary Volts Lines To 400 H1, H2, H3 380 H1, H2, H3 360 H1, H2, H3 Secondary Volts 240 120

InterConnect 1 2 3

Connect Secondary Lines To

X1, X2, X3 X1 to X4 or X2 to X4

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

79

PRIMARY: 277/480 Volts SECONDARY: 208/277 Volts TAPS: NONE

H1 H2 H3 H4 H5 H6

77

PRIMARY: 400 Volts Delta SECONDARY: 240 Delta/120 Volts TAPS: 2, 2 1/2 % ANFC, 4, 2 1/2 % BNFC
H1 7654 321 H2 7654 321 H3 7654 321

78

PRIMARY: 277/480 Volts SECONDARY: 208/277 Volts TAPS: NONE

H1 H2 H3

X5 X6 X3 X4

X2 X1

X1
X1 X4 X2 X3

X2

X3

Connect Primary Primary Volts Lines To 420 H1, H2, H3 410 H1, H2, H3 400 H1, H2, H3 390 H1, H2, H3 380 H1, H2, H3 370 H1, H2, H3 360 H1, H2, H3 Secondary Volts 240 120

InterConnect 1 2 3 4 5 6 7

Connect Secondary Lines To

Connect Primary Primary Volts Lines To 277 H1 & H2 480 H1 & H3 Secondary Volts 208 277

InterConnect

Connect Secondary Lines To

Connect Primary Primary Volts Lines To 277 H1 - H5 480 H1 - H6 Secondary Volts 208 277

InterConnect H2 to H4 H3 to H4 X2 to X4 X3 to X4

Connect Secondary Lines To

X1- X5 X1- X6

X1 to X2 X1 to X3

81

PRIMARY: 480 Volts Delta SECONDARY: 208Y/120 Volts TAPS: 2, 2 1/2 % ANFC, 2, 2 1/2 % BNFC
H1 54 3 21 H2 54 321 H3 54 321

80
X1, X2, X3 X1 to X4 or X2 to X4

PRIMARY: 480 Volts Delta SECONDARY: 208Y/120 Volts TAPS: 1-5% ANFC & 1-5% BNFC
H1 3 21 H2 3 21 H3 3 21
X0 X1

X2

X3

X0

X1

X2

X3

Connect Primary Primary Volts Lines To 504 H1, H2, H3 480 H1, H2, H3 456 H1, H2, H3 Secondary Volts 208 120 1 phase

InterConnect 1 2 3

Connect Secondary Lines To

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

Connect Primary Primary Volts Lines To 504 H1, H2, H3 492 H1, H2, H3 480 H1, H2, H3 468 H1, H2, H3 456 H1, H2, H3 Secondary Volts 208 120 1 phase

InterConnect 1 2 3 4 5

Connect Secondary Lines To

X1, X2, X3 X1 to X0 X2 to X0 X3 to X0

156

ACME ELECTRIC, POWER DISTRIBUTION PRODUCTS DIVISION LUMBERTON, NC 800-334-5214 www.acmepowerdist.com

Integral Horsepower AC Induction Motors ODP, WPI, WPII Enclosure TEFC Enclosure Explosion Proof

Installation & Operating Manual

2/07

MN400

Table of Contents
Section 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2 Installation & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doweling & Bolting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conduit Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First Time Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coupled Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jogging and Repeated Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3 Maintenance & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication & Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type of Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 11 11 12 14 14 14 14 21 21 21 21 21 22 22 22 22 24 24 24 31 31 31 31 31 33 34 35

MN400

Table of Contents i

Section 1 General Information

ii Table of Contents

MN400

Section 1 General Information

Overview
This manual contains general procedures that apply to Baldor Motor products. Be sure to read and understand the Safety Notice statements in this manual. For your protection, do not install, operate or attempt to perform maintenance procedures until you understand the Warning and Caution statements. A Warning statement indicates a possible unsafe condition that can cause harm to personnel. A Caution statement indicates a condition that can cause damage to equipment. This instruction manual is not intended to include a comprehensive listing of all details for all procedures required for installation, operation and maintenance. This manual describes general guidelines that apply to most of the motor products shipped by Baldor. If you have a question about a procedure or are uncertain about any detail, Do Not Proceed. Please contact your Baldor distributor for more information or clarification. Before you install, operate or perform maintenance, become familiar with the following: S NEMA Publication MG2, Safety Standard for Construction and guide for Selection, Installation and Use of Electric Motors and Generators. S The National Electrical Code S Local codes and Practices

Important:

Limited Warranty
1. Most Baldor products are warranted for 18 months from the date of shipment to Baldor's customer from Baldor's district warehouse or, if applicable, from Baldor's factory. Baldor Standard-E standard efficient motors are warranted for 24 months. Standard-E is limited to three phase, general purpose, 1-200 HP ratings that fall under the Energy Policy Act (EPAct). Baldor Super-E premium efficient motors are warranted for 36 months. Baldor IEEE841 motors are warranted for 60 months. All warranty claims must be submitted to a Baldor Service Center prior to the expiration of the warranty period. 2. Baldor will, at its option repair or replace a motor which fails due to defects in material or workmanship during the warranty period if: a. the purchaser presents the defective motor at or ships it prepaid to, the Baldor plant in Fort Smith, Arkansas or one of the Baldor Authorized Service Centers and b. the purchaser gives written notification concerning the motor and the claimed defect including the date purchased, the task performed by the Baldor motor and the problem encountered. 3. Baldor will not pay the cost of removal of any electric motor from any equipment, the cost of delivery to Fort Smith, Arkansas or a Baldor Authorized Service Center, or the cost of any incidental or consequential damages resulting from the claimed defects. (Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above exclusion may not apply to you.) Any implied warranty given by laws shall be limited to the duration of the warranty period hereunder. (Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.) 4. Baldor Authorized Service Centers, when convinced to their satisfaction that a Baldor motor developed defects in material or workmanship within the warranty period, are authorized to proceed with the required repairs to fulfill Baldor's warranty when the cost of such repairs to be paid by Baldor does not exceed Baldor's warranty repair allowance. Baldor will not pay overtime premium repair charges without prior written authorization. 5. The cost of warranty repairs made by centers other than Baldor Authorized Service Centers WILL NOT be paid unless first authorized in writing by Baldor. 6. Claims by a purchaser that a motor is defective even when a failure results within one hour after being placed into service are not always justified. Therefore, Baldor Authorized Service Centers must determine from the condition of the motor as delivered to the center whether or not the motor is defective. If in the opinion of a Baldor Authorized Service Center, a motor did not fail as a result of defects in material or workmanship, the center is to proceed with repairs only if the purchaser agrees to pay for such repairs. If the decision is in dispute, the purchaser should still pay for the repairs and submit the paid invoice and the Authorized Service Center's signed service report to Baldor for further consideration. 7. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

MN400

General Information 11

Safety Notice:

This equipment contains high voltage! Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt installation, operation and maintenance of electrical equipment. Be sure that you are completely familiar with NEMA publication MG2, safety standards for construction and guide for selection, installation and use of electric motors and generators, the National Electrical Code and local codes and practices. Unsafe installation or use can cause conditions that lead to serious or fatal injury. Only qualified personnel should attempt the installation, operation and maintenance of this equipment. WARNING: Do not touch electrical connections before you first ensure that power has been disconnected. Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the installation, operation and maintenance of this equipment. Be sure the system is properly grounded before applying power. Do not apply AC power before you ensure that all grounding instructions have been followed. Electrical shock can cause serious or fatal injury. National Electrical Code and Local codes must be carefully followed. Avoid extended exposure to machinery with high noise levels. Be sure to wear ear protective devices to reduce harmful effects to your hearing. This equipment may be connected to other machinery that has rotating parts or parts that are driven by this equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt to install operate or maintain this equipment. Do not bypass or disable protective devices or safety guards. Safety features are designed to prevent damage to personnel or equipment. These devices can only provide protection if they remain operative. Avoid the use of automatic reset devices if the automatic restarting of equipment can be hazardous to personnel or equipment. Be sure the load is properly coupled to the motor shaft before applying power. The shaft key must be fully captive by the load device. Improper coupling can cause harm to personnel or equipment if the load decouples from the shaft during operation. Use proper care and procedures that are safe during handling, lifting, installing, operating and maintaining operations. Improper methods may cause muscle strain or other harm. Before performing any motor maintenance procedure, be sure that the equipment connected to the motor shaft cannot cause shaft rotation. If the load can cause shaft rotation, disconnect the load from the motor shaft before maintenance is performed. Unexpected mechanical rotation of the motor parts can cause injury or motor damage. Disconnect all electrical power from the motor windings and accessory devices before disassembly of the motor. Electrical shock can cause serious or fatal injury. Do not use non UL/CSA listed explosion proof motors in the presence of flammable or combustible vapors or dust. These motors are not designed for atmospheric conditions that require explosion proof operation.

WARNING:

WARNING:

WARNING:

WARNING:

WARNING: WARNING:

WARNING:

WARNING:

WARNING:

WARNING:

12 General Information

MN400

Section 1 General Information

Safety Notice Continued WARNING: Motors that are to be used in flammable and/or explosive atmospheres must display the UL label on the nameplate along with CSA listed logo. Specific service conditions for these motors are defined in NFPA 70 (NEC) Article 500. WARNING: UL Listed motors must only be serviced by UL Approved Authorized Baldor Service Centers if these motors are to be returned to a hazardous and/or explosive atmosphere. To prevent premature equipment failure or damage, only qualified maintenance personnel should perform maintenance. Do not over-lubricate motor as this may cause premature bearing failure. Do not lift the motor and its driven load by the motor lifting hardware. The motor lifting hardware is adequate for lifting only the motor. Disconnect the load from the motor shaft before moving the motor. If eye bolts are used for lifting a motor, be sure they are securely tightened. The lifting direction should not exceed a 20 angle from the shank of the eye bolt or lifting lug. Excessive lifting angles can cause damage. To prevent equipment damage, be sure that the electrical service is not capable of delivering more than the maximum motor rated amps listed on the rating plate. If a HI POT test (High Potential Insulation test) must be performed, follow the precautions and procedure in NEMA MG1 and MG2 standards to avoid equipment damage.

Caution: Caution: Caution:

Caution:

Caution:

Caution:

If you have any questions or are uncertain about any statement or procedure, or if you require additional information please contact your Baldor distributor or an Authorized Baldor Service Center.

MN400

General Information 13

Section 1 General Information

Receiving
Each Baldor Electric Motor is thoroughly tested at the factory and carefully packaged for shipment. When you receive your motor, there are several things you should do immediately. 1. 2. Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered your motor. Verify that the part number of the motor you received is the same as the part number listed on your purchase order.

Storage

If the motor is not put into service immediately, the motor must be stored in a clean, dry and warm location. Several precautionary steps must be performed to avoid motor damage during storage. 1. Use a Megger periodically to ensure that the integrity of the winding insulation has been maintained. Record the Megger readings. Immediately investigate any significant drop in insulation resistance. Do not lubricate bearings during storage. Motor bearings are packed with grease at the factory. Excessive grease can damage insulation quality. Rotate motor shaft at least 10 turns every two months during storage (more frequently if possible). This will prevent bearing damage due to storage. If the storage location is damp or humid, the motor windings must be protected from moisture. This can be done by applying power to the motors' space heater (if available) while the motor is in storage.

2. 3. 4.

Unpacking

Each Baldor motor is packaged for ease of handling and to prevent entry of contaminants. 1. To avoid condensation inside the motor, do not unpack until the motor has reached room temperature. (Room temperature is the temperature of the room in which it will be installed). The packing provides insulation from temperature changes during transportation. When the motor has reached room temperature, remove all protective wrapping material from the motor. Use the lugs or eye bolts provided to lift the motor. Never attempt to lift the motor and additional equipment connected to the motor by this method. The lugs or eye bolts provided are designed to lift only the motor. Never lift the motor by the motor shaft or the hood of a WPII motor. When lifting a WPII (Weather Proof Type 2) motor, do not lift the motor by inserting lifting lugs into holes on top of the cooling hood. These lugs are to be used for hood removal only. A spreader bar should be used to lift the motor by the cast lifting lugs located on the motor frame. If the motor must be mounted to a plate with the driven equipment such as pump, compressor etc., it may not be possible to lift the motor alone. For this case, the assembly should be lifted by a sling around the mounting base. The entire assembly can be lifted as an assembly for installation. Do not lift using the motor lugs or eye bolts provided. If the load is unbalanced (as with couplings or additional attachments) additional slings or other means must be used to prevent tipping. In any event, the load must be secure before lifting.

2.

Handling

The motor should be lifted using the lifting lugs or eye bolts provided. 1.

2.

3.

14 General Information

MN400

Section 2 Installation & Operation

Overview
Installation should conform to the National Electrical Code as well as local codes and practices. When other devices are coupled to the motor shaft, be sure to install protective devices to prevent future accidents. Some protective devices include, coupling, belt guard, chain guard, shaft covers etc. These protect against accidental contact with moving parts. Machinery that is accessible to personnel should provide further protection in the form of guard rails, screening, warning signs etc. It is important that motors be installed in locations that are compatible with motor enclosure and ambient conditions. Improper selection of the motor enclosure and ambient conditions can lead to reduced operating life of the motor. Proper ventilation for the motor must be provided. Obstructed airflow can lead to reduction of motor life. 1. 2. Open Drip-Proof/WPI motors are intended for use indoors where atmosphere is relatively clean, dry, well ventilated and non-corrosive. Totally Enclosed and WPII motors may be installed where dirt, moisture or dust are present and in outdoor locations.

Location

Severe Duty, IEEE 841 and Washdown Duty enclosed motors are designed for installations with high corrosion or excessive moisture conditions. These motors should not be placed into an environment where there is the presence of flammable or combustible vapors, dust or any combustible material, unless specifically designed for this type of service.

Mounting

The motor must be securely installed to a rigid foundation or mounting surface to minimize vibration and maintain alignment between the motor and shaft load. Failure to provide a proper mounting surface may cause vibration, misalignment and bearing damage. Foundation caps and sole plates are designed to act as spacers for the equipment they support. If these devices are used, be sure that they are evenly supported by the foundation or mounting surface. After installation is complete and accurate alignment of the motor and load is accomplished, the base should be grouted to the foundation to maintain this alignment. The standard motor base is designed for horizontal or vertical mounting. Adjustable or sliding rails are designed for horizontal mounting only. Consult your Baldor distributor or authorized Baldor Service Center for further information.

Alignment

Accurate alignment of the motor with the driven equipment is extremely important. 1. Direct Coupling For direct drive, use flexible couplings if possible. Consult the drive or equipment manufacturer for more information. Mechanical vibration and roughness during operation may indicate poor alignment. Use dial indicators to check alignment. The space between coupling hubs should be maintained as recommended by the coupling manufacturer. EndPlay Adjustment The axial position of the motor frame with respect to its load is also extremely important. The motor bearings are not designed for excessive external axial thrust loads. Improper adjustment will cause failure. Pulley Ratio The pulley ratio should not exceed 8:1. Belt Drive Align sheaves carefully to minimize belt wear and axial bearing loads (see EndPlay Adjustment). Belt tension should be sufficient to prevent belt slippage at rated speed and load. However, belt slippage may occur during starting. Do not over tension belts. Sleeve bearing motors are only suitable for coupled loads.

2.

3. 4.

Caution: 5.

MN400

Installation & Operation 21

Section 1 General Information

Doweling & Bolting
After proper alignment is verified, dowel pins should be inserted through the motor feet into the foundation. This will maintain the correct motor position should motor removal be required. (Baldor motors are designed for doweling.) 1. 2. 3. 4. 5. Drill dowel holes in diagonally opposite motor feet in the locations provided. Drill corresponding holes in the foundation. Ream all holes. Install proper fitting dowels. Mounting bolts must be carefully tightened to prevent changes in alignment. Use a flat washer and lock washer under each nut or bolt head to hold the motor feet secure. Flanged nuts or bolts may be used as an alternative to washers.

Power Connection
Conduit Box

Motor and control wiring, overload protection, disconnects, accessories and grounding should conform to the National Electrical Code and local codes and practices. For ease of making connections, an oversize conduit box is provided. The box can be rotated 360 in 90 increments. Auxiliary conduit boxes are provided on some motors for accessories such as space heaters, RTD's etc. Connect the motor leads as shown on the connection diagram located on the name plate or inside the cover on the conduit box. Be sure the following guidelines are met: 1. AC power is within 10% of rated voltage with rated frequency. (See motor name plate for ratings). OR AC power is within 5% of rated frequency with rated voltage. OR A combined variation in voltage and frequency of 10% (sum of absolute values) of rated values, provided the frequency variation does not exceed 5% of rated frequency.

AC Power

2. 3.

Performance within these voltage and frequency variations are shown in Figure 22.

Figure 21 Accessory Connections

One heater is installed in each end of motor. Leads for each heater are labeled H1 & H2. (Like numbers should be tied together).

Three thermisters are installed in windings and tied in series. Leads are labeled T1 & T2.

Winding RTDs are installed in windings (2) per phase. Each set of leads is labeled W1, W2, W3, W4, W5, & W6. * One bearing RTD is installed in Drive endplate (PUEP), leads are labeled RTDDE. * One bearing RTD is installed in Opposite Drive endplate (FREP), leads are labeled RTDODE. * Note RTD may have 2-Red/1-White leads; or 2-White/1-Red Lead.

22 Installation & Operation

MN400

Section 1 General Information

Figure 22 Typical Motor Performance VS Voltage Variations
+20 Full Load Current +15 Changes in Motor Performance (%) Maximum Torque

+10 Power Factor Full Load Current

+5

0 Efficiency Efficiency

-5

-10

-15 Maximum Torque -15 -10 -5 0 +5 +10

Power Factor +15

-20

Voltage Variations (%)

MN400

Installation & Operation 23

Section 1 General Information

First Time Start Up Be sure that all power to motor and accessories is off. Be sure the motor shaft is disconnected from the load and will not cause mechanical rotation of the motor shaft. 1. 2. 3. 4. 5. 6. 7. 8. 9. Make sure that the mechanical installation is secure. All bolts and nuts are tightened etc. If motor has been in storage or idle for some time, check winding insulation integrity with a Megger. Inspect all electrical connections for proper termination, clearance, mechanical strength and electrical continuity. Be sure all shipping materials and braces (if used) are removed from motor shaft. Manually rotate the motor shaft to ensure that it rotates freely. Replace all panels and covers that were removed during installation. Momentarily apply power and check the direction of rotation of the motor shaft. If motor rotation is wrong, be sure power is off and change the motor lead connections. Verify rotation direction before you continue. Start the motor and ensure operation is smooth without excessive vibration or noise. If so, run the motor for 1 hour with no load connected.

10. After 1 hour of operation, disconnect power and connect the load to the motor shaft. Verify all coupling guards and protective devices are installed. Ensure motor is properly ventilated.

Coupled Start Up

This procedure assumes a coupled start up. Also, that the first time start up procedure was successful. 1. 2. 3. Check the coupling and ensure that all guards and protective devices are installed. Check that the coupling is properly aligned and not binding. The first coupled start up should be with no load. Apply power and verify that the load is not transmitting excessive vibration back to the motor though the coupling or the foundation. Vibration should be at an acceptable level. Run for approximately 1 hour with the driven equipment in an unloaded condition.

4.

The equipment can now be loaded and operated within specified limits. Do not exceed the name plate ratings for amperes for steady continuous loads.

Jogging and Repeated Starts Repeated starts and/or jogs of induction motors generally reduce the life of the motor
winding insulation. A much greater amount of heat is produced by each acceleration or jog than by the same motor under full load. If it is necessary to repeatedly start or jog the motor, it is advisable to check the application with your local Baldor distributor or Baldor Service Center. Heating Duty rating and maximum ambient temperature are stated on the motor name plate. Do not exceed these values. If there is any question regarding safe operation, contact your local Baldor distributor or Baldor Service Center.

24 Installation & Operation

MN400

Section 3 Maintenance & Troubleshooting

WARNING: UL Listed motors must only be serviced by UL Approved Authorized Baldor Service Centers if these motors are to be returned to a hazardous and/or explosive atmosphere.

General Inspection

Inspect the motor at regular intervals, approximately every 500 hours of operation or every 3 months, whichever occurs first. Keep the motor clean and the ventilation openings clear. The following steps should be performed at each inspection: WARNING: Do not touch electrical connections before you first ensure that power has been disconnected. Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the installation, operation and maintenance of this equipment.

1.

Check that the motor is clean. Check that the interior and exterior of the motor is free of dirt, oil, grease, water, etc. Oily vapor, paper pulp, textile lint, etc. can accumulate and block motor ventilation. If the motor is not properly ventilated, overheating can occur and cause early motor failure. Use a Megger periodically to ensure that the integrity of the winding insulation has been maintained. Record the Megger readings. Immediately investigate any significant drop in insulation resistance. Check all electrical connectors to be sure that they are tight.

2.

3.

Relubrication & Bearings

Bearing grease will lose its lubricating ability over time, not suddenly. The lubricating ability of a grease (over time) depends primarily on the type of grease, the size of the bearing, the speed at which the bearing operates and the severity of the operating conditions. Good results can be obtained if the following recommendations are used in your maintenance program. A high grade ball or roller bearing grease should be used. Recommended grease for standard service conditions is Polyrex EM (Exxon Mobil). Equivalent and compatible greases include: Texaco Polystar, Rykon Premium #2, Pennzoil Pen 2 Lube and Chevron SRI.

Type of Grease

Relubrication Intervals

Recommended relubrication intervals are shown in Table 31. It is important to realize that the recommended intervals of Table 31 are based on average use. Refer to additional information contained in Tables 32, 33 and 34.

Table 31 Relubrication Intervals *

NEMA / (IEC) Frame Size Up to 210 incl. (132) Over 210 to 280 incl. (180) Over 280 to 360 incl. (225) Over 360 to 5800 incl. (300) * ** 10000 ** 6000 2700 Hrs. ** ** ** Rated Speed RPM 3600 1800 5500 Hrs. 12000 Hrs. 3600 Hrs. 9500 Hrs. * 2200 Hrs. 7400 Hrs. *2200 Hrs. 3500 Hrs. 1200 18000 Hrs. 15000 Hrs. 12000 Hrs. 7400 Hrs. 900 22000 Hrs. 18000 Hrs. 15000 Hrs. 10500 Hrs.

Relubrication intervals are for ball bearings. For vertically mounted motors and roller bearings, divide the relubrication interval by 2. For motors operating at speeds greater than 3600 RPM, contact Baldor for relubrication recommendations.

MN400

Maintenance & Troubleshooting 31

Table 32 Service Conditions

Severity of Service Standard Severe Extreme Low Temperature * ** Hours per day of Operation 8 16 Plus 16 Plus Ambient Temperature Maximum 40 C 50 C >50 C* or Class H Insulation <-29 C ** Atmospheric Contamination Clean, Little Corrosion Moderate dirt, Corrosion Severe dirt, Abrasive dust, Corrosion, Heavy Shock or Vibration

Special high temperature grease is recommended (Dow Corning DC44). Note that Dow Corning DC44 grease does not mix with other grease types. Thoroughly clean bearing & cavity before adding grease. Special low temperature grease is recommended (Aeroshell 7).

Table 33 Relubrication Interval Multiplier

Severity of Service Standard Severe Extreme Low Temperature Multiplier 1.0 0.5 0.1 1.0

Some motor designs use different bearings on each motor end. This is normally indicated on the motor nameplate. In this case, the larger bearing is installed on the motor Drive endplate. For best relubrication results, only use the appropriate amount of grease for each bearing size (not the same for both).

Table 34 Bearings Sizes and Types

Bearing Description (These are the Large bearings (Shaft End) in each frame size) Volume of grease Weight of Grease to to be added Bearing add * in3 teaspoon oz (Grams) 6203 0.08 (2.4) 0.15 0.5 6205 0.15 (3.9) 0.2 0.8 6206 0.19 (5.0) 0.3 1.0 6307 0.30 (8.4) 0.6 2.0 6309 0.47 (12.5) 0.7 2.5 6311 0.61 (17) 1.2 3.9 6312 0.76 (20.1) 1.2 4.0 6313 0.81 (23) 1.5 5.2 6316 1.25 (33) 2.0 6.6 6319 2.12 (60) 4.1 13.4 6328 4.70 (130) 9.2 30.0 NU328 4.70 (130) 9.2 30.0 NU319 2.12 (60) 4.1 13.4 6207 6210 6213 0.22 (6.1) 0.32 (9.0) 0.49 (14.0) 0.44 0.64 0.99 1.4 2.1 3.3

Frame Size NEMA (IEC) 56 to 140 (90) 140 (90) 180 (100-112) 210 (132) 250 (160) 280 (180) 320 (200) 360 (225) 400 (250) 440 (280) 5000 to 5800 (315-450) 5000 to 5800 (315-450) 360 to 449 (225-280) AC Induction Servo 76 Frame 180 (112) 77 Frame 210 (132) 80 Frame 250(160) * Weight in grams = .005 DB of grease to be added

Note: Not all bearing sizes are listed. For intermediate bearing sizes, use the grease volume for the next larger size bearing.

32 Maintenance & Troubleshooting

MN400

Caution: To avoid damage to motor bearings, grease must be kept free of dirt. For an extremely dirty environment, contact your Baldor distributor or an authorized Baldor Service Center for additional information. Relubrication Procedure Be sure that the grease you are adding to the motor is compatible with the grease already in the motor. Consult your Baldor distributor or an authorized service center if a grease other than the recommended type is to be used. Caution: Do not over-lubricate motor as this may cause premature bearing failure. With Grease Outlet Plug 1. 2. With the motor stopped, clean all grease fittings with a clean cloth. Remove grease outlet plug. Over-lubricating can cause excessive bearing temperatures, premature lubrication breakdown and bearing failure.

Caution: 3. 4. 5.

Add the recommended amount of grease. Operate the motor for 15 minutes with grease plug removed. This allows excess grease to purge. Reinstall grease outlet plug.

Without Grease Provisions Note: Only a Baldor authorized and UL or CSA certified service center can disassemble a UL/CSA listed explosion proof motor to maintain it's UL/CSA listing. 1. 2. Disassemble the motor. Add recommended amount of grease to bearing and bearing cavity. (Bearing should be about 1/3 full of grease and outboard bearing cavity should be about 1/2 full of grease.) Assemble the motor.

3.

Sample Relubrication Determination Assume NEMA 286T (IEC 180), 1750 RPM motor driving an exhaust fan in an ambient temperature of 43 C and the atmosphere is moderately corrosive. 1. 2. 3. Table 31 list 9500 hours for standard conditions. Table 32 classifies severity of service as Severe. Table 34 shows that 1.2 in3 or 3.9 teaspoon of grease is to be added.

Note: Smaller bearings in size category may require reduced amounts of grease.

MN400

Maintenance & Troubleshooting 33

Section 1 General Information

Table 35 Troubleshooting Chart
Symptom Motor will not start Excessive humming Motor Over Heating Possible Causes Usually caused by line trouble, such as, single phasing at the starter. High Voltage. Eccentric air gap. Overload. Compare actual amps (measured) with nameplate rating. Single Phasing. Improper ventilation. Possible Solutions Check source of power. Check overloads, fuses, controls, etc. Check input line connections. Have motor serviced at local Baldor service center. Locate and remove source of excessive friction in motor or load. Reduce load or replace with motor of greater capacity. Check current at all phases (should be approximately equal) to isolate and correct the problem. Check external cooling fan to be sure air is moving properly across cooling fins. Excessive dirt buildup on motor. Clean motor. Check voltage at all phases (should be approximately equal) to isolate and correct the problem. Check air gap clearance and bearings. Tighten Thru Bolts. Check input voltage at each phase to motor. Check stator resistance at all three phases for balance. Perform dielectric test and repair as required. Inspect all electrical connections for proper termination, clearance, mechanical strength and electrical continuity. Refer to motor lead connection diagram. Check and align motor and driven equipment. Reduce belt tension to proper point for load. Reduce the end thrust from driven machine. Remove grease until cavity is approximately 3/4 filled. Add grease until cavity is approximately 3/4 filled. Clean bearing cavity and bearing. Repack with correct grease until cavity is approximately 3/4 filled. Check and align motor and driven equipment. Isolate and eliminate cause of rubbing. Have rotor balance checked are repaired at your Baldor Service Center. Tune system or contact your Baldor Service Center for assistance. Remove rotor and foreign material. Reinstall rotor. Check insulation integrity. Clean ventilation openings. Replace bearing. Clean all grease from cavity and new bearing. Repack with correct grease until cavity is approximately 3/4 filled.

Unbalanced voltage. Rotor rubbing on stator. Over voltage or under voltage. Open stator winding. Grounded winding. Improper connections.

Bearing Over Heating

Misalignment. Excessive belt tension. Excessive end thrust. Excessive grease in bearing. Insufficient grease in bearing. Dirt in bearing. Misalignment. Rubbing between rotating parts and stationary parts. Rotor out of balance. Resonance.

Vibration

Noise Growling or whining

Foreign material in air gap or ventilation openings. Bad bearing.

34 Maintenance & Troubleshooting

MN400

Suggested bearing and winding RTD setting guidelines

Most large frame AC Baldor motors with a 1.15 service factor are designed to operate below a Class B (80C) temperature rise at rated load and are built with a Class H winding insulation system. Based on this low temperature rise, RTD (Resistance Temperature Detectors) settings for Class B rise should be used as a starting point. Some motors with 1.0 service factor have Class F temperature rise. The following tables show the suggested alarm and trip settings for RTDs. Proper bearing and winding RTD alarm and trip settings should be selected based on these tables unless otherwise specified for specific applications. If the driven load is found to operate well below the initial temperature settings under normal conditions, the alarm and trip settings may be reduced so that an abnormal machine load will be identified. The temperature limits are based on the installation of the winding RTDs imbedded in the winding as specified by NEMA. Bearing RTDs should be installed so they are in contact with the outer race on ball or roller bearings or in direct contact with the sleeve bearing shell.
Winding RTDs - Temperature Limit In 5C (405C Maximum Ambient) Motor Load Class B Temp Rise 3 80C (Typical Design) Alarm Trip 130 140 140 150 Class F Temp Rise 3 105C Class H Temp Rise 3 125C Trip 185 185

Alarm Trip Alarm 3 Rated Load 155 165 175 Rated Load 160 165 180 to 1.15 S.F. Note: S Winding RTDs are factory production installed, not from Mod-Express. S When Class H temperatures are used, consider bearing temperatures and relubrication requirements.

Bearing RTDs - Temperature Limit In 5C (405C Maximum Ambient) Anti-Friction Sleeve Bearing Type Oil or Grease Alarm Trip Alarm Standard* 95 100 85 High Temperature** 110 115 105 Note: * Bearing temperature limits are for standard design motors operating at Class B temperature rise. ** High temperature lubricants include some special synthetic oils and greases. Trip 95 110

Greases that may be substituted that are compatible with Polyrex EM (but considered as standard lubricants) include the following: - Texaco Polystar - Rykon Premium #2 - Chevron SRI #2 - Mobilith SHC-100 - Pennzoil Pennzlube EM-2 - Chevron Black Pearl - Darmex 707 - Darmex 711 - Petro-Canada Peerless LLG

See the motor nameplate for replacement grease or oil recommendation. Contact Baldor application engineering for special lubricants or further clarifications.

MN400

Maintenance & Troubleshooting 35

36 Maintenance & Troubleshooting

MN400

Baldor District Offices Baldor District Offices Baldor District Offices

BALDOR ELECTRIC COMPANY World Headquarters P.O. Box 2400 Fort Smith, AR 72901-2400 (479) 646-4711 Fax (479) 648-5792 www.baldor.com

Baldor Electric Company MN400

Printed in USA 2/07

t ns uc tio od ca Pr ne ifi Li pec S

MAXI-BEAM Sensors

Highly versatile modularized photoelectric sensing controls

Printed in USA

Highly versatile, self-contained, modularized photoelectric sensors; especially suited to industrial environments Wide selection of rotatable sensor heads, power blocks, and logic timing modules to suit any application Power blocks for AC or DC operation and for switching of AC or DC loads Sensor heads include patented AID indicator device, which lights a top-mounted LED when the sensor "sees" its own modulated light source and pulses the LED at a rate proportional to the received light signal strength Status indicator LEDs on power block continuously indicate the state of the output circuit Models are available in all sensing modes
P/N 32883F4A

MAXI-BEAM
Modular Sensors
Banner MAXI-BEAM sensors are highly versatile, self-contained, modularized photoelectric sensing controls that are ideally suited to industrial environments. The basic MAXI-BEAM is an ON/OFF switch consisting of three modules: a sensor head, a power block, and a wiring base. The sensor head contains the complete modulated photoelectric amplifier as well as the emitter and receiver optoelements. A unique, patented, "programming ring" (supplied with each sensor head) enables you to program your choice of "light" or "dark" operate mode, sensing range, and response time. MAXI-BEAM sensor heads have an easily-accessible multi-turn SENSITIVITY control for precise adjustment of system gain. Interchangeable sensor heads are rotatable in 90degree increments, and are available in opposed, retroreflective, diffuse, convergent, and fiber optic models. Each sensor head also includes Banner's exclusive, patented Alignment Indicating Device (AID, U.S. patent #4356393), which lights a top-mounted LED when the sensor "sees" its own modulated light source and pulses at a rate proportional to the received light signal strength. The power block provides the interface between the sensor head and the external circuit. It contains the power supply for the MAXI-BEAM plus a switching device to interface with the circuit to be controlled. DC power block versions operate on 10 to 30V dc and have solid-state sourcing and sinking outputs rated at 250mA each (maximum). AC models are available for 120V or 240V ac operation, and are offered in both 2-wire and 3- or 4-wire formats. The plug-in design of the wiring base enables easy exchange of the entire sensing electronics without disturbing the field wiring. Status LEDs on the power block module continuously indicate the state of the output circuit. Optional logic modules are available which easily convert the basic ON/OFF MAXI-BEAM into either a one-shot or delay logic function control. The logic module comes with a programming ring which is used to select one of several timing ranges for each logic function. Timing adjustments are made via two 15-turn clutched potentiometers, accessible from the outside. Once programmed, the logic module may be rotated in 90-degree increments to allow time adjustment access from the most convenient location.

MAXI-BEAM Sensor Heads

All MAXI-BEAM components are encapsulated within rugged, corrosion-resistant VALOX housings which meet or exceed NEMA 1, 3, 4, 12, and 13 standards. Modules simply snap and bolt together, with no interwiring necessary. Module interfaces are o-ring and quad-ring sealed for the ultimate in dirt, dust, and moisture resistance. All MAXI-BEAM components (except for power block model RPBR) are totally solid-state for unlimited life. MAXI-BEAM assemblies have the same mounting configuration as Banner MULTI-BEAM sensors, and are physically interchangeable with heavy-duty industrial limit switches. Most MAXI-BEAM sensors are CSA certified and UL listed. See the power block information on pages 8 to 13.

WARNING

MAXI-BEAM photoelectric presence sensors do NOT include the self-checking redundant circuitry necessary to allow their use in personnel safety applications. A sensor failure or malfunction can result in either an energized or a de-energized sensor output condition.

Never use these products as sensing devices for personnel protection. Their use as a safety device may create an unsafe condition which could lead to serious injury or death. Only MACHINE-GUARD and PERIMETER-GUARD Systems, and other systems so designated, are designed to meet OSHA and ANSI machine safety standards for point-of-operation guarding devices. No other Banner sensors or controls are designed to meet these standards, and they must NOT be used as sensing devices for personnel protection.

Composite Functional Schematic, MAXI-BEAM Sensors

RWB4

Selection of MAXI-BEAM Components

The modular design of the MAXI-BEAM allows you to create a sensor which is tailored to your exact requirements. To order a MAXI-BEAM, follow these steps: 1) SELECT A SENSOR HEAD (see pages 3-7). Sensor heads are available for opposed, retroreflective, diffuse, convergent, and fiberoptic sensing modes. 2) SELECT A POWER BLOCK (see pages 8-13). Power blocks are available for low voltage dc with either a solid-state or an electromechanical relay output. AC power blocks are available in either 2-wire design with solid-state output or 4-wire design with a choice of solidstate or electromechanical relay output. 3) SELECT A WIRING BASE (see page 8, top). Model RWB4 wiring base is used for all MAXI-BEAM assemblies (purchase separately). 4) SELECT A LOGIC MODULE, if needed (see pages 14-15). MAXI-BEAMs operate in the ON/OFF mode (i.e. the output follows the action within the sensing beam) when no logic module is used. The addition of a programmable logic module can add process timing control as part of the MAXI-BEAM sensor assembly. 5) SELECT ACCESSORIES, as needed (see pages 15-16).

Exploded view, MAXI-BEAM Sensor

Sensitivity Control LED/AID Indicator Rotatable Sensor Head

Programming Ring Optional Logic Module Programming Ring for Logic Power Block RWB4 Wiring Base

MAXI-BEAM Dimensions

Output OFF LED Output ON LED Quick Disconnect (optional)

Conduit Entrance

Specifications: MAXI-BEAM Sensor Heads

SUPPLY VOLTAGE: Input power is supplied by the power block (see pages 8 to 13). RESPONSE TIME: Programmable for 10, 1, and 0.3 milliseconds (most models). See specifications on particular model. Independent of signal strength. NOTE: see power block specifications for information on additional output switching response delays. REPEATABILITY OF RESPONSE: See individual sensor specifications. NOTE: Response time and repeatability specifications are independent of signal strength. SENSITIVITY ADJUSTMENT: Easily accessible; located on top of sensor head beneath o-ring gasketed cover. 15-turn clutched control (rotate clockwise to increase gain).

Functional Schematic, MAXI-BEAM Sensor Head

ALIGNMENT INDICATOR: Red LED on top of sensor head. Banner's exclusive "AID" circuit lights the LED when the sensor sees its own modulated light source and pulses the LED at a rate proportional to the received light signal strength. CONSTRUCTION: Reinforced molded VALOX housing, molded acrylic lenses, oring and quad-ring gasketed components. Electronic components are fully epoxy-encapsulated. NEMA 1, 3, 4, 12, and 13. OPERATING TEMPERATURE RANGE: -40 to +70 degrees C (-40 to +158 degrees F). FALSE-PULSE SUPPRESSION ON POWER-UP: 100 millisecond delay on power-up, all models.

MAXI-BEAM Sensor Heads

Sensing Mode Models
RSBE & RSBR
1000

Excess Gain

Beam Pattern

OPPOSED Mode

Range: 300 feet (90 m) in RSBE/RSBR RSBE/RSBR 15 "HP" (high power) and 2W E 10 (2 wire) modes X 100 HP, 2W I HS C N 5 Beam: infrared, 880nm; E SP HP, 2W HS C 0 S H visible red tracer beam S SP E S 5 Effective Beam: 0.5" dia. G 10 10 A Response: II 15 N HP, 2W mode: 10ms on/ 80 160 240 320 400 0 5 off 1 OPPOSED DISTANCE --FE 1 FT 10 FT 100 FT 1000 FT HS mode: 1ms on/0.5 off DISTANCE SP mode: 0.3ms on/off Repeatability: HP, 2W= MAXI-BEAM emitters have a visible red "tracer beam". This beam is non-active, 1.4ms; HS = 0.1ms; and is used as a means of visual alignment during installation. A retroreflector SP = 0.04ms temporarily attached to the receiver lens provides an effective target for the tracer beam during alignment. The narrow beam of the RSBESR/RSBRSR pair is ideal RSBESR & for sensing small parts (effective beam diameter is 0.14 inch).

RSBRSR

Range: 15 feet (4,5m) in "HP" (high power) and 2W (2 wire) modes Beam: infrared, 880nm Response: HP, 2W modes: 10ms on/5 off HS mode: 1ms on/0.5 off SP mode: 0.3ms on/off Repeatability: HP, 2W= 1.4ms; HS = 0.1ms; SP = 0.04ms

1000

E X C 100 E S S G A 10 II N

RSBESR & RSBRSR

HP, 2W HS SP
I N C H E S

24 16 8 0 8 16 24

RSBESR & RSBRSR

SP

HS

HP, 2W

1 .1 FT

1 FT

10 FT

100 FT

3 6 9 12 OPPOSED DISTANCE--FEET

15

DISTANCE

RSBEF & RSBRF

Range: see excess gain curves Beam: infrared, 880nm. Response: HP, 2W modes: 10ms HS mode: 1ms SP mode: 0.3ms on/off Repeatability: HP, 2W= 3.3ms; HS = 0.3ms; SP = 0.1ms

1000 SP E X C 100 E S S G 10 A II N 1 .1 IN HS IT23S fibers, no lenses

RSBEF & RSBRF

6 4 I N 2 C 0 H E S 2 4 6 0

RSBEF & RSBRF

HP, 2W SP HS

HP, 2W

IT23S fibers, no lenses 8 16 24 32 OPPOSED DISTANCE --INCHES 40

1 IN 10 IN DISTANCE

100 IN

OPPOSED FIBER OPTIC Mode (glass fibers)

This sensor pair is designed for opposed mode operation using Banner glass fiber optics. Maximum range (HP mode) using L9 lenses is 12 feet. Maximum range using L16F lenses is 50 feet.

RSBLV
Range: 6 inches to 30 feet (9 m) in all program modes Beam: visible red, 650nm Response: HP, 2W, SP modes: 4ms HS mode: 1ms Repeatability: HP, 2W, SP = 1.3ms; HS = 0.3ms

1000

E X C 100 E S S G A 10 II N

RSBLV
BRT-1 1" reflector BRT-3 3" reflector

6 4 I N 2 C 0 H E S 2 4 6 0

RSBLV
with BRT-3 reflector

BRT-T tape 1 .1 FT 1 FT 10 FT DISTANCE 100 FT

6 12 18 24 DISTANCE TO REFLECTOR--FEET

32

RETROREFLECTIVE Mode
(anti-glare filter) Range: 1 to 15 feet (4,5 m) in all program modes Beam: visible red, 650nm; with polarizing filter Response: HP, 2W, SP modes: 4ms HS mode: 1ms Repeatability: HP, 2W, SP = 1.3ms; HS = 0.3ms

RSBLVAG

1000

RSBLVAG
E X C 100 E S S G 10 A II N 1 .1 FT with BRT-3 reflector

3 2 I N 1 C 0 H E S 1 2 3 0

RSBLVAG

1 FT

10 FT

100 FT

3 6 9 12 DISTANCE TO REFLECTOR--FEET

15

DISTANCE

MAXI-BEAM Sensor Heads

Sensing Mode Models
RSBD
Range: 5 feet (1,5 m) in HP and 2W modes Beam: infrared, 880nm Response: HP, 2W modes: 10ms HS mode: 1ms SP mode: 0.3ms Repeatability: HP, 2W= 3.3ms; HS = 0.3ms; SP = 0.1ms

Excess Gain
1000 E X C 100 E S S G A 10 II N

Beam Pattern
3

RSBD
RANGE BASED ON OBJECT OF 90% REFLECTANCE

RSBD

2 I N 1 C H 0 E S 1 2 HS SP HP, 2W

HP, 2W HS

SP 1 .1 IN 1 IN 10 IN DISTANCE 100 IN
12 24 36 48 60 0 DISTANCE TO 90% WHITE TEST CARD--INCHE

DIFFUSE Mode

RSBDSR
(short range) Range: 30 inches (76cm) in HP and 2W modes Beam: infrared, 880nm Response: HP, 2W modes: 10ms HS mode: 1ms SP mode: 0.3ms Repeatability: HP, 2W= 3.3ms; HS =0.3ms; SP =0.1ms

1000

RSBDSR
E X C 100 E S S G 10 A II N HP, 2W HS SP range based on 90% reflectance white test card

1.5 1.0 I N 0.5 C H 0 E S 0.5 1.0 1.5

RSBDSR
SP HS HP, 2W

1 .1 IN

1 IN 10 IN DISTANCE

100 IN

6 12 18 24 30 0 DISTANCE TO 90% WHITE TEST CARD--INCHE

RSBC
Focus at 1.5 in. (38mm) Beam: infrared, 940nm Response: HP, 2W modes: 10ms HS mode: 1ms SP mode: 0.3ms Repeatability: HP, 2W= 3.3ms; HS = 0.3ms; SP= 0.1ms

1000

RSBC
E X C 100 E S S G A II N 10 Range based on 90% reflectance white test card

.2 .1

RSBC

HP, 2W modes

I N C 0 H E S .1 .2

HS, SP

HP, 2W modes

1 .1 IN

HS, SP modes 1 IN 10 IN 100 IN DISTANCE

1.0

2.0

3.0

4.0

5.0

DISTANCE TO 90% WHITE TEST CARD--INCHES

CONVERGENT Mode
RSBCV
Focus at 1.5 in. (38mm); performance equal in all program modes. Beam: visible red, 650nm. Response: HP, 2W, SP modes: 4ms HS mode: 1ms Repeatability: HP, 2W, SP= 1.3ms; HS = 0.3ms

Powerful infrared beam reliably senses objects of low reflectivity. Ideal for counting the flow of radiused products at a fixed distance from the sensor.
1000

RSBCV
E X C 100 E S S G A 10 II N range based on 90% reflectance white test card

.030 .020 I N .010 C 0 H E S .010 .020 .030 0 .50 1.0 1.5 2.0 2.5

RSBCV

all modes

1 .1 IN

1 IN 10 IN DISTANCE

100 IN

DISTANCE TO 90% WHITE TEST CARD--INCHES

Powerful visible red beam detects small objects only a fraction of an inch away from backgrounds. Useful in many high-contrast color registration applications.

FIXED-FIELD Mode
RSBFF models
Far limit cutoff at: 50mm (model RSBFF50) or 100mm (model RSBFF100) Beam: infrared, 880nm. Response: HP mode: 10ms Repeatability: HP mode: 3.3ms

Fixed-field sensor heads have an emitter element and two differently-aimed receiver elements. This creates a highgain sensing field able to detect objects of low reflectivity, and a sharp far-limit sensing cutoff of 50mm (2 inches) or 100mm (4 inches) which ignores backgrounds beyond cutoff. These sensors are ideal for detecting a part or surface that is only a fraction of an inch in front of another surface. RSBFFs may not be used with 2-wire power blocks.

1000

MAXI-BEAM Fixed-field Sensor Heads

E X 100 C E S S G 10 A I 5 N 1 0.1 mm
(Range based on 90% reflectance white test card)

50 mm

100 mm

1 mm 10 mm DISTANCE

100 mm

MAXI-BEAM Sensor Heads

Sensing Mode Models
RSBF
Range: see excess gain curves Beam: infrared, 880nm Response: HP, 2W modes: 10ms HS mode: 1ms SP mode: 0.3ms Repeatability: HP, 2W= 3.3ms; HS = 0.3ms; SP = 0.1ms
1000 SP E X C 100 E S S G 10 A II N 1 .1 IN HS HP, 2W

Excess Gain

Beam Pattern

RSBF

6 4 I N 2 C 0 H E S 2 4 6 0

Opposed mode with IT23S fibers

RSBF
HP, 2W SP HS

Opposed mode IT23S fibers

1 IN 10 IN DISTANCE

100 IN

8 16 24 32 OPPOSED DISTANCE --INCHE

40

FIBER OPTIC Mode (glass fibers)

OPPOSED MODE

1000

OBJECT

RETRO MODE

RETROREFLECTOR

NOTE: if the retroreflective sensing mode is used in conjunction with the HP or 2W program mode, the GAIN control must be reduced from the factory setting in order to avoid optical feedback from the lens assembly.

E X C 100 E S S G A 10 II N

RSBF

Retroreflective mode, with BRT-3 reflector and BT13S fibers

6 4

RSBF
HS with L16F lenses

HS HS with L9 lenses

with L16F lenses

I N 2 C 0 H E S 2 4

HS with L9 lenses

6 Retroreflective mode with BT13S & BRT-3 0 4 8 12 16 20

1 .1 FT

1 FT

10 FT

100 FT

DISTANCE TO REFLECTOR --FEE

DISTANCE

1000

OBJECT
E X C 100 E S S

RSBF
Diffuse mode BT23S fibers HP, 2W HS SP

.3 .2 I N .1 C 0 H E S .1 .2 .3

RSBF
HP, 2W SP HS

DIFFUSE MODE

OBJECT

For information on the complete line of Banner glass fiber optics, see Banner product catalog.

G A 10 II N 1 .1 IN

Diffuse mode with BT23S fibers

1 IN 10 IN DISTANCE

100 IN

1 2 3 4 5 0 DISTANCE TO 90% WHITE TEST CARD--INCHES

RSBFP
Range: see excess gain curves Beam: visible red, 650nm. Response: HS mode only, 1ms on/off Repeatability: HS = 0.3ms

1000

RSBFP
E X C 100 E S S G A 10 II N PIT26U, no lens 1 .1 IN 1 IN 10 IN DISTANCE 100 IN PIT46U, no lenses Opposed mode, plastic fibers

1.8 1.2 I .6 N C H 0 E S .6 1.2 1.8 0

RSBFP

PIT26U

PIT46U

PIT46U with L2 lenses

Opposed mode
4 1 2 3 OPPOSED DISTANCE--INCHES 5

FIBER OPTIC Mode (plastic fibers)

OPPOSED MODE
OBJECT

The model RSBFP will function only when programmed for the "HS" response mode. The model RSBFP will not operate with 2-wire power blocks (models R2PBA and R2PBB).

Model RSBFP is a visible-light sensor head designed for use with plastic fiber optics. It is compatible with all standard Banner plastic fiber optic assemblies (see Banner product catalog). In order to function properly, the RSBFP must be programmed for the "HS" response mode. The RSBFP is not for use with glass fiber optics (instead use model RSBF or RSBFV).
1000

RSBFP
E X C 100 E S S G A II N 10 with PBT26U fiber 1 .01 IN .1 IN

Diffuse mode, plastic fibers (Range based on 90% reflectance white test card)

.15 .10 I .05 N C 0 H E .05 S .10 .15 0 .3 .6

RSBFP

DIFFUSE MODE
OBJECT

For information on the complete line of Banner plastic fiber optics, see Banner product catalog.

PBT26U

PBT46U

with PBT46U fiber

Diffuse mode

1 IN

10 IN

1.2 1.5 .9 DISTANCE TO 90% WHITE TEST CARD--INCHES

DISTANCE

MAXI-BEAM Sensor Heads

Sensing Mode Models
RSBFV
Range: see excess gain curves Beam: visible red, 650nm. Response: HS mode only, 1ms on/off Repeatability: HS = 0.3ms The model RSBFV will function only when programmed for the "HS" response mode. The model RSBFV will not operate with 2-wire power blocks (models R2PBA and R2PBB). Model RSBFV is a visible-light sensor head designed for use with glass fiber optics. It is compatible with all standard Banner glass fiber optic assemblies (see Banner product catalog). In order to function properly, the RSBFV must be programmed for the "HS" response mode. The RSBFV is not for use with plastic fiber optics (instead use RSBFP).

Excess Gain
1000

Beam Pattern

RSBFV
3
E X C 100 E S S G A 10 II IT13S fibers N 1 .1 IN Opposed mode

2 I 1 N C 0 H E S 1 2 3 0

RSBFV

IT13S Opposed mode

IT23S

IT23S fibers

1 IN

10 IN

100 IN

2 4 6 8 OPPOSED DISTANCE--INCHES

10

DISTANCE

FIBER OPTIC Mode (glass fibers)

OPPOSED MODE
OBJECT

1000

RSBFV
E X C 100 E S S G 10 A II N 1 .1 IN Retroreflective mode w/BRT-3 reflector with L16F lens and BT13S fibers

6 4 I 2 N C 0 H E 2 S 4 6 0

RSBFV

w/L9 lens w/L16F lens

with L9 lens and BT13S fibers 1 IN 10 IN 100 IN

BT13S fiber, retroreflective mode, with BRT-3 reflector

4 8 12 16 20 DISTANCE TO REFLECTOR--INCHES

RETROREFLECTOR

DISTANCE

RETRO MODE
OBJECT

1000

.1

RSBFV
E X C 100 E S S G A II N 10 Diffuse mode Range based on 90% reflectance white test card. BT23S fibers BT13S fibers 1 .01 IN

.075 .050 I N .025 C 0 H E S .025 .050 .075 .1 0 .2 .4

RSBFV

BT13S

BT23S

DIFFUSE MODE
OBJECT

Diffuse mode

.1 IN

1 IN

10 IN

.8 1.0 .6 DISTANCE TO 90% WHITE TEST CARD--INCHES

DISTANCE

Programming the MAXI-BEAM Sensor Head

MAXI-BEAM sensor heads may be programmed for sensor response time (and range) and for LIGHT/DARK operate. Each sensor head is supplied with a programming ring which attaches below the the sensor head by a system of pegs. There are four programming notches around the perimeter of the ring. To program the sensor head, simply find the notch which will line up with the desired program combination (see diagram, right). NOTE: the programming ring may have to be turned upside-down in order to line up the notch with the program. If LIGHT OPERATE is selected, the MAXI-BEAM output will energize on a dark-to-light transition. If DARK OPERATE is selected, the MAXI BEAM output will energize on a light-to-dark transition. In the illustration, the MAXI-BEAM is set for high speed (HS) operation in the LIGHT OPERATE output state. See the information about each individual sensor head for the response time and range associated with each setting (HP, 2W, HS, SP). NOTE: when programming the RSBE, RSBSER, or RSBEF emitter, select the mode which is programmed for the receiver. EXCEPTION: if the receiver is programmed for the 2-wire (2W) mode, select high power (HP) on the emitter.

MAXI-BEAM
HS: HI SPEED HP: HI POWER
DARK OPERATE

2W: 2 WIRE SP: SPECIAL

LIGHT OPERATE

H S 2 H H S 2 H S P WP S P W P

Programming ring

Notch

MAXI-BEAM Power Blocks and Wiring Base

MAXI-BEAM power blocks provide regulated low voltage dc power to the sensor head and logic module (if one is used), and all power blocks (except emitter-only types) contain an output switch for interfacing to loads or to control circuitry. Power blocks plug into the model RWB4 wiring base which has heavy-duty screw terminals that accept up to #12 gauge wire (no lugs are necessary). The RWB4 wiring base is necessary for all MAXI-BEAM sensor assemblies (except sensors using the RPBTLM power block), and must be purchased separately. All power blocks, except the emitter-only types, include status LEDs which continuously indicate the state of the output circuit and input power. MAXI-BEAM power blocks are epoxy-encapsulated and rated for -40 to +70 degrees C (except models RPBR and RPBR2). All MAXI-BEAMs have circuitry to prevent false closure of the output on power-up.

Power Block

RWB4 Wiring Base

(order separately)

DC Models

Connections

Functional Schematic

RPBT RPBT-1 (for emitters)

LOAD Source

RPBT 4
LOAD Sink

INPUT: 10 to 30V dc, 20mA, exclusive of load current; 10% maximum ripple. OUTPUT: one open-collector NPN (current sinking) and one open-collector PNP (current sourcing) transistor. 250mA continuous, short-circuit and reverse polarity protected (both outputs). ON-STATE VOLTAGE DROP: PNP output: less than 1 volt at 10mA and less than 2 volts at 250mA. NPN output: less than 200 millivolts at 10mA and less than 1 volt at 250mA. OFF-STATE LEAKAGE CURRENT: less than 10 microamps.

3 2

10-30V dc

Power block RPBT is the one most often used in low voltage dc applications. There are two solid state output switches (transistors), each rated at 1/4 amp. The NPN output at terminal #3 of the wiring base sinks current to the negative side of the power supply. The PNP output at terminal #4 sources current to the load from the positive side of the power supply. Both outputs may be used simultaneously. Response time of a MAXI-BEAM which uses model RPBT is the response time which is programmed at the sensor head (plus logic delays, if any). Model RPBT-1 is the dc power block to use with model RSBE, RSBESR, and RSBEF emitter sensor heads. The RPBT-1 has no switching elements.

Hookup Diagrams for RPBT and RPBT-1 Power Blocks

Hookup to dc Relay or Solenoid (using sinking output)
When using the power block with current sinking (NPN) output, simple loads connect between terminal #3 and the positive supply (terminal #1).
10 - 30V dc

Hookup to dc Relay or Solenoid (using sourcing output)

When using the power block with current sourcing (PNP) output, simple loads connect between terminal #4 and dc common (terminal #2).
10 - 30V dc

Hookup to Logic Gate (using sinking output)

A logic zero (0 volts dc) is applied to the GATE input when the MAXI-BEAM sinking output is energized. When de-energized, a logic one is applied. The logic supply must be common to the MAXI-BEAM +5V to 30V dc supply negative. Logic Supply
RPBT *
4 3 2 1

RPBT
LOAD 4 3 2 1

RPBT
4 3 2 1 LOAD

10 - 30V dc

* Use pullup resistor to logic supply

(-) dc

Hookup to a Programmable Controller requiring a current sink

Use MAXI-BEAM NPN output (terminal #3) to interface to PLCs and other logic devices requiring a current sink at the inputs. Connect terminal #3 of RPBT the power block to any input of the PLC. Also connect the negative of the MAXI-BEAM +10 - 30V dc power supply (terminal #2) to the negative of the PLC power supply. The hookup shown is typical for all inputs.

Hookup shown is typical for all inputs

1 2 3 4 5 I N P U T S P r o g. C t r l.

Hookup to a Programmable Controller requiring a current source Hookup shown

Use MAXI-BEAM PNP output (terminal #4) to interface to PLCs and other logic devices requiring a current source at the inputs. Connect terminal #4 of RPBT the power block to any input of the PLC. Connect the negative of the MAXI-BEAM power +10 - 30V dc supply (terminal #2) to the negative of the PLC power supply. The hookup shown is typical for all inputs.
is typical for all inputs
1 2 3 4 5
4 3 2 1

P I N P U T S r o g. C t r l.

4 3 2 1

6 7 8 dc+ dc com

6 7 8 dc+ dc com

MAXI-BEAM Power Blocks and Wiring Base

Hookup Diagrams for RPBT and RPBT-1 Power Blocks (continued)
Parallel Hookup of RPBT Power Blocks to a Common Load
Any number of MAXI-BEAMs may be connected in parallel to a load to create "LIGHT-OR" (light operate mode) or "DARK-OR" (dark operate mode) multiple sensor logic. The diagram at the right shows the current sinking outputs of two MAXI-BEAMs connected in parallel to control a load which requires a current sink (power block terminal #3). For loads requiring a current source, connect the wires from the load instead between terminals #4 and #2 (common). NOTE: series connection of dc MAXI-BEAM sensors may be accomplished using power block model RPBR (see below).
10 - 30V dc

Hookup of a DC Emitter
MAXI-BEAM emitter only sensor heads use dc power block model RPBT-1, which connects directly across the dc supply as shown.
RPBT
4 3 2 1

RPBT-1 10 - 30V dc
RPBT
LOAD 4 3 2 1

4 3 2 1

Hookup to MAXI-AMP Logic Module

The current sinking output of MAXI-BEAM power block RPBT may be connected directly to the input of CL Series MAXI-AMP modules. A MAXI-AMP which is powered by ac voltage offers a dc supply with enough capacity to power one MAXI-BEAM sensor, as is shown in this hookup diagram. When an emitter/receiver pair is used, the emitter should be powered from a separate power source CL3RA CL3RB (e.g.- use power block CL5RA RPBA-1, etc.).
9 10 11 1 2 3 4 5 6 7 8

Hookup to MICRO-AMP Logic (MPS-15 Chassis)

The current sinking output of an RPBT power block may be connected directly to the primary input (terminal #7) or the other inputs of MICRO-AMP logic modules. The following logic modules may be used:
4 3 2 1

NO

7 Micro- 6 8 Amp 5 1 Logic 4 2 3 MODEL MPS-15

NC

RPBT

RPBT
4 3 2 1

CL5RB

MA4-2 MA5 MA4G MA4L

One shot On/off delay 4-input "AND" Latch

Relay

120 Vac

N N O C C

AC/DC Model

Connections
Dry Contact RPBR 250V ac max. 30V dc max. 5 amps max. 12 to 250V ac 12 to 30V dc
LOAD

Functional Schematic

RPBR
INPUT: 12 to 30V dc, 40mA, exclusive of load current (at 30V dc); or 12 to 250V ac, 50/60Hz. OUTPUT: SPST electromechanical relay contact. Contact rating: 250V ac max., 30V dc max., 5 amps max. (resistive load); install MOV across contact if switching inductive load. Contact response: 20ms open and close (NOTE: add to sensor head response). Mechanical life: 10,000,000 operations. OPERATING TEMPERATURE: -40 to +50 degrees C (-40 to +122 degrees F).
4 3 2 1

Model RPBR operates the MAXI-BEAM with either ac or dc. It offers an SPST "hard" relay contact between wiring base terminals #3 & #4, which allows the MAXI-BEAM sensor to directly interface with loads which draw high current. It also allows series connection ("AND" logic) with multiple dc sensors.

Application caution: power block models RPBR and RPBR2

Power block modules RPBR and RPBR2 use "partial phase firing" power conversion to enable their wide range of ac input voltage (12 to 250V ac). AC power is applied to the sensor for only a small portion of each ac halfcycle. The current demand during this period may be as high as 1 to 2 amps per sensor. The collective current demand of several of these sensors on a common ac line is significant. If several sensors are wired directly to the ac mains, it is unlikely that any adverse effects will be noticed. On the other hand, problems may be noticed if several sensors are connected to a common circuit that is isolated from the ac mains by a transformer. The collective peak current demand may rob other components on the same circuit of enough power to function properly. In the worst case, a transformer with inadequate reserve current capacity may overheat. Barring a transformer failure, the sensors themselves will operate normally. As a general rule, if more than three or four MAXI-BEAM sensors using RPBR or RPBR2 power blocks must be connected to the same transformer-isolated ac circuit, consider the substitution of power block model RPBAR2 (for 105-130V ac) or model RPBBR2 (for 210-250V ac), which use conventional ac-to-dc power conversion circuitry. These power blocks connect exactly like model RPBR2, but do not exhibit the peak power demand of a phase-fired design. Output relay specifications are identical to model RPBR2. Contact your Banner representatiove or distributor for pricing and availability. NOTE: Peak power demand is not an issue when the RPBR or RPBR2 are powered from direct current (12 to 30V dc).

MAXI-BEAM Power Blocks and Wiring Base

AC Models Connections Functional Schematic

RPBR2
INPUT: 12 to 30V dc, 40mA, exclusive of load current (at 30V dc); or 12 to 250V ac, 50/60Hz. OUTPUT: SPDT electromechanical relay contacts. Contact rating: 250V ac max., 30V dc max., 5 amps max. (resistive load); install MOV across contact if switching inductive load. Contact response: 20ms open and close (NOTE: add to sensor head response). Mechanical life: 10,000,000 operations. OPERATING TEMPERATURE: -40 to +50 degrees C (-40 to +122 degrees F). RPBR2 is an SPDT output version of model RPBR, with both contacts common to terminal #1. Terminal #3 is normally open; terminal #4 is normally closed. See application caution, page 9.
RPBA

3- and 4-wire operation

RPBA
INPUT: 105 to 130V ac, 50/60Hz; 2 watts exclusive of load.
Supply Voltage RPBA: 105 to 130V ac RPBB: 210 to 250V ac
LOAD Jumper

4 3 2 1

RPBB
INPUT: 210 to 250V ac, 50/60Hz; 2 watts exclusive of load. OUTPUT: SPST solid-state switch for ac, 3/4 amp maximum (derated to 1/2 amp at 70 degrees C). Maximum inrush 10 amps for one second or 30 amps for one ac cycle (non-repeating). On-state voltage drop of less than 2.5V ac at full load. Off-state leakage current less than 100 microamps. NOTE: ac loads require up to 8.3 milliseconds to turn OFF in addition to the response time of the sensor head and delay logic (if any).

Power block models RPBA and RPBB are the most commonly used for ac MAXI-BEAM operation. As the typical hookup shows, they are intended to switch the same ac voltage as is used to power the MAXI-BEAM. However, both can switch any ac voltage that is lower than the supply voltage, as long as both ac circuits share a common neutral. Observe local codes whenever mixing ac voltages in a common wiring chamber. These blocks are designed to handle the inrush current of ac inductive loads like motor starters and solenoids. There is no mimimum load requirement, and they will interface directly to inputs of all ac programmable logic controllers (PLCs). Special order models RPBAT (120V ac) and RPBBT (240V ac) are available for interfacing to dc loads of up to 100 milliamps.

RPBA-1
For RSBE, RSBESR, and RSBEF emitters
INPUT: 105 to 130V ac, 50/60Hz; 2 watts.
RPBA-1: 105 to 130V ac RPBB-1: 210 to 250V ac 4 3

RPBB-1
For RSBE, RSBESR, and RSBEF emitters
INPUT: 210 to 250V ac, 50/60Hz; 2 watts.

Supply Voltage

2 1

2-wire operation
R2PBA
INPUT: 105 to 130V ac, 50/60Hz; 2 watts exclusive of load
Supply Voltage
LOAD

4 3 2

R2PBA: 105 to 130V ac R2PBB: 210 to 250V ac

R2PBB
INPUT: 210 to 250V ac, 50/60Hz; 2 watts exclusive of load. OUTPUT: SPST solid-state switch for ac, 3/4 amp maximum (derated to 1/2 amp at 70 degrees C). Maximum inrush 10 amps for one second (non-repeating). On-state voltage drop: 5.2V rms at a 1/2 amp load; 14V rms at a load of 10 milliamps. Off-state leakage current less than 1.7 milliamp (resistive or inductive load).

Power block models R2PBA and R2PBB both offer the simplicity of wiring which is associated with 2-wire sensor design. They wire directly in series with an ac load, exactly like a limit switch. Use of a 2-wire power block requires programming of the sensor head to the "2W" (2-wire) operating mode. As a result, MAXI-BEAM sensing response time is fixed at 10 milliseconds for 2-wire operation. There are some hookup considerations which are unique to 2-wire interfaces. See hookup information on page 12 for details.

10

MAXI-BEAM Power Blocks and Wiring Base

Hookup Diagrams for RPBA, RPBA-1, RPBB, & RPBB-1 Power Blocks
Hookup to a Simple Load
AC voltage is connected to terminals #1 and #2 to provide power to the MAXI-BEAM. The solid-state output switch behaves as if there were a contact between terminals #3 and #4. L1 is most conveniently applied to terminal #3 by jumpering terminals #1 and #3 inside the wiring base. Alternatively, the load could be installed between terminal #3 and L1, with L2 connected to terminal #4 by jumpering from #2 to #4.
L1 L 2

Hookup of an ac Emitter
MAXI-BEAM emitter-only sebnsor heads use ac power block model RPBA-1 (120V ac) or RPBB-1 (220/240V ac) which connect directly across the line, as shown.
L1 L 2

V ac (See Specifications)

V ac (See Specifications)

RPBA RPBB

4 3 2 1

LOAD
4 3 2 1

RPBA-1 RPBB-1

CAUTION: the output switch will be destroyed if the load is shorted.

Hookup in Parallel or Series with Contacts or Switches

Any number of "hard" contacts may be wired in series or in parallel to MAXI-BEAMs which use power block model RPBA or RPBB. This circuit illustrates a start-stop function in which CR can be energized only when the MAXI-BEAM output is energized. Once energized, CR is latched ON by its normally open contact. CR is reset by depressing the STOP switch
L1 L

Hookup to Programmable Logic Controller (PLC)

Interfacing to a PLC I/O is direct with MAXI-BEAMs which use RPBA or RPBB. The off-state leakage current is only 100 microamps (0.1 milliamp) maximum.
AC "hot" L1 AC neutral L 2

V ac (See Specifications)
CR

1 2 3 I N P U T S

P r o g. C t r l.

V ac (See Specifications)

Hookup typical for all 8 inputs

4 5 6 7

RPBA RPBB
START

4 3 2 1

CR STOP

RPBA RPBB

4 3 2 1

8 neutral

Hookup in Series with other MAXI-BEAMs

MAXI-BEAMs which use RPBA or RPBB power blocks may be wired in series for the "AND" logic function. The total voltage drop across the series will be the sum of the individual voltage drops across each power block (approximately 3 volts per block). With most loads, 10 or more sensors may be wired together in series.

Hookup in Parallel with other MAXI-BEAMs

Any number of MAXI-BEAMs using RPBA or RPBB power blocks may be wired together in parallel to a load. Parallel sensor connection is usually used to yield "OR" logic (i.e.-if an event occurs at any sensor, the load is energized). The total off-state leakage current through the load is the sum of the leakage currents of the individual power blocks. However, the maximum leakage current of MAXIBEAM RPBA or RPBB power blocks is only 100 microamps. As a result, the installation of an artificial load resistor in parallel with the load is necessary only for very large numbers of sensors wired in parallel to a light (i.e.-high impedance) load.
L1 L

V ac (See Specifications)

L1

L2

V ac (See Specifications)

RPBA RPBB
4 3 2 1

RPBA RPBB

4 3 2 1

RPBA RPBB

4 3 2 1

LOAD

RPBA RPBB

4 3 2 1

LOAD

11

MAXI-BEAM Power Blocks and Wiring Base

Hookup Diagrams for R2PBA and R2PBB Power Blocks
Basic 2-wire Hookup
L1 L 2

2-wire MAXI-BEAMs in Parallel

Multiple 2-wire MAXI-BEAMs may be wired together in parallel to a load for "OR" or "NAND" logic functions. When sensors are wired in parallel, the off-state leakage current through the load is equal to the sum of the leakage currents of the individual sensors. Consequently, loads with high resistance like small relays and electronic circuits may require artificial load resistors. MAXI-BEAM sensors have a 100 millisecond power-up delay for protection against false outputs. When 2-wire MAXI-BEAMs are wired together in parallel, any power block which has an energized output will rob all other 2wire power blocks of the voltage needed to operate the sensor. When the energized output drops, there will be a 0.1 second delay before any other MAXI-BEAM can energize. As a result, the load may momentarily drop out.
L1 L 2

V ac (See Specifications)

V ac (See Specifications)

R2PBA R2PBB

4 3 2 1

R2PBA R2PBB

4 3 2 1

LOAD

R2PBA R2PBB

2-wire MAXI-BEAM sensors cannot wire in series with other 2-wire sensors. If series connection of 2-wire AC sensors is required, consider models within the VALUBEAM or MINI-BEAM sensor families. 4-wire ac power blocks can wire in series (see RPBA, RPBB).

4 3 2 1

LOAD

2-wire MAXI-BEAMs with Parallel Contacts

MAXI-BEAM sensors using power block R2PBA or R2PBB wire in series with an appropriate load. This combination, in turn, wires directly across the ac line. A 2-wire sensor may be connected exactly like a mechanical limit switch. The MAXI-BEAM remains powered when the load is OFF by a residual current which flows through the load. This off-state leakage current is always less than 1.7 milliamps. The effect of this leakage current depends upon the characteristics of the load. The voltage which appears across the load in the OFF state is equal to the leakage current of the sensor multiplied by the resistance of the load: V (off) = 1.7mA x R(load). If this resultant OFF state voltage is less than the guaranteed turn-off voltage of the load, then the interface is direct. If the OFF state voltage causes the load to stay ON, then an artificial load resistor must be connected in parallel with the load to lower its effective resistance. Most loads, including most programmable logic controller (PLC) inputs, will interface to 2-wire sensors with 1.7mA leakage current, without the need for an artificial load resistor. There is no polarity requirement. Either wire may be connected to terminal #3, and the other to terminal #4. CAUTION: all components of a MAXI-BEAM 2-wire sensor assembly will be destroyed if the load becomes a short circuit. 2-wire MAXI-BEAM sensors may be wired in parallel with mechanical switch or relay contacts. The load will energize when either a contact closes or the sensor output is energized. When a contact is closed, it shunts the operating current away from the MAXI-BEAM. As a result, when all of the contacts open, the MAXI-BEAMs 0.1 second power-up delay may cause a momentary drop-out of the load.
L1 L

2-wire MAXI-BEAMs with Series Contacts

When 2-wire MAXI-BEAM sensors are connected in series with mechanical switch or relay contacts, the sensor will receive power to operate only when all of the contacts are closed. The false-pulse protection circuit of the MAXIBEAM will cause a 0.1 second delay between the time that the last contact closes and the time that the load can energize.

V ac (See Specifications)

L1

V ac
(See Specifications)

L2

R2PBA R2PBB

4 3 2 1

LOAD

R2PBA R2PBB
4 3 2 1 LOAD

Hookup of 2-wire MAXI-BEAMs to a Programmable Logic Controller (PLC)

MAXI-BEAM 2-wire sensors operate with low (1.7mA) off-state leakage current. As a result, they will interface directly to most PLCs without the need for an artificial load resistor. If the off-state voltage (1.7mA x input resistance of PLC) is higher than the PLC sensing threshold, install a 10K to 15K, 5 watt resistor for each 2-wire sensor. The resistor connects between the input terminal and ac neutral. If you have a question on hookup to a specific brand of PLC, contact the Banner Applications Department during normal business hours.
AC "hot" L1 AC neutral L 2

Photoelectric Latch with Manual Reset

1CR relay will latch ON whenever the 2-wire MAXIBEAM output is energized. 1CR is reset when the normally-closed pushbutton switch is pressed.

V ac (See Specifications)

1 2

P I N P U T S C t r l.
R2PBA R2PBB
4 3 2 1 LATCH 1CR

Hookup typical for all 8 inputs

R2PBA R2PBB
4 3 2 1

r o g.

L1

L2

3 4 5 6 7 8

V ac
(See Specifications)

neutral
1CR RESET

12

MAXI-BEAM Power Blocks Model RPBTLM Low Profile DC Power Block

Model RPBTLM is a miniature dc power block for MAXI-BEAM sensors. It may be used with any of the MAXI-BEAM sensor head models. The RPBTLM is supplied with stainless steel hardware used for assembly of the MAXI-BEAM components. Components simply bolt together, with no interwiring necessary. The screws supplied are extra-long, and serve as a means to mount the complete MAXI-BEAM sensor assembly to an object or surface. The RPBTLM may be attached to its sensor head at any of four 90-degree increments to allow the best cable exit direction (front, rear, or either side). A logic module may be added and can be independently rotated (in the same manner) for easiest access to the timing adjustments. Outputs are in the bi-polar configuration: one current-sinking (NPN) plus one current-sourcing (PNP). This design permits direct interfacing of the MAXIBEAM sensor to almost any type of dc logic input. Each output is rated for 150 mA. Either output may be used alone, or both may be used simultaneously. The outputs may be configured for either normally open or normally closed operation via the sensor head (or logic module) programming ring. The RPBTLM includes an LED indicator to show the output status. The RPBTLM is completely solid-state and epoxy-encapsulated. It is gasketed to other MAXI-BEAM components by a quad-ring seal. See pages 3,7, and 1415 for information on the assembly and programming of MAXI-BEAM sensors. RPBTLM Dimensions

Hookup Diagram

Functional Schematic

Specifications
INPUT: 10 to 30V dc, 10% maximum ripple. OUTPUT CONFIGURATION: bi-polar. One current sinking (NPN) and one current sourcing (PNP) open-collector transistor switch. OUTPUT RATING: 150mA maximum each output at 25C (derated to 100mA at 70C). Derate 1mA per C. OUTPUT PROTECTION: protected against false pulse on power-up, inductive load transients, power supply polarity reversal, and continuous overload or shortcircuit of outputs. ON-STATE VOLTAGE DROP: NPN output less than 200 millivolts at 10mA and less than one volt at 150mA. PNP output less than 1 volt at 10mA and less than 2 volts at 150mA. OFF-STATE LEAKAGE CURRENT: less than 1 microamp.

Model RPBU Power Block: universal power input and output

INPUT: 12-250V ac (50/60Hz) or 12-30V dc, 40mA exclusive of load at 30V dc. OUTPUT: Optically-isolated SPST solid-state relay; 240V ac or dc max., 100mA max. On-state voltage drop is 2 volts max. at 100mA (full rated load). DC hookup is without regard to polarity.

WARNING: Connection of voltage directly across pins 3 and 4, without a load present, will destroy the switching element.

13

MAXI-BEAM Logic Modules

MAXI-BEAM sensors offer built-in timing logic with the addition of a logic module. There are two logic modules available. Model RLM5 is programmable for ON-DELAY, OFFDELAY, and ON/OFF DELAY timing logic. Model RLM8 offers both ONE-SHOT and DELAYED ONE-SHOT functions. A programming ring is supplied with each logic module. Programming of the logic function, timing range, and output state is similar to sensor head programming. Both logic modules feature 15-turn, clutched potentiometers for accurate timing adjustments. Once programmed, the logic module may be rotated in 90-degree increments to position the timing adjustments for easiest access. Logic modules are housed in the same tough molded VALOX which is used for the other MAXI-BEAM components. The logic module and its programming ring simply slip between the MAXI-BEAM sensor head and power block (see photograph, page 3). The assembly is bolted together with no interwiring necessary. The component interfaces are quad-ring sealed.

MAXI-BEAM Logic Module Specifications

SUPPLY VOLTAGE: input power is supplied by the power block (see pages 8-13). RESPONSE TIME: RLM5: add sensor response delay of approximately 2% of maximum OFF-DELAY time. RLM8: no added response time for ONE-SHOT mode. TIMING ADJUSTMENTS: two 15-turn clutched potentiometers with brass element, accessible from outside of logic module, under oring gasketed cover screws. TIMING REPEATABILITY: plus or minus 2% of the maximum time of the selected range, assuming conditions of constant operating temperature and power supply voltage. TIMING RANGE: 15 second ranges: 0.5 to 15 seconds; 1 second ranges: 0.1 to 1 second; 0.1 second ranges: 0.01 to 0.1 second. CONSTRUCTION: reinforced molded VALOX housing, quadring gasketed. Electronics fully epoxy encapsulated. NEMA 1,3,4,12, 13. OPERATING TEMPERATURE: -40 to +70 degrees C (-40 to +158 degrees F).

Model and Logic Functions

Programming
PROGRAM CHOICES: 1) Timing Logic Function: a) ON-delay b) OFF-delay c) ON/OFF-delay 2) Timing Adjustment Range (see options below) 3) Output State: a) normally open b) normally closed TO PROGRAM LOGIC MODULE: 1) Find the programming notch which lines up with the program choice. NOTE: the programming ring may have to be turned upside-down in order to find a notch that lines up with the desired program. 2) Press the programming ring and logic module together. They will be held together temporarily by their interlocking pegs. 3) Orient the logic module for easiest access to the timing adjustments, and assemble between the programming ring of the sensor head and the power block (see exploded view on page 3). Bolt all parts together with the long bolts that are supplied with the logic module. 4) Apply power to the MAXI-BEAM and adjust timing, using a small flat-blade screwdriver. Timing potentiometers are located behind the nylon o-ring gasketed cover screws.

RLM5

Program Definition

14

MAXI-BEAM Logic Modules

Model and Logic Functions Programming
PROGRAM CHOICES: 1) Timing Logic Function: a) ONE-SHOT b) Delayed ONE-SHOT 2) Timing Adjustment Range (see options below) 3) Output State: a) normally open b) normally closed TO PROGRAM LOGIC MODULE: 1) Find the programming notch which lines up with the program choice. NOTE: the programming ring may have to be turned upside-down in order to find a notch that lines up with the desired program. 2) Press the programming ring and logic module together. They will be held together temporarily by their interlocking pegs. 3) Orient the logic module for easiest access to the timing adjustments, and assemble between the programming ring of the sensor head and the power block (see exploded view on page 3). Bolt all parts together with the long bolts that are supplied with the logic module. 4) Apply power to the MAXI-BEAM and adjust timing, using a small flat-blade screwdriver. Timing potentiometers are located behind the nylon o-ring gasketed cover screws.

RLM8

Program Definition

MAXI-BEAM Accessories
Replacement Upper Covers (Lens Assemblies)
An upper cover consists of the optical element for the MAXI-BEAM sensor head. An upper cover may be used as a replacement part or for modifying the optical response of a sensor. Upper cover assemblies include lens, replacement bezel, o-ring, and stainless steel screws.

Replacement Lenses
Sensor Head Upper Cover
RUC-L RUC-L RUC-L RUC-AG RUC-L RUC-D RUC-C RUC-F RUC-FP
CONVERSION FROM - TO

Lens Interchangeability
USE UPPER COVER CONVERSION FROM - TO USE UPPER COVER

RSBE ....................................... RSBR ....................................... RSBLV .................................... RSBLVAG .............................. RSBD ...................................... RSBDSR, ESR, & RSR ........... RSBC, CV ............................... RSBF, FV ................................ RSBFP .....................................

RSBLV to RSBLVAG ... RUC-AG RSBLV to RSBCV ......... RUC-C RSBD to RSBDSR ......... RUC-D RSBD to RSBF ............... RUC-F RSBDSR to RSBF .......... RUC-F

RSBLVAG to RSBLV ... RUC-L RSBCV to RSBLV ......... RUC-L RSBDSR to RSBD ......... RUC-L RSBF to RSBDSR .......... RUC-D

15

MAXI-BEAM Accessories
Mounting Brackets
Model SMB700 (right) is a general-purpose two-axis mounting bracket that is supplied with a cable gland assembly which is used to attach the MAXI-BEAM wiring base to the bracket. The gland assembly is threaded through the bracket and into the conduit entrance at the base of the scanner block. A large lockwasher is supplied to hold the scanner block firmly in place. The bracket is 11-gauge zinc plated steel. Model SMB700SS is an 11-gauge stainless steel version of the SMB700. It is sold alone, without the cable gland assembly and lockwasher. Model SMB700F (photo, below) is a flat, single-axis version of the SMB-700. It is sold without hardware.

HF1-2NPS
This is a black nylon cable gland assembly for use with the MAXI-BEAM and other sensors having a 1/2NPS conduit entrance. The flexible extension keeps the sensor cable from bending too sharply, and mimimizes cable fatigue due to repeated flexing. The HF1-2NPS includes a neoprene gland that accommodates cables with diameters from .20 to .35 inch for a liquid-tight seal. This flexible gland assembly is resistant to gasoline, alcohol, oil, grease, solvents, and weak acids. It has a working temperature range of -30 to +100C (-22 to +212F). It is UL recognized and CSA certified. The HF1-2NPS is sold in packages of 10 pieces.

Model SMBLS (not shown) is a twopart bracket assembly which allows adjustment in three directions. It consists of two 11-gauge zinc plated steel rightangle brackets which fasten together so that they rotate relative to each other. The MAXI-BEAM wiring base attaches to the upper bracket and slots are provided for vertical adjustment. The bottom bracket is a modified version of the SMB700. Assembly hardware and a cable gland are included.

SMB700M

SMB700P

RF1-2NPS

Cable gland assembly for MAXI-BEAMs. Includes cord grips for .1 to .4 inch diameter cable. Bracket lockwasher is also included.

MBC-4

MBCC-412

Heavy-duty 1/4-inch (6mm) zinc plated steel bracket that allows the MAXI-BEAM to retrofit to installations of MICRO-SWITCH models MLS8 or MLS9 sensors. Includes cable gland and lockwasher. Banner Engineering Corp.

Heavy duty 1/4-inch (6mm) zinc plated steel bracket that allows the MAXIBEAM to retrofit to installations of PHOTOSWITCH series 42RLU and 42RLP sensors. Includes cable gland and lockwasher.

MBC-4 is a 4-pin male industrial-duty connector that threads into the base of all MAXI-BEAMs. MBCC-412 is a 12-foot long (3,6m) "SJT" type cable. It is interchangeable with standard industry types of several different manufacturers. FAX (applications): (612)544-3573

9714 Tenth Ave. No. Minneapolis, MN 55441

Telephone: (612)544-3164

MAXI-BEAM

Power Blocks, RWB4 Wiring Base

~ the
photoelectric specialist

Banner MAXI-BEAMsensors are highly versatile, self-contained, modularized photoelectric sensing controls that are ideally suited to industrial environments. The basic MAXI-BEAM is an ON/OFF switch consisting of three modules (sensor head, power block, and wiring base) and a unique, patented, rotatable "programming ring" that enables you to program your choice of "light" or "dark" operate mode, sensing range, and response time. MAXI-BEAM sensor heads have an easily-accessible mulli-tum SENSITIVITY control for precise adjustment of system gain. Interchangeable sensor heads are rotatable in 90-degree increments and are available in retroreflective, diffuse~opposed, conv:ergentrand fibeIo.pti~nsing"roQdes..~ac~nso~~ also includes Banner's exclusive AIDTM circuit (Alignment Indieating Device, US patent no. 4356393), which features an LED alignment indieator that lights whenever the sensor "sees" its own modulated light source, and pulses at arate proportional to the strength of the received light signa!. A wide selection of MAXI-BEAM power block modules is available to interface the sensor head to the circuit to be controlled. The plug-in design of the wiring base enables easy exchange of the entire sensing electronics without disturbing the field wiring. Power block and wiring base are separate items and each must be purchased seperately. Optional customer-instaHable logic modules easily convert the basic ON/OFF MAXI-BEAM into either a one-shot or delay logic function control, with several programmable timing ranges for each function. MAXI-BEAM sensors are ruggedly constructed of molded VALOXto NEMA standards 1,3,4,12, and 13, and have interchangeable molded acrylic lenses. Modules simply snap and boll together, with no interwiring necessary. Module interfaces are o-ring and quad-ring sealed for the ultimate in dust, dirt, and moisture resistance. To order a MAXIBEAM, follow these steps: - 1) Select a sensor head module, 2) Select a power block module, 3) Select a wiring base (must be purchased separately from power block), 4) Select a logic module if needed, 5) Select accessories as needed (see Banner product catalog). Sensor Head Modules (described in data sheet P/N 03416) range to 300' RSBE & RSBR opposed mode RSBESR & RSBRSR opposed mode (short range; narrow beam) range to 15' range to 30' RSBLV retroreflective mode range to 15' RSBLVAG retrorefleetive mode (anti-glare filter) range to 5' RSBD long range diffuse proximity mode range to 30" RSBDSR short-range diffuse proximity mode 1.5" RSBCV visible red convergent mode, focus at: 1.5" RSBC infrared convergent mode, focus at: RSBF infrared fiber optic; for glass fibers RSBFV visibLe red fiber optie; for glass fibers RSBEF & RSBRF infrared fiber optie opposed mode; for glass fibers RSBFP visible red fiber optic; for plastie fibers Power Block Modules (described in this data sheet, P/N 03418) RPBT 1O-30V dc; one sinking and one sourcing solid-state output RPBT-l 1O-30V de; for use with RSBE, ESR, EF emitters (no output eireuit) RPBTLM 1O-30V de low-profile power block (requires no RWB4 wiring base) RPBA 105-130V ae (50/60Hz); SPST solid-state output RPBA-l 105-130V ae (50/60Hz); for use with emitter (no output eircuit) R2PBA 2-wire operation; 105-130V ac (50/60Hz); SPST solid-state output RPBB 21O-250V ae (50/60Hz); SPST solid-state output RPBB-l 21O-250V ae (50/60Hz); use with emitter (no output circuit) R2PBB 2-wire operation; 21O-250V ac (50/60Hz); SPST solid-state output RPBU 12-250V ae or 12-30V de; SPST solid-state output (ae or de) RPBR 12-250V ae (50/60Hz) or 12-30V dc; SPST E/M relay output RPBR2 12-250V ac (50/60Hz) or 12-30V dc; SPDT E/M relay oltput WiringBase RWB4 (described in this data sheet, P/N 03418) 4-terminal wiring base for all models (exeept RPBTLM)

General Specifications
Construction: Reinforced molded VALOX housing. Electronie components fully epoxy encapsulated. O-ring seal between components: NEMA 1,3,4, 12, and 13. Operating Temperature: -40 to +70C (-40 to + 158F), except models RPBR and RPBR2 (whose range is -40 to +50C, or -40 to +122F). False Pulse Suppression on Powerup: AH models.
VALOX@ is a registered trademark ef General Electric Ce.
seSimii:t'r-~""
Conlrol---~~!'Ir~-_

~-.......~-LED/AID""

Indlcafor

_ _- - Prograrnming Ring lor Logic

OU1P/
Outputon LEO

Logic Modules (deseribed in data sheet P/N 03417) RLM5 ON/OFF delay (both funetions adjustable up to 15 seeonds) RLM8 DELAYED ONE-SHOT (delay and pulse adjustable up to 15 seeonds) Printed in USA

PIN 03418G0C

Models RPBT, RPBT-l

10 to 30V de

INPUT: 10-30V dc, 20mA exclusive of load; 10% max. ripple. OUTPUT: Bi-polar; one open collector NPN (sinking) and one PNP (sourcing) open collector transistor, 250mA continuous, short circuit and reverse-polarity protected (both outputs). On-state voltage drop for PNP output is less than I

listed

~ certified

volt at lO mA and less than 2 volts at 250 mA;for NPN output less than 200 millivolts at lOmA and less than I volt at 250 mA. Off-state leakage current is less than 10 microamps.
RWB4 Wiring Base
(Purchased separately)

RPBT

10-30V de

~-- ---+j---IO~111
__

NOTE: mode! RPBT-! is used lo power the model RSBE , RSBESR, or RSBEF emitler sensor head. RPBT-l has an inpul range of 1O-30V de, and no swilehing elemenls.

Models RPBA, RPBA-l

l20Vae

INPUT: 105-130V ac (50/60Hz); 2 watts, exclusive of load. OUTPUT: SPST solid state switch for ac, 3/4 ampo maximum (derated to 1/2 amp at 70 degrees C). Maximum inrush is 10 amps for l second or 30 amps for
Wiring Base

listed

~ certified

one ac cycle (non-repeating). On state voltage drop of less than 2.5V ac at full load. Off state leakage current is less than lOO microamps.
RWB4 Wiring Base
(Purchased separately)

WARNING: Connection o/ voltage directly across pins 3 and 4, without a load present, will destroy the switching element.

Supply voltage!=
T.
L"li< Module

105 to 130V ae

l=-------It==j;~

NOTE: ae loads require up lo 8.3 milliseeonds lo lum "off' in addition lo the response time of the sensor head and delay logie (if any). NOTE: model RPBA-l is used lo power lhe model RSBE, RSBESR, or RSBEF emitler sensor head. RPBA-l has an inpul range of 105-130V ac, and no swltching elemen!.

Models RPBB, RPBB-l

220/240Vae

INPUT: 210-250Vac (50/60Hz); 2 watts, exclusive of load. OUTPUT: SPST solid state switch for ac , 3/4 ampo maximum (derated to 1/2 amp at 70 degrees C). Maximum inrush is 10 amps for I second or 30 amps for
Wiring Base

listed

~ certified

one ac cycle (non-repeating), On state voltage drop of less than 2.5V ac at full load. Off state leakage current is less than 100 microamps.

....
T. LOlli< Module

....

WARNING: Connection o/ voltage directly across pins 3 and 4, without a load present, will destroy the switching element.

Supply VOltage!= 210 to 2S0V ae

l=-------It==~~

Senior HI.d~----------'

NOTE: ac loads require up lo 8.3 milliseconds lo lum "off' in addilion lo lhe response lime of lhe sensor head and delay logic (if any). NOTE: model RPBB-l is used lo power lhe model RSBE. RSBESR, or RSBEF emitter sensor head. RPBB-I has an inpul range of21O-260V ac, and no Swilching elemen!.

Models R2PBA & R2PBB

2-wire ae operation

INPUT: 105-130V ac (50/60Hz) for model R2PBA; 21 0-250V ac (50/60Hz) or mo e R P watts exc USlve o oa. OUTPUT: SPST solid-state switch for ac, 3/4 amp maximum (derated to 1/2 amp at 70 degrees C). Maximum inrush is 10 amps for I second (non-repeat-

listed

~ certified

ing). On-state voltage drop is 5.2V rms at a I 2 amp load; 14V rms at a load of lO milliamps. Off-state leakage current is less than 1.7 milliamps (resistive or inductive load).

.v

EL~":i'~M~O:dO:I'~~~~tq~~o~
SenIor Head

To

R2PBA Power Block

Wiring Base

o o

R2PBA or R2PBB
WARNING: all components o/ a MAXI-BEAM 2-wire assembly will be destroyed i/ the load becomes a short circuito NOTE: use o/ a 2-wire power block requires programming o/ the sensor head to the "2W" (2-wire) operating mode.

Froto
Logic Modllle Seuor Head

Supply [ Voltage

------++----J~I

R2PBA: 105 lo 130V ae R2PBB: 21010 2S0V ae

To Logic Module

-v ~-o-,-+---'----'~I-----'
Sensor Head 1--

--'

Model RPBR

SPST electromechanical relay output

INPUT: 12-250Vae (50/60Hz) or 12-30V de, 40mA exclusive of load at 30V de. OUTPUT: SPST eleetromeehanieal relay; 250V ae max, 30V de max, 5 amps max. Peak switching vo/tage is 750V ae (install MOV aeross eontaet if

listed

<i!

certified

switehing induetive load). Mechanica/life ofre/ay is 10,000,000 operations. Contact response time is 20 milliseeonds, open and close.
Dry Contaet

To
tOlle Module

.y

Senior Head 11~-~1L...!'~!..-":~

From

"

_;::;:~P~ow~.~r~B~l~o~Ck~h=t_...:. w~ir~ig ~ n

RPBR

Base

RPBR

I
250Vae max. 3OVdemax. 5ampsmax. 1210 250Vae 1210 30V de

Lo,je Module
On/Off

Sultor Head

l=---tt=jg~

To

Loe Module

Senior Head

" [===-__

----.:=-------.:=::r-~-t==j_-~---~~-------------..L----.i---

Model RPBR2

SPDT electromechanical relay output

switehing induetive load). Mechanica//ife ofrelay is 10,000,000 operations. Contact response time is 20 milliseeonds, open and elose.

INPUT: 12-250Vae (50/60Hz) or 12-30V de, 40mA exclusive of load at 30V de. OUTPUT: SPDT eleetromeehanieal relay; 250V ae max, 30V de max, 5 amps max. Peak switching voltage is 750V ae (install MOV aeross eontaet if
RPBR2

Poyer Block
To

W"iring Base

+ y

Locie Module
01'

Sensor Bead

5amps max. (eeeh oulpUI)

Prom
On/Off
Lape Module
01'

Sensor Head

Input VOllag e [ 1210 250V ac 1210 30V dc

To
V

Lacie Module
01'

"-

"-

Sensor Head

Model RPBU--- -

Universal power input and ouiPU---

Dimension Drawing, MAXI-BEAM Sensor

INPUT: 12-250V ae (50/60Hz) or 12-30V de, 40mA exclusive ofload al 30V de. OUTPUT: Optieally-isolaled SPSTsolid-slale relay; 240V ae or de max., lOmA max. On-state voltage drop is 2 vOllS max. al 100mA (full raled load). De hookup is withoul regard lO polarily.
RWB4 =~~:~~nlale Wiring Base @

'AID' indieator LED

WARNING: Connection directly across pins 3 and 4, without a load present, will destroy the switching element.
o( voltage

(Purchasedsepasalely)

Oulpul: [ 240V ee or de mex. ,-----+l'--#Jml 100 mA mex.

!.nI!l1t..'&~:[ 1210 250V ee or 121030Vde ---~t:=~~

Nota: Hookup lO de is withoul regard lO polarity '----_ _----'

Lene centerline
1.69' ith logie 1.19 ithout

Logie modulo and lecond programming rin,

RPBU Power Block

To Logic Module

WB4

Wiring Base

2.36" (60mm)

or

or Sensor Head

FJ;om

On/Orr

}-'Lo",.","'-=."O;:,d",U'''-'-++J
or Sensor Head

,376" (9,6mm)

To Logic Module

or Sensor Head

Model RPBTLM Low Profile Power Block

Model RPBTLM is a miniature dc power block for MAXI-BEAM sensors. It may be used with any of the MAXI-BEAM sensor head models. It also allows timing logic modules to be added if needed. The RPBTLM is supplied with stainless steel hardware used for assembly of the MAXI-BEAM components. Components simply bolt together, with no interwiring necessary. The screws supplied are extra-long, and serve as a means to mount the complete MAXI-BEAM sensor assembly to an object or surface. The RPBTLM may be attached to its sensor head at any of four 90-degree increments to allow the best cable exit direction (front, r~ar, or either side). A logic module, if used, can be independently rotated (in the same manner) for easiest access to the timing adjustments. Outputs are n the bi-polar configuraton: one current-sinking (NPN) and one current-sourcing (PNP). This design permits direct interfacing of the MAXIBEAM sensor to almost any type ofdc logc input. Either output may be used alone, or both may be used simultaneously. The outputs may be configured for either normally open or normally e10sed operation via the sensor head (or logic module) programming ringo Both outputs are rated for 150 milliamps, sufficient capacity for direct switching of most electromechanical dc loads like relays and solenoids. The RPBTLM ineludes an LED indicator to show the output status. The RPBTLM is completely solid-state and epoxy-encapsulated. It is gasketed to other MAXI-BEAM components by a quad-ring sea!. Refer to the data sheets for MAXI-BEAM sensor heads (PIN 03416) and MAXI-BEAM logic modules (PIN 03417) or to the Banner product catalog for complete information on the assembly and programming of MAXI-BEAM sensor components.

Dimension Drawing

1.57" with loCic 1.07 without

#6-32 'J,: Z' long stainles8 lIteel serew (4-) (1.20" square serel!' pattero)

6 ft. cable

NOTE: #6-32 x 2 1/2" long screws are also supplied lritb RPBTlJd for assembly lI'hen a logie module is added.

Functional Schematic
RPBTlJl POYER BLOCK
To Loric Module o.. Sen80r 8ead

Specifications
Input: 10 to 30V dc, 10% maximum ripple. Output Gonfiguration:~Bi-polar: One current-sinking (NPN) and one current sourcing (PNP) open-collector transistor switch. Output Rating: 150mA maximum each output at 25C (derated to 100mA at 70C). Derate lmA per oc. Output Protection: Protected against false pulse on power-up, inductive load transients, power supply polarity reversal, and continuous overload or short-circuit of outputs. On-state Voltage Drop: NPN output less than 200 millivolts at lOmA and less than one volt at 150mA. PNP output less than 1 volt at lOmA and less than 2 volts at 150mA.
On/Off

hom LoC1c Module or Seneor Head

L,--~....J

To Lo(ic Module
01' Seneor H".d '-----

....J

OfT-state Leakage Current: Less than 1 microamp.

Hookup Information, model RPBTLM low-profile power block

MAXI-BEAM Sensor head and programming ring
r-~"'-!.!.-'-'-_----~P---

+10 to 30V de

The RPBTLM powers the sensor head from a 10 lo 30VOC supply. It contains oulpul circuitry lO a1Iow an interface of the-signal-from.the.sensor.h.ead.lO-aJoad.ouo.a-logic..inpul. The RPBTLM offers bi-polar OUlputs: one current sinking (NPN) and one current sourcing (PNP). Either oUlpul may be used, or both oUlputs may be used al the same time. The swilching capacity of each oulpul is 150 mA max.

Loads: 150 mA max. eaeh

BLUE

deeommon

W ARRANTY: Banner Engineering Corporation warrants its producls lo be free from defects for one year. Banner Engineering Corporation will repair or replace, without charge, any product of its manufacture found to be defective at the time it is retumed to lhe faclory during lhe warranty periodo

This warranty does not cover damage or liability for the improper use ofBanner products. This warranty is in lieu of any other warranty either expressed or implied.

Banner Engineering Corp.

9714 10th Ave. No., Minneapolis, MN 55441

Te!. (612) 544-3164

FAX (applications): (612) 544-3573

NAL Series
Lubricator
NAL1000, 2000, 3000, 4000, 5000, 6000

Modular Air Components

ANSI Symbol

Provides accurate lubrication of down stream equipment Oil drop rate is adjustable depending on equipment requirements NAL 3000~6000 can be refilled under pressure Modular design connects with other SMC air preparation equipment

NAL3000

NAL2000

Specifications
Model Port Size NPT Proof pressure psig (MPa) Max. oper. pressure psig (MPa) Min. oper. flow scfm* Bowl capacity ozs. (cm ) Recommended oil Ambient and media temperature Bowl material Weight lbs. (Kgf) Accessory (Standard) Bowl guard
3

NAL1000 10-32 NOM. (M5)

NAL2000 1/8 1/4

NAL3000 1/4 3/8

NAL4000

NAL4000-N06

NAL5000 3/4 1

NAL6000 1

0.14 0.24 (7)

0.53 0.85 (25)

1/4 3/8 1/2 3/4 220 (1.5) 150 (1.0) 1/4: 1.06 1/4: 1.06 3/8: 1.41 1.77 3/8: 1.41 1/2: 1.77 1.70 (50) 4.40 (130) 4.40 (130) Turbine Oil #1, ISO VG32 23 ~ 140 F (-5 ~ 60 C) Polycarbonate 0.66 (0.28) G 1.23 (0.52) G 1.28 (0.58) G

6.71 4.40 (130)

7.77 4.40 (130)

0.15 (0.07)

0.49 (0.22) G

2.38 (1.08) G

2.60 (1.19) G

*Conditions: Supply pressure - 70 psig, Number of drop - 5 drops/min, ISOVG32, 70 F

Accessories (Optional)
Part No. Type NAL1000 Bracket NAL2000 B240A NAL3000 B340A NAL4000 B440A NAL4000-N06 B540A NAL5000 B640A NAL6000 B640A

NAL1000 Principle

Precautions
<Installation> 1 Recommended oil is ISO VG32. 2 Air flush piping before installation. 3 If intended for use with power press, consult SMC representative . 4 Never reverse the flow through this unit, i.e. Supply to OUT port. <Atmosphere> 1Polycarbonate bowls may be damaged and possibly fail if exposed to synthetic oils, thinner solvents, trichlorethylene, kerosene or other aromatic hydrocarbons. If used in above atmosphere, please use a metal bowl. <Refill> 1 A minimum air flow is required for proper operation. (See specifications). 1 Please ensure the minimum requirements are met. 2 NAL1000, 2000 lubricators cannot be refilled under pressure. Shut off air pressure before refilling.

A portion of the air entering from "IN" pressurizes the surface of the oil. The remainder of the air is passed through a needle valve and flows out to "OUT". By differential pressure between the pressure in the bowl at that time and the pressure of the damper vane , oil inside the bowl is passed through the lead tube and dropped through fill tube to bl "OUT". Counter-clockwise turn of needle valve increases oil capacity and clock-wise turn (fully closed) stops lubrication.

60

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Modular Air Components

NAL Series
How To Order
NAL1000, 2000, 3000, 4000, 5000, 6000

How To Order

N AL 30

00

03

23
Optional specifications Nil None
1 10 11 2 3 6 8 C R 3W 34 oz (1000cm3) tank 34 oz (1000cm3) tank/with switch (Float down ON) 34 oz (1000cm3) tank/with switch (Float down OFF) Metal bowl With drain cock Nylon bowl Metal bowl with level gauge With bowl guard (Only NAL2000) IN-OUT reversal (Right Left) Drain Cock with barb fitting for nylon tube (6mm OD/4mm ID) (NAL3000~6000)

Lubricator

Body size
10 20 30 40 50 60 M5 1/8 3/8 1/2 3/4 1
When specifying more than one option, please list numerically, then alphabetically. Example: 23R

Accessory
Code Nil B

Description Bracket

Applicable model NAL2000~NAL6000

Construction
00 Damper type (NAL2000~NAL4000)

Port size
M5 01 02 03 04 06 10 10-32 Nom. (M5) 1/8 1/4 3/8 1/2 3/4 1

*NAL1000 is an adjustable flow restrictor.

Port Thread
Nil F N Rc(PT) G(PF) NPT

Accessories and Combinations

Accessories 1000cm3 tank 1000cm3 tank (Switch ON) 1000cm3 tank (Switch OFF) Metal bowl With Drain Cock Nylon bowl Metal bowl with level gauge With bowl guard In-Out reversal Drain cock with Barb Fitting Suffix -1 -10 -11 -2 -3 -6 -8 -C -R -3W 1 10 11 2 3 6 8 C R M M M M M M M M M 3W

M Combination No Combination G Refer to How to Order

Applicable model NAL1000 NAL2000 NAL3000 M M M M M M M M M NAL4000NAL6000 M M M M M M M M M

M M M M M

M G

M M M

M M M M M

M M M

61

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NAL Series
Flow Characteristics
NAL1000, 2000, 3000, 4000, 5000, 6000

Modular Air Components

Flow Characteristics
NAL1000
14.5
Number of needle rotation 2 turns from fully open

NAL4000-06
5P SI 43.
I
72 .5 PS I

14.5 Number of needle rotation 2 turns from fully open

SI

ary p ressu re 14 5 P SI

5P

Pressure deop (PSI)

.5

PS

11.6 Pressure deop (PSI)

43.

72

14 5

7.3

. 01

PS

PS

8.7

Prim

0 0 1.8 3.5 Flow SCFM 5.3 6.4 0 88.3 176.6 264.9 353.1 Flow SCFM

NAL2000
re 14 5 PSI

NAL5000
14.5
PS
PS

14.5 11.6 Pressure deop (PSI)

Pr im

2.9

ar y

pr es su

5.8

10

re

5 1.

PS

PS

PSI

1.5

ressu

10

72

Pressure deop (PSI)

4.5

43

.5

.5

Prim

5.8

2.9

2.9 0 0 17.7 35.3 53 70.6 88.3 0 176.6 353.1 529.7 Flow SCFM Flow SCFM

NAL3000
145 PSI

NAL6000
14.5
PS
SI

14.5 11.6 Pressure deop (PSI)

Prim

5.8

ary

pre

ssu

8.7

ary p

8.7

re 1

43

5P

PS

SI

72

10 PS I .5 43 72
1 . 01 5 PS I

1.5

ure

43.

.5

10

ress

Pressure deop (PSI)

14.

Prim

5.8

2.9

2.9 0 0

Pri

5.8

ma

70.6 Flow SCFM

141.3

176.6

ry

pre

8.7

ssu

8.7

ary p

re

353.1

.5

PS

11.6

5P

1.5

.5

11.6

.5

PS

PS

PS I

72

529.7

Flow SCFM

NAL4000
11.6 Pressure deop (PSI)
5P SI

8.7
ur e 1 45

43.

72
1 . 01 5 PS I

PS

5.8
Pr im ar y pr

s es

2.9

0 35.3

105.9

176.6 Flow SCFM

247.2

317.8

62

.5

PS I

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Modular Air Components

NAL Series
Construction/Parts List
NAL1000, 2000, 3000, 4000, 5000, 6000

ANSI Symbol NAL1000

NAL2000

NAL30004000

NAL50006000

Main Parts
No. Name Body Housing NAL1000 2000 Zinc die casting Material NAL3000 4000 4000-N06 NAL5000 6000
Aluminum die casting

Note
Platinum silver painting Platinum silver painting

1 bk

Aluminum die casting

Component Parts List

Name Material NAL1000 12132 NC100L 111325 NAL2000 12316 122962A 122953 12297PA NC200L-C 11297 NAL3000 12155A 12159A 121521A 121522A NC300L 111512 Part No. NAL4000 12155A 12164A 121611A 121522A NC400L 1 1163 6
12165 -2 (1/2) -1 (3/8) 121623 (1/4)

NAL4000-N06 NAL5000 12155A 12164A 121611A 121616A NC400L 111636

12165-2

NAL6000 12155A 12164A 12335A 121616A NC400L 111636

123310A

2 3 4 5 6 7 8 9

Sight Dome Ass'y Polycarbonate Filter Cap Ass'y Damper Guide Ass'y Needle Valve Ass'y Bowl Ass'y Bowl O-ring NBR Damper Housing O-ring
Synthetic Resin

12155A 12164A 12325A 121616A NC400L 111636

123210A

122933 -2 (1/4) 12158 -2 (3/8) -1 (1/8) -1 (1/4)

NBR

111710

11189

63

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NAL Series
Dimensions
NAL1000, 2000, 3000, 4000, 5000, 6000

Modular Air Components

NAL10002000

NAL30004000

NAL50006000

Model NAL1000 NAL2000 NAL3000 NAL4000 NAL4000-N06 NAL5000 NAL6000

Port size 10-32 Nom. (M5) 1/8 1/4 1/4 3/8 1/4 3/8 1/2 3/4 3/4 1 1

A .98 (25) 1.57 (40) 2.09 (53) 2.76 (70) 2.95 (75) 3.54 (90) 3.74 (95)

B 3.21 (81.5) 4.80 (122) 5.59 (142) 6.97 (177) 6.97 (177) 10 (254) 10.55 (268)

C 1.00 (25.5) 1.50 (38) 1.50 (38) 1.61 (41) 1.54 (39) 1.77 (45) 1.77 (45)

D .98 (25) 1.57 (40) 2.09 (53) 2.76 (70) 2.76 (70) 3.54 (90) 3.74 (95)

F 1.18 (30) 1.61 (41) 1.97 (50) 1.97 (50) 2.76 (70) 2.76 (70)

G 1.06 (27) 1.57 (40) 2.13 (54) 2.13 (54) 2.60 (66) 2.60 (66)

H .87 (22) .91 (23) 1.02 (26) .98 (25) 1.38 (35) 1.38 (35)

J .21 (5.4) .26 (6.5) .33 (8.5) .33 (8.5) .43 (11) .43 (11)

K .33 (8.4) .31 (8) .41 (10.5) .41 (10.5) .51 (13) .51 (13)

L 1.57 (40) 2.09 (53) 2.76 (70) 2.76 (70) 3.54 (90) 3.54 (90)

M 0.09 (2.3) .09 (2.3) .09 (2.3) .09 (2.3) .13 (3.2) .13 (3.2)

P 1.06 (27) 1.57 (40) 2.20 (56) 2.87 (73) 2.87 (73)

R 1.97 (50) 3.15 (80) 3.74 (95) 4.72 (120) 4.72 (120) 4.72 (120) 4.72 (120)

Semi-standard Type 34oz. (1000cm3) Tank

Metal bowl

Metal bowl with level gauge

l owl w Metal Bowl MetaeBgaugeith lev l B B NAL1000 24.24 (81.5) NAL2000 37.12 (122) NAL3000 43.28 (142) 49.38 (162) NAL4000 53.95 (177) 60.04 (197) NAL4000-N06 53.95 (177) 60.04 (197) NAL5000 77.42 (254) 83.51 (274) NAL6000 81.68 (268) 87.78 (288) Model

Float Switch Specifications Description IS400-1~2 Capacity AC:15VA, DC: 15W Voltage AC100V, DC250V Proof Pressure 220 psig Max. Oper. Press. 150 psig Media Water, Oil Ambient/Fluid Temp 40~140F

Model NAL3000-02-03-1

Port size 1/4 3/8

A 4.17 (106) 4.17 (106) 4.17 (106) 4.17 (106) 4.17 (106)

*B 12.76 (324) [14.92 (374)] 13.15 (334) [15.12 (384)] 13.15 (334) [15.12 (384)] 13.23 (336) [15.20 (386)] 13.23 (336) [15.20 (386)]

C 1.50 (38) 1.61 (41) 1.54 (39) 1.77 (45) 1.77 (45)

D 4.17 (106) 4.17 (106) 4.17 (106) 4.17 (106) 4.17 (106)

NAL4000-02-04-1 1/4 3/8 1/2 NAL4000-N06-1 NAL5000-06-10-1 NAL6000-N10-1

* [ ]: With Float switch

3/4 3/4 1 1

E 2.09 (53) 2.76 (70) 2.95 (75) 3.54 (90) 3.74 (95)

F 2.76 (70) 2.76 (70) 2.76 (70) 2.76 (70) 2.76 (70)

With Bracket G H J 2.60 .98 .43 (66) (25) (11) 2.60 .71 .43 (66) (18) (11) 2.60 .63 .43 (66) (16) (11) 2.60 1.38 .43 (66) (35) (11) 2.60 1.38 .43 (66) (35) (11)

K .51 (13) .51 (13) .51 (13) .51 (13) .51 (13)

L 3.54 (90) 3.54 (90) 3.54 (90) 3.54 (90) 3.54 (90)

M .13 (3.2) 13 (3.2) 13 (3.2) 13 (3.2) 13 (3.2)

R 8.27 (210) 8.27 (210) 8.27 (210) 8.27 (210) 8.27 (210)

64

Return to Menu

Series 2300 Applicator

Par! 104 445D

cFirds;j)
NORDSON CORPORATION AMHERST, OHIO USA

Nordson Corporation welcomes requests for information, comments and inquiries about its products. Address all correspondence to Nordson COrporation 11475 Lakefield Orive Ouluth, GA 301551511

Nollee
This is a Nordson Corporation publication which is proteeted by copyright. Original copyright date 1993. No part of this document may be photocopied, reproduced, or translated to another language without the prior writlen consent of Nordson Corporation. The information contained in this publication is subject to change without notice.

Trademarks
AquaGuard, elue Box, Control Coat. Equi=Bead, F1oMelt. FoamMeft, FoamMix, Helix, Hot Shot. Hot Stitch, Meltex, MicroSet, MultiScan, Nordson, the Nordson logo, OmniScan, Porous Coat, Posl-Stop, RBX, Sure-Bond, UniScan, UpTime, and Versa-Spray are registered trademar1<s of Nordson Corporation. BetterBookSM CF. Controtled Fiberlzation, Easy-Screen, Fibermelt. Flo-Tracker, PrintGuard. and Package of Values are trademarks of Nordson Corporation.

PIN 104 4450

412300 Issued 11195

1995 Nordson Corporalion AII rights reserved

Generallnformation

0-3

HOW TO USE THIS MANUAL

The Page Numbering 5ystem
The page number is composed of Iwo parts: Ihe seclion number followed by Ihe section page. Page 5-3, for example, is Ihe Ihird page in Seclion 5.

Finding Information Quickly

Before Irying lo find informalion in Ihis manual, become familiar with ils organizalion and conlents. Afterwards: 1. Use the Brief Summary of Manual Contenls (below) lo delermine which seclion conlains Ihe information you are seeking. 2. Use Ihe labs lo find Ihe seclon Ihal conlains Ihe desired informalion. On Ihe firsl page of each secton is aTable of Conlenls for Ihat section. It gives Ihe slarting page number of all Ihe malerial in Ihe seclion.

Brief Summary of Manual Contents Section 1: Safety Summary

---------

The following summary lisIs Ihe most importanl informalion in each section and prevides a general idea of where lo look for malerial not ncluded in the summary.
o

Explanation of safely symbols Safety during installation, operalion and servlcing Safely in handling solvents Safely in handling thermoplaslic hot mell malerial and in handling PUR hot mell material

o
o

Section 2: Equipment Famitiarization

o

General descriplion Descriplion of equipmenl and fealures Operation Glossary of terms

o o

Sec1ion 3: Instatlation

o o
o

Unpacking and inspeelion Installing Ihe unil, hoses and guns Electrical inslallalion

<t)

NOfdson Co,pOf<llion 1993 AII Righls Reserved

P/N 104 4458 412300 - Issuad 8/93

0-4

General Informa/ion

Srief Summary of Manual

Contents
(contlnued)

Section 4: Operating Instructions

Loading adhesive, ineluding flushing the system Daily operating proeedures

Section 5: Preventive Maintenance Section 6: Troubleshooting

General maintenanee and filter flushing proeedures Troubleshooting funetional problems

Troubleshooting adhesive and adhesive-applieation problems Wiring diagrams and sehematies

Section 7: Disassembly and Repair

Meehanieal repairs
Eleclrieal repairs Gun heater and RTD replaeement

Section 8: II/ustrated Parts Lists

JIIustrations of the unit and its subassemblies Matehing parts Iists Listings of reeommended spare parts and serviee items/kits

Section 9: Technical Data

Meehanieal speeifieations Eleetrieal speeifieations Material safety data information about Nordson Type R solvent

Section 10: Optional Parts and Equuipment

Lislings of various field-inslalled options, guns, hoses, fillers ele.

NOTE: If at any time you are unable to find needed informalion in this manual, eontaet your local Nordson representative or your regional sales offiee.

PN 1044456 41-2300 - Issued 8193

re Nordson COfpomhon 199:1 AII H"lhl'> Hoservfl/j

SERVICES PROVIDED TO NORDSON CUSTOMERS

Customer Support Before And Alter The Sale
For more than 35 years Nordson has offered unpara11eled service to its customers before, during and after the sale. Nordson representatives will work with you to choose the best system for your application. We'll assist you during start-up and help train your employees to maintain and operate the equipment. Plus, parts and service are only a phone ca11 away from one of our strategica11y located sales and service centers.

System Engineerlng
Custom designs and modification of standard equipment are available to meet your particular needs. From a complete new system for automotive assembly to a special nozzle used in the production of diapers, Nordson has the expertise to integrate adhesive and sealant equipment with your manufacturing operation.

Parts And Accessorles

In addition to standard replacement parts, many accessories are avallable to help improve

productivity and reduce downtime. For example, heated and non-heated in-line filters reduce stoppages from clogged nozzles, and nozzles in multi-orifice, offset, right-angle and other designs are available for special needs. Also, gloves, solvent, spare parts kits and other components are in stock for immediate delivery. Conversion kits for tapers, labelers and box-forming equipment are also avallable. To help you eliminate downtime and costIy inplant repairs, Nordson has developed a Rebuilt Exchange (RBXSM) ProgramO which can save you up to 50 percent of the cost of new equipment. You may trade in your old wom units, hoses and guns for rebuilt Nordson equipment which has the same warranty as new equipment.

The Nordson Package of Values

From specifications assistance to post-installation troubleshooting, the Nordson Package of Values is designed to keep our customers productive and profitable by providing: Carefully engineered, durable products Strong service support The back-up of a we11-established international company with financial and technical strength A corporate commitrnent to deliver what was specified

This service not available in a11 countries.

306-18-662

NORDSON CORPORATION 1893

Issue<! 2J93

A11 Rights Reserve<!

7704973400 7704973400

7704973500 7704973500

3/05

US contact numbers updated 3/05

SECTION 1

## TABSHEET ##

SECTION 1

Safety Instructions
1. 2. 3. 4. 5. Operate safely! Safety symbols Intended use Installation and electrical connections Operation Action in the even of unit malfunction Danger of burns Maintenance/Repair Cleaning Thermoplastic hot melt material Polyurethane Reactive ("PUR') hot melt material 1-1 1-1 1-2 1-2 1-3 1-3 1-3 1-4 1-4 1-5 1-5

6. 7. 8. 9.

This Page Intentionally Left Blank

Safety Instructions

1-1

Section 1 Safety Instructions

1. Operate safely!
Salety recommendalions conlained in this seclion and Ihroughoul the manual apply to lasks thal may be performed on or with the unil or with materials used wilh the uni\. IT IS VERY IMPORTANT THAT THESE SAFETV RECOMMENDATIONS ARE ALWAYS FOLLOWED. FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY AND/OR DAMAGE TO THE UNIT OR OTHER EQUIPMENT. Wilh this in mind, here are sorne basic salety recommendalions: Read and become lamiliar wilh Ihis Salely Inslruclions Section prior lo installing, operating, mainlaining or repairing Ihe uni\. Slore this manual within easy reach 01 personnel operaling or mainlaining the uni!. Be lamiliar wilh and always observe salety symbols. Wear adequale personal prolective equipmenl and clolhing such as salety goggles and gloves. Familiarize yoursell wilh and lollow all salety inslructions prescribed by your company, general accidenl prevenlion regulalions and governmenl salety regulalions.

2. Safety symbols

The lollowing symbols are used Ihroughout Ihe manual lo warn againsl dangers or possible sources 01 danger. Become lamiliar wilh them' Failure to heed a warning symbol could lead lo personal injury and/or damage to Ihe unit or o!her equipmen\. WARNING: Failure lo observe may resull in personal injury, dealh or equipmenl damage. WARNING: Risk 01 electrical shock. Failure to observe may result in personal injury or dealh. WARNING: Disconnecl equipmenl Irom line vollage. Failure lo observe may resull in equipmenl damage, personal injury or death. WARNING: Ho\. Risk 01 burns. Wear proteclive clolhing/salety goggles (ANSI Z87.11989 or equal)/prolective gloves (P/N 902 514) depending on the symbol shown.

,el Nordson Corporahon 1993 Al! R,ghts Reservad

P/N 104 4456

41-23OQ8/93

1-2

Safety Instructions

2. Safety symbols
(continued)

WARNING: Risk 01 explosion or lire. Fire, open Iighls and smoking prohibited. Failure lo observe may resul! in personal injury or death. WARNING: System or malerial pressurized. Release pressure. Inlerrupl compressed air, sel molor swilch lo "O" and release hot mell malerial pressure by aclualing the exlrusion guns. Failure lo observe may resull in serious burns.

3. Intended use

The unil is designed and inlended lo be used only lor Ihe purpose described in Section 2 "Equipment Familiarizalion". Uses not in accordance wilh Ihe Section are considered uninlended uses and nol in accordance with governing regulalions. The following actions 01 the owner or operator of Ihe unt are some bul not all examples 01 unintended use whlch would permit Nordson to claim it is nol responsible lar personal injury or property damage arising from such unintended use: unapproved modificalions or changes lo the unt failure lo comply with Ihe Salely Inslructions lailure lo comply with inslruclions concerning installalion, use, operalion, mainlenance, or repair, ar when Ihese lasks are carred oul by unqualilied personnel
use 01 inappropriate or incompatible foreign materials or auxiliary

equipmenl lalure to observe workplace safely rules or regulations issued by

government authorities or safety councils

NOTE: Operalors or maintenance workers are regarded as being "qualilied personnel" when Ihey have gained, Ihrough lraining and experience, an understandng 01 the manner in which the unit 15 to be operaled, serviced and repaired, and based on sale workplace praclces are lamiliar with relevant regulations.

4. Installation and electrical connections

AII eleclrical, pneumalic, gas, and hydraulic connections and installations of healed hoses and hol mel! applicalors may only be carried oul by qualified personnel. Be sure lo observe inslallalion instruclions for components and accessories. Equipmenl musl be properly grounded and lused according lo ils raled currenl consumplion (see ID plate). Cables which run oulside the unil must regularly be checked lor wear and tear or damage. The conduclors 01 cables connecting Ihe unl lo lhe main eleclrical supply must have adequate diamelers according lo lhe rated currenl
consumption.

P/N 104 4458

((1

412300 8/93

Nordson CorporahOn 199:l AII Aights ReselVed

Safety Instructions

1-3

4. Insrallaron and elecrrcal connecrons

(continued)

Cables musl never be squeezed or pinched. They should be localed or posilioned lo eliminale Ihe opportunily for an operalor to stumble or Irip. A disconnect switch wilh lockout capability must be provided belween Ihe power source and Ihe equipment.
WARNING: It Ihe inslallalion is not carried out according lo instructions. especially in case 01 electrlcal connections, Ihis will result in imminent danger 01 serious personal injury including dealh.

5. Operaron

The unit should be operated according lo relevant instruclions and by qualilied personnel.
NEVER have the unil operated by personnei under the inlluence 01 subslances reducing their reaction times, or who are not able to operate the equipment lor physical reasons.

At regular intervals, check protective and warning devices lo delermine Ihal Ihey are in a funclioning condition. DO NOT OPERATE THE UNIT IF THESE OEVICES ARE NOT FUNCTIONING PROPERLY. When Ihe removal 01 safety equipment is required lor installation, mainlenance, or repair 01 the unit, it musl be reconnected immedialely upon complelion of the work and prior lo unit start-up. In a humid environmenl, only equipmenl leaturing a corresponding class 01 protection may be operated. Do not operate the unit in an explosive environmen!. Keep endangered parts 01 the body or clothing away lrom rolating parts. Take off wrist watches, rings, necklaces, or similar pieces 01 jewelry and pin up or cover long hair belore periorming any work on or wilh the unit. To carry oul measurements on work pieces, swilch off the unil and wail unlil it comes lo a slandstlll. Never poin! hand guns or applicator nozzles at yourself or other persons.

Action in the even oi unit malfunction

In Ihe event Ihe unil experiences a maifunction, switch off Ihe unit immedialely. Swilch olf the main switch or, il available, the emergency lurnoff swilch or use olher salely equipment to stop the uni!. Alter turning the unit off and prior lo swilching it on again, Ihe mallunclion has to be eliminated by qualilied personnel.

Danger oi bums

Contact with hol areas 01 the ho! melt applicator as well as to the hot mel! matenal may produce asevere skin burn. Take ulmost care when using hot mell material. Even solidilied material may slill be very hot.

Nordson Corpoo-atron 1994

p,N 104 445C

Al! Righls Reservad

41230012/94

1-4

Safety Instructions
Always wear protective clothing which salely covers all endangered body parts. In case 01 burns: Immediately cool affected skin areas using cold, clean water. Do not lorcelully remove hot melt material lrom the skin. Immediately seek medical attention.

Danger of bums
(contnued)

6. Maintenance/Repair

Allow only qualilied personnel to perform maintenance, repair and troubleshooting. AII activities should only be carried out wearing personal protective clothing and equipment and when the equipment is switched off and unpressurized.

lA. ill

WARNING: Even when the main switch is set to OFF there remains residual voltage inside the switchboard. So. on principie, carry out the lollowing work prior to maintenance and repair:

Disconnect. lock out and tag external power supply.

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.

II the unit energizes, repeat the disconnect, lock out and tag procedure. Retest the unit. Manually actuate the applicators/hand guns to release the system pressure in the entire unit. Secure pneumatically or hydraulically operated equipment against uncontrolled movement. Only use spare parts which do not compromise the salety 01 the uni!. A Iist 01 Nordson spare parts is provided in Section 8 01 this manual. AlWAYS use a rubber handle screwdriver when removing or installing components.

7. Cleaning

NOTE: Always reler to the Material Salety Data Sheet or material inlormation sheet belere working with the material.

ffi

PoI.

WARNING: Never clean any aluminum part or Ilush any system using halogenated hydrocarbon solvents. Examples 01 common halogenated hydrocarbons are dichleromethyline, 1,1,1-trichloroethylene, perchloroethyline. Halogenated hydrocarbons may react violently with aluminum parts.

NEVER use an open llame to c1ean the unit or components 01 the uni!. Use only cleaning solvents designed or intended to be used with the hot melt material being used in the uni!. NEVER USE PAINT SOlVENTS UNDER ANY CIRCUMSTANCES.

P/N 1044458

(Q

Nordson Corpofalion 1993

AII R,ghls Resarved

412300 8193

Safety Instructions

1-5

7. Cleaning
(continued)

Note the Ilash point 01 the cleaning solvent used. Only use a controlled heating method to heat solvents. Ensure sufficient room ventilation to draw off generated vapors. Avoid prolonged breathing 01 vapors.
WARNING: Fire, open lights and smoking are prohibited when cleaning solvents are used. Risk 01 explosion or lire. Failure to observe may result in personal injury or death.

8. Thermoplastic hot melt material

NOTE: Always reler to the Material Salety Data Sheet or material inlormation sheet belore working with the material.

Ensure the work area is adequately ventilated. Do not exceed recommended processing temperatures. Doing so creates a danger to personnel due to decomposition 01 the material.

9. Polyurethane Reactive ("PUR') hot melt material

NOTE: Always reler to the Material Salety Data Sheet or material inlormation sheet belore working with the material. WARNING: Exercise extreme caution and always provide adequate ventilation when using reactive materials. Failure to observe may result in personal injury or death. WARNING: Only use PUR material in units that are designed to process such material. Usng PUR material in units that cannot process them can cause damage to the unit and premature reaction 01 the hot melt material. WARNING: PUR material contains isocyanate ingredients whch will irrtate skin, mucous membranes 01 eyes and respiratory passages.

Because isocyanate ingredients are lound in various concentrations in reactive materals produced by different manulacturers, it is imperative that the manulacturer's or supplier's Material Salety Data Sheet or material inlormation sheet be consulted BEFORE using reactive material. Pay particular attention to the discussion 01 material toxicity, heallh effects and reactivity conditions. There are certain universal salety guidelines that should be lollowed
when using any reactive material:

Recommended processing temperatures must not be exceeded. When handling and using reactive material, always wear protective clothing and use personal protective equipment such as salety goggles and gloves.

(t)

Nordson Corpora~on 1993

AlI Aights Reserve<!

P/N 104 4458 41 -2300 6193

1-6

Safety Instructions

9. Polyurethane Reactive ("PUR'? hot melt material

(contlnued)

The regular use of barrier creme for hands and face is recommended as preventive skin protection. Do not eat, drink, smoke or store food in working areas where PUR material is being processed. Wash hands thoroughly after working with reactive material. Remove hot melt material vapors using suitable extraction equipmenl. This also holds true for the vapors released by Iresh hol melt material applications. Use appropriate respiratory equipment where there is the danger 01 inhaling isocyanate vapors or 01 olher ingredients used in the production 01 PUR malerial in concenlrations exceeding permissible limil values. In case 01 very high concentrations 01 harmlul substances or il environmenl conditions are not c1ear, respiratory prolective equipment operating independent 01 lhe open air must be used. In order lo determine concentralions 01 harmlul subslances samples of the air should be taken and evaluated.

P/N 104 4456 4123008/93

(el Nordson COIporallon 1993 AlI A,ghts Aeservad

SECTION 2

## TABSHEET ##

SECTION2

Equipment Familiarization
1. Introduction 2. Functional description 01 standard leatures Hot melttank Hot melt adhesive pump Distribution manilold Tank, hose, and gun temperature controls Automatic gun hoses Handgun hoses Automatic extrusion guns (H20 and H200) Manual extrusion gun 3. Functional description 01 optional leatures Parent machine interlock (PMI) Digital readout Low temperature setback Low level indicator 4. Glossary
2-1 2-2 2-2 2-2 2-4 2-4 2-5 2-5 2-5 2-6 2-7 2-7 2-8 2-9 2-' O 2-11

List of lIIustrations
Figure 2.1 - Series 2300 Hot Mel! Applicator 2-1 (Model 2305 Shown) Figure 2.2 - Air-Driven, Dual-Acting Piston Pump During Upstroke 2-2 Figure 2.3 - Air-Driven, Dual-Acting Piston Pump on Downstroke .2-3 Figure 2.4 - Model 2305 Indicator Panel with Parent Machine Interlock (PMI) and Low Level Indicator options 2-4 Figure 2.5 - Controls and Indicators on Units with Digital Readout. 2-8 Figure 2.6 - Controls and Indicators on Units with Low Temperature Setback. . 2-9 Figure 2.7 - Basic Low Levellndicator Components (mercury switch and lamp not shown) 2-10

This Page Intentionally Left Blank

Equipment Familiarization

2-1

Section 2 Equipment Familiarization

1. Introduction
The Nordson Series 2300 Hot Melt Applicators are designed to melt adhesives and other thermoplastic materials with visco sities ranging Irom 1,000 to 30,000 centipoise and deliver them through hoses and extrusion guns to a substrate. The hot melt material is melted in a TEFLON-coated aluminum tank and translerred by an air-driven, dual-acting piston pump into a distribution manilold and through a lilter, heated hoses, and heated extrusion guns. The tank, hoses, and guns are all electrically heated: the tank by a cast-in resistive heater in its aluminum wall, the hoses by a spirally wound heating element, and the guns by a cartridge heater. The heating control system utilizes solid-state electronics throughout, with proportional control lor the tank, each hose, and each gun. Resistance temp8rature detectors (RTD's) are used to sense the temperature in the tank, hoses, and guns. An automatic, sequential start-up routine ensures that the entire system powers up in the optimum manner.
Figure 2. 1 - Series 2300 Hat Melt Applicator (Model 2305 Shown)

--------

Some 01 the standard leatures 01 the Series 2300 applicators include a liberglass reinlorced plastic enclosure lor cooler surface temperatures, a large lilter lor less Irequent cleaning, a special wear-resislant valve shifter lor extended purnp lile, and reeessed external parts lor increased salety. A recessed cireuit breaker prevents accidentally turning the unil on during servicing and a reces sed liller bung and drain valve prevent accidental burns during operation. The Series 2300 applieators come in lour standard conligurations: Two-hose unit (the 2302) Four-hose unit (the 2304) Five-hose unit (the 2305, shown in Figure 2.1) Six-hose unit (the 2306) In addition, there are lour major optional leatures: System-ready indicator lor parent machine interlock Digital readout 01 temperature on all channels Temperature setback switch lor production interruptions Low-Ievel indicator The parent machine interlock and the low level indicator can be easily added to the applicator at any time, but the digital readout and the temperature setback options cannot be added after purchase 01 the applicator without ordering a new cireuit board.

,~)

NOldson Corporalion 1993 AII Aighls Reserved

P/N 104 4458

4123006/93

2-2

Equipment Familiarization

1. Introduction
(contlnuedl

Three types 01 extrusion guns can be used with the Model 2300: H20 automatic gun (available with or without a micro-adjuster), H200 automatic gun (available in 1, 2, 4, and 8 module units and in close, extended, and low-prolile conligurations) AD-31 handgun. Hoses lor the automatic guns are available in lengths 01 2, 4, 6, 8, 10, 12, and 16 lee!. AII 01 the automatic hoses are provided with quick-disconnect electrical connections on both ends 01 the hose. Hoses lar the AD-31 handgun are available in lengths 01 8 and 16 leet and come with a quick-disconnect on the applicator end 01 the hose. Reler to Section 9 01 this manual lar Series 2300 applicator dimensions.

2. Functional description of standard features

Hat melt tank

The following paragraphs divide the Series 2300 applicators Into their
various standard components and describe the operation of each

componen!. Optional features are discussed later in Section 2. The applicator melts adhesive or other thermoplastic materials in a cast aluminum tank with a cast-in resistive heating elemen!. Temperature
control is accomplished by means of a resistance temperature detector

(RTD) mounted in the tank wall and solid-state circuitry located in the electrical enclosure. The temperature control range is lrom 220'F to 400F (105C to 205C). Either granular, ribbon, or chunk lorms 01 adhesive may be used in the tank, which is Teflon-coaled to prevent char buildup and secured with a loading lid to prevent contamination 01 the adhesive. The loading lid is composed 01 two pieces, a hinged cover which is made 01 liberglass reinforced plastic (FRP) and an inner detachable condensate tray of
aluminum. The condensate tray is designed to prevent hat adhesivo

from spilling onto the exterior 01 the applicator when the loading lid is opened and to prevent breakage 01 the plastic lid when the unit cools down. When the unit is cool, the metal condensate tray adheres to the top surface of the tank pan and cannot be opened, but the hinged plastic lid, which is connected to the condensate tray by a ball-and-stud mechanism, separates Irom the tray and swings open. This design prevents the lid from being damaged if someone tries to open It when the unit is cold.

P,iN 1044458 41-23008193

(o Nordson Corporahon 1993 AII R'ghls Reserved

Equipment Familiarization

2-3

AIR CYLlNDER - - - .

TANK_

DISTRIBUTION MAHIFOLD

DRAIN
VALVE-'

AIR REGULATOR

==0
HOSE--l

fllTER .--AIRSUPPLY

l~~~'.'~" I .
[~~:=l
B

.~.~

AUTDIoIATlC EXTRUSION GUN

SENSING DEVICE - - -

('-0L.)
Figure 2.2 - Air-Odven, Dual-Acting Pistan Pump on Downstroke

--.:CONVEYOR DIRECTION Of TRAVEL

,~ Nordson Corpora~on 1993 AII R'ghts Reserved

P/N 104 4458

41-23008/93

2-4

Equipment Familiarization
Series 2300 applicalors use an air-driven, dual-acting Diston pump lo transfer Ihe adhesive from Ihe tank to Ihe subslrale. The pump assembly consists 01 a regulalor, a solenoid val ve, an alf piston wlth a four-way control valve, a valve shifter, and a dual-acting hydraulic pump. The air cylinder and hydraulic pump are lied togelher Ihrough a common shaft. A crossover lube connecls Ihe oulpul of Ihe hydraulic pump lo the dislribulion manifold. The pump delivers adhesive lo Ihe dislribulion manifold on both Ihe upstroke and lhe downslroke of lhe pislon. On Ihe upslroke (see Figure 2.2) compres sed air enlers Ihe air cylinder below the air piston, forcing it upward. As the attached pump shaft moves up, Ihe large ball check valve is lifted off ils seal, sucking adhesive inlo Ihe chamber from the applicalor lank. The small bail check valve remains on ils seal during Ihis time because Ihe pump shaft is moving up. The upward movemenl of Ihe plunger at Ihe lower end of the pump shaft also pushes the adhesive above il inlo Ihe crossover lube and from Ihere into Ihe dislribulion manifold. In Ihe downslroke of Ihe pump (see Figure 2.3) compressed air enlers Ihe air cylinder above Ihe air pislon, forcing il down. As Ihe attached pump shaft moves down, Ihe adhesive pressure forces Ihe large ball check valve againsl its seat and Ihe small ball check valve off its seal, allowing Ihe adhesive lo move up the pump cylinder and inlo the crossover tube. Il Ihen passes Ihrough a filler in the distribution manifold and from Ihere lo the hose(s) and gun(s). Overpressure proteclion is provided by a relief valve in Ihe dislribulion manifold II opens at 1,500 psi (10.3 MPa) lo relieve syslem pressure back to lhe adhesive lank.

Hot melt adhesive pump

~-- AlR CYUNOER

rOUR-WAY

-AIRVALVE
: "------ "IR EXHAUST

1l~-=--PUMP SHAFT

S......LL BALL CHECK YAlVE

REU[f VALVE
CROSSOVER TUBE

Figure 2.3 - Alr-Onven, OualActing Pistan Pump During Upstroke

Distribution manifold

An aluminum manifold assembly mounled on Ihe bottom of Ihe hol melt lank receives hol adhesive from Ihe air-driven pump, fillers il, and dislributes il to Ihe healed hoses and exlrusion guns. Because the dislribulion manifold is mounled to Ihe tank, il is indirectly heated by the tank healers. The filler consisls of a core and fine mesh screen lo filler oul conlaminanls and charo The filler is threaded inlo a sleeve lo prevenl overtorquing and allow easy removal for inspection and c1eaning. A drain valve in the manifold allows malerial lo be pumped through the filler assembly witnout lhe use of Ihe hoses and extruslon guns. The valve aiso provides a convenienl melhod lo relieve pressure in Ihe system during maintenance operations. The manifold conlains six ports for connecling hol mell hoses: four in the side of Ihe manifold and two in the bottom.

P/N 104 4456 41 -2300 8193

(~)

Nordson Corporahon 1993

AIlf.\"lhl'>Hp'.""""l

_________________________--=-Equipmen/ Familiariza/ion Tank, hose, and gun temperature controls

2-5

~:d: O ',d ,
'%.~ij'

NO. 1 HOSE CHANNE YELLOW LEO

The temperature controller in Series 2300 applicators is a solld-state device that monitors and controls the temperatures within the hot mel! tank and heated hoses and guns. Temperature is sensed in the tank and in each 01 the hoses and guns by a resistance temperature detector (RTO) in each componen!. Each 01 thesp hpAting zones or channels has an operating range 01 220"F to 400"F (105"C to 205"C). The six-hose, Model 2306 applicator has thirteen individual channels lor heating: one lor the tank, six lor the hoses, and six lor the guns. The live-hose, Model 2305 applicator has eleven individual channels lar heating: one lar the tank, live lor the hoses, and live lor the guns. The Model 2304 has nine separate temperature controls: one lar the tank, lour lar the hoses, and lour lor the guns. The Model 2302 has live individual channels for heating: one lar the tank, two for the hoses, and two lar the guns .. Each channel has a separate dial potentiometer on the control panel and a yellow light emitling diode (LEO) on the indicator panel (see Figure 2.4). The yellow LEO acts as a load lighl: it glows continuously when the temperature \S below the control sensor temperature, Ilashes when the controller is maintaining the sensor temperature within 2.7"F (1.5"C), and remains off when the temperature exceeds the sensor temperature by approximately 2.7"F (1.5"C). Actual tank, hose, and gun temperatures can be determined within 10"F (6"C) at any time by rotating the temperature control knob until the yellow LEO begins to Ilash. The dial reading at this point corresponds to the temperature in the wall 01 the tank, hose, or gun. An important salety leature 01 the temperature control system is overtemperature protection. A red LEO on the indicator panel comes on when either 01 two laul! conditions arise: when an open or short circuit occurs in any 01 the RTO's (Iailure 01 the RTO) ar when the temperature 01 any channel reaches 425"F (220"C), indicating a lailure 01 some other component in the hot melt system. In either case, a solid-state time delay is activated. The time delay gives an operator approximately 1 minute lar troubleshooling the overheating or RTO problem belore it trips the circuit breaker, shutting off power to the applicator. The circuit breaker may be reset immediately to allow an additional 1 minute interval lor troubleshooting. I! may be reset indelinitely in this way unlil the lault condition is corrected or until the tank sensor temperature reaches 500"F (260"C). When temperature rises above 500"F (260"C) on the surface 01 the tank, a close-on-rise thermostat causes the circuit breaker to trip. It cannot be reset until the tank sensor temperature lalls below SOO"F (260"C).

. . . . . - NO. 1 GUN CHANNEl .....- NO. 2 HOSE CHANNEL YELLOW LEO .........-- NO. 2 GUN CHANNEL _ NO. 3 HOSE CHANNEL YELLOW LEO NO. 3 GUN CHANNEL NO. 4 HOSE CHANNEL

'O'' ~ ...

..

~:Q"

el ''O'

'%.:Q
el , el
'-

, 'O'
_
_1

..

YElLOW LED
NO. 4 GUN CHANNEL NO. 5 HOSE CHANNE YELLOW LEO NO. 5 GUN CHANNEL

'%.:0;
t."

D' _ -, 'I!!IO I - + - - TANK CHANNEL YELLOW LEO 1

I
:

ffi~''l
(!J

"FAULT" L1GHT REOLED

,----~

"WAIT" UGHT rOR

L - - . _ ---.J

: 4--

PARENT ~ACHIN[ INTERLOCK

:'-~ , - - _ . . ........-- LOW LEVEl ,61 L

---J

INOICATOR

Figure 2.4 - Model 2305 Indlcatar Panel wlth Parent Machine Interlock (PMI) and Low Levellndlcator optlons.

e; Nordson Corporation 1993 AII R,ghts Reserlled

P/N 104 4458

41-23008193

26

Equipment Familiarization
The automatic gun hoses lor Series 2300 applicators come in lengths 012, 4, 6, 8, 10, 12, and 16 leet, and all have quick-disconnect electrical connectors at both the applicator end and the gun end 01 the hose. Constructed 01 aircrafl-type hydraulic hose with a Tellon liner reinlorced by stainless steel braid, the hoses are both durable and Ilexible. Heat is generated in the hose by a resistive-type healing wire wrapped spirally around lhe steel braid. Insulation is provided by wrapped layers 01 polyester lelt, vinyl tape, and a special high-temperature insulating lelt. An electrical cordset runs the length 01 lhe hose to provide power lo lhe gun and connect the RTD's to the circuit board. Electrical power to lhe hose and gun is 230 VAC lrom the hot melt applicator electrical system. Temperature in the hose is monitored and controlled by an RTD in the hose wall and solid-state circuitry in the hot melt applicator.

Automatc gun hoses

Handgun hoses

The handgun hoses lor Series 2300 applicators come in lengths 01 8 and 16 leet. They are equipped wilh a quick-disconnect plug on the applicator end 01 the hose and with a live-wire cordset on the gun end 01 the hose. In all other respecls, they are identical to the automatic gun hoses. Two 01 Nordson's automatic guns, the H20, and the H200, have been equipped with RTD's lor use with Series 2300 applicalors. The H20 gun is available as a single module gun, eilher with or wilhoul a micro-adjusler. The H200 gun is available in 1, 2, 4, and 8 module units and in three conligurations: one with close cenler-to-center dislances (c1ose), one with wider center-to-center distances (expanded), and one designed lor use on case sealers with short compression sections (Iow profile). AII 01 the automatic guns are equipped with a quick-disconnecl electrical plug, and all may be mounled either vertically or horizontally. The automatic guns consist 01 two major parts: a service block and a liring mechanism, both made 01 aluminum. The liring mechanism lor the H20 and H200 guns is a rectangular-shaped "module" which bolts onto the lace 01 the service block. It consists 01 an air cylinder, an air piston with a needle and ball altached, a seat, and a nozzle. It can be repaired in the lield. Standard, mulliple-orilice, and right-angle nozzles can be used with all 01 the automatic guns. The service block contains one or lwo cartridge heaters, an RTD, and the inlet connections lor air and hot mell material. During operation, hot melt material is supplied to the automatic gun(s) by the pump in the applicator (see Figure 2.3). It enters the inlet por! 01 the service block and is directed lhrough drilled passages in the block to the extrusion module(s). When the gun solenoid valve is energized by a signal lrom a sensing device (such as a microswitch or a photosensor), compressed air enlers lhe module by way 01 lhe service block and lorces the air piston upward, lifting lhe altached ball off its sea!. The pressurized hot melt Iluid is extruded lrom the nozzle while the ball is heId off its seat by air pressure.

Automatc extruson guns (H20 and H200)

P/N 1044458 41.23008193

Nordson Corporahon 1993 A11 R'ghts ReseNed

Equipment Familiarization Automatic extrusion guns (H20 and H200)

(continued)

2-7

When Ihe sensing device or limer deenergizes Ihe solenoid valve, the air under the air pislon and in Ihe service block venls lo the almosphere and Ihe pislon-relurn spring lorces Ihe ball against its seat, stopping the Ilow 01 hol mell material. Each 01 Ihe automatic guns offers certain advanlages. The H200 gun has an adjuslmen! screw which enables Ihe liring 01 one module to be synchronized wilh another. The H20 may be ordered wilh a microadjusler which enables bead Ihickness lo be changed without changing Ihe hydraulic pressure ollhe system. AII 01 Ihe automalic guns, wilh Ihe exceplion 01 Ihe H20 gun with Ihe microadjuster, are available in a 200 VAC version as well as in the slandard 230 VAC version.

Manual extrusion gun

The AD-31 handgun, designed lor applications requiring manual placemenl 01 adhesive bead deposits, has been equipped with an RTD lar use wilh Series 2300 applicators. Like all Nordson handguns, Ihe AD-31 is operated by a manual Irigger which is isolated trom the gun lo keep it cool. The trigger is connected by a linkage to a packing cartridge in the gun body. At the end 01 the packing cartridge is a carbide ball tip thal seals against a matching sea!. Heat is supplied by a cartridge heater, which is controlled by Ihe RTD. When the Irigger is squeezed, the carbide ball is Iifted Irom its seat by Ihe linkage mechanism, lorcing the pressurized hot melt material Ihrough Ihe opening in the seat and oul the nozzle. When Ihe trigger is released, a spring lorces the ball back against its seat, stopping material ftow. The AD-31 handgun is available in 200 VAC and 230 VAC versions.

Nordsol1 Corporabon 1993 AU Aights Reservad

P/N 1044458

4123008/93

2-8

Equpment Familiarzatan

3. Functional description of optional features

Four optional features may be purchased with Series 2300 applicators: parent machine interlock, digital readout, low temperature setback, and low level indication. Each of these four is described in the followlng paragraphs. A Parent Machine Interlock performs two basic functions: it provides a way for an operator to tell when the adhesive in the tank has reached application temperature (an indicator light turns off) and, once this temperature is reached, it energizes a contact which may be used to operate a normally open or a normally closed switch on a parent machi ne. If, for example, a system user wants to ensure that a packaging line does not run unless the adhesive is fully melted, a PMI can be used to achieve this purpose. Although an operatar can easily tell when the tank walls have reached application temperature--the yellow LEO of the tank circuit begins to flash-it typically takes 15-20 minutes longer, depending upon Ihe adhesive used, far all of lhe adhesive to reach the same temperature. The PMI is essentially a lime delay which takes this difference into account. It begins timing when the tank control channel reaches the set, or application, temperature, that is, when it begins proportionlng and the tank's yellow LEO is flashing. It completes its time-delay cycle when the number of minutes for which it is set (determined from past experience with the adhesive used) have passed. The delay cycle is adjustable between 12 and 22 minutes. Once the set time period has elapsed, the PMI "wait" light on the indicator panel (see Figure 2.4) turns off and an output relay is actuated, allowing interface with either normally closed or normally open contacts. After the initial start-up sequence, the PMI operates somewhat differently. Ouring normal operations the adhesive may occasionally drop below the application temperature for several reasons, the most common one being the refilling of the tank with fresh adhesive. If enough cold adhesive is added that the temperature of the tank wall drops more than about 3'F (1.5'e) below application temperature (also called the setpoint temperature), the tank heating circuil will stop proportioning and will apply heat steadily until the set temperature is reached again. In this situation the PMI may be set by a switch on the interlock board to do one of two things: either to ignore the drop of the tank below application temperature ar to activate the "wait" Iight and deenergize the output relay. In the first situation the applicatar will operate as it would without a PMI. In the second situation the PMI will perform as follows. If the tank temperature falls below the application temperature for only a short period of time (Iess than about six minutes), the output relay will be deenergized only until the tank heating Gircuit begins to proportion again. But if the tank is out of the proportioning range for longer than six minutes, the time delay will be activated and the wait period will include the time delay, allowing the adhesive in the tank to reach the application temperature again.

Parent machine interlock (PMQ

P/N 104 4458

~1_"'lnn

<l10'>

'<.' Ncrdson Co,porat,on 1993

Equipment Familiarization
Parent machine interlock (PMI)
(continued)

2-9

During a power failure or a temporary shul down of the applicator, the parent machine interlock will operate in the same way, no matter how the switch on the interlock board is sel. If, after power is restored, it takes less than 6 minutes for the tank temperature control circuit to begin proportioning (and its yellow LED to begin !!3sh i ng), the output relay will be deenerglzad only until the set temperature is reached again. But if it takes longer than 6 minutes for the set temperature to be reached, the output relay will be deenergized until the time delay has elapsed. Parent Machine Interlock is an optional feature which may be either purchased with the applicator or added at a later date. See Section 3, Installation, for instructions on installing and setting up Parent Machine Interlock.

Digital readout

Digital Readout providas a numerical LED display of the temperature reading on any channel, or heating zona. A three-digit temperature display window and a channel selector switch are located on the control panel of applicator (see Figure 2.5). The selector switch determines which channel"the tank channel or any of the gun or hose channels"will be displayed. Because the temperature is displayed instantaneously, the temperature on all channels can be quickly monitored by turning the selector switch from channel to channe!. Or a single channel can be monitored continuously by leaving the selector switch in one position. A small red switch along the lower edge of the circuit board allows the customer to select whether the temperature will display in F or C. Pushing the right half of the switch in (with a pencil or some other pointed object) selec1s 1he F readou1; pushmg 1he left hall 01 the switch in selects the readoul.

NOTE: If the selector switch is turned to an unused channel, a number between 725 and 735 if F readout is selected (or between 950 and 960 if readout is selected) will appear in the temperature display window. This number has no significance and does not mean that any channel is overheating.

Digital Readout is available only on the Model 2302 (two-hose), the Model 2304 (four-hose:, and the Model 2305 (five-hose) units. It must be ordered at same time the unit is purchased; it cannot be added later without ordering a new circuit board.
CHANNEL SELECTOR SWITCH

TEliIPERATURE DISPLAY WINDOW

02
'&2 '

'!1.3
I ...

7
Figure 2.5 - Contro/s and Indicators on Units with Digital Readout.
P/N 104 4458

01-'0
%1'

03
-'!1.4

...

'04

DDD

:0, Nordson Corporallon 1993 AII Rights Aeserved

41-23006193

2-10

Equipment Familiarization
Low Temperature Setback prevides a means to reduce the temperature

Low temperature setback

01 the heating channels without changing all 01 their setpoints or without

shutting the unit down. It is especially uselul when normal operations must be interrupted lor a while. The adhesive in the system can be kept hot during such periods but at a lower temperature, thus reducing the amount 01 char that will lorm when the system is idle and reducing energy consumption as well.
~ON/OFF INDICATOR (YELLOW LEO)

/ - - - ON/OFF TOGGLE SWITCH

DIAL FOR SErrING AMOUNT OF TEMPERATURE SETBACK

'F SETIlACK

Figure 2.6 - Controls and /ndicators on Units with Low Temperature Setback.

The Low Temperature Setback leature is activated by a toggle switch on the control panel 01 the applicator (see Figure 2.6). Once the switch is turned on, a yellow LED on the control panel and the lower hall 01 the power indicator lamp on the Iront 01 the unit will begin to Ilash. They will continue to Ilash as long as the applicator is in the setback mode 01 operation. The amount by which the temperature is to be set back is determined by turning a dial potentiometer, which is located on the control panel. The setback range is adjustable Irom 60"F (16"C) to 150"F (66"C). 11, lor example, the temperature is set back by 70"F (21"C), the temperature on all channels will be reduced by this amounl. As soon as the temperature setback leature is turned on, the yellow LED's lor the tank, hoses,and guns will go off because the unit is cooling down, but when the setback temperature is reached, the yellow LED's will begin flashing, just as they do at the normal operating setpoints. The pump, however, will not operate when the applicator is in the setback mode because the pump solenoid valve is disabled. A special leature can be obtained with Digital Readout a plug on the circuit board lor activating the temperature setback mode 01 operation remotely and automatically instead 01 manually by a switch on the contrel panel. Low Temperature Setback must be ordered at same time the unit IS purchased; it cannot be added later without ordering a new circuit board.

PIN 104 4458

;e) Nordson Corporatlon 1993

4123008193

Al! R,ghls Reservad

Equipment Familiarization
Low level indicafor

2-11

A Series 2300 applicator equipped with a Low Level Indicator will display a warning whenever the level of adhesive in the tank fa lis to the point that the unit should be refilled. The low-Ievel light (see Figure 2.4) will come on and stay on until the tank is refilled.
~--

COUNTERWEIGHT

_~--

PIVOT POINT

/ .~-

LEVER ROO

rLOAT

---.J

AoHESIVE LEVEL

Figure 2.7- Basic Low-Levellndicator Components (mercury switch and lamp

not shown).

The Low Level Indicator consists of a float, a counterweight, a lever rod, a mercury switch, and a light (see Figure 2.7 for basic components). The float is balanced by the counterweight such that it rides half in the adhesive, half out. As the adhesive level drops, the lever rod to which the fioat is attached drops down and the mercury switch, which is attached to the pivot point on the lever rod, tilts forward. This action causes the mercury switch to close and turn on the Iight on the indicator panel. The Low Level Indicator is an optional feature which may be either purchased with the applicator or added at a later date. It may be obtained with a kit which will permit the warning to be displayed (or sounded) remotely. See Section 10, Optional Parts and Equipment, for instructions on installing and setting up the Low Levellndicator.

'0

NOfdson COfporatiofl 1993

AII A'ghts Res8Ived

P/N 104 4458

4123008/93

2-12

Equipment Familiarization

4. Glossary

Appllcator. That part of the hot melt system which is used to heat adhesive to its required application temperalure and pump it to the hoses and guns. It consists of a tank, a pump, a filter, a distribution manifold, and a temperature controlled heating system. Bead Thickness. The width of an adhesive bead which has been deposited on a substrate. The measuremenl is of course laken before lhe bead has been f1atlened by adhering it to another surface. The thickness may be adjusled in three ways: by adjusting the hydraulic pressure of lhe system (increasing lhe pressure produces thicker beads), by varying the speed of applicalion, or by using a gun with a microadjuster, like the H20 (see Section 4, Operating Instructions). Extruslon Gun. A spring-Ioaded triggering device for dispensing or deposiling adhesive. There are two basic types of gun, the manual gun, in which the spring is actuated by a hand trigger, and the aulomalic, in which lhe spring is actualed pneumalically. For a more detailed description of the operation of extrusion guns, see Section 2, Equipment Familiarization. Hot Melt System. The applicator, the hose(s), and the gun(s).

LEO (Light Emitting Dlode). A device that converts applied voltage to lighl. LED's are used to display operaling conditions on the indicator panel of the Model 2300 Applicator. Maximum Instantaneous Pumplng Rale. The adhesive delivery measured at the manifold oullet, wilh lhe condilions lhat produce maximum flow without exceeding any operating parameler limils. The rate in the specifications is based on an adhesive with a viscosity of 32,000 centipoise. Service Block. One of the two main parts of a Nordson automatic extrusion gun, the other being either a module or a cartridge, depending upon the design of the gun. The automatic guns are constructed so that the module or cartridge contains the spring-Ioaded firing mechanism of the gun and lhe service block supplies the needed air, adhesive, and heat to make lhe gun operate. It consists of an aluminum block drilled with air and adhesive passages and with a cavity for a cylindrical heater, which is referred to as a cartridge heater. IlIustration of various service blocks may be found in the parts Iists for automatic guns, Seclion 8. Substrate. The malerial or surface upon which the adhesive IS applied. System Melt Rate. The amount of adhesive, measured in pounds per hour, that an applicator (including hoses and guns) can melt and pump continuously within 10F (5.6C) of the set application temperature. The measurement is based upon an adhesive with a specific heat of 0.77 BTU/lboF (cal/gOC) at 247F (199C) and upon a syslem consisting of a Model 2302 Applicator, two hoses (6 fl. and 8 fl.), and two H20T (RTD temperature sensor) automalic guns.

PiN 1044458 41-23008193

Nordson CorporatlOn 1993 AlI Aighls Reservad

Equipment Familiarization

213

4. Glossary
(continued)

Tank Capacity. The weight 01 adhesive that a tank can hold when it is filled to the top Ilange. The measurement is based upon an adhesive with a speeifie gravity 01 1.0. See delinition 01 Tank Volume. Tank Volume. The volume that the tank can hold when it is Iilled to the top Ilange. The displaeement 01 the pump is taken into aeeount in this measuremenl. The usable volume will be somewhat less sinee Nordson reeommends lhat the tank be lilled no more than one ineh lrom the topo Thermoplastic Material. A material whieh is solid at room temperature, becomes soft when healed, and returns to Solid lorm upon eooling.

1\;)

Nordson Corporation 1993

AII Aighls Ael>ervoo

P/N 1(}4 4458

4123008/93

214

Equipment Familiarization

This Page Intentionally Left Blank

P/N 1044456

4123008193

a:J Norson CorpOIation 1993 Al! Alyhts Reserved

## TABSHEET ##

SECTION 3

SECTION3

Installation
1. Introduction 2. Unpacking 3. Inspection

4. Installation General requirements Automatic gun installation Manual gun installation Applicator instaliatior, Electrical instaliation AII Units Except European Units: European Units Only:

3-1 3-1 3-1 3-2 3-2 3-3 3-4 3-6 3-7 3-8 3-8

List of lIIustrations
Figure 3.1 . Figure 3.2 Figure 3.3 . . . Figure 3.4 Figure 3.5 Figure 3.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . Figure 3.7 Figure 3.8 Figure 3.9 Figure 3.10 3-1 3-1 3-2 3-3 3-3 3-4 3-5 3-6 3-6 3-7

This Page Intentionallv Left Blank

Instaflation

3-1

Section 3 Installation
1.lntroduction
Seclion 3 conlains information necessary for lhe proper inslallalion of lhe applicalor, hoses and guns. Instruclions for preparing the Series 2300 Applicalor for operalion, loading and changing adhesive and daily operalion are included in lhis section~

2. Unpacking

NOTE: Do not attempt to lift the applicalor by any of the fiberglass panels or hose conneclors~ Uft lhe unil from the hand grips in Ihe melal base (see Figure 3.1).

r--~-I----~~--~~~--~=- .(b
!
-'lU
I

No special inslruclions are necessary lo unpack the applicalor, hoses or guns~ The applicalor IS shlpped preassembled~ Hoses and guns are shipped separalely, also preassembled~ Normal care should be exercised nol lo damage the equipmenl during unpacking~

-1

""O .,;,;;l,~ _ ~
I

~ ---;rr;-'
,~~o;

-1._':---l /

Figure 3. 1

3. Inspection

After unpacking is compleled, lhe following inspeclion should be pertormed: 1 ~ Inspecllhe fiberglass cover for evidence of cracks and lhe olher surlaces tor scratches, corrosion, or other damage.
2~

Remove the eleclrical enclosure and inspecl for loose eleclrica\

connections.

3~

Inspect hose for broken conneclors, rips in lhe ouler cover, and evidence of kinks or other damage. Inspecl guns for loose mechanical and eleclrical connections and for evldence of denls, scratches, and corrosion~

4~

5. Inspecl all fasleners and mechanical connections for lightness~

',C

Norson empolatian 1993

AII Rights ReserveO

P/N 1044458

41-23008193

3-2

Installation

4. Installation General requirements

Install the applicator so panels can be removed and the unit is otherwise accessible for operalion. See Figure 3.2 for reQuired clearances.

'~,IIII~=E . i

.~

F=

T
T 17\4 7.& \C.J <"'l
1...-

(218 mm)

8.1'n. 12' \61 L

-1 ..
,'"

11.0 In. (279 mm)

2.2 In.
(56

mm>t--<J8i

:,. . b tr'CR,
'"
,
0
I

\2J

/7;"\5

(5.411 mm)

21.6 In.

...

[\
Fgure3.2: 1 C/earance for opening daor panol 2 G/earance for lilter remo val 3 G/earanee for pump ene/asure remova/ 4 Cfearance for eleelrieal ene/asure removal 5 Top al applicator motor cover lo botlom 01 1001 pad spacng 6 Top o( tank cover lo botomof tool pad spacing

I '-:L .
, ,

-j'-'

r+-=~--\
11.7 In. W, '01 o: (297mm)l:-1'nI.:( ;'"i" ,~r,

IF

'"1,)

"'1

'

I I .... ~--,
mm)
2.4 In. . (51 mm)

'

15 O I n . '
mm) --

4.2 In.

(107

[i-

. 9.6 ln.j (249 mm) 13.81". mm)

j'

(41 mm)

1.6In.

(544 ....... )

21.41".

(351

v\\

Make sure that the applieator overhangs its support platform by about 2 inches (5 cm.) so that the unit will nol drain onlo the platform (see Figure 3.3). Avoid unusual ambient temperature conditions, sueh as below 32"F (O"C) or aboye 120"F (50"e).

__

:.

Proteet the applicator from unusual dust eonditions and severe vibration. If the applicator is installed in a drafty area, shield the guns from the draft. Rapid heat dissipation due to air movement aeross the guns can prevent the guns from operating properly. The applicator is not designed for water-washdown environments.

ill

lA

WARNING: Risk of eleetrical shock. Spraying water on the

Series 2300 Applicator may cause water to enter the unil,

resulting in an electrical shock hazard.

[:J
FIQure3.3
P/N 1044458

Ensure that the applicator is level to prevent the tank from overflowing.

OC'

41-2300 8193

Nordson C"'I""ahon 1'193 AlI 14lgh!:> He~rved

Installaton Automatic gun instal/ation

33

.r... WARNING: Allow only qualified personnel lo perform lhe ill installation. Observe the inlormalion provided in Seelion 1 Salely Inslruetlons. 1. Inslall lhe gun on lhe parenl maehine in proper alignmenl wilh lhe subslrate. Il the mounling relainer is used lor lhis purpose, use a 0.5 ineh (13 mm) diameler bar. Guns may be installed eilher vertieally or horizonlaliy. NOTE: For optimum eonlrol 01 bead posilion, oplimum response lime, and minimum heal loss, Nordson reeommends lhal, wherever possible, nozzles should be posilioned aboul 0.5 ineh (13 mm) Irom lhe subslrale (see Figure 3.4). NOTE: The gun mounl should be proleeled Irom vibralion and seeured so lhal lhe gun will nol ehange posilion during appliealion. NOTE: Nordson reeommends lhe inslallalion 01 a healcd or a nonhealed inline liller belween lhe gun and hose and lhe inslallalion 01 insulalion on lhe littings lhat eonneel lhe hose lo lhe gun. NOTE: Reler lo lhe inslallatiOn inslruelions provided wilh lhe hose belore performing any inslalialion 01 hoses. 2. Meehanieally eonneet lhe hose lo lhe gun (see Figure 3.5). 3. Eleclrically connee! lhe hose lo lhe gun by connecling lhe plug on lhe gun lo lhe receplacle on lhe hose (see Figure 3.5).

()

c,-,...J 0.5 In. (13 mm)

Figure 3.4

Figure 3.5

NOTE: Save lhe dusl cap. It is needed lo perform some 01 lhe eleclrical lroubleshooting proeedures deseribed in Seetion 6 or lo operate Ihe unit wilh a gun removed. Wilhoul eilher a gun plug or Ihe dusl cap eonneeled lo lhe hose reeeplaele, Ihe unil will sense an open oireuil in lhe gun channel and shul down aUlomalicaliy. 4. Connecl a filler/regulalor and solenoid valve (both supplied by Ihe euslomer) to Ihe gun NOTE: The solenoid valve should be placed as close as praelieal lo lhe gun lo prevenl inlroduclion 01 lag lime belween solenoid valve aclualion and gun operalion.

'.) Nordson COlpo/abon 1993 Al! R,ghts Rese'''ed

P!N 104445B
41-23008/93

3-4

Instal/afion
5. Sel lhe regulalor lo zero pressure (fully counlerclockwise) and connecl lhe air supply line lo il. NOTE: The air supply should deliver a minimum of 30 psi (205 bar) of unlubricaled air lo lhe filler/regulalor lo ensure proper gun operalion. The recommended air pressure supply is 70-100 psi (485-690 bar). 6. Connecl lhe solenoid leads lo lhe appropriale liming device. The solenoid valve vollage musl correspond lo lhe inpul vollage from lhe lriggering device.

Automatc gun nstal/aton

(continued)

Manual gun nstal/afion

ill

1.\

WARNING: Allow only qualified personnel lo perform lhe inslalialion. Refer lo lhe informalion provided in Seclion 1 Safely Inslrucllons.

1. Remove lhe pivol sleeve shelis by removing lhe four screws lhal hold lhem logelher (see Figure 3.6).
2. Remove lhe wire relaining clip from lhe pivOl sleeve. 3. Remove lhe caplug on lhe swivel conneclor.

4. Attach Ihe hose fitting lo Ihe gun swivel conneclor and lighlen firmly.

""-..
3

4 5
6

8
9

Figure 3.6: 1 Gun Body 2 Nozzle 3 Ground connection screw 4 RTD terminal block 5 Heater terminal block 6 Wire retaining clp 7 Pivot s/eeve 8 Thrust bearmg 9 $wivel connector 10 Pivot sfeeve shefls

WARNING: Always connecl lhe handgun lo lhe hose hydraulically and eleclrically before connecling lhe hose lo lhe applicalor lo prevenl eleclrical shock. NOTE: To ensure a lighl conneclion between lhe hose and gun, hold Ihe swivel conneclor wilh an open-ended wrench across lhe tlal portion. Tighlen lhe hose fitting wilh anolher open-ended wrench. 5. Connecl lhe ground wire (green/yeliow in color) from lhe hose lo lhe ground screw localed on lhe pivol sleeve.

piN 1044458 41 2300 8193

.C' Nordson Corporolloon 19!1J AII H'!,!lIlS Reserved

Installation Manual gun installation

(continued)

3-5

6. Connecl wires 3 and 5 (lhe smaller diameler wires) extending from lhe end of the hose to lhe ceramic terminal block on the same side of the pivol sleeve as lhe ground connection. (The RTD is connecled lo lhis terminal block. 7. Connect wires 1 and 2 (lhe larger diameler wires) eXlending from lhe end of lhe hose lo the ceramic lerminal block on lhe opposile side of lhe pivot sleeve from the ground connection. (The heater cartridge, which is larger than lhe RTD, is connected lo lhis terminal block.) NOTE: Be sure lhal these connections are made correctly. Connecling lhe wires incorreclly may cause an eleclrical short and damage lhe equipmenl. 8. Roule lhe ground wire and wires 3 and 5 down lhe recessed slol which is nearest the ground conneclion in lhe pivot sleeve. 9. Roule wires 1 and 2 down lhe recessed slot on lhe opposite side of the pivot sleeve. 10. Replace lhe wire retaining clip. NOTE: Make certain that all wires lie ftal and side by side, not crossing each olher wilhin lhe slol. 11 . Replace lhe pivOl sleeve shells, making sure lo clamp lhem around alleast lhree corrugalions of lhe proteclive covering on the hose (see Figure 3.7). 12. Secure lhe shells wilh four screws. 13. Inslalllhe handgun hose support brackel on lhe underside of the applicalor base before lhe applicator is bolled down. (This bracket is shipped with lhe hose. Inslruclions for installing it come with il.)

Figure 3.7-- 1 Pivot sleeve shell, 2 Hose cov8nng

NOTE: Do nol permillhe hose lo drag on lhe floor. Nordson offers a Handgun Hose Hanger Kit (P/N 271 486) lo prevent lhis from happening. Nole thallhere musl be a place where lhe hanger can be suspended.

,e,> Nordson Corporalion 1993

PiN 104 4458

AII Rlghls Aeserved

4123008193

3-6

Insta/lation

Applicator installation

ill

WARNING: Allow only qualilied personnel lo perform lhe inslallalion. Observe Ihe inlonmalion provided in Section I Salely Inslructions.

1. Mounl Ihe hol mell applicalor securely lo lhe parenl machine or in sorne olher localion so Ihal Ihe conlrols and panels are accessible and required clearances (see Figure 3.2) are provided. Four mounling leel wilh bolt holes are provided in Ihe base 01 lhe applicalor lor mounling (see Figure 3.8 lor c10seup 01 one 01 lhe mounling leel). Nordson recommends Ihe use 01 inch (7.9 mm) mounling bolts.

ev'6

0.751NCH

(19 ,

1~~=

NOTE: Hoses muSI be rouled lO prevenl damage Irom kmkmg, abrasion and olher physical damage. Do nol inslall Ihe hose wilh a bend radius less Ihan 8 inches (20.3 cm). 2. Roule lhe hoses Irom Ihe guns lo applicalor. NOTE: Fallure lo connecl a hose lo one 01 lhe rear-mosl ports in Ihe manilold (eilher Ihe one in Ihe side 01 Ihe manilold or lhe one in the bottom) will creale a dead end in Ihe manilold where char can build up.

Figure 3.8 - 1 Applicator, 2 Mounting surface, 3 Mounting bolt

3. Using Ihe fittings provided wilh Ihe hoses and Tellon pasle (P/N 900 236) on Ihe Ihreads, connect Ihe lirsl hose lo one 01 Ihe Iwo-hose ports shown in Figure 3.9.

,---J\;
("

NOTE: The posilion 01 lhe olher hoses, il more Ihan one is used, is nol importanl, bul perhaps Ihe mosl logical arrangemenl is lo connecl Ihe second hose nexl lo Ihe Ilrsl one, working in lhe same direclion thal the eleclrical receplacles are numbered (lhal is, loward Ihe lronl ollhe applcalor). Four hoses may be connecled in Ihis way lO Ihe side 01 the manilold and a Illth hose, ilone is needed, may be connecled lo eilher ollwo ports on lhe bottom 01 lhe manilold.
1

~rg~~

4. Sel Ihe air pressure regulalor lo lhe pump lor zero pressure (Iully cou nlerclockwise). 5. Connecl an alr supply to lhe regulalor, which has 1/4 inch NPT lhreads. Use Never-Seez on lhe threads belore lighlning. NOTE: The air supply should be capable 01 supplying a range 01 70-100 psi (4.83-6.89 bar) lo lhe applicalor. The supply lo lhe pump should be filtered and unlubricaled. Nordson offers an oplional liller (P/N 901515) lo meel Ihis requirement. Nordson also recommends lhat a shuloff valve be inslalled in lhe supply line lo isolale lhe applicalor supply air lor mainlenance. The valve musl be lurnished by lhe cuslomer. 6. Connecl lhe hoses lo lhe applicalor eleclrically by connecling lhe hose plugs lo lhe receplacles on lhe applicalor.

@ @ @ ~. --

r~

FIgure 3.9 Arrows point lo hose ports.

P/N 1044456

41-2300 8193

Ir., Nordsuo COlpOIi.ll10n 1993

AlI Hights Rese",,,,j

Installation

3-7

Electrcal nstallaton

WARNING: Allow only qualified personnel to pertorm the inslallalion. ObseNe Ihe inlormation provided in Section 1 Salety Instructions.

The Series 2300 Applicator is oflered in two versions: Factory wired to accept either 200 VAC or 230 VAC three-phase seNice. Factory wired lo accept 380-Y VAC Ihree-phase, lour-wire seNice (three-phase with a neutral). 200/230 unils can be converted lo single-phase seNice via a jumper Irom kit P/N 276 084; 3BO-Y unils can be converted to 220 VAC single-phase seNice via a jumper Irom kit P/N 276 236. Reler to Ihe lollowing inslructions lar eleelrical instalialion. WARNING: Disconnect and lock out external power lo Ihe applicalor bEllore opening Ihe electrical enclosure. Failure lo do so may resull in personal injry or death.
~

o o o o o o o o o o
LI
,~'

"

.. ~

-1 2

.-O-J7

~OC(:3
~-4
Figure 3 101 Terminal block (TB 1) 2 Circuit board

WARNING: Do not touch the black heat sinks extending Irom the green circuil board when power lo Ihe unit is on. They are electrically energized and therelare present a shock hazard. NOTE: Never connecl Ihree-phase power to a unit wired lor single-phase operation, that is, to a unlt with a Jumper installed al J7 on the circuil board. Doing so will destroy Ihe lusible link in Ihe jumper. 1. Disconnect and lock oul input electrical power. 2. Remove the electrical control cabinet enclosure by unscrewing Ihe captive screw on top 01 the cabinet. 3. Route the seNice line through the cnduit located below and to the left of the control panel door. Secure it inside the cabinet wilh the two screws which are used lo lighlen Ihe slrain reliel brackel (see Figure 3.10). NOTE: Make sure thal sufficienl power is supplied lo lhe applicalor lo operate bolh the applicalor and lhe equipmenl connecled lo it (the guns, lhe hoses and any other power-drawing equipment, Iike a healed filter). 4. Make lhe appropriale conneclions al lhe live-slalion inpul lerminal block (TB1) according to lhe inslructions provided below (see Figure 3.10). NOTE: The instructions for single-phase unils are diflerenl Irom Ihe inslruclions lor lhree-phase unils. Likewise, lhe inslructions are diflerenl lar European and non-European unils.

3 Conduit openmg 4 Gandult

{. NordSOIl Corpo/abon 1993 AII Rights Res8fved

F'/N 104 58 4123008193

3-8

Installation
AII Units Except European Units: a. 200 VAC or 230 VAC three-phase serviee: Conneet the three input power leads to terminals L1, L2, and L3. Conneet the ground wire to the terminal marked with the symbol for ground. b. 200 VAC or 230 VAC single-phase serviee: Conneet the two input power leads to terminals L1 and L2. Do not use L3. Conneet the ground wire to the terminal marked with the symbol for ground. Find junetion terminal J7, Figure 3.9, and install a jumper (supplied in the ship-with parts) between the two terminals labeled

Electrical installation
(conUnued)

1J.
European Units Only: a. 380-Y VAC three-phase four wire serviee (three-phase with neutral): Conneet the three input power leads to terminals L1, L2 and L3. Connect the neutral to terminal N. Conneet the ground wire to the terminal marked with the symbol for ground. b. 220 VAC single-phase serviee: Conneet the two input power leads to terminals L1 and N. Connect the ground wire to the terminal marked with the symbol for ground. Find junetion terminal J7, Figure 3.9, and install a jumper (supplied with the ship-with parts) between the two terminals labeled 1J. 5. Replaee the eleetrieal cabinet enelosure and seeure it with the eaptive serew. 6. If the plant eleetrieal system is not grounded, make sure that the ground wire attaehed to TB1 is seeured to a reliable earth ground. NOTE: Do not energize input electrieal power at this time. Conneet input power al lhe appropriale slep in lhe Preparation of Equipment.

PIN 104 445B

412300 8/93

Norsol1 Corporation 1993 Al! Alghls Reservad

## TABSHEET ##

SECTION 4

SECT/ON4

Operation
1. Introduction 2. Preparation 01 equipmenl 3. Adhesive loading . .. Daily Loading 01 Adhesive . . . . . . . . . . . . . . . . . . . . . . Flushing the system 4. Daily operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily startup procedure Daily shutdown procedure .4-1 .4-1 .4-5 .4-5 .4-6 .4-6 .4-6 .4-8

This Page Intentionally Left Blank

Operation

4-1

Section 4 Operation
1. Introduction
Seetion 4 eontains inlormation neeessary lor preparing the Series 2300 Applieator lor operation, loading it with adhesive, ehanging the adhesive used and operating the unit on a daily basis.

ill
2. Preparation o( equipment

WARNING: Allow only qualified personnel to perlorm the preparation and operation 01 this applieator. Reler to lhe inlormation provided in Seetion 1 - Salety Instruetions.

1. Verify that the air pressure to lhe pump reads zero (O) on lhe gauge.

PSI (O BAR)

2. Use a metal or plastie seoop to lill the adhesive tank with elean material.

3. Close the applieator tank lid immediately to prevent lhe introduetion 01 eontaminants.

4. Set all temperature eontrols to the reeommended temperature seltings lor the adhesive being applied.

TEMP

5. Turn the external power supply ON.

Nordson Carpo,ation 1993

P/N 104 4458

AII Alghls Reserved

4123008193

4-2

Operation

2. Preparation of equipment
(contlnued)

6.Turn the main electrical switch ON at the applicator. NOTE: The tank and hose(s) will begin to heat up first, as indicaled by the lit yellow LEO for each channel. As the tank and hose(s) reach setpoint temperatures, the gun(s) will begin to heat, as indicated by the lit yellow LEO for each gun channel. As a channel reaches selpoinl temperature, the yellow LEO will begin to flash. 7. After the adhesive material in the tank becomes mollen, remove the nozzles from the guns.

GUN AIR

@
36 PSI (2.4- BAR)

8. (Automatic guns only) Increase the air pressure to the guns to 35 psi (2.4 bar).

9. Keep the guns triggered 50 that no pressure will build up in the system. (Manual guns cannot be triggered without first releasing the trigger safety.)

WARNING: Burn hazard. Wear protective clothing/safety goggles/protective gloves (P/N 902 514).

~~Il

10. Place a pan or other suitable waste container under the manifold drain valve. Using a screwdriver, open lhe drain valve in the applicator manifold. NOTE: Failure to use a screwdriver may turn the valve body resulling in equipment damage and possible discharge of molten material. 11. Gradually pressurize the pump and allow adhesive to flow in order to remove air trapped in filler.

PUMP AIR

P/N 104 445B

41-2300 8193

(q

Norclson COIpo(ation 1993 AlI R'ghts Reserve<!

Operation

4-3

2. Preparatan af equpment
(contjnued)

12. Using a serewdriver, elose the drain valve alter all air within the filter is removed. 13. Allow material to exit the gun(s) until all trapped air and impurities are flushed out of the system.
WARNING: Burn hazard. Trapped air may still be in lhe hose(s) and gun(s) causing the spitling of air and molten material.

NOTE: It may be necessary lo nerease lhe pump air pressure lo produce flow in lhe syslem. NOTE: The pump will lransfer adhesive malerial from lhe lank to the manifold, hose(s) and gun(s). The syslem is full when lhe pump slalls or slows noliceably. 14. When material flows free of trapped air and conlaminants, stop lriggering lhe gun(s).

15. Reduce lhe pump air pressure lo zero (O) al lhe regulalor.

o PSI (O

BAR)

16. Trigger lhe gun(s) lo relieve all syslem pressure.

WARNING: Syslem or malerial pressurized. Be sure lhal pump air pressure is al zero (O) and lhal no malerial flows from lhe gun(s) when lriggered. Failure lo observe these sleps can resull in serious burns in lhe following step.

17. Using a screwdriver, open lhe manifold drain valve.

;;, Non:lson Corporalion 1993

AII A'ghts Reserved

P/N 104 4458 41 . 2300 8193

4-4

Operation

2. Preparaton 01 equpment
(continued)

18. Atlach lhe nozzles lo lhe guns.

IV
I I 11m
19. Remove and clean lhe adhesive filler in accordance wilh Filler Assembly Cleaning in Seclion 5 - Prevenlive Mainlenance.

I I 11m
PUMPAIR

20. Replace lhe filler and close lhe manifold drain valve using a screwdriver.

21. Sellhe inpul air pressure lo lhe pump lo 20 psi (1.4 bar).

20 PSI (L4 BAR)

CUN AIR

@
36 PSI (2.4 BAR)

22. (Aulomalic guns only) Sel lhe inpul air pressure lo lhe gun solenoid valve(s) lo 35 psi (2.4 bar). Further adjuslmenl of gun air pressure may be necessary. depending on lhe viscosity of lhe malerial and gun response requiremenls.

23. (Manual guns only) Adjusl lhe discharge force of material Irom the nozzle by adjusling lhe inpul air pressure lo lhe applicalor pump.

18 [N. MAX

(46 CII)

24. Mulliple Series H200 modules or guns maybe adjusled as follows:

III
TOP VIEW 011
H200 MODULE:

a. Briefly lrigger lhe guns allhe desired line speed. b. Note lhe posilion 01 each bead (see example al left). c. To delay malerial flow (make lhe bead slightly shorter), loasen lhe locking nul and lum lhe loading screw clockwlse (see iIIustratlon alleft). d. To advance malerial flow (make lhe bead slighlly longer), loosen lhe locking nul and lum lhe loading screw counlerclockwise (see iIIuslralion alleft). e. Repeal lhe procedure as necessary lO coordinale the modules.

P/N 1044458 412300 8193

Nordson Corporation 1993

AII RIgnts AeseNad

Operation

4-5

2. Preparation of equipment
(continued)

f. After adjusting a loading screw, tighten the locking nut. NOTE: The adjustable loading screw is intended for minor adjustments in bead position. If bead positioning varies greatly from one gun to another, check lo see that the time intervals on the timer are set to deposillhe beads in the same position. 25. The system is ready for use.

3. Adhesive loading Daily Loading of Adhesive

1. Be sure lhat lhe adhesive level in lank does nol drop below hall lull. NOTE: Keeping lhe adhesive level in the lank above lhe half-Iull point eliminales lhe problem 01 "starving" the pump due to lack of material and also reduces the problems caused by charring 01 material.

2. Use a metal or plastic scoop to refill the lank with fresh, clean adhesive to a point 1 inch (25 mm) below the lop 01 the tank.

3. Immediately c10se the tank lid to prevent contamination 01 the adhesive.

4. To prevent the adhesive supply from becoming contaminated, store the Iresh adhesive in a closed container. NOTE: Foreign material in the adhesive supply may damage lhe pump, c10g the filter screen, or clog the lank strainer.

,00 Narclson Co,po,ation 199:1

Al! Rlghts Reservad

P/N 1044458

41 2300 8/93

4-6

Operatan
WARNING: To avoid possible equipment damage and personal injury, refer to the information provided in Seclion 1 - Safety Instructions before proceeding. Be sure to check product compalibility before changing adhesives. If they are compatible, an old adhesive may be purged out by the new one. It is advisable to have only a small quantity of lhe old material In lhe tank to avoid loo much mixing between them. Remove the old material by draining the applicator or by operating the unil until empty. If the two different materials are nol compatible, empty and ftush the applicator using a flushing solvent matched to lhe material by following System Cleaning in Section 5 - Prevenlive Maintenance. Properly dispose of f1ushed material and solvent by referring to the manufacturers' instructions and recommendalions.

Flushng the system

4. Daily operation
Daily startup procedure
1. Turn the main electrical switch N al the applicator.

2. Verify that tank, hose, and gun temperature controls are allhe desired settings.

TEMP

3. When all yellow LED indicators are flashing or off, adjusllhe pump input air pressure to lhe desired selting.

SET

PUMP A'R

4. (Systems wilh automatic guns only) Adjust the gun input air pressure lo the desired selting.

GUN AIR

PfN 1044458

4 \ 2300 8193

<O Nordson Corporation 1993

AII Hiqh1:> Hcscrvlld

Operatan Daily startup procedure

(conlinued)

4-7

8.' .. .
::
.

5. Check the level 01 material in the tank and, using a metal or plastic scoop, add material as necessary. NOTE: In the space provided, record Ihe temperature and pressure settings recommended by Nordson personnel or Ihe adhesive representative. Pump Air Pressure Tank Temperature Hose 1 Temperature Gun 1 Temperature Gun 1 Air Pressure Hose 2 Temperature Gun 2 Temperature Gun 2 Air Pressure Hose 3 Temperature Gun 3 Temperature Gun 3 Air Pressure Hose 4 Temperature Gun 4 Temperature Gun 4 Air Pressure _ _ _ _ _ _ _ _ _ _ _ _ _ _

:"

.;

NordsOfl Corporalion 1993 AH R,ghts Reserved

PIN 104 4458

412300 8/93

4-8

Operation

Daily shutdown procedure

1. Turn Ihe main electrical swilch OFF al Ihe applicalor.

2. Trigger Ihe gun(s) lo relieve all syslem pressure.

3. Reduce pump air pressure lo zero (O) al Ihe regulalor.

o PSI (O BAR)

4. (Syslems wilh aulomalic guns only) Reduce gun air pressure(s) lo zero (O) al Ihe regulalor(s).

o PSI (O BAR)

5. (Syslems wilh manual guns only) Place Ihe gun Irigger safely in Ihe locked posilion and hang Ihe handgun by Ihe hale in ils handle.

P/N 104 445a

412300 8/93

(e)

Nordson Corpo.ahon 1993 A11 A'yhls ReselVed

## TABSHEET ##

SECTION 5

SECT/DN5

Preventive Maintenance
1. Inlroduclion 2. Daily mainlenance General mainlenance Filler 11ushing 3. Weekly mainlenance Filler assembly cleaning 4. Semiannual mainlenance Gun wiring inspection Thrusl bearing lubricalion (Handguns only) S. Unscheduled mainlenance General mainlenance
Syslem cleaning Nozzle cleaning S-1 S-2 S-2 S-2 S-3 S-3 S-S S-S S-S S-7 S-7 S-7 S-8

This Page Intentionally Left Blank

Preventive Maintenance

5-1

Section 5 Preventive Maintenance

1.lntroductlon
Section 5 outlines the preventive maintenance procedures that are recommended for the Series 2300 Applicator. The procedures are organized according lo lhe recommended frequency of performance: daily, weekly, semiannual and unscheduled. The last calegory, unscheduled, covers maintenance procedures Ihat have no recommended frequency. WARNING: Allow only qualified personnel to perform maintenance on this equipment. Refer lo the information provided in Section 1 - Safely Inslructions.

1<;)

Nordson Corporalion 1993 AII A'9hls Aeservtld

PIN 10"" 445B

4123006193

5-2

Preventive Maintenance

2. Daily maintenance
General maintenance
1. Keep the applicator clean at all times. 2. Keep the supply of ho! melt material clean and free of contaminants. Foreign particles in the hot melt adhesive can block the filter or damage lhe pump. A plugged filter can shut down the system. 3. Clean all exterior gun surfaces. Accumulated hot melt material can char and cause erratic gun operation.

Filter f1ushing

Flush the adhesive filter once a day unless operating experience indicates that less frequenl flushing is required.

(fi;\ /

'S:J)

tr!S\jf1!i\

~ goggles/gloves (PiN 902 514) during the following procedure.

WARNING: Risk of burns. Wear protective clothing/safety

1. Heat the system to operating temperature. NOTE: The applicatar must be at operating temperature to prevent damage to the filler screen. 2. Reduce the pump air pressure to zero (O) at the regulator. 3. Trigger all gun(s) until the system has been relieved of pressurized molten material.

A t:il::i.

WARNING: Before performing the next step, be sure that all system pressure has been relieved to avoid spraying of moilten material.

4. Place a pan or other suitable waste container under the drain valve. Using a screwdriver, open the manifold drain valve. 5. Increase the pump air pressure until adhesive material flows steadily from the drain. Allow material to flow until it is clean and free from all contaminants. 6. Shut off the input air pressure to the pump at the regulatar. 7. Close the manifold drain valve.

PIN 104 4456

41-23008193

ot

Nordson Corporatlon 1993 AlI Rlghts Reservad

Preventive Maintenance

53

3. Weekly maintenance
Fifter assembly cleaning
Clean the adhesive filter once a week, unless operating experience indicates that more or less frequent cleaning is required.

\$.J/

~ / ~/~ WARNING: Risk of burns. Wear protective c1othing/safety \J;;j) ~ goggles/gloves (P/N 902 514) during the following procedure.
1. Heat the system to operating temperature. NOTE: The applicator must be at operating temperature befare the filter is removed for cleaning. 2. Reduce the pump air pressure to zero (O) at the regulator. 3. Trigger the gun(s) until the system is relieved of all pressurized mollen material.

A
~

WARNING: Befare per1arming the nex! step, be sure that all system pressure has been relieved to avoid the spraying of molten material.

4. Place a pan ar other suitable waste container under the drain valve. Open the manifold drain valve. 5. lncrease the pump air pressure until adhesive material flows steadily from the drain. Allow material to flow until it is clean and free form all contaminants. 6. Shut off the input air pressure to the pump at the regulator.
~

Lh

WARNING: Risk of burns. The use of a straight wrench in the following step may result in the hand being under the filter when the connection is broken.

7. Use a 1/2 inch or 13 mm socket wrench to unscrew the filter assembly and remove it from the manifold. 8. Remove the screw from the filter bung and disassemble the filter. 9. There are several methods for cleaning the filler screen depending on the type of hot melt adhesive material used, as noted below.
~ WARNING: Risk of explosion or fire. Fire, open lights and smoking prohibited.

':t:I

a. Place the filter components in a container of Nordson Type R solvent and heat it above the melling point of the melting temperature of the adhesive. Scrub the filter screen with a fine bristle brush.

,.:, Nordson Corporation 1993 AII Aighrs Reserved

PIN 104 4458

4123008/93

5-4

Preventive Maintenance
NOTE: Do nol use a melal brush lo elean Ihe filler sereen. A metal brush may damage Ihe sereen. b. Heal Ihe filler sereen wilh a flameless eleelrie heal gun. Wipe il with a elean, dry elolh. e. Use an ullrasonie eleaner filled wilh solvenl lo elean Ihe filler sereen. 10. Inspeel Ihe sereen for damage. Replaee Ihe sereen if there are any denls or breaks in Ihe sereen mesh. NOTE: The appliealar is shipped with a 0.006 ineh (0.15 mm) mesh filler sereen. The size of Ihe screen mesh should always be smaller Ihan Ihe smallesl gun nozzle. 11. Slide Ihe sereen over Ihe eare of Ihe filler. 12. Inser! the serew through Ihe core inlo Ihe filler bung and tighlen the
screw.

Filter assembly cleaning

(continued)

13. Replaee Ihe O-ring wilh P/N 941 172. 14. Wilh the appliealor al operaling lemperalure, serew the filler assembly ;nlo Ihe manifold and lighlen.

PIN 1044458

412300 8193

'" Nordson COJIl<"alli)O 1991 AIlH,qtol',HI),.""",,(j

Preventive Maintenance

5-5

4. Semiannual maintenance Gun wiring inspection

~ ~

WARNING: Disconnect input electricai power from the applicator. Failure to observe may result in personal injury or death.

1. Reduce the pump air pressure to zero (O) at the regulator. 2. Trigger all gun(s) untii the system has been reiieved of all pressurized molten material. 3. Wearing safety gloves, remove either the gun cover (automatic gun) or the pivot sleeve shells (handgun). 4. Inspect all wiring for signs of wear or damage to the insulation. 5. Check all electrical connections for tightness.

Thrust bearing lubricaton (Handguns only)

WARNING: Disconnect input electrieal power from the applicator. Failure to observe may result in personal injury or death. 1. Reduce the pump air pressure to zero (O) at the regulator. 2. Trigger all gun(s) until the system has been relieved of ali pressurized mollen material. 3. Wearing safety gloves, remove either the pivot sleeve shells by
removing the six screws that secura them in place.

NOTE: Carefully handle the gun to prevent strain on the internal wiring and hose cordset.
4. With the swivel connector and hose fitting hot, remove the hose from the gun at the hose connector. 5. Remove the two screws and washers that secure the swivei connector to the pivot sleeve. 6. Remove the swivel connector and conical spring from the pivot sleeve. 7. Using snap-ring pliers, remove the retaining ring form the end of the gun body. Do not remove the pivot sleeve from the gun body. 8. Remove the thrust bearing. 9. Clean and repack thrust bearing with lubricant (P/N 900 301).

NOTE: Repack the thrust bearing only with Nordson high temperature grease (P/N 900 301). Do not use a standard grease to iubricate thls
bearing. The temperaturas encountered in this area will carbonize

standard greases, causing the bearing to bind. 10. Inspect the swivel connector seal and backup ring located inside the gun body. Replace these parts if they show evidence of hardening, cracking, or other damage. 11. Lubricate the swivel connector seal with bearing lubricant (P/N 900 301). 12. Reassemble the swivel connector seal and backup ringo

,;, No.-dson Corpon:llion 1993 AII Aights Reservad

P/N 104 445B

412300 8/93

56

Preventive Maintenance

Thrust bearng lubricaton (Handguns only)

(continued)

13. Reinslall Ihe Ihrusl bearing wilh Ihe prinled side of Ihe bearing facing Ihe gun body. 14. Using snap-ring pliers, reinslall Ihe relaining ring inlo Ihe relaining 5101 in Ihe gun body. 15. Reinslall Ihe conical spring (small end firsl) and Ihe swivel conneclor inlo Ihe gun body. 16. Inslall Ihe two screws and washer lo relain Ihe swivel conneclor. Tighlen Ihem only finger lighl. 17. Rolale Ihe pivol sleeve lo allow Ihe swivel conneclor lo self-cenler. 18. Tighlen Ihe screws and check for free rolalion. If binding occurs, loosen Ihe screws and rolale Ihe pivol sleeve. Tighlen Ihe screws and check for free rolalion. Repeal as necessary. 19. Connecl Ihe hose lo Ihe gun al Ihe hose connector and lighlen securely. 20. Replace Ihe pivol sleeve shells, clamping Ihem around al least three corrugations of Ihe plastic hose covering. 21. Secure Ihe shells wilh the six screws previously removed.

P/N 104 445t:1

e', NunJson Corporabon 1993

41-2300 8193

AII R'gnls Aeserved

Preventive Maintenance

57

5. Unscheduled maintenance
General malntenance
1. Clean the filler (customer-supplied) lo the air regulators for Ihe pump and guns. 2. Carefully clean Ihe inside ot Ihe electrical enclosure with pressurized dry airo Take care nol to damage or dislodge any componenls inside Ihe enclosure. 3. Ensure thal all electrical connections and lerminal blocks are secure. 4. Check for leakage around the hose connections lo the service block and applicator manifold. If leakage is found, replace Ihe O-ring in accordance wilh Ihe instruclions provided in Section 7, Disassembly and Repair.

System cleanlng

The enlire hol mell applicalion syslem musl be flushed periodically lo remove excess dirt and charred material. The following procedure should also be used if Ihe adhesive in Ihe system is changed and Ihe old and new adhesives are incompatible.

\J!S}/

ffi:\ / ~/f1!r\ 'S::!/ ~

WARNING: Risk of burns. Wear proleclive clolhing/safely goggles/gloves (P/N 902 514) during Ihe following procedure.

1. Reduce the.Q!!!!!Q air pressure to zero (O) at the regulator. 2. Trigger Ihe gun(s) until the system has been relieved of all pressurized molten material. WARNING: Belore pertorming Ihe next step, be sure lhat all ~ system pressure has been relieved to avoid Ihe spraying of mollen malerial. 3. Place a pan or other suilable wasle container under Ihe drain valve. with Ihe system al o,Jeraling lemperalure, open Ihe manifold drain valve. 4. Reduce Ihe gun air pressure lo zero (O) allhe regulalor. 5. With Ihe untt al operating lemperalure, increase E!!!!lE alr pressure and remove all adhesive from the syslem in one 01 Ihe following ways: a. Remove a nozzle from its gun and pump Ihe adhesive out Ihrough the gun. b. Or, open the manifold drain valve and pump the adhesive into a suitable waste container.
C.

Or, disconnect a hose hydraulically (but nol electrically) from a gun and pump Ihe adhesive inlo a suitable waste container. WARNING: If the guns are removed from the hoses, the sockets on Ihe hose quick disconnecls are eleclrically energized wilh full voltage. Conlacl wilh these pins can cause equipment damage or severe electrical shock.

lA ill

d. Or, disconnect a hose from its gun hydraulically and eleclrically, making sure lo replace the dust cover over the electrical receptacle on the hose. After lhe dust cover is on, pump the adhesive into a suitable waSle container.
Nordson Corporalion 1993
AIt Righls Raserved

P/N 104 4456

4 j.23oo llI93

5-8

Preventive Maintenance
6. Reduce the QI,l!!!2 air pressure to zero (O) at Ihe regulator as draining is completed.

5ystem cleaning
(continued)

NOTE: Type R solvenl may be used instead 01 adhesive malerial lo Ilush the lank, pump and manilold. DO NOT PUMP TYPE R SOLVENT THROUGH THE HOSE(S). 7. Using a metal or plastic scoop, place several pounds 01 Iresh, uncontaminated adhesive material normally used in productlon into Ihe appllcator tank. NOTE: lt is recommended thal the hose(s) be posilioned over Ihe lank so Ihal molten marterial can be circulated through the syslem. 8. Heat Ihe malerial lo application temperalure, then pump Ihe molten material Ihrough the system lor 15 minutes. 9. Alter malerial has been pumped Ihrough the syslem, decrease the pump air pressure to zero (O). 10. Turn oft the power lo the uni\. 11. Remove and clean Ihe lilter assembly according lo the inslructions under Filter Assembly Cleaning in this seclion. 12. If it is necessary to c1ean the inside 01 the tank, use a slift brislle brush lo scrub the inside 01 the lank. Do not use a metal brush or scraper. Using these ilems will remove Ihe Teflon coating. 13. Reconnect the guns to Ihe hoses (il step 5c or step 5d was lollowed). 14. Restore the system lo operation.

Nozzle cleaning

t7i:\ I VI

~/f1!r\
~

WARNING: Risk 01 burns. Wear proleclive c1othing/salety ~ goggles/gloves (P/N 902 514) during the lollowing procedure

1. Heat the syslem to operating lemperature. 2. Reduce lhe pump air pressure lo zero (O) at the regulalor. 3. Trigger all guns unlil the syslem has been relieved 01 all pressurized molten malerial.

b..
~

WARNING: Belore performing Ihe next slep, be sure thal all system rpessure has been relieved to avoid the spraying 01 molten material.

4. Using a screwdriver, open Ihe manilold drain valve over an open waste container. 5. (Automatic guns only) Reduce the gun air pressure lO zero al the reguiator. 6. Remove the nozzle(s).

\:t:;I

~ WARNING: Risk 01 explosion or lire. Fire, open lights and

smoking prohibited.

7. Place the nozzle(s) in a container 01 Nordson Type R solvenl and heal the solvent to Ihe melting temperature 01 the adhesive material being used.

P/N 104 4458

41 -2300 8193

<"! Nor(Jwn C0'l.>Of1oon 1993

AlI A.ghlS

Re~ervec1

Preventive Maintenance
Nozzle cleaning
(continued)

5-9

NOTE: See Seelion 10- Oplional Equipmenl for nozzle eleaning kils. Do nol use an open loreh, drill, or broaeh lo elean a nozzle. Damage may resull.

8. Clean lhe nozzle bore wilh a pin-type proba inserted inlo lhe nozzle in a direelion opposile lo lhe f10w of adhesive.
NOTE: Allernalive melhods of nozzle healing and eleaning inelude: a. Heallhe nozzle wilh a flameless eleetrie heal gun, then wipe nozzle wilh a c1ean eloth. b. Or, submerge lhe nozzle in an ultrasonie eleaner. 9. After eleaning, reassemble lhe nozzle(s) onlo lhe gun(s).

c, Nordson Corporatlon 1993 AII A'ghts Aeserved

P/N 104 445B 4123008/93

5-10

Preventive Maintenance

This Page Intentionally Left Blank

P/N 1044458

412300 8193

NOfdson Corporatlon 1993 AU A,ghls Af!servf>d

SECTION 6

## TABSHEET ##

SECT/ON6

Troubleshooting
1. Inlroduclion (Procedures) Pump Nol Slroking Pump Slroking Erralically or Too Fasl Aulomalic Gun Fails lo Deposil When Triggered Adhesive/Air Leaks Irom Gun Module Bleed Hole Individual Gun Module Mislires Mulli-Gun Modules Do Nol Fire al Same Time Operalion 01 lhe Red and Yellow LEDs Localing lhe Faully Channel Red LED Lighls Tank, Hose or Gun Fails lo Heal or Underheals Hol Mel! Malerial Applicalion Problems Graphs 01 Nickel RTD Resislance Values 6-1 6-2 6-7 6-8 6-9 6-9 6-9 6-10 6-11 6-12 6-13 6-23 6-28

List o'lIIustrations
Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 - Wiring Diagram - 200/230 VAC Units 6.9 - Wiring Diagram - 380 VAC Unils 6.10 - Schemalic - 200/230 VAC Unils 6.11 - Schemalics - 380 VAC Unils 6-4 6-5 6-14 6-15 6-17 6-17 6-18 6-30 6-31 6-32 6-33

This Page Intentionally Left Blank

Troubleshooting

6-1

Section 6 Troubleshooting
1./ntroduction
The lollowing troubleshooling lables help Ihe expert but cannol compensale lor specilic lroubleshooling using a circuil diagram as well
as required measuring devices.

In Ihe lollowing lables, Ihe column labeled Reler lo direcls you lo specilic parts, sections and olher pages 01 Ihis manual which contain lurther inlormation on corrective actions.
WARNING: Allow only qualilied personnel lo perform troubleshooting. Observe and lollow all salety instructions.

c, Nordson COfDorahon 1993 AII R,gllts Reserved

PN 104 4458

412300 6/93

6-2

Troub/eshooting

Pump Not 5troking

Problem

Possible Reason

Corrective Action

Refer to

1. Adhesive not melled

Tank lemp setting ineorreel

Check lank lemp setting and eorreet 1I neeessary Go to Tank/Hose/Gun Fails to Heat or Underheats Sel pump air supply lo 10 - 60 psi (07 - 4 bar) Resolve problem wilh shop air supply Replaee solenoid

Seetlon 4

Tank temp ehannel not funetioning properly 2. No or inadequale air pressure lo pump Ineorreel setting al filter/regulalor

Laler in this sectioll Seetion 4

Faull wilh shop air supply Faulty pump solenoid To lest: (a) Shut pump air off (b) Diseonneel air inlelline from solenoid valve (e) Remove solenoid from pump air eonlrol valve (d) Reeonneel air inlel line lO solenoid (e) Gradually increase air pressure at filler/regulalor (f) Normal eondilion = air flows from lhe solenoid

3. Problem in hydraulie system

Various (eharred malerial from tank lodged in hydraulie syslem, bloeked filler, elogged gun nozzle, ele.) To lest: (a) Shul pump alr off (b) Open drain valve slighlly (e) Inerease pump air pressure slowly (d) Note if pump begins lo slroke Charred material from tank lodged in filter sereen Temperature al joint loo low for adhesive lO Ilow

Go lo slep 4 if ves " problem is downstream 01 drain valve Go lo step 8 if no " bloekage is upslream 01 drain valve

4. Clogged filter in manifold 5. Cold hose-toappliealor or hose-to-gun joints

Relieve syslem pressure, remove and elean filter Inslall insulation around joinl Inslall heated inline filler al joinl Go lo Tank/Hose/Gun Fails to Heat or Underheats

Seetlon 5

Laler in Ihis seelion

6. (Auto guns)
Inpul air pressure to gun ineorreet

Setting ineorreel

Set gun air supply lo 35 - 80 psi (2.4 5.5 bar)

P/N 1044456 41-2300 8193

(C)

Nordson Corporatlon 1993

AII Ri\jhh HeserveiJ

Troubleshooting

63

Pump Not Stroking

(conlnued)

Problem

Possible Reason

Corrective Action

Refer lo Section 5 Later in lhis section

7. Clogged gun nozzle

Charred malerial Irom tank or hose lodged in gun nozzle To check: (a) Relieve syslem pressure (pump air off, lrigger all guns, open manilold drain) (b) Remove gun nozzles, clase drain valve (e) Gradually inerease pump air pressure while triggering gun (d) Note il adhesive f10ws Irom gun module

1I yes, c1ean gun nozzle 1I no, go lo Automatic Gun Fails to Depasit When Triggered

,... Nordson Co'pora~on 1993 AH R'gllts Ae,;erved

PIN 1044458

41-23008/93

6-4

Troubleshooting

Pump Not Stroking

(continued)

UPPER AIR VALVE GASKET TOP POPPET SEAT - - ,

_ - - - O-RING SEAL

AIR SUPPLY--~~ UPPER PISTON CUP SEAL

D:;::=::;:;:::;=::;::lf...----BOTTOlot POPPET SEAT AIR EXHAUST

LOWER PISTON CUP SEAL

j
LOWER AIR VALVE

.11">--- O-RING SEAL

Figure 6.1

Problem 8. With pump air on, pump stalis on upstroke (with shifter block above spring eams) and air control valve will not begin shifting even with spring cams manually pressed together

Possible Reason

Corrective Action

Refer to

With pump air at 30 psi (2 bar), check lor air leakage at lollowing points (Figure 6.1 and Figure 8.8): (a) Where pump piston enters air eylinder beneath pump mount (Seetion 8, Figure 8, item 28) (b) Excessive leakage al air control valve bottom exhaust port (Section 8, Figure 8.8, item 7) (c) At air control valve top exhaust port (Section 8, Figure 8.8, item 7) (d) At bottom 01 air eylinder (Seetion 8, Figure 8.8, item 23) between cylinder and pump mount (Section 8, Figure 8.8, item 28) (e) Between air control valve and air cylinder 1I no leakaqe, qo to steo 10

Replace lailed seal(s) (Figure 6.1 and Figure 8.8): (a) U-cup (Section 8, Figure 8.8, item 27) (b) Lower piston cup seal (Seetion 8, Figure 8.8, item 21) (e) Top poppet seat (Seehon 8, Figure 9, item 3) (d) Pump mount o-ring (Section 8, Figure 8.8, item 18) (e) Upper air valve gasket (Section 8, Figure 8.8, item 13) II one air eylinder seal requires replaeement, replace all air cylinder seals

Sectlon 8

P/N 1044458

41-23006193

'.0' No'd50n Corporallon 1993 AII R,g!'lS Reservwj

Troubleshooting

6-5

Pump Not Stroking

(contnued)

UPPER AIR VALVE GASKET

~--- O-RING SEAL

UPPER PISTON CUP SEAL

1 1

LOWER PISTON CUP SEAL

) )
.-/
. - - - - O-RING SEAL

BOTTOlot POPPET SEAL

LOWER AIR VALVE GASKET

Figure 6.2

Problem

Possible Reason

Corrective Action

Refer lo Seetion 8

9. With pump air on, pump stalls on downstroke (with shifter block below spring eams) and air control valve wlll not begln shlftlng even with sprlng cams manually pressed together

Wth pump air at 30 psi (2 bar), check lar air leakage at lollowing ponts (Figure 6.2 and Figure 8.8): (a) Exeessive leakage at air control valve top exhaust por! (Seetion 8, Figure 8.8, Item 7) (b) At air control valve bottom exhaust por! (Seelion 8, Figure 8.8, item 7) (e) At top 01 air eylinder (Seetion 8, Figure 8.8, item 23) between cylinder and eylinder head (Seetion 8, Figure 8.8, Item 17) (d) Between air control valve and air eylinder 1I no leakage, go to step 10

Replaee failed seal(s) (Figure 6.2 and Figure 8.8): (a) Upper pistan eup seal (Seetion 8, Figure 8.8, item 21 ) (b) Bottom poppet seat (Seeton 8, Figure 9, item 3) (e) Air eylinder head o-ring (Seetion 8, Figure 8.8, item 18) (d) Lower air valve gasket (Seetion 8, Figure 8.8, item 13) If one air eylinder seal requires replaeement, replaee all air eylinder seals

NOJ<hon Crrporat,on 1983

AH H"Jllh H,~erllcd

PiN 104 4458 41-23008/93

6-6

Troubleshooting

Pump Not Stroking

(continued)

Problem 10. With pump air on, shifter block stops between spring cams,
or air control

Possible Reason Out 01 line or loose components

Corrective Action

Refer lo

valve will shift only il spring cams manually pressed logether

Shifter rod out 01 adjustment and binds at air control valve spool To check: (a) Shut pump air off (b) Remove shifter block (e) Manually move shifter rod up and down (d) Normal shifter rod travel ; 0.15 - 0.20 in. (3 - 5 mm) and rod does not bind Pump requires delente upgrade

(a) Shul pump air off (b) Tighlen screws that secure cams to springs (c) Align springs with slide (d) Replace bent shifter rod (e) Tighlen loose shifter block (1) Adjust assembly so that shifter slide is perfectly Ilush against shifter stop when shifter in down posilion (g) Realign air control valve and shifter assemblies with pump assembly (h) Align rectangular body 01 air control valve with air cylinder rectangular mounting lace Adjust shifter rod il required

Secton 8, Figures 8.8,8.9 and 8.10

Section 7

Install Nordson Detente Kit (P/N 134 944 lor domestie unils; P/N 136 184 lor international units) Replaee valve/spring assembly

Section 8,

11. (Pump air on) Pump shifts

once if

Failed valve/spring assembly

Figures 88.89 and 8.10 Seetion 8, Figure 8.10

up/down manual pressure applied to valve/spring assembly spring nuts 12. (Pump air on) Pump will nol shift even il up/down
manual

Failed pump hydraulie eomponents

Rebuild/replaee pump

Seeton 8

pressure applied lo valve/spring assembly

spring nuts

P/N 1044456

412300 8:93

re, Nor(hon Curpor<.ll'On 1993

AII R,qhts ReseJVP,j

Troubleshooting

6-7

Pump 5troking Erratically or Too Fast

Problem
1 . Tanklesslhan

Possible Reason

Corrective Action

Refer lo Section 4

No relili during normal operation

Relili tank to at least hall luli

halffuli

2. Adhesive not

Tank temp setting incorrect

melted Tank temp channel not lunctioning properly

Check tank temp setting and correct il necessary Go to TankjHose/Gun Fails lo Heal or Underheals Later in this section

3. Blocked tank

reliel valve

Charred material Irom tank lodged in tank reliel valve

Clean or replace tank reliel valve

4. Char or loreign material lodged at pump siphon bali seat (Note that rapid strokeup indicates upper bali check valve not seated; rapid strokedown indicates lower bali check valve not seated)

See above

With pump assembly removed, ciear char/loreign material Irom siphon bali seat

Section 7

5. Pump
hydraulic seetion requires attention

See above

Disassemble, clean and reassemble pump hydraulic section

Section 7

e; Nordson Corpo,ation 1993 AII Rlghls Reservad

P/N 104 4458

41-23006/93

6-8

TroubJeshooting

Automatic Gun Fails to Deposit When Triggered

P,oblem
1. Tank, hose o, gun temp setting(s) too low

Possible Reason

Corrective Action

Refer to

Ineorreet settings used

Resettemp dials

2. Clogged gun nozzle

Charred material Irom tank or hose lodged in gun nozzle

Remove and elean gun nozzle

Seetion 5

3. Clogged gun module

Charred material lrom tank o, hose lodged in gun module To check: (a) Relieve system pressure (b) Remove module Irom serviee block (e) Trigger gun and note il air Ilows Irom serviee block

II yes, go to step 4 II no, go to step 5

4. Clogged gun seat

Charred material Irom tank or hose lodged in gun seat

Remove and elean gun seat If eondition pe,sists after reassembly, rebuild/replaee module

Gun
manual

5. Faulty gun solenoid valve

Worn eomponents To check: (a) Shut solenoid air off (b) Remove input air line lrom solenoid (e) Slowly inerease air pressure (d) Note il air Ilows Irom open line

1I yes, replaee solenoid 1I not, go to step 6

6. Faulty lilter!regulator

Worn eomponents To check: (a) Shut gun lilte'/regulato' ai, off (b) Remove input air line Irom lilter/regulator (e) Slowly inerease air pressure {dI Note il air Ilows lrom ooen line

If yes, replaee filter/regulator 1I not, resolve problem with shop ai, supply

P/N 104 4458

Ci;,

Nordson Corporat,on 1993

AII RIQtll5 Reserved

412300 8/93

Troubleshooting

6-9

Adhesive/Air Leaks from Gun Module Bleed Hole

Problem

Posslble Reason Internal components worn excessively

Corrective Action

Refer to

1. Material/air seeping past o-rings, seals

Rebui Id or replace gun module

Gun manual

Individual Gun Module Misfires

Problem

Possible Reason

Corrective Action

Refer to

1. Clogged nozzle

Charred material Irom tank or hose lodged in nozzle

Remove and clean nozzle

Section 5

2. Clogged gun seat

See aboye

Remove and clean gun seat

Section 5 (Nozzle Cleaning)

3. Mallunctioning module

See aboye; or worn out mechanical components

Rebuild or replace module

Gun manual

Multi-Gun Modules Do Not Fire at Same Time

Problem

Possible Reason

Corrective Action

Refer to

1. Modules out 01 synch with each other

Adjustment required

Turn loading screw at module top to adjust bead deposit: CW = delays deposit CCW = advances deposit

Gun manual

Module cannot be synchronized (failed module)

Rebuild or replace gun module(s)

Gun manual

No'dson Co'pOTajion 1993 AII Aighls Reservad

P/N 1044456

4123008193

610

Troubleshooting

Operation o( the Red and YellowLEDs

The red and yellow LEOs (Iight emitting diodes) on the indicator panel show when the Series 2300 hot melt system is operating normally and when it is nol. Normally, the red LEO remains off while the yellow LEOs far the tank, hoses and guns are either on, off ar flashing. The yellow LEO for a component lights when that component is heating, flashes when the sel temperalure for the component has been reached and goes off when the component has exceeded the sel point by more lhan 2.7F (1.5C). The LEOs also indicate malfunction and can be used to isolate the problem. The red LEO lights when either of two faull conditions occur in the tank channel or any 01 the hose or gun channels: When an RTO fails closed (short circuil) or open, When anolher componenI of the hot melt system lails, allowing any of lhe channels to overheal. The temperature at which the red LEO will light may vary from 425F (218C) to 475F (246C). A time delay built into the circuitry allows lor up to 1112 minutes Irom the time the red LEO Iights in arder to lroubleshoot belore the circUlt breaker trips, shutting off power lrom the applicalor. The circuit breaker may be sWllched on agaln for anolher 1112 minules of troubleshooting time. The circuit breaker may be reset indefinitely untilthe tank wall temperature reaches 450F (230C). At that poinI, a c1ose-on-rise thermoslat automatically prevents lurther attempts to resellhe circuit breaker until the tank wall temperature drops below 450F (230C). Note that on some units, if the tank channel is the laully channel, the tank thermoslat may cause the circuit breaker lo trip before it is tripped by lhe solid-stale overtemperalure proteclion circuilry on lhe tank channe!. This is because there is some tolerance overlap in lhe setpoint range 01 the tank thermostat 430F (221C) to 470F (243C) and of lhe solid state overtemperature circuitry. If the circuit breaker is tripped by the lank thermostat, it cannot be resel until the temperature of the lank wall drops below the setpoint 01 the thermostal. See the chart below for a summary of LEO operation.

Red LED lo
OFF OFF OFF OFF ON ON

Yellow LED is

The Componen!
(tank, hose, gun) Is heatino
15 al the set noiot 15 slinhtl" aboye set ooint

Condition Normal
Normal Normal

ON
Flashinn

OFF ON ON OFF

Is nol heatlnn liS cold) Has an RTD that has failed closed Ishart'
15 overheating (above 425F
1220C) or jt has an ATD that

Abnormal Abnormal
Abnormal

has failed onen*

Further troubleshootina reauired lo determine which of the lwo fault conditions exists.

P/N 1044456

412300 8193

(e) Nordson Corporatlon 1993 All R,ghts Reserved

Troubleshooting
- -.. _ - - - - - - - -

6-11

Locating the Faulty Channel

1. Turn lhe circuil breaker off. 2. Eleclrically disconnecl (unplug) lhe hose from channel No. 1 from the unit. 3. Switch lhe circuil breaker on and note if lhe red LEO is off or on. 4. If il is off, lhe problem is in either lhe No. 1 hose channel or No. 1 gun channel. If lhe red LEO remains on, lurn the circuil breaker off, and repeal sleps 2 and 3 with channel No. 2. 5. If lhe red LEO remains on after al! channels have been unpiugged, lhe problem is in lhe tank channel.

f.

Nord$Orl Corporabon t 993

AII Righls Reseved

P/N 104 4458

4123006/93

6-12

Troubleshooting

Red LED Lights

Problem 1. Problem in tank, hose or gun ehannel

Possible Reason

Corrective Action

Reler lo Earlier in this seetion

Failed eomponents, bad eonneetions, etc.

Loeate faulty ehannel

Defeetive hose or gun To check: (a) Switch eireuit breaker off (b) Reeonneet all ehannels (e) Eleetrieally unplug gun from hose, install dust cap to the open hose reeeptaele (d) Switch eireuit breaker on LED stays on Faulty gun/hose eleetrieal eonneetion To check: Red LED turns off when dust cap is replaeed with gun plug after steps a, b, e and d (from above) Short in tank or gun RTD To check: Red LED and yellow lank or gun LEDs on after a, b, e and d (from above), Open eireuit in tank or gun RTD To check: (a) Red LED on and tank or gun yellow LED off after a, b, e and d (from above) (b) Resistanee (power OFF!)of gun (between pins 3 and 5 of gun plug) or lank (between pins 6 and 8, eireuit board eonneelor J6) > 1 megohm or other very high reading Failed eireuit board To check: Gun overheats and resistanee (power off) = 138-309 ohms (normal) OR Tank overheats and resistanee (power off) aeross two large prongs of lank triae >100 ohms Falled tank triae To check: Tank overheats and resistanee (power off) aeross two large prongs of tank triae <100 ohms
p~

Replaee hose

Resume normal operation

Replaee RTD in tank or gun

Seelion 7

Replaee RTD in tank or gun

Section 7

Replaee eireuit board

Seetion 7

Replaee tank trlae

Seetion 7

104445B

4123008193

(C) Nordson Corporahon 1993 AII R,gh!s Aeserved

Troubleshooting

6-13

Tank, Hose or Gun Fails to Heat or Underheats

Problem

Possible Reason

Corrective Action

Reter to

1. Incorrect settng
2. Circuit breaker will nol stay
on even afier

Misadjustment

Reset conlroller and resume normal operalion Replace tank thermostal

Section 4

repealed attempls lo reset (il circuit breaker stays on, go to step 4) 3 Low voltage al Inpul terminal block (TB 1)

Faulty tank thermostat To check: Wth power off, thermostat has continuity (stays closed) at less than 450F (230C) Faulty circuit breaker To check: With power off, thermostat has no conlinuity (opens) alless than 450F (230C) Faulty inpul power supply To check: Normal vollage on 200 VAC applicator = 170 - 200 VAC line-to-line Normal vollage on 230 VAC applicator = 194 - 254 VAC line-to-line Normal voltage on 220/380-Y VAC applicator = 198 - 242 VAC line-to-neutral

Section 7

Replace circuit breaker

Secton 7

Troubleshoot and lix input power supply to applicator

lC,

Nordson Corpo'ation 1993 AII AighlS Reserved

PN 1044456 4123008/93

614

Troubleshooting

Tank, Hose or Gun Fails to Heat or Underheats

(continued)

~
Problem 4a. Hose and gun nol heating
(units with circuit board
P/N 276 881

[~~:I I
~;

~~~
11
__~.::::..;f

1~

3
Figure 6.31 =Une No. 2 (guns) 2 = Fuse holders 3 =Une No. 4 (hoses) 4 ::: Circuit board plug
Possible Reason Corrective Actio"

Reler lo

through 276 888)

Failed circuit board luse(s) To check: Remove luse lar nonhealing gun and hose (see schematic) and check lar continuily. 1I luse OK, reinslall and go lo slep 10 or 1201 Ihis procedure Failed circuil board luse(s) lo check: Remove luse lar nonhealing gun or hose pair (see schemalic) and check lor conlinuily. 1I fuse OK, reinslall and go to step 10 or 12 01 Ihis procedure

Replace lalled luse(s), then go lo slep 12 01 this procedure (check heater and healer-Io-ground)

4b. Hose 1 and hose 2 nol healing or Gun 1 and gun 2 nol healing
(units with circuit board

Replace lalled luse(s), Ihen go lo slep 12 01 this procedure (check heater and healer-Io-ground)

P/N 276884
through 276 888)

5a. Hose or gun nol healing

(units with circuit board

P/N 276 881

through 276 a88)

5b. Hose or gun not heating

(units with circuij board

P/N 276 889 or 276 890)

Failed circuil board luse(s) lo check: Remove luse(s) lar nonhealing gun or hose (see schemalic) and check lar conlinuily. 1I luse(s) OK, reinslall and go lo slep 12 al this orocedure Failed inline luse lo check: Remove fu se for nonhealing gun or hose (see Figure 6.3) and check for conlinuily. 1I fuse OK, reinslall and go lo steps 10, 11 and 12 01 Ihis orocedure

Replace lailed luse(s) , Ihen go lo slep 12 01 this procedure (check heater and healer-Io-ground)

Replace lailed luse, then go to step 12 01 Ihis procedure (check heater and heater-to-ground)

P/N 1044458

Nordson Corporalion 1993

AII Rio:hlS Aeserved

412300 6J93

Troubleshooting

6-15

Tank, Hose or Gun Fails to Heat or Underheats

(continued)

0G}Figure 6.4

008 000

Problem

Possible Reason

Corrective Action

Reter lo Seclion 7

6. lank nol heali ng wilh yellow LEO on or off and red LEO on)

Failed lank RlO lo check (Figure 6.4 circuil board conneclor J6): Abnormally high resislance reading (power off!) belween pins 6 and 8 al eonneelor J6 on eireuil board Failed cireuil board lo check: Resislanee reading (power off!) belween pins 6 and 8 al conneelor J6 on circuil board; 133 ohms al 70F 121 C\ lo 309 ohms al 400F 1205C\ Failed lank healer lo check: Abnormally high resislanee reading (power off!) belween tank lriae wire 6 and circuil breaker wire 2A (Normal; 26 - 31 ohms) Failed lank lriac Normal resislanee reading Failed circuil board lank slill does nol heal even wilh new lriac

Replace RlO

Replaee cireuil board

7. lank nol heali ng wilh yellow LEO on, and red LEO off

Conlacl your Nordson represenlalive for serviee reeommendations

Replaee tank lriae

Seclion 7

Replace cireuil board

Seclion 7

'<;;

Nordsoo Corporalion 1993 AII AlgtllS Reserved

P/N 104 445B

41-23008/93

616

Troubleshooting

Tank, Hose or Gun Fails to Heat or Underheats

(continued)

Problem

Possible Reason

Corrective Action

Refer to

8. Yellow LED for nonheating channel off, red LED off

Defective wire or contact To check (power offl, circuit breaker set to on): No continuily on any of circuit breaker legs L1, L2 and L3 (European units L1, L3 and N) between input terminal board TBl and circuit board J7 OR No continuily on any circuit breaker leg between the input terminal board TBl and line side of the breaker OR No continuily between load side of circuit breaker (lA, 2A and 3A) and circuit board (L1, L2 and L3 on J7) Faully circuit breaker To check: Is continuily between load side of circuit breaker (lA, 2A and 3A) and circuit board (L1, L2 and L3 on J7) Failed circuit board To check: Is continuily on circuit breaker legs L1, L2 and L3 (European units L1, L3 and N) between input terminal board TBl and circuit board J7, but unit not wired for single-phase operation OR Is continuily on circuit breaker legs L1, L2 and L3 (European units L1, L3 and N) between input terminal board TBl and circuit board J7, unit is wired for single-phase operation and jumper 10J at J7 shows continuily Incorrect wiring, failed single-phase ;umner

Repair/replace defective wiring or contact

Replace circuit breaker

Section 7

Replace circuit board

Section 7

Repai r/replace incorrect wirinn/sinnle-nhase iumner

PiN 1044456

41-2300 8193

<tJ Nodson Corporalion 1993 AII R,ghls Reserved

Troubleshooting

6-17

Tank, Hose or Gun Fails to Heat or Underheats

(contnued)

8000
5 6

,....
~

800 000 ,... @G@

Corrective Action
Refer lo

0)

8
L

0(~0 -

088@
Figure 6.5 Connectors J 1A -

J5A

Figure 6.6 Connectors J 1 - J5

Problem

Possible Reason

9. Hose alone not heating; yellow LEO off, red LEO on

Failed hose To check (Figure 6.5, connectors J1A " J5A): (a) Oisconnect hose plug (nonheating hose) !rom applicator (b) Abnormal resistance reading (power off!) between hose plug pins 8 and 9 (RTO) at appropriate connector J1A J5A Normal = 133 ohms at 70F (21 e) to 309 ohms at 400F (205C) Failed circuit board To check: Normal resistance reading (power off!) between hose plug pins 8 and 9 (J1A J5A as above) ANO (a) Oisconnect circuit board plug (nonheating hose) !rom circuit board (b) Normal resistance reading (power off!) between hose plug pins 8 and 9 (RTO) at appropriate connector J1 . J5 (Figure 6.6, connectors J1 "J5) Failed hose/gun connector assembly To check: Normal resistance reading (power off!) between hose plug pins 8 and 9 (Jl . J5 as above) ANO Abnormal resistance reading (power off!) between hose plug pins 8 and 9 IJ1 . J5 as above\

Replace hose

Replace circuit board

Section 7

Replace hose/gun connector assembly

Section 7, Section 8

'.'" NordSOfl Corporahon 1993 AII HlgtllS Reserved

P/N 1044458

4123008193

618

Troubleshooting

Tank, Hose or Gun Fails to Hest or Underhests

(continued)

Figure 6.7

Problem 10. Hose and gun DR Gun alone nol healing; yellow LEO off, red LEO on

Possible Reason Faiied hose To check (Figure 6.6): (a) Oisconnect hose plug (nonhealing gun) from applicalor (b) Abnormal resislance reading (power off!) belween hose plug pins 3 and 5 (RTO) al conneclor J1A - J5A Normal = 133 ohms al 70F (21 C) lo 309 ohms al 400F (205C) ANO (a) Oisconnecl gun plug (nonhealing gun) from hose (b) Normal resislance reading (power off!) belween hose plug pins 3 and 5 (RTO) al connector J1 B - J5B (Figure 6.7) Failed RTO or wiring To check (Figure 6.6): (a) Oisconnecl hose plug (nonhealing gun) from applicalor (b) Abnormal resislance reading (power off!) belween hose plug pins 3 and 5 (RTO) al conneclor J 1A - J5A Normal = 133 ohms al 70F (21 C) lo 309 ohms al 400F (205C) ANO (a) Oisconnecl gun plug (nonhealing gun) from hose (b) Abnorma! resislance reading (power off!) belween hose plug pins 3 and 5 (RTO) al connector J 1B - J5B (Fiaure 6.7\

Correclive Aclion Replace hose

Reter lo

Replace RTO, repair wiring as required

Seclion 7, Seclion 6 (wiring diagrams)

PiN 104 4458

412300 8193

(e) Nordson Corporalion 1993 AII Rlghls Reserved

Troubleshooting

6-19

Tank, Hose or Gun Fails to Heat or Underheats

(continued)

Problem

Possible Reason

Corrective Action

Reter lo

10. Hose and gun OR Gun alone not heating; yellow LEO off, red LEO on (continued)

Failed circuit board To check (Figure 6.5): (a) Oisconnect hose plug (nonheating gun) trom applicalor (b) Normal resistance reading (power off!) between hose plug pins 3 and 5 (RTO) al connector J1 A - J5A Normal = 133 ohms at 70F (21 C) lo 309 ohms at 400F (205C) ANO (a) Oisconnect circuit board plug (nonhealing hose) from circuil board (b) Normal resistance reading (power off l ) belween hose plug pins 3 and 5 (RTO) al appropriate connector J1 J5 (Figure 6.6) Failed hose/gun connector assembly To check: Normal resislance reading (power off!) belween hose plug pins 3 and 5 (J1A - J5Aas above) ANO Abnormal resistance reading (power off!) belween hose plug pins 3 and 5 J1 - J5 as above\

Replace circuit board

Section 7

Replace hose/gun connector assembly

Section 7, Section 8

"J

Norn"()r1 Corporatlon 1993

P/N 104 4458

AII R,ghts Aeserved

4123008193

6-20

Troubleshooting

Tank, Hose or Gun Fails to Heat or Underheats

(contnued)

Problem 11. Hose alone not heating; yellow LEO on, red LEO off

Possible Reason

Corrective Action

Reter to

Failed hose lo check (Figure 6.5): (a) Oisconnect hose plug (nonheating hose) Irom applicator (b) Abnormal resistance reading (power off!) between hose plug pins 4 and 6 (heater), pins 4 and 7 (healer-to-ground), and pins 6 and 7 (heater-to-ground) al appropriate connector J1 A - J5A Normal (pins 4 and 6) = % 10% 01 resislance value listed in Section 9; (pins 4 and 7) > 1 megohm; (pins 6 and 7) > 1 megohm Failed circuit board lo check: Normal resistance reading (power off!) between hose plug pins 4 and 6, 4 and 7 and 6 and 7 (J1A - J5A as above) ANO (a) Oisconnect circuit board plug (nonheating hose) lrom circuit board (b) Normal resistance reading (power off') between hose plug pins 4 and 6, 4 and 7 and 6 and 7 (J1 - J5 as above; Figure 6.6) Failed hose/gun connector assembly lo check: Normal resislance reading (power off!) between hose plug pins 4 and 6, 4 and 7 and 6 and 7 (J1A - J5A as above) ANO (a) Oisconnect circuit board plug (nonheating hose) lrom circuit board (b) Abnormal resislance reading (power off!) between hose plug pins 4 and 6, 4 and 7 and 6 and 7 (J1 - J5 as above\

Replace hose

Replace circuit board

Section 7

Replace hose/gun connector assembly

Section 7, Seclion 8

PN 1044458

\iOJ Nordson CorporallOn 1993

412300 8193

AlI A,ghls Reserved

Troubleshooting

6-21

Tank, Hose or Gun Fails to Heat or Underheats

(continued1

--------Possible Reason Corrective Action

Problem

Refer lo

11. Hose and gunOR Gun alone not heating; yellow LEO on, red LEO off

Failed hose To check (Figure 6.5): (a) Oisconnect hose plug (nonhealing hose) Irom applicator (b) Abnormal resistance reading (power off!) between hose plug pins 4 and 6 (heater), pins 4 and 7 (heater-to-ground), and pins 6 and 7 (heater-to-ground) at appropriate connector J1A - J5A Normal (pins 4 and 6) = % 10% 01 resistance value listed in Section 9; (pins 4 and 7) > 1 megohm; (pins 6 and 7) > 1 megohm ANO (a) Oisconnect gun plug (nonheating gun) lrom hose (b) Normal resistance reading (power off l) between hose plug pins 1 and 2 (heater), pins 1 and ground (heater-to-ground), and pins 2 and ground (heater-to-ground) at appropriate connector J1 B - J5B (Figure 6.7) Normal (pins 4 and 6) = % 10% 01 resistance value listed in Section 9; (pins 4 and 7) > 1 megohm; (pins 6 and 7) > 1 megohm Failed heater or wiring To check: (a) Oisconnect hose plug (nonheating gun) Irom applicator (b) Abnormal resistance reading (power off!) between hose plug pins 4 and 6 (heater), pins 4 and 7 (heater-to-ground), and pins 6 and 7 (heater-to-ground) at appropriate connector J1A - J5A as above ANO (a) Oisconnect gun plug (nonheating gun) from hose (b) Abnormal resistan ce reading (power off l) between hose plug pins 1 and 2 (heater), plns 1 and ground (heater-to-ground), and pins 2 and ground (heater-to-ground) at appropriate connector J1 B - J5B (Fiaure 6.7\ as above

Replace hose

Replace heater, repair wiring as required

Section 7, Section 6 (wiring diagrams)

,O) Nordson Corprabon 1993

AII Aighls Res ....ved

P!N lO44456

4123008/93

6-22

Troubleshooting

Tank, Hose or Gun Fails to Heat or Underheats

(continued)

Problem 12. Hose and gun OR Gun alone not heating; yellow LEO on, red LEO off (continued)

Possible Reason

Corrective Action

Reler lo Section 7

Falled circuil board To check (Figure 6.5): (a) Oisconnect hose plug (nonhealing gun) from applicator (b) Normal resistance reading (power off!) between hose plug pins 4 and 6 (heater), pins 4 and 7 (heater-to-ground), and pins 6 and 7 (heater-to-ground) at appropriate connector J1A - J5A Normal (pins 4 and 6) = %10% 01 resistance value listed in Section 9; (pins 4 and 7) > 1 megohm; (pins 6 and 7) > 1 megohm ANO (a) Oisconnect circuit board plug (nonheating hose) from circuit board (b) Normal resistance reading (power off!) between hose plug pins 4 and 6 (heater), pins 4 and 7 (heater-to-ground), and pins 6 and 7 (heater-to-ground) at appropriate connector J1 - J5 (Figure 6.6) Fai!ed hose/gun connector assembly To check: Normal resistance reading (power off!) between hose plug pins 4 and 6 (heater), pins 4 and 7 (heater-to-ground), and pins 6 and 7 (heater-to-ground) at appropriate connector J1 A - J5A as above ANO (a) Oisconnect circuit board plug (nonheating hose) from circuit board (b) Abnormal resistance reading (power off!) between hose piug pins 4 and 6 (heater), pins 4 and 7 (heater-to-ground), and pins 6 and 7 (heater-to-ground) at appropriate connector J1 - J5 as above

Replace circuit board

Replace hose/gun connector assembly

Section 7, Section 8

P/N 1044456

41 2300 8193

(0 Nordson COIporaloon 1993 Al! R,ghls Aeserved

Troubleshooting

6-23

Hot Melt Material Application Problems

Problem Adhesive Spilting on Extruslon

Possible Reason

Corrective Action

Refer lo

Adhesive output exeeeds maximum eontinuous delivery rate 01 system Hydraulie pressure set below reeommended minimum hydraulie pressure Adhesive in tank is eold or tank is low or empty and pump is drawing in air

Reduce output to maximum 01 10 Ibsihr (4.5 kgihr) Inerease hydraulie pressure lO at leas! 300 psi (20 bar) Seetion 4

" adhesive is eold, either inerease tank setpoint, or complete Tank, Hose

Seetion 4, Seetion 6

or Gun Fails to Heat or Underheats

troubleshooting proeedure in this Seetion; il tank is low, relill as reouired. Inerease setpoints to appropriate level Inerease ambient temperature Prevent draft Set gun temperature to appropriate level Set distanee to 0.50 in. (13 mm) Set distanee to 0.50 in. (13 mm) Seetion 4 Seetion 4

Waviness in bead deposlt

Hot melt material in system is too eold Ambient temperature below 32F (OC) Gun nozzles exposed to draft Rated gun temperature too low

Seetion 4

Exeessive hot melt material at beginning 01 bead

Nozzle distanee Irom substrate too lame Nozzle distanee Irom substrate too large Partially elogged nozzle tnsuffieient alr pressure to gun Pump hydraulie pressure too high Nozzle too large, resulting in excessive instantaneous deliverv rata Hydraulie pressure too low

Ciean nozzle
Increase air pressure

Seetion 5

Lower hydraulie pressure as required Use proper nozzle size

Increase hydraulic pressure as required

Seeton 4

Excessive

Seetian 4

Adhesive al End 01 Bead Adhesive too eold

Insufficient air pressure
~o

Raise ehannel setpoints as required

Seetion 4 Seetion 4

gun

Increase air pressure to gun as reouired

<c; Norl1son Corpofalion 1993

AII R'ghls R8~a'V8d

P/N 104 4458 4123008/93

6-24

Troubleshooting

Hot Melt Material App/ication Problems

(continued)

Problem Adhesive Slringlng al Cut-Off

Possible Reoson Nozzle positioned too far from subslrale

Corrective Action

Reler lo Section 4

Reposilion nozzle closer lo subslrate (recommended dlstance is 0.50 in./13 mm from substrale) tncrease lemperalure slightly, or change lo compalible adhesive wilh lower viscosily Raise channel setpoints as required Use a faster-acling gun, use an air-piloted relay valve between solenoid and gun, or reduce dislance belween solenoid and gun Flush syslem and refill wilh fresh adhesive Increase aun lemoeralure as reauired Readjust gun spring lension as required. Clean or replace gun module

Adhesive too viscous

Seclion 4

Cold adhesive Gun speed loo slow

Section 4 Seetion 4

Adhesive loo old

Section 5

Adhesive Drooling from Gun

Gun lemoerature loo low Spring lension 01 gun loo low

Unequal Deposils Setween Nozzles in Mulli-Module Inslallalion

Sall or needle and/or seal of gun module worn or partially clogged by char Differenl nozzle sizes Unequal spring tension or irnproper needle 11ft adjustmenl in zero-cavity guns Nozzle clogged or damaged Foreign malerial in gun module Insufficienl and/or unequal air pressure to guns Hydraulic pressure nol equal al guns

Section 4 Gun manual (all versions)

Use same size nozzles Adjusl modules

Gun manual (all versions)

Clean or replace nozzle Rebuild or replace module Adjusl as required

Cornpensale for difference by using different nozzle sizes or adjusting gun Iravel Clean or replace nozzles

Debris or slighl imperfeclions in nozzles Adhesive in alr motor seclion of module

Rebuild or replace module

PIN 1044458
41 -2300 8/93

rq N01dson Corporatlon 1993 AII RIghls Aeserved

Troubleshooting

6-25

Hot Melt Material Application Problems

(continued)

Problem

Possible Reason

Corrective Action

Reler to Section 4

Adhesive Bounclng or Splashing Irom Substrate

Adhesive too hot

Decrease channel setpoints as required Decrease hydraulic pressure as required Decrease temperature slightly, or change to compatible adhesive with lower viscosity Chanae to a lamer diameter nozzle Increase channel setpoints slightly Increase channel setpaints slightly. II condition persists, check with
adhesive manufacturar for compatible

Hydraulic pressure too high

Section 4

Adhesive viscosity too low

Section 4

Adhesive Not Penetrating Substrate

Nozzle diameter too small Adhesive not hot enough Special caating on substrate

Section 4 Section 4

adhesive Not enough adhesive being applied Use higher tlow-rated nozzle, increase temperature slightly, or increase hydraulic pressure Increase temperature slightly, or change to compatible adhesive with lower viscositv Section 4

Adhesive viscosity too high

e, Nordson Corporallon 1993 Al! Rlghts Re'i.erved

P/N 1044458

41-23008193

6-26

Troubleshooting

Hot Melt Material Application Problems

(conUnued)

Problem Container Pops Open After Leaving Compression Section

Possible Reason

Corrective Actioo

Refer lo

Adhesive not cooling fast enough

(Any or all) Decrease bead size, decrease adhesive temperature slightly, increase distance between nozzle and substrate, increase distance between bead deposit and bead compression, increase length of compression section, reduce line speed through compression section, coolthe substrate, use a lower flow-rated nozzle, or use stitched bead pallern Use an adhesive with a shorter open time, or reduce application temperature slightly (Any or all) Increase bead size,
increase adhesive temperature

Open time of adhesive too long

Adhesive cooling too fast

slightly, decrease distance between nozzle and substrate, shorten distance between bead deposit and bead compression, heat the substrate, use a hlgher flow-rated nozzle, increase bead length and avoid stitched bead pallern, or protect bead deposit and/or gun from cold or moving air Open time of adhesive too short Use an adhesive with a longer open time, 01 increase application temperature slightly Shearing of adhesive deposit Check for twisting, compression/relaxing/more compression or other adverse
movement in the compression

section. If movement through compression section is smooth, check with adhesive manufacturer Insufficient compression force Increase compression force as required Insufficient hot tack Change to new batch or different formuiation of adhesive

PiN 1044456 4123006193

0(:'

Nordson Corporahon 1993 AII HU.jt<\s Ae~t)f\le<1

Troub/eshooting

6-27

Hot Melt Material Application Problems

(continued)

Problem

Possible Reason

Corrective Action

Refer lo

Gelling 01 Adhesive

Syslem not properly llushed belare changing lo an incompatible adhesive

Attempt lo pump remaining adhesive lrom system, then properly llush system; relill wilh Iresh adhesive Allempllo pump remaining adhesive lrom system, then properly f1ush syslem. See Section 9 ot this manual on Type R solvenl lar recommendations on choosing a compatible solvent Do nol heat adhesive longer lhan recommended pOi lile 01 adhesive. Use system STANDBY mode during prolonged hold situalions Reduce temperature ar consult with adhesive manulacturer about recommended adhesive lemperature ranoe
Lower setpoints as required

Type R solvent used lo f1ush a system which was operating with Polyamide, Surlyn, Polyesler or certain other high periormance hot melt materials

Adhesive heated lar too long

Adhesive healed al too high a temperature

Adhesive Charring in System

Temperature setpoints too high Zone overheats

Section 4

Complete troubleshooting procedure lor overhealing channel as required Keep tank at least one-hall lull al adhesive Keep tank lid closed during operation. 11 problem persisls, change the adhesive or switch to an applicator with a nitrogen blanket Reduce channel temperatures during arolonoed hold situations Lower selpoints as required Chanoe adhesives

Adhesive level kept too low

Adhesive oxidizing in tank

Adhesive
Fuming or

System maintained at operating temoerature with no deliverv Temperalure setpoints too high Use al unstable adhesive

Section 4

Smokinq

le, Nordson Corporation 1993

PIN 1044458

AII Righls Reserved

41-23008193

6-28

Troubleshooting

Graphs of Nickel RTD Resistance Values

GUN RTD RESISTANCE VS. TEMPERATURE

260 250
__ .J __ .1 __ 1. __ L.__ L _ _ '
I
I I

I
I I
I

1
1 1
1

1
I I

1__ J __

J _ _ .1 __ 1. __ L _

I I

fii ::
Q.
()

240 230 220 210 200 190 180 170

__ J __ l __ t __ L __ L __ l
1 I I I

I 1

I 1

I I

1 1
~

I __ 1

__

J __ !__
I I

1 1

1 I

__~

__

I
I

I
1

I
1

1
I

I
I

1
I

1
I

I
I

I
I

I
I 1

I
I

J:

--'--'--r--r--r--~-'--,-1 I I I 1 1 1 I 1 I 1 I 1 1 I
--""f--~--"--"" --~--l--

-r--r--r-I I I

-,~

1
1 I
~

1
I 1
~

I I
I
I
1

I
1
~

-"1--~--'"

--r- --1- - __

(fJ

f!'
W

__

I I
~

__

I I
~

__

1 I
~

__

1 I
~

__

1 I l '
~

1_

__

I
~

__

__

1 1
~

__

L __ 1 __
I
I _
I

ji

I
I

I
1

I
I

I
I
1

1
1 1
I

I
I
I

I
I
I

1
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I

I
I
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a:

_ _ J __ .1 __ 1_

.... a:

:MAX:
1
I

_L __ '
I

' __ J __ J __ .l __ 1 __ L __ 1

--11
., -., -

r--r--~--I---I--l--1--i--r--r--~--

MIN:::::::::
t I
I I I I I 1 I , I

I
T -

1
-1- -

I
-

I
T -

I
- -

I
-.- -

I
-1- - -

r- - - , -

-1- - , - - , -

1 1 1 I 1 1 1 1 I 1 1 1 1 1 1 I I I I 1 +~T-r_1~__r~_r__r_r__._;_~_;_~T-r_1~_;_~_r_~T-r_1~__1

170 180

190 200 210 220 230 240 250 260 270 280 290 300 310

TEMPERATURE (DEGREES F)

RANGE: 170-310 DEGREES F

350
1
I 1
1 1 1 1

1
1 1 1 1

1
1

I
I I

1
1

1
1

I
I I
_1- -

I
I I I I

I
1 I

I
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~--

340 330

--~--~--~--~--1---1---1--4--4-_4--~--~-_

I 1

--~--~--I_

__

j) ::

1 1

I I I I 1 I_--I---I- - - 1 - - - 1 - I I I 1 1 I 1 1 1 1

... --~-

I I

9
Z

J:
W

320 310 300 290 280 270 260 250

--~--~--~--~--I---I---I--~--_I--

-1--.-I
1 I
1

I I

1
I - - ~ I

I
I

1
-1 "" -

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1
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1 1 1 I I 1 - ~ - - 1- - -1- - -1- - -1- - -1- - -11 1 1 1 I I

I
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w

- - ro - 1
1

- -

- -

-1- -

1
1

1
1

I
1

I
I

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1

1
1

1
I

lIt
1 I 1

ji

--r--r--r--r--It 1 I I 1 I 1 I --r--r--~-I 1 1 1 I

-I--~--'--,--,--,--,--

a:

.... '" a:

1
1

---1---1--1--"'--'--'--'--'-1
1

1 1

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MIN
I I 1

-r--I---I---'--'--'--'--'--'--'-1
1

1
1

I
1

I
1

I
I

1
I

I
I

I
I

1
1 I

r--r--r--'---I---'--'--'--'--'--'--T-I f
~

310 320 330 340 350 360 370 380 390 400 410

420

430 440 450

TEMPERATURE (DEGREES F)

RANGE: 310-450 DEGREES F

P/N 1044456 41-2300 8193

(O)

Nordson COIporatlon 1993 AII RtOhls Reserved

Troubleshooting

6-29

Graphs of Nickel RTD Resistance Values

(Continued)

HOSE TTD RESISTAN CE VS. TEMPERATURE

270
I

260

I I I I 1 I I I - - ... - - ~ - - .. - - ~ - -t- - -1- - -1- - -4 - I I I I 1 I I I I I 1 I I I

t

I 1 I I -t - - . - - .. - - .. 1 I I I I 1 1 1
1

::;
I

I I

250 240 230 220 210 200 190

--'--'--r--r--~--I--'--~--'--T--

--r--r
1
I I r --,--1 I I I

Q
W

1 I 1 1 1 I , I --,- -.,-- r --r--,---,---,--,- -,I

~ m ; w
o::
tt-

--,---,-__ J
I I I

1 1

I I 1 I I I I I 1 I --r--r--r--l--~I I I I I 1 I --r--r--~-

--,-- --r--r--r-I I 1 I I I I I -1--i--r--r--~--

I 1

L __
1

I
I
~

__

J __ J __ ! __ L __ L __
1
I

I
~

__

I
I I

I
I

1
I
~

1
I

I
I

__ J__
I

MAX

_L __ L

_L __ I__ J __ J __
I 1 1__
1
1

__

1
~

__

L __ L __ L __
_

I MIN I I I _ . __ L __ L __ 1
I
I I

I I
~

__

1 1
~

1 I 1 I 1 1 I I __ J. __ . __ ... __ 1
I I
I
' _ _

1
1

f
I

I
I

I
I

I
1

1
1

I
I

180

-~--~--'--~--~--I--~--4-_~

__ J. __
I

L __ I
I

170 +~"""''''''''~-'-~''''''''''''''~--r~+-,....,c--.--+-~+-~'''''''''--+~+-..--l 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310

TEMPERATURE (DEGREES F) RANGE: 170-310 DEGREES F

360 350 340

--,--,--,--,--,--,--,--,--,--,--,--,I I I I I I I I 1 1 I I I 1 I I I I I I I I ,
~ ~ ~ ~ ~_

.-I I
~

::;
I

330 320 310 300 290 280 270 260 250 310

--r--f--f--~--'---I---l--~--~--~---1--1-I , 1 t __ I __ 1 1 I __ , __ 1 __ L __ 1 __ 1 __ I L L I I __
I 1 , 1 1 1 , 1 I 1 l i t 1 1 1 1 1 1 I 1 1 t 1 1 I 1 I I I I 1

Q w

--r--r--r--r--I---l---'--- -,--,-- --,--.,--

~ ; w
o::
tt-

--r--f--'---I---I---'-- ---1---__ L __ L __ L __ 1
1 1 1 1 1 I I I

1 1

1 1

1 ,

1 I

1 1

1 1 I

-.--i--1--1-I I 1 I l i t

I 1

1 1

__1
I t

1 I

1_ _

1 I

_ _ .J __ J __ .J __ J __ .1 __
1

1
I 1
I

1
I

1
I 1

I
1

I
1 1
I __

1
I I
__

I
1 1

1
I 1

1
1 ,

I
I I

--~--~--~-

MAX

~--I---I
1 1
I

-1--4--4--~--~--~--1-1 I 1
~

--r--

--r--~-_~

1---1---1--,--~--,--'--'--1--

__ 1 __ 1 L
1

MIN __ I

J 1 __ J 1 __ J1 __ JI __
1 1 1 1 I 1 1 I

l1 __
1 I

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 I I -1- - -1- _ 1 I 1 I

...c __ ... __ ... __ .. __ .. __

I I I 1 1 1 I I I I

320

330 340

350

360

370

380 390 400

410

420

430 440

450

TEMPERATURE (DEGREES F) RANGE: 310-450 DEGREES F

,el NordSOrl Corporaliorl 1993 AII A,ghls Ae:;"rved

P/N 1044458

4123006/93

6-30

Troubleshooting

.~" "Ulllr

-",,,.;;,,,,

~CH

~"","Z.I'O' "'D

1I1IT

"""""'iT mn mrl 11l "..".,.""""""" lIT mil

LI~C __

l]i:
,,-o~

-~_

Figure 6.8

Wiring Diagram - 200/230 VAC Unts

P/N 1044456

41-2300 6193

n Corporatlon 1993 NordSOAll R":Jhts Aeserved

Troubleshootng

6-31

I
" :..'.__ Jo' ._~

,"

jJH:'Bn~:nn. m.i!. i}:JA~m,~ FJm..1E~ u:.rETIP; rHJ[! !H!,~

" ::.:-

I
""''''''.~ -;; .-;

'O"''",-uC'' "'-''''' J~

"

..

~,.

"~-

,. 'A'.

"

;:rJTt?

~r'

,",,. 'ti'" --40:r~= 6<1"..1ft:' ""'. n"'U

~,1t::-::,,"<-<

'"

-~--

-----_.

, ...._It<_, .
~."',,.""

.,~"

Figure 6.9 -

Wiring Diagram . 380- Y VAC Units

(c,

Nmdson Corporabon 1993 AII HlghlS fle~"rved

PN 1044458

41 -2300 8193

6-32

Troubleshooting

eH.Al A

~MOOH
:-

use -

~30<
20

"r re

oo:"~o p,~-

,2JO~

JI, J 2 2 1 G a a ' "HOSEiOUH JI, ".J3.'" ,'""e'-"HOSElGUN

JI,

Ji JJ..I<O. J5

"'6e8' 5 HOSEiGUN

L ""'"

JI. J" J3..I<O, J5, JI' 2W!90 6 HOSE/OUN

. NOTE WlRf le QtUY APPEARS ON '"uM' TYPE

C'~CuIT BREAKfRS

'"
'
"'N~

CO""ONHIT TfRMINAl BlOC" C""NEnOIl CiRCU"-llflfAHA

"fATER
TRIAC

oPTIQNS,,,lERfACf IlOA.RD{PiN 2768S20IIOPT10HJ

CAN 8f. uSEO 'N PLACE OF PMJ BOARO IPIN 2146sel

J'

1"
I ~;" I ,,J ,1
~
I I TH5J

---

l' - - (,~",.;)),~;, L-f---~_J

---t---l

W""

..

n
THST
AJDJ

IAN~

THEAOdOSIAT SOLNOIO VAW:

REslSTNC, TE ..POElfCIOf'
R~SlSlANCf

' 'OH

IE,,"P [)[ lfCTon ,.)';r

AToe;

. /11

"' ~ "'>e~
J1 ~,o J1A J5A J18 J5B

"FSISTANCf lf"'P !lETfOOl< (";"N ;:';SE ':{"TE~

OUN HE.(R
TEodP'co..T"O\. CIRCun !lOARO
co..~-Ec-TOc'RCuii liOiJlo

CON'lCTOR. u"l1

HOS~

CO"HEe TQR HOSE W" LAMP. UHIT P<;>WEA, NH'N

fUSE.2SOV.63AMP
"'-"DS1ATEAElAV

lWE"T'PPROTECIlON Lavi Voi:fAOE P<)WER $l)PP, y

TRO,H$f0R"'EA

pe

eoARO

iJ,MP.

PAAEN! ""'CHN(;TEA~oC~ PAA-~ NJ ..... CH-'.. I':-,NiERl<X:.

fS(J~O"

J.,MP. ~o"i ~E v 'NOICA TOA

'<"A"'P-

Figure 6.10 -

Schematic - 200/230 VAC Uni!s

PIN 1044456 4123008193

(e) Nordson Corporahon 1993 AII H,ghls ReSANe,l

Troubleshooting

6-33

,"M".
..,ni}" "
\lOARO P.. ~ 1
'IO~E,GuN "()~'F''-M''

o ,

r
,
,
-J~- 1 , ~'"",~. L,,,., . l'

"", jJ'

J.'J'J'"''

,KX;('(;""
,,"~IIGU~

J1 JO'"

"J'.

(,

(~F~~":f;;:~~Yt<i~~1 ~"~!)tJ ,lu",' lYPl

r:,J--- _--t--, \ _~ r
I
"

L -f--,

,,'"" '"

'-"-""-'Cc'L:::'lJ ~. ,. "

I
I
I

11'

k, "

i'~~T
'"

",",.,,",..

' ,...... ~....;:.)=

~,~

l-

-; t)
f--l0. =-1

Figure 6. 11 -

Schemalic - 380-Y '''c Umts . Vf1

PN 1044456

4123008.'93

634

Troubleshooting

This Page Intentionally Left Blank

F'IN 1044456

4123008193

ot) Norclson COJporation 1993

AII Righls Reservad

SECTION 7

## TABSHEET ##

SECTION 7

Disassembly and Repair

1.lntroduction 7-1 2. Repair of applicator (mechanical) 7-1 Preparation for repairs on hydraulic system 7-1 Replacement of o-rings on hose connectors and o-ring plugs ..7-1 Pump disassembly and repair . . . ..7-2 Pump assembly 7-5 Air control valve repair or replacement 7-8 Replace Top Poppet Seat ....... . 7-8 Replace Bottom Poppet SeatNalve Assembly 7-9 Shifter and spring assembly replacement 7-11 Drain valve o-rin9 replacement 7-11 3. Repair of applicator (electrical) 7-12 Circuit board replacement 7-12 Tank triac replacement 7-13 Circuit breakerreplacement 7-14 Tank RTD replacement 7-15 Tank thermostat replacement 7-16 4. Repair of Guns 7-18 Heater cartridge replacement 7-18 Gun RTD replacement . . 7-19

List of /IIustrations
Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 7.1 7.2 (1 of 2) 7.2 (2 of 2) 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7-1 7-2 7-3 7-6 7-6 7-6 7-7 7-8 7-9 7-10

List o( lIIustrations
Figure 7.10 Figure 7.11 Figure 7.12 Figure 7.13 Figure 7.14

(continued)

7-10 7-11 7-12 7-13 7-15

Disassembly and Repair

7-1

Sectian 7 Disassembly ano Repair

1.1ntroduction
Seclion 7 conlains inslruclions for repairing or replacing various parts of lhe Series 2300 Applicalor syslem. The inslruclions describe how lo disassemble, repair or replace, and reassemble syslem components. WARNING: Allow only qualified personnel lo perform repair on lhis equipment. ObseNe the safely instructions In Sectlon 1. Failure lo do so may result oin equipment damage, personal injury or death.

2. Repair of applicator (mechanical) Preparation for repairs on hydraulic system

If the pump is operable, flush the syslem before disassembly. If the pump is not operable, but the heating system is functional, heat the applicator lo operating temperature to ease disassembly. Otherwise, a heat gun or other flameless heating device musl be used to melt solidified material in or on system components. The O-rings on lhe hose connectors and o-ring plugs on the applicator manifold and gun service blocks should be replaced whenever lhere is evidence of leakage or whenever lhese fittings are removed. Refer lo Figure 7.1 for locating lhe correct O-ringo
o

Replacement of o-rings on hose connectors and o-ring plugs

@)
.,

..,.......MANIFOLD

:;0~~ "B;~(~V~' o~ , I
...

NOTE: Use only o-ring P/N 945 032 as a replacement. 1. Remove the hose conneclor or the o-rlng plug from lhe manifold with a sockel wrench . 2. Remove lhe o-rlng on the connector or plug. 3. Be sure lhal the new o-ring and its groove are clean, then lubricate wilh Teflon paste (P/N 900 236). 4. Slrelch lhe o-ring and carefully roll it over lhe threads and onto the groove in the hose connector or o-ring plug. Be sure nol lo strelch the o-ring any more than is necessary for installation. 5. Lubricate the fitting threads with Teflon paste (P/N 900 236).

.........O-AING

i1~v

O-AING/

~~O-AING
PLUG

I
PLUG

Figure 7. 1

6. Thread lhe fitting by hand into the lhreaded port in lhe manifold or gun seNice block. 7. Ttghten the fitting only enough to seat it (7 lo 10 ft-Ibs or 10 to 14 N-m of torque), slopping when lhe body of the metal fitting conlacts the manifold or seNice block 8. Trigger lhe gun(s) lo remove any trapped air, lhen resume operation.

NOo'dson CorpO/abon 1993 AII Rights Rese/ved

P/N 1044458 41 .2300 6193

7-2

Disassembly and Repair

Refer lo Figure 7.2 lor idenlificalion 01 pump componenls (enclosure not included).

Pump disassembly and repair

@'/ n

I /

'W

~!fJff'l\

WARNING: Risk of burns. Wear protective clolhing, salety ~ goggles, and salety g'<,vco (['IN 902 514).

1. Wilh Ihe applicator at application temperature, lurn Ihe main eleclrical swilch OFF at lhe applicalor. Allow lime for lhe adhesive lo cool down bul nol lo solidify.
NOTE: Removing the pump after lhe adhesive has begun to solidify could damage the o-ring on lhe crossover tube of the pump.

WARNING: Trigger lhe gun(s) lo relieve aH system pressure in arder lo avoid lhe release 01 pressurized molten material.

2. Remove Ihe pump enclosure by removing the screw on lop 01 lhe housing.

CYLlNDER HEAO

O.RING
PIPE PLUG

_.,.........
-'-~
.-HEX HEAD

------t

SCAEW
1 4.... LOCKWASHER

l'J

GASKET>./ ~(J{J /

/' AlA CONTROL VALVE

/ ./

./'

, ~ , '. e----T ~
"".
/
......

HEX NUT
LOCKWASHER CUPWASHER

./
/' /" _

/ /

~ GASKET~~~

-+-",

\
PUMPTOWER BAACKET

~,~~/

\
LOCKWASHER

~ /"

~/

PISTON SEAL - WASHEA

...
.

1
I
I

PISTON CUP

--...~~
I@

HEX HEAD ....... SCREW

(SY"

WA$HER

HEX HEAD SCAEW

~\ ~ ~ LOCKWASHER SHIFTER STOP

ii!\~

'"

a
~~

.. / /

// .
/

CUPWASHER_~~.: i
, HEX

PISTON CUP

+O-RING

LOCKWASHER~

NUT~

u-cup_'
SEAL
I

:@~
HEX HEAD

.~
/

' ./

.(\.:

SCREW-....... SHAFT

Q'D.. ' -"

CLAMP~

..... _~

;'

"J I'. ~~~o-~~'--'1/

SCREW

~~<,/
"'PUMP MOUNT

~.'
-

LOCK'.#~

LOCKNUT_

~ ~~//l!o:::::~
(
, j

WAS,:/'1

LOCKWASHER--(cl) ,

Figure 7.2 (1 012)

..---'

P/N 104 4458

412300 8193

cCl NordsOfl Co'pOfahon 1993 1\11 f-l"jtll~ Aesorvod

Disassembly and Repair

Pump disassembly and repair
(continuedO

73

3. Set the pump air regulator to zero (O) and shut off a valve upstream 01 the regulator in the air supply line. 4. Remove the air regulator Irom the pump mount. 5. Disconnect the solenoid valve eleclrical plug Irom its receptacle. 6. Remove the three hex head screws and washers that secure the pump and pump mount to the applicatar.

~ outlet, and bleed hole.

if'

WARNING: Molten material will Ilow Irom the pump inlet,

7. Rotate the pump slightly in a circular motion to the break suction and then pull it straight up lo disengage the crossover tube Irom the manilold. Take it lo a convenient location lor lurther disassembly. 8. Remove the airline connecting the solenoid valve and the base 01 the pump mount. 9. Remove the a:r control valve by removing the lour hex heads screws and lockwashers and the two washers that secure it to the pump cylinder. 10. The two gaskels between the air control valve and the cylinder, the shiller stop and the pump tower bracket will come off at this time also. Inspect Ihe gaskets and replace them il they are damaged. 11. Remove the cylinder head Irom the pump cylinder by removing the lour hex head screws and lockwashers that secure it to the pump mount. 12. Check the o-ring on the cylinder head lor any delormities or loreign particles. Replace the o-ring il necessary. 13. Hold the shaft 01 Ihe piston with a wrench (a wrench Ilat is provided on the shall) and remove Ihe hex nut and lockwasher at the top 01 the piston shaft.
__ PIPE PLUG

....i.......- RElAINING
Y
--WASHER

f1ING

~ .... - PUMPSEAL

... -- PUMPBODY

14. Remove the two pistan cup washers, the two pistan cups and the piston seal washer Irom the pump shaft. 15. Inspect the cups and the seal washer lor damage and lar any metallic residue. Clean or replace them il necessary.

.-- CRQSSOVER

TUBE

16. Loosen the nut on the hex head screw that secures the shall clamp to the pump shall. Slide the shall clamp up the shall. 17. Using a screwdriver, straighten the lock tab on the tab lockwasher that keeps the locking nut Irom tuming. Loosen the locking nut and slide it and the tab lockwasher away lrom the pump bady. 18. Pull the pump body away lrom the pump mount. Set the shall clamp, the locking nut and the tab lockwasher aside. 19. Inspectthe u-cup seal and Ihe o-ring in the upperface 01 the pump mount. Replace them il they show evidence 01 damage or wear. 20. Using a retaining ring tool, remove the retaining ring al the top 01 the pump body. 21. Manually stroke the pump shall up and dawn to loosen the pump seal and washer and remove them. It may be necessary to apply a Ilameless source 01 heat to remove these parts. Inspect the seal and replace it il necessary.

O
O

8~?N~UP
O_AING

__ PUMPPISTON

6,.0" PRi~~~AE

~~ :~~~;::TALL
~:I
CAGE
.~,

~.- PRESSUAE

__

... ..
-

~"-SIPHON
- 1>

6-- SIPHON BALL

SEAT BALL

Figure 7.2 (2 0(2)

'Cj

NOlson eOlporahon 1993

P/N 1044456
41-23008/93

,0.11 RlghlS Aeserved

7-4

Disassembly and Repair

22. Secure Ihe pump body wilh either a jawless vise or a 16-inch-handle adjustable wrench on the wrench 510t5. Remove the crossover tube; then use a large wrench lo unscrew Ihe siphon ball seat from the pump body. 23. Pull the siphon ball and ils cage from the bollom of the pump body. If there is cold adhesive in the pump. il may be necessary to use a source of Ilameless heat to soften the adhesive. NOTE: Avoid scratching the pump pistan or Ihe inside 01 the pump body during disassembly and repair 01 pump. Surface scratches on these parts may cause excessive leakage during operation. 24. Garelully pull the pistan out 01 the pump body. 25. Remove the pressure ball seat and the pressure ball lrom the pistan by unscrewing Ihe seat Irom the pistan. 26. With the pump now lully disassembled, inspect both the pressure and the siphon balls and their seats for wear or damage. Inspect the o-ring on [;,e crossover tube. Replace Ihem il necessary. 27. Glean all components 01 the hydraulic section by heating thom in a container 01 Type R solvent to the melling point 01 the adhesive. NOTE: Aiternate heating and cleaning methods include: a. Heat the components with a f1ameless eleclric heat gun. Wipe them with a clean cioth. b. Or, submerge the componenls in an ullrasonic cleaner. WARNING: Do nol clean any component 01 a pressurized fluid system in halogenated hydrocarbon solvents. See the Salety Summary, Section 1, lor furlher details. Using a halogenated hydrocarbon solvent could cause an explosion c. Or, subrnerge the components in an appropriate chemical c1eaner.

Pump disassembly and repair

(continuedO

P/N 104 4456

41-2300 8193

,~,

No(dson Corpordllon 1993

Al! Rlghts I'leserved

Disassembly and Repair

Pump assembly

7-5

NOTE: Read the inslruclions and noles in this procedure carelully. The positioning and alignment 01 certain parts in Ihis assembly are crilical lo satislactory performance 01 Ihe pump. Reler to Figure 7.2 lor identilication 01 parts.
1. After putting Ihe pressure ball inlo Ihe plunger 01 Ihe pislon, screw Ihe pressure ball seal onlo Ihe piston. Torque the seat 50-60 ft-Ibs (68-81 N-m). 2. Carelully insert the pislon into the pump body, taking care not lo scralch Ihe surfaces of Ihese parts. 3. Pul the siphon ball onto Ihe siphon ball seal. Attach Ihe siphon ball cage to Ihe seal. If Ihe cage does nol fit securely, so Ihat the assembly can be turned upside down without Ihe cage falling off, bend Ihe legs of the cage slighlly inward by hand and then reattach il. 4. Apply Loctile adhesive (P/N 900 419) lo Ihe Ihreads of Ihe seal and screw il inlo Ihe pump body. Use either a jawless vise or a 16-inch adjuslable wrench to secure the pump body. 5. Wilh Ihe o-ring and backup ring assembled onto Ihe crossover lube, apply Teflon paste lo the threads of the lube and screw il onto Ihe pump body. Torque it 140-160ft-lbs (190-217 N-m). 6. Lubricale the seal wilh Parker lubricanl (P/N 900223) and pull Ihe shaft up from Ihe top of Ihe pump body. Insert the seal into the body wilh the groove in Ihe seal facing down. Pul Ihe washer on the shaft and slide Ihe shaft down lo help guide Ihe washer and seal into place.

NOTE: Remove all adhesive from the seal cavily and the relaining ring groove in Ihe pump body before inslalling this seal.
7. Using a retaining ring 1001, snap Ihe retaining ring inlo place. 8. Guide Ihe upper part of the pump body and the piston shaft through Ihe bottom hole in the pump mounl. The shaft must be inserted Ihrough three parts before il passes Ihrough Ihe top hole in the mounl. From bottom to top, these are the lockwasher, the locknut, and the shaft clamp (see Figure 7.2, part 1 of 2).

NOTE: The Iwo prongs on the shaft clamp must be posilioned so Ihat Ihey are poinling lowards Ihe shifter and spring assembly when the mount is attached to Ihe applicalor.
9. Secure Ihe pump body lo the pump mount wilh Ihe locking nul, bul do nol tighten Ihe locking nul at this lime. The pump body should be loose enough thal it can still be rotated. The tab lockwasher should still be loose. 10. Insert Ihe u-cup seal inlo the upper face of the pump mount wilh the groove facing up. 11. Insert Ihe -ring into Ihe upper face of the pump mounl.

lC)

NOldson Corporation 1993 AII Rights Aeserved

P/N 104 4456 41-23008193

7-6

Disassembly and Repair

12. Pull the piston shafl up as far as possible and install the two piston
cup washers, lhe two piston cups, and lhe piston seal washer onto the shafl in the proper order, making sure lhat lhey are Iree 01 loreign particles. NOTE: The curved edges 01 the lower piston cup should be poinling down; the curved edges 01 the upper piston cup should be pOlnting up.

Pump assembly
(continued)

13. Holding the piston with a wrench at the wrench Ilats, replace the hex nut and lockwasher. Torque the hex nutto 100-120 in.-Ibs (11-14
N-m).

14. RolI the O-ring into place on lhe cylinder head.

15. Place the cylinder on the pump mount with the maling lace lor the air valve positioned as shown in Figure 7.3. The cylinder should be aligned as shown in Figure 7.4.

'"

.~.
Figure 7.3
MAKE
PARALLEl~

- f-

~
Figure 7.4

""

+11

...J-ti

POSIT10N
NOTCH

FOA AlA
PA.SSAGE

16. Altach the cylinder head with the lour hex head screws and lockwashers. Torque the screws 45-55 in.-Ibs (5-6 N-m). NOTE: The notch in the cylinder head, which serves as an air passage, must lace toward the air valve. This notch is identilied in Figure 7.5.

TOWAAO AlR CONTROL

VALVE

Figure 7.5

P/N 10-4 .ol45B

41-2300 S/93

19 Nordson Co.poralion 1993 AlI Rlghls Resel'lled

Disassembly and Repair

Pump assembly
(continued)

77

17. Wilh Ihe two gaskels. Ihe pump tower bracket and shifter slop in place, attach Ihe air conlroi valve assembly and shifter spring assembly lo Ihe air cylinder wilh Ihe lour hex screws, lour lockwashers and lwo washers as shown in Figure 7.2, par! 1 012. Torque lhe screws lo 100-120 in.-Ibs (11-14 N-m). NOTE: Make sure Ihal Ihe gaskels are nol kinked or 10m. Kinked or 10m gaskels could cause air leakage. NOTE: The valve and attached shifter should be visually aligned wilh Ihe pump pislon. NOTE: The bottom 01 Ihe shifter slop goes under Ihe lop par! 01 lhe shifter. 18. Torque Ihe hex nut on the shaft clamp to 100-120 in.-Ibs (11-14 N-m). NOTE: The shaft clamp should be sealed on Ihe shoulder 01 lhe pislon. 19. Replace Ihe air line connecling Ihe solenoid valve and Ihe base 01 Ihe pump mount. 20. Pick up Ihe pump solenoid assembly and carelully posilion Ihe crossover lube ollhe pump inlo Ihe inlel por! 01 Ihe manilold. Rolate Ihe pump mount unlillhe boll holes lor Ihe lhree hex head screws line up correctly. The appropriate posilion ollhe pump body in relalion lo Ihe lank walls can be delermined Irom Ihe culout on Ihe lank cover (see Figure 7.6). 21. Replace lhe Ihree hex head screws and washer Ihal secure lhe pump and solenoid assembly lo the applicator. Torque Ihe screws lo 15-17 ft-Ibs (20-23 N-m).

o 0"'0""0']]:)o
PUMPBODY

'NLE"N

OF T....NK FOA CROSSOVER TUBE

:W. ([ ~

curOUT FOR TANK LOADING

22. Tighlen Ihe locking nut. Lock il in place by bending one lab 01 Ihe lab lockwasher inlo one 01 lhe slols 01 lhe locking nut.
23. Reconnecllhe eleclrlcal plug on lhe solenoid to ils receplacle.

Figure 7.6

24. Attach Ihe air regulalor lo Ihe pump mounl, using Tellon paste (P/N 900236) on Ihe Ihreads ollhe pipe nipple. 25. Connecl Ihe air regulalor lo Ihe air supply line and open lhe shuloff valve in Ihe supply line. 26. Replace Ihe lank enclosure and inslall Ihe screw which secures it.

27. Resume operalion by Iriggering lhe gun(s) lo remove air Irapped in lhe syslem, Ihen reapply power and resume normal syslem operalion.

(e) Nordson Corparatian

993

PIN 1044458

AII Aights Reservad

41-23008193

7-8

Disassembly and Repair

NOTE: Because of lhe danger of bending lhe shifter rod, il is nol recommended to do any repair on the air conlrol valve excepl replacemenl of lhe poppet seals. Even a small bend in lhe shifter rod will cause lhe shifter lo malfunclion.

Air control valve repair or replacement

Replace Top Poppet Seat

To replace the top poppel seal, perlorm lhe following sleps while refering lo Figure 7.7.

tf.fi:\ / ~ / f1!r\ / 'S:JJ/ ~

~------------.:..._~

WARNING: Risk of burns. Wear proleclive clolhing, safety goggles, and safety gloves (P/N902514).

1. Turn lhe main eleclrical swilch OFF al the applicalor. Allow the unil to cool down. 2. Sellhe pump air pressure to zero (O).

WARNING: To avoid the spraying of molten malerial, lrigger the gun(s) to relieve lhe syslem of all pressurized molten malerial.

3. Remove the lank enclosure by removing lhe screw on lop 01 the enclosure. 4. Remove lhe four screws, two spacers, detenl pin and detenl that secure lhe poppel seat lo lhe valve. Install a new seat. Torque the screws 20-25 in.-Ibs (2-3 N-m). 5. Replace lhe lank enclosure and resume normal operalion.

-aODY

l
o_
."

I
SH'FTEA
ROO

~
I

I ,

.-aOTTOM
POPPET
SEAT

&-SCREW

Figure 7.7

P/N 1044458 41-23008193

((;) Nordson Corporalion 1993 AlI RlghlS Aeserved

Disassemb/y and Repair

Alr control va/ve repalr or rep/acement
(contnued)

7-9

Replace Bottom Poppet SeaWalve Assembly

To replace Ihe botlom poppel seal or lo replace Ihe enlire valve assembly, perform Ihe following sleps and refer to Figures 7.8, 7.9, and 7.10.

f7,i;;\ /

'S:J)

~!~

WARNING: Risk of burns. Wear proleclive clolhing, salety

~ goggles, and salety gloves (P/N 902 514).

1. Turn Ihe main eleclrical swilch OFF al Ihe applicalor. Allow the unit to cool down. 2. Sel the pump air pressure lo zera (O).

/!i;i},.

WARNING: To avoid Ihe spraying 01 mollen material, Irigger Ihe gun(s) to relieve the system 01 all pressurized mollen malerial.

2. Sellhe pump air pressure lo zera. 3. Remove the tank enclosure by removing Ihe screw on lop 01 Ihe enclosure. 4. Separate Ihe solenoid valve eleclrical plug from ils receplacle. 5. Disconnecl one end 01 the air line running between the solenoid valve and the base 01 Ihe pump mounl (see Figure 7.8).

HEX HEAD SCREW ANO

lOCKWASHEA

HEX HEAO
SCREW. WASHEA ANO LOCKWASHER

Figure 7.8

6. (Figure 7.2, part 1 012; also Figure 7.8) Remove Ihe lour hex head screws, Ihe two washers and lour lock- washers that secure Ihe air conlrol valve lo the air cylinder 01 the pump. The pump tower brackel, the shifter stop and Ihe valve gaskets will also come off at Ihis lime.

,tl

Nordson Corporalion 1993

P/N 1044458

AJI R,ghls Reservad

4123006/93

7-10

Disassembly and Repair

Air control valve repair or replacement

(continued)

7. Reler to Figure 7.9 and use a wrench on the shifter rod f1ats to remove the locknut and lockwasher at the bottom 01 the shifter assembly (see Figure 7.10). 8. The two large washers the spring shifter block and the shifter assembly can now be removed and set aside.

NOTE: The entire air control valve may be replaced at this point by removing the solenoid valve (Figure 8.7, item 2) and attaching it to a new air control lIalve. After this procedure is complete, proceed 10 step

11.
9. Remove the poppet seat by removing the lour screws that secure it
to the air control valve.
Figure 7.9

10. Install a new poppet seat on the air control valve and secure with the lour screws previously removed. Torque the screws 20-25 in.-Ibs
(2-3 N-m).

11. 81ide the shifter assembly onto the shifter rod (see Figure 7.7) and
lollow il with the two washers, the shifter block, the lockwasher, and the locknut in the order shown at Figure 7.10.

12. Using a wrench on the wrench slots in the shifter rod (see Figure 7.9) torque the locknut 45-50 in.-Ibs (5-6 N-m).

13. With the two gaskets, the pump tower bracket, and the shifter stop in place, attach the air control valve assembly/shifter assembiy 10 the
SHIFTER ------' A$SEMM8L.Y

air cylinder with lour hex head screws, lour lockwasher and two washers (see Figure 7.2, par! 1 012; also Figure 7.8). Torque the screw 100-120 in.-ibs (11-14 N-m).

BLOCK_0
,
WASHEA-(4J
L.OCKWASHER_'7E: LOCKNUT_

WASHER_c5

NOTE: Make sure that the gaskets are not kinked or tom. Kinked or tom gaskets could cause air leakage. NOTE: The valve and attached shifter should be visually aligned with lhe piston pump shaft. NOTE: The bottom 01 the shifter stop goes under the top par! 01 the shifter.

Fgure 7.10

Details.

14. Reconnect the air line running between the solenoid valve and the base 01 the pump mount. 15. Connect the electrical plug 01 the solenoid valve to ils receptacle. 16. Replace the pump enclosure and tighten its securing screw on topo 17. Resume operation.

P/N 104 4458

412300 8193

Nordson COIporat,on 1993 AII RighlS ReseNad

Disassembly and Repair

7-11

Shifter and spring assemb/y rep/acement

It is not recommended lo repair or replace parts on the shifter and spring assembly. The alignment 01 parts in this assembly is critical to proper performance 01 the pump. The entire assembly may be replaced by lollowing steps 1 through 8 and 11 through 17 within the procedure Replace Boltom Poppet SeaWalve Assembly 01 the Air Control Valve.

Drain va/ve o-ring rep/acement

~

The drain valve O-ring should be replaced whenever lhere is leakage at lhe manilold connection. WARNING: Risk 01 burns. Wear protective clothing, salety goggles, and salety gloves (P/N 902 514).

f7.i::\ '.!/!J// 'S:2J// f1Jr\ ~

1. Turn the main electrical switch OFF al the applicator. 2. Set the pump alr pressure to zero (O). 3. Trigger lhe gun(s) until the system has been relieved 01 all pressurized molten material.

1).

WARNING: Belore performing the neX! step, be sure lhat all

~ system pressure has been relieved to avoid the spraying

01

molten material. 4. Open the drain valve over a suitable container and drain lhe manilold. 5. Remove the positioning screw and lockwasher (see Figure 7.11).

POSITION(NG~a SCAEW
-..~'"

LOCKWASHEA~
fJ

6. Use a deep-end socket wrench to remove the drain valve Irom the manilold. 7. Remove the o-ring and lhe backup ring Irom their groove in lhe valve.

~-<~o. V ~RING
FIgure 7.11

""-MANIFOLD

BACKUPRING

NOTE: The o-ring and backup ring should be replaced any time the valve is removed. Otherwise, leakage may occur at the manilold connection. NOTE: Clean the valve il it is charred. Use a retaining ring tool to remove the retaining ringo Clean the valve body, the ring, the ball, and the ball tipo Use the procedures described in Section 4 under Nozzle Cleaning. Reassemble the valve wilh a new o-ring and backup ringo 8. Install a new O-ring (P/N 940 101) and backup ring (P/N 940 105) according to the lollowing procedure: a. Make sure that the groove in the valve is Iree 01 loreign material. b. Inspect the new O-ring and backup ring lor nicks and loreign material.

C. Inslall the backup ring in the groove and push it lo the side 01 the groove that is nearest the threads 01 the valve (see Figure 7.11).
d. Lubricate lhe O-ring with Tellon paste. e. Carelully roll the O-ring into its groove, taking care not to strelch it any more than necessary. 7. Using the deep-end sockel wrench, screw the drain valve into lhe manilold until it is Ilush with the surface 01 the manilold. 8. Back the valve out until the drain port is lacing down.

NordSOIl Corporation 1993 AU Righls Reservad

P/N 104 445B

4123008/93

7-12

Disassembly and Repair

9. Wilh lhe lockwasher in place, inslalllhe posilioning screw lhrough lhe 5101 in lhe flal part of lhe hex nu!. 10. Resume operalion by triggering the gun(s) to remove any lrapped air in lhe syslem.

Drain valve o-ring replacement

(conUnued)

3. Repair of applicator (electrical) Circuit board replacement

1. Turn lhe main electrical switch OFF allhe applicalor and disconnecl inpulline vollage from the applicalor_
~ ~

WARNING: Shock hazard. Disconnecl lhe applicalor from inpul eleclricalline vollage. Failure lo disconneclline vollage from lhe applicalor may resull in a serious eleclrical shock.

2. Remove lhe eleclrical cabinel cover by unscrewing lhe caplive screws on lop of lhe cabine!. 3. Disconnecllhe while circuil board plug from ils connector (Iabelled J6 on lhe board) in lhe lower righl comer of lhe circuil board.
JUMPER SINGLE-PHASE;-\ OPERATlON ONLY \.__ ri"
(
\~.-

4. Disconnect circuil board plug J7 from ils receplacle on lhe circuil board (see Figure 7.12). 5. Disconnecllhe while circuil board plugs from lheir conneclors along lhe lop of lhe circuil board. There will be two of lhese plugs on a Model 2302 Applicalor, four on a Model 2304, and five on a Model 2305. 6. Using a long screwdriver, remove the two screws which secure lhe frame for lhe circuit board and control panel door lo lhe base 01 the uni!. 7. Rolale lhe lop of lhe Irame away from lhe unil and down lowards lhe Iloor. Now lhe whole frame assembly may be removed from lhe base.

,-

02
3A 2A

lA

Figure 7.12

B. Remove lhe six screws which secure lhe circuil board lo lhe Irame. 9. Secure lhe new circuil board lo lhe frame wilh lhe six screws removed in slep B. 10. Connecl circuil board plug J710 ils receplacle on lhe circuil board. 11. Holding lhe frame so lhal ils lop is lilled away from applicalor, malch the 51015 in the bottom of lhe frame with lhe slots in lhe base of lhe uni!. When the keyed 51015 interlock, rotale lhe lop of lhe Irame up and lowards lhe unil unlil il is slanding uprigh!. 12. Secure lhe frame lo lhe base of lhe unil wilh lhe two large screws. 13. Connect lhe hose eleclrical plugs lo their connectors along the top 01 the circuil board. Connecllhe plug labeled 1 to the conneclor labeled Jl on lhe circuil board, plug No. 2 lo conneclor J2, and so lorth unlil all plugs are connecled. 14. Replace the eleclrical cabinel enclosure and secure il with lhe caplive screw on top 01 lhe cabine!. 15. Reconnecl input electricalline vollage to the applicalor and resume operation.

PIN 104 4458

41-2300 1il93

(\;) Nordson Corporation 1993 AII A,ghts Reserved

Disassembly and Repair

7-13

Tank triac replacement

1. Turn the main electrlcal switch OFF al the appllcator and disconnect input line vollage Irom the applicator.

@
.

WARNING: Shock hazard. Disconnect the applicator Irom input electricalline voltage. Failure to disconnecl line voltage Irom the applicator may result in a serious electrical shock.

2. Remove electrical enclosure cover by lirst removing Ihe captive screw on top 01 the cabine!. 3. Disconnect the three wires Irom the tank trlac attached to the base 01 the uni!. 4. Remove the two screws that secure the triac to the base uni!. 5. Secure the new triac to the base 01 the unit with the two screws removed in step 4. The orientation 01 the Iriac is not importan!.

WIRES 6 AND

6~
"

6. Connect the three wires to the tank triac in accordance with the lollowing instructlons (see Figure 7.13). 7. Locate the smallest 01 the three prongs on the relay. There will be one narrow prong and two wider ones. 8. Connect wire 7 to the narrow prong. 9. Connect wire 4 to the first prong c10ckwise (Iooking down) lrom the narrow prong.

) (-WIRE7 J--WIRE4

10. Connect wires 6 and 6A (Iastened together in one crimp socket) to

the lirst prong counterclockwise (Iooking down) lrom the narrow prong. 11. Replace the electrical cabinet enclosure and secure it with the captive screw on top 01 the cabine!.
Figure 7.13

12. Set Ihe temperature controls lo the minimum setting. 13. Reslore input eleclrical power lo the applicator. 14. Restore the system to operation in accordance with the Oaily Startup procedure in Seclion 3.

(e) Nordson Corporalion 1993 AII A,ghlS Reserved

P/N 104 4458 41 2300 8193

714

Disassembly and Repair

1. Turn lhe main eleetrical swilch OFF allhe applicalor and disconnect inpulline vollage lrom lhe applicalor.

Circuit breaker replacement

@
.

WARNING: Shock hazard. Oisconnecllhe applicalor lrom input eleclricalline voltage. Failure lo disconneet line voltage Irom lhe applicalor may resull in a serious eleclrical shock.

2. Remove lhe eleclrical enclosure cover by removing lhe caplive screw on top 01 lhe cabine!.

3. To obtain working room, remove lhe while plugs along lhe lop 01 the circuil board Irom lheir receptacles on lhe board (lhere will be two 01 lhese on a Model 2302 applicalor, lour on a Model 2304 and live on a Model 2305).
4. Remove the two screws which secure lhe conlrol panel Irame lo lhe base 01 lhe uni!. Tilllhe circuil board away Irom lhe unit until it can be removed Irom the slots that secure it at the bottom 01 the board. It can now be pulled away lrom the circuit breaker area to provide more working room.

NOTE: Do nollry lo remove il enlirely lrom lhe applicalor because it is still connecled by several wires.
5. Remove the screws which secure the circuit breaker assembly to the base 01 lhe applicalor.

6. Pulllhe circuit breaker and lhe attached laceplate away Irom the base. Remove alllhe wires allhe six screw-lype lerminals and from lhe one push-on terminal.
7. Remove lhe two screws lhal secure lhe laceplale to the breaker, lhen remove lhe laceplate.

8. Attach lhe laceplale lo lhe new circuil breaker wilh the two screws removed in slep 7. 9. Attach lhe wires removed in Slep 610 the new circuit breaker in accordance with lhe wiring diagram in Section 6. The line wires connecl to lhe lop lerminals and lhe load wires connecllo the botlom terminals. (Refer lo Section 6 Table of Contents lor lhe correct wiring diagram.) NOTE: Take care to wire the circuil breaker correctly. Failure to do so may cause the applicator lo mallunction or lhe circuit board to be deslroyed. 10. Place lhe laceplale in ils slol in lhe base and secure illo the base with lhe lwo screws removed in Slep 5. 11. Holding lhe circuil board Irame so lhal ils lop is tilted away Irom lhe applicator, malch lhe slots in lhe botlom 01 the Irame wilh lhe slots in the base ollhe uni!. When lhe keyed slols inlerlock, rolale the lop 01 the Irame up and toward the unit until it is standing uprigh!. 12. Secure lhe Irame to lhe base ollhe unil wilh the two screws removed in slep 4.

PIN 1044458

41-2300 8/93

{e! Nordson Corporahon 1993 Al! Hlgtlts Reserved

Disassembly and Repair Circuit breaker replacement

(continued)

715

13. Connect the hose eleclrical plugs to lheir connectors along the top 01 the circuil board. Connecllhe piug labeled plug 1 to the connector labeled J1 on the circuit board, plug 2 to connector J2, and so lorth until all plugs are connected. 14. Replace the electrical cabinet enclosure and secure il wilh the caplive screw on top 01 the cabine!. 15. Restore inpul electrical line voltage and resume operation.

Tank RTD replacement

1. Turn lhe main electrical switch OFF at the applicator and disconnect input line voltage Irom the applicator.
~
~

WARNING: Shock hazard. Oisconnect the applicator Irom input electricalline voltage. Failure to disconnect line voltage Irom the applicator may result in a serious electricel shock.

2. Remove the lour screws that secure the panel 01 lhe hose connector assembly lo the base 01 lhe applicator. 3. Remove the cut-away part 01 the lank insuiation. This cutaway part is located directly behind lhe panel that was jusI removed. NOTE: The cut-away insulation is stHI attached to the rest 01 the insulation at the corners, but il can be easily pulled away. II a knile is used to sever lhis connection, take care not lo cut any 01 the wires behind lhe insulalion. 4. Remove the two screws lhat secure the RTO retainer plate to lhe tank, lhen remove lhe plate (see Figure 7.14). 5. Oisconnect the leads lo the RTO at the terminals on the left side 01 the 2-station parcelain conneclar. Pull terminals lhrough lhe liberglass tubing lhal insulales lhe wire. 6. Thread lhe lead 01 the new RTO (P/N 937 283) lhrough the liberglass tubing. 7. Place the new RTO in Its slot in the tank. Pul lhe relalner plate over it and secure with the two screws previously removed. 8. Connecl lhe leads Irom the RTO lo lhe 2-s1alion porcelain conneclor.

TANK/MAN1FOLD
ASSEMBLY

//

~LOCKWASHER
//"'--,~ 4:,-.....----SCAEW

"

TERMINAL

./

'"

"~2-STATION
~ ~.

" , ' ..- POACElAIN

RTD TANI(~
, SENSOR

.~ :;"~'_SCREW ~!... ~. +
SCAEW ATO
PLATE

CONNEcrOR

FIBERGLASS TUBING

'~

[,,,

RETAINER

SCREW

I
THEAMOSTAT

tg~~&fb~

Figure 7.14
'c, Nordson Corpo/alion 1993 AII Aighls Resefved

P/N 1044458
41.23008/93

7-16

Dsassembly and Repar

9. Replace the cut-away piece 01 insulation with the loil side lacing out. It should not be necessary to tape the insulation in place. II tape is used, it should be high-temperature tape, such as aluminum furnace tape.

Tank RTD replacement

(contlnusd)

10. Install the hose-connector assembly plate with lour screws. 11. Resume normal operation.

Tank thermostat replacement

1. Turn the main electrical switch OFF at the applicator and disconnecl input line voltage lram the applicator.

@
.

WARNING: Shock hazard. Disconnect the applicator lram input electricalline voltage. Failure to disconnect line voltage lram the applicator may result in a serious electrical shock.

2. Remove the electrical cabinet cover by unscrewing the captive screw on top 01 the cabinet. 3. Disconnect the incoming power supply at the input terminal block, remove the strain reliel bracket by removing the two screws that secure il. Pull the incoming power line out through the cord connector hole. 4. Shut off the alr supply to the pump air regulator. Disconnect the incoming air line Irom the regulator. 5. Remove the pump enclosure by removing the screw on topo 6. Disconnect the quick-disconnect electrical plug to the pump solenoid (see Figure 7.8). 7. Remove the three hex head screws securing the pump mount to the applicator (see Figure 7.2, 1 0(2) and carelully pull the entire pump assembly straight up and away Irom the applicator. 8. Remove the seven screws securing the tank enclosure, then remove the tank enclosure and the tank cover. 9. Remove the hose connector assembly by removing the lour screws that secure it to the base and then disconnecting the hose electrical plugs lram the circuit board.

10. Remove the tank insulation and the bollom insulation. 11. Pull the rubber thermostat insulator lram the tank thermostat and
slide it back along the thermostat leads. 12. Remove the tank thermostat by removing the two screws that secure it to the tank. 13. Untwist the two wire nuts which connect the leads 01 the lank thermostat to two other wires, then discard the old thermostat. 14. Twist each lead 01 the new tank thermostat into one 01 the ceramic wire nuts with one 01 the other wires. NOTE: It does not maller which lead is connected to which wire because the thermostat is not polarity sensitive. 15. Replace the thermostat with two screws. The top screws must go through the ring-tongued terminal 01 the ground connection (the green wire).

P/N 1044456

,q

4123008193

NOIdson Corporiltion 1993 Al! R'qtols Aeserved

Disassembly and Repair Tank thermostat replacement

(continued)

7-17

16. Slide Ihe rubber insulalor over Ihe Ihermoslat.

17. Pul Ihe lank insulalion back into place. The double Ihickness goes on Ihe side 01 the lank nearesl Ihe eleclrical cabinet. Keep the loil
side out.

18. Attach Ihe hose conneclor assembly to Ihe base and secure with lour
screws. Connect Ihe hose eleclrical plugs lo Iheir receptacles on Ihe lop 01 Ihe circuil board. The hose plug labeJed No. 1 goes in receplacle J1, and so lorth, unlil all plugs are connected.

19. Place Ihe lank cover on top 01 Ihe lank. 20. Place Ihe lank slrainer in Ihe lank. 21. Carelully place Ihe hose conneclor assembly wires along Ihe base, under Ihe lank insulalion on Ihe side 01 Ihe lank. 22. Replace lhe lallk enclosure, being carelul nollo lear the insulalion.
Make sure lhal Ihe eleclrical conneclor to Ihe pump solenoid is pulled up lhrough lhe nolch provided lor il in Ihe lank cover. Aboul 6 nches (15 cm) 01 cord will be needed in order lo plug Ihe two ends 01 Ihe quick-disconnecl logelher. Do nol connecl them al Ihis lime.

23. Carefully maneuver the pump inlo posilion unlil Ihe crossover lube
drops inlo ils cavily in lhe tank/manilold. Secure Ihe pump wilh lhree hex head screws and washers. Torque Ihe screws 15-17 ft-Ibs (20-23 N-m). 24. Reconnecllhe electrical plug to Ihe pump solenoid. 25. Make Ihe incoming power conneclions lo Ihe unil in accordance wilh the inslruclions in Section 3, Eleelrieal (nslal/afion. 26. Replace Ihe eleclrical enclosure. 27. Reconneel the air suppJy line lo Ihe pump air regulalor. 28. Replace Ihe pump enclosure. 29. Resume operalion by Iriggering Ihe gun(s) lo remove any Irapped air in Ihe syslem.

Jo) Narclson Corporalion 1993

AII Rights Aeserved

P/N 104 4456

41-23008/93

7-18

Oisassembly and Repair

4. Repair of Guns Heater cartridge replacement

1. Turn Ihe main electrical swilch OFF al Ihe applicalor and disconnecl inpul line vollage trom lhe applicalor.

@
.

WARNING: Shock hazard. Disconnecllhe applicalor trom inpul electricalline vollage. Failure lo disconneclline vollage trom Ihe appl calor may result in a serious eleclrical shock.

2. Disconnecl Ihe eleclrical conneclion between Ihe gun and lhe hose. 3. Remove Ihe screws Ihal secure Ihe cover lo Ihe service block. NOTE: A cartridge healer is larger in diameler Ihan an RTD and ils leads are connecled lo olher leads by porcelain wire nuls. 4. Remove Ihe cylindrical cartridge healer trom ils mounling hole in Ihe service block. 5. Unlwisl Ihe wire nuls Ihal connecl Ihe healer leads lo lwo olher wires and lhrow Ihe healer away. 6. Twisl each lead ot Ihe new healer inlo a ceramic wire nul wilh one 01 Ihe wires disconnecled in slep 5. 7. Slide Ihe healer inlo ils mounling hole in Ihe service block. 8. Replace Ihe service block caver and cover screws. 9. Reconnecl Ihe hose lo lhe gun electrically and reslore inpUI electrical line vollage.

10. Resume operalion.

P/N 104 4456

41-23008193

re) Nordson Corporation 1993 Al! A,ghts Reservad

Disassembly and Repair

7-19

Gun RTD replacement

Use lhe RTO Replacement Kit (P/N 274 783) lo replace delective RTOs in the H20 and H200 guns lor the Series 2300 Applicator. 1. Turn the main electrical switch OFF at the applicator and disconnect input line voltage Irom the applicator.
~
~

WARNING: Shock hazard. Oisconnecl the applicator Irom input electricalline voltage. Failure to disconnect line voltage Irom the applicator may result in a serious electrical shock.

2. Oisconnect the electrical connection between the gun and the hose. 3. Remove the screws that secure the cover to the service block. 4. Remove the cylindrical RTO Irom its mounting hole in the service block. NOTE: Although an RTO looks somewhat like a cartridge heater, which is also contained in a hole in the service block, it is smaller in diameter than a heater and, unlike a heater, it is a part 01 the cordset. 5. Cut the two RTO lead wires approximately 1;2 inch (1.3 c m) Irom the delective RTO, then discard the RTO. 6. Strip about 114 inch (0.6 cm) 01 msulation Irom the cut wires. 7. Using parts supplied in the RTO Replacement kit, twist each 01 the new RTO leads with a cordset lead , then secure each pair with the two ceramic wire nuts. 8. Slide the RTO into its mounting hole in the service block. 9. Replace the service block cover and cover screws. 10. Reconnect the hose to the gun electrically and restore input electrical line voltage. 11. Resume operation.

((1

Nordson Corporalion 1993

AII RjOhls Res...-ved

PIN 1044458 41 -2300 8193

7-20

Oisassembly and Repair

Thls Page Intentionally Left Blank

P/N 104 445B

412300 8193

Nordoon Cotporal'on 1993

Al! R.ghts ReSeNad

## TABSHEET ##

SECTION 8

SECTION 8

IlIustrated Parts Lists

1. Inlroduction 8-1 2. Use 01 the IlIuslrated Parts Lisl 8-1 Seleclion Chart 01 Series 2300 Applicators (and their circuil boards): 200/230 VAC 8-3 Selection Chart 01 Series 2300 Applicators (and their circuit boards): 380 VAC 8-3 (Parts Lists) Unit Assembly 8-4 8-8 Base Assembly List #1 8-12 Base Assembly List #2 8-14 Base Assembly Lis! #3 Tank/Manilold Assembiy 8-16 Filler Assembly Pump/Solenoid Assembly Pump Assembly Air Control Valve Shifter and Spring Assembly Recommended Spare Parts Service Parts 8-18 8-19 8-20 8-24 8-25 8-26 8-27

List of lIIustrations
Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 8.1 - Series 2300 Unil Assembly (Drawing 1 012) 8-6 8.1 - Series 2300 Unil Assembly (Drawing 2 012) 8-7 . .8-10 8.2 - Series 2300 Base Assembly #1 (Drawing 1 012). 8.2 - Series 2300 Base Assembly #1 (Drawing 2012) .....8-11 8.3 - Series 2300 Base Assembly #2. .. . . . . .. . . . . .8-13 8-15 8.4 - Series 2300 Base Assembly #3 8.5 - Tank/Manilold Assembly. . 8-17 . 8-18 8.6 - Filler Assembly. 8.7 - Pump/Solenoid Assembly 8-19 8.8 - Pump Assembly (Drawing 1 012). . 8-22

L~tofmusuaHons~oo~u~
Figure 8.8 - Pump Assembly (Drawing 2 01 2). . Figure 8.9 - Air Control Valve Assemb!y. . Figure 8.10 Shifter and Spring Assembly. .

8-23 8-24 8-25

lIIustrated Parts List

81

Section 8 lIIustrated Parts Lists

1. Introduction
Seelion 8 eonlains illustralions and malehing parts lists for the Series 2300 Applieator and all hoses thal can be used with i1. The eomponents of the various assemblies whieh make up the Series 2300 unit are shown here and refereneed by part number where appropriate. Parts list pages shipped with the guns used in this system should also be inserted at lhe end of Seetion 8. In addition to the illustrated parts list in this seetion is a list of reeommended spare parts, a ship-with par!s list (eontaining those items shipped with the una and used or assembled later), and a serviee kils parts lis1.

2. Use of the iIIustrated parts

1. Refer to lhe table of eontenls of this seelion under Parts Lists to find
the page number of the Iist that eontains the part or parts you want to idenlify.

list

2. Sludy lhe illuslralion lo find the specifie par! you wanllo idenlify, then
nole lhe ilem number lhal goes wilh i1.

3. Loeale lhe ilem number in lhe parts lis1.

4. Use lhe nexllhree eolumns of lhe parts Iist lo find lhe part number, part deseriplion and quantity of lhe par! used per assembly.
The Part Number eolumn eonlains any of lhree possible designalions " a six-digil par! number, a dash (-) or an aslerisk (*). a. If lhe par! number is given, the par! is saleable and can be ordered using lhis number. b. A dash means that the part is nonsalable and eannot be arder by itself; in lhis case the assembly to whieh the part belongs or the serviee kit eonlainmg the part must be ordered. e. An aslerisk refers the reader to a foolnote al the bottom of lhe page. In lhe Deseription eolumn, bullets Oindieate the level of assembly of lhe part in question. For example, a deseription preceded by one bullet () is a eomponent of the assembly above it whose deseription is preceded by no bulle1. A par! preceded by two bullets ( ) is a eomponenl of lhe assembly above it whieh is preceded by one bullet (). See the example below. Ilem No.
1 2

Par! No.
274700 274996 274669 901 137

Description

Required

Pump/Solenoid Assembly Pump Assembly

Solenoid Valve/Wiring Assembly

Valve, Solenoid, Two-Way, 230 VAC, NC

Connector, Receptacla

Rel 1 1 1 1
P'N 104 4458

e NOl050n CorpOlaban 1993 AH Rrghts Reserved

4123008193

8-2

lIIustrated Parts List

The Required column conlains Ihe quanlity of Ihe part required per assembly in the iIIuslralion. This is expressed either by a number or by an amounl, such as feet or inches. A dash (-) in this column means that the ilem exists but not in a quantifiable formo This is true with such items as Teflon paste. Ref indicates that the part is Iisted lor relerence purposes only and may not actually be shown on the accompanying iIIustration.

Use of the lIIustrated Parts List

(continued)

P/N 104 4458

412300 8193

<t) Nordson Corporahon 1993 AII R'yhl>; Reserved

lIIustrated Parts List Selection Charl of Series 2300 Applicators (and their circuit boards): 200/230 VAC
Model2302
Options
Uni! P/N (CS P/N)

8-3

Model2304
Uni! P/N (CS P/N)

Model230S
Uni! P/N (CS P/N)

Model2306
Unit P/N (CS P/N)

None IStd. Unit\ LL PMI LL + PMI S S + LL S + PMI S + PMI + LL S+D S + D + LL S + D + PMI AII lour ootions

2760331276881\ 276478(276881) 276477 1276 88n 276479 1276 881) 276 246 1276 882) 276 481 1276 882) 276 480 1276 882) 276 482 (276 882\ 276 242 1276 883\ 276 484 1276 883) 276 483 (276 883) 276 386 1276 883)

276034 276494 276493 276495 276 248 276 497 276 496 276 498 276 244 276 551 276 499 276 388

(276884\ (276884) (276884) (276884) 1276 885) 1276 885) 1276 885) (276 885\ 1276 886\ 1276 886) 1276 886\ 1276 886)

276 035 276561 276560 275 562 276 250 276 564 276 563 276 565 276 818 276 822 276 820 276 824

(276 887) 1276 887) (276887\ (276 887\ (276 888\ 1276 888) 1276 888) 1276 888) 1276 889) 1276 889\ 1276 889\ 1276 889\

276 808 276 812 276 810 276814

1276 890\ 1276 890\ 1276 890\ 1276890\

xxx xxx
xxx xxx xxx xxx
xxx xxx

xxx xxx xxx xxx

xxx xxx xxx xxx

Selection Charl of Series 2300 Applicators (and their circuit boards): 380-Y VAC
Model2302
Options Unit P/N (CS P/N)

Model2304
Uni! P/N (CS P/N)

Model2305
Uni! P/N (CS P/N)

Model2306
Uni! P/N (CS P/N)

276240 (276884) None ISld. Unitl 276 239 (276 881\ 276 241 1276 887) 276 809 1276 890\ 276 486 (276 88 n 276553 (276884) LL 276 567 1276 887\ 276 813 1276 890) PMI 276 485 (276 88 n 276552 (276884) 276 566 1276 887\ 276 811 1276 890) LL + PMI 276 487 1276 881\ 276554 (276884) 275 568 1276 887\ 276 815 1276 890\ 276 247 1276882\ 276 249 1276 885) S 276 251 1276 888\ xxx xxx 276 489 1276 882\ 276 556 1276 885) 276570 (276888) S + LL xxx xxx S + PMI 276 488 1276 882\ 276 555 1276 885) 276 569 1276 888) xxx xxx S + PMI + LL 276 490 1276 882) 276 557 1276 885) 276571 1276 888\ xxx xxx 276 243 1276 883\ 276 245 1276 886) S+D 276 819 1276 889\ xxx xxx S + D + LL 276 492 1276 883\ 276 559 1276 886) 276 823 1276 889) xxx xxx S + D + PMI 276491 1276883\ 276 558 1276 886) 276821 (276 889\ xxx xxx AII lour oolions 276 387 1276 883\ 276 389 1276 886) 276 825 (276 889\ xxx xxx NOTE: Two 01 Ihe lour opllonal leatures (Parent Machlne Interlock and Low Levellndlcator) may be added lo the appllcator any time. The PMI leature par! number is 274 658; the Low Levellndicator par! number lor Ilal-bottom tanks IS 276 176; the Low Level Indicalor par! number lar linned tanks is 276 334.
LL PMI D S xxx xxx Low Level Indicator Parent Machine Interlock = Digital Readou! := Temperature Setback = Not Available
:=

:=

c; Nordson Corporallon 1993

AII Rlyhls Reserved

P/N 1044458 4123006/93

8-4

lIJustrated Parts List

Unit Assembly Parls List

I!em No. Par! No, Deserip!!on Series 2300 Hot Mell Applicator (Models 2302, 2304, 2305 and 2306; Required Rel 5 1 1

1 2 3 3 4 5 274507 276237 274589 965112

200/230 and 380-Y VAC) Rival, Blind, 3/32 x 0.250 in.

Nameplate Tag, Input Power (360-Y V units only) Tag, Input Power (200/230 V units only) Tag Set, HM Unit
Control Frame Assembly

1
1
1

Frame, Control Panel Door, Control Panel

1 1

985112 981 657 981 858 981 855 981 856 6

274590 276091 276584 981 016 981008 981 759

Hinge, Ooar Rivet, Blind Slud (Door Latch) Washer, Special (Door Latch) Receptacle (Door Latch) Nul, Special (Door Latch) Circuit Board Assembly

1
6 1

1
1
1

Graphics Panel Knob, Control, Panel Knob, Control Panel, Digital (units w/digital readout only) Filler, Optical, Red (units w/digital readout only)
Tag, Warning, Heatsink

1 1 10 1 1
1 2 2 1 6 2 1 1 1

Screw, Round Head, Slotled, Tap, 4-40 x V. in. (all unils except 9-channel units w/digital readout) Screw, Self-Tapping (9-channel units w/digital readout only), 4-40 x 1/4 in. Screw, Pan Head, 4-40 x 0.312 in. Screw, Hi-Lo, 4-24 x 0.375 in. Screw, Pan Head, M5-0.8 x 10 mm
Electrical Enclosure Assembly

7 8 9

981 727 962119 274706 274504 274993 983408 940073 983523

Enclosure, Electrical Screw, Captive, M5 x 0.8 x 25 mm Washer, Flat, Narrow, M5

O-Ring, Viton Washer, Neoprene Base Assembly Decal, Graphics Panel, 5-Channel (ModeI2302) Decal, Graphics Panel, 9-Channel (Model 2304) Decal, Graphics Panel (all other unils) Strainer (Units

1
1 1
1

10 11 11 11 12

**
274638 274637 274516 276200*** 276084 276236 276334 276176 274658 939665 242867 118949

1 1
1

w/o Low Levellndjcator nly)

Single-Phase Jumper (Domestic Single-Phase Operation Only) Single-Phase Jumper (European Single-Phase Operation Only) Low Level Indicator, Finned Tanks (Optional Feature)**** Low Levellndicator, Flat-Botlomed Tanks (Optional Feature)**** Parent Machina Interlock (Optional Feature) Lamp, PMI Tag, Warning (380-YV units only) Adapter Assembly, % ISO x 1'4 NPT

13

1 1 1 1 1 1

1
2 1

* See Selection Chart on previous page for part number of specific units.

*'* See the Base Assembly parts lists (three parts).

*** The strainer part number for units with low level indication is either 276 330 **** See Seeton 10 for the Low Levellndicator parts list.
P/N 1044456 41 2300 8193

(finned tanks) or 276329 (f1at-bottomed tanks).

1;)

Nordson Co,poration 1993 Al! R'ghts ReseNed

lIIustrated Parts List

8-5

This Page Intentionally Left Blank

Nordson Corporahon 1993

AII R,ghls Reserved

P/N 1044458

4123008193

8-6

lIIustrated Parts List

I ,

"/

/ "..

13

/-

11

Figure 8.1 - Series 2300 Unt Assembly (Drawing

1 0(2).

P/N 1044458

(t)

4123008193

Nordson Corporahon 1993 AII Aigtlts ReseNed

/IIustrated Parts List

8-7

fl
00

80 0 0 0 00 0 000 0 80 0 0 8 00800 0 0 0 o 0000 00 000800 000000 0000 0 0 8 0 00 0 0 0 0 0 0 0 0 8000 00000800 00 0800 0000 ooo o 8 8 00

08oQo 00 0l:5 00 00

8 8

008

"

Figure B. 1 2012).

Series 2300 Uni! Assembly (Orawing

C.' Nordsof) Corporalion 1993 AII Rlghls Reserved

P/N t04 4458 412300 8193

8-8

I/Iustrated Parts List

Base Assembty Parts List #1 (see Figure 8.2)

Ilem No. Par! No.

Description
Base Assembly (Models 2302, 2304, 2305 and 2306' Drawing 1 of 3) Screw, Hex Head, Self-Tap, M8 x 16 mm Bracket, Mounting Rivel, Pop Nameplate Screw, Pan Head, M4 x 8 mm Base Unil, Palnted Triac, Tank Control, 25 A Screw, Pan Head, M3 x 6 mm Clip, Strain Relief Screw, Pan Head, M5 x 20 mm Wiring Harness, Non-380-Y VAC unlts Wiring Harness, 380-Y VAC units Circuit Brcaker Panel Assembly (units w/out temp setback)
Circuit Breaker Panel Assembly (units wl temp setback)

Required Ref 4 4 4 1 2 1 1 4 1 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 3 3 1

1 2 3 4 5 6 7 8 9 10

276215 274659 985112 982096 274690 939644 982091 274636 982214 274767 276231 274616 276165

11

274514 274585 982 123 939646 276120

Panel, Circuit Breaker Circuit Breaker, 3 Pale, 30 A Screw, Pan Head, M3 x 6 mm

12 13

276316 933295 933297 939537 933320 933369 276578

Lamp, Rectangular, White (units w/ouf temp sefback) Lamp, Rectangular, While (units wl temp setback) Terminal Block Assembly Terminal Block, 5 Station (TB1) Strip, Marker, 5 Station

Connector, 9-Pin (J6) Connector, Plug (Solenoid Valve) Connector, 6-Station (J7) Cover, Circuit Breaker
Wires and Wire Terminals

14 15 16 17 18 19 19 19 19 20 21 22 23 24 25 26 982124 982212 983414 274518 276899 276900 276901 276832 274653 982119 982232 240674 271 221 983401 984702 275386

Screw, Pan Head, M4 x 20 mm Screw, Hex Head, Cap, M8 x 30 mm Washer, Flat, M8 Tag, Patent
Spacer, Tank

Hose Connection Assembly, 2-Plug Hose Connection Assembly, 4-Plug Hose Connection Assembly, 5-Plug Hose Connection Assembly, 6-Plug Dust Caver Screw, Pan Head, M5 x 10 mm Screw, Pan Head, M5 x 35 mm Tag, Ground Lug, Terminal Lockwasher, Spiit, M5 Nut, Hex, M5

(2302)" (2304)" (2305)" (2306)"

6 1 1 1 1 2-6 4 1 1 2 4 3

Compound. Thermal Joint

* The various wires

and terminals in the wiring harness are saleable parts but they are too numerous to list. Contact your local Nordson representative for part numbers. ** A kit for replacing a single-hose wiring harness and the hose receptacle is available as Nordson P/N 276 319.

PIN 104 4458 412300819:3

Nordson Corporahon 1993 AII A,ghls Aeserverl

lIIustrated Parts List

8-9

This Page Intentionally Left Blank

'jo;

Nordson Corporatioo 1993

AII Rlghls Reservad

P/N 1044456

4123008/93

8-10

lIIustrated Parts List

10

15

Figure 8.2 -

Series 2300 Base Assembly # 1

(Drawing 1 of 2).

PiN 1044458

4123008193

.,) NUl<Joon Curpur<thun 1993

AII R,ghls Reserved

lIIustrated Parts List

8-11

19

------@

Figure 8.2 - Senes 2300 Base Assembly #1 (Drawing 2 012).

'0 NonJ50o CorpOfalion 1993 AlI RlghlS Reserved

P/N 104 5S

4123008193

8-12

lIIustrated Parts List

Base Assembly Parts List #2 (see Figure 8.3)

Ilem No.

Par! No.

Description

Required

Base Assembly (Models 2302, 2304, 2305 and 2306 " Orawing 2 01 3) Not Used 276313 274631 274625 274612 Not Used 276312 274511 276209 983400 939586 982213 276022 933056 274667 937283 276029 931 123 982091 900341 900413 " " " " " Kit, Insulation Replacement Insulation, Bottom, Tank Insulation, Side Insulation, Tank Tank Cover Assembly Caver, Tank Gasket, Tank Tank/Manifold Kit* Lockwasher, Split, M3 Connector, Porcelajn, 2 Slalian Screw, Pan Head, M3 x 18 mm Thermostat w/lnsulator, 450F Connector, Porcelain Plate, Retainer, RTO Sensor, ATO, Tank Tubing, Fiberglass Sleeving, Insulation, 0.20 in. ID Screw. Pan Head, M3 x 6 mm Never Seez Sealant, Silicone, RTV-106

Rel

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 1 1 1 1 1 1 1 2 1 1 3.25 0.27 5

* See the Tank/Manilold Assembly Parts Lis\.

PN 1044458 412300 8193

Nordson Corporalion \993 AII R,ghls Reserved

lIIustrated Parts List

8-13

/~.~ ./~" ----_.( _.j ("')

Figure 8.3 - Seres 2300 Base Assembly #2.

(e;)

Nordson Corporation 1993 AII Rights Reservad

P!N 104 4458

41-23008/93

8-14

lIIustrated Parts List

Base Assembly Parls List #3 (see Figure 8.4)

Item No.

Par! No.

Description Base Assembly (Models 2302, 2304, 2305 and 2306 " Drawing 3 01 3)

Required

Re! 1 2 2 1 2 4 2 2 1 2 1 1 1 1 3 1 1 1 2 2 1 3 3 1 1 1 1 1 1 1 1 7

1
2

3 4

Not Used 274716 981 017 983 100 274656 902523 981 759 902522 275366 274505 900419 274646 274710 274506 274993 275075 986316 983408 940073 985 112 271 960

Lid Assembly Screw, Bind Head, 6-32 x 0.25 in.

Lockwasher Lid, Inner, Flat Stud, Serraled Screw, Pan Head, 440 x 0.312 in.

Retaner, Stud SaU Brace, Retainer, Sal! Stud

Lid, Pin Hinged, Tank Adhesive, Relaining Cylindrical Pin, Hinged Lid Pump Enclosure Assembly Enclosure, Pump Screw, Captive, M5 x 24 mm Nameplate, Oval Ring, Retaining, Push-On

Washer, Flal, Narrow, M5

" O-Ring, Viton, 0.16 in. ID x 0.28 in. OD

Tag, Maximurn Air Pressure " Rivel, Pop " Washer, Backup, 0.09 in. ID x 0.25 in. OD Pump /Solenoid Assembly' Screw, Cap, Hex Head, M8 x 30 mm " Washer, Flal, M8

5 6 7 8

982212 983414 274691 901 491 901 254 973372 900236 973001 274979 274503 982214 900341

Regulator Assembly Regulator, Air, Ports

1/ 4

in. NPT
1/ 4

Gage, Air, '''' in. NPT Bushing, Pipe, Hydraulic, " Paste, Teflon "

in. x 1;a in.

9 10 11 12

Nipple, '''' x 2.50 in. Tag, No Olled Air Spring, Lid Support Enclosure, Tank Screw, Pan Head, M5 x 20 mm

Never Seez

1<

Sea the Pump/Solenoid Assembly Parts List.

P/N 104445B 4123008193

(~j

NOldson CorporatKln 1993 AII AIghl5 Aeserved

lIIustrated Parts L 1St

8-15

LJ1I

J 'V
DETAlL A

Figure 8 .4 - Selles 2300 Base Assembly #3. .

AII

Nordson

Aig" Re orporation
s
eserved

1993

P/N 104 4456 41-23008193

8-16

lIIustrated Parts List

Tank!Manifold Assembly Parts Lisf (see Figure 8.5)

lIem No. Par! No. 276209 276310 Tank/Manifold Assembly Kit, TanK wrrag
Tank, Finned Tag, Warranty Valve, Pressure Relief, 1600 psi O-Ring, Viton, 1.50 in. OD x 1.38 in. ID

Description

Required Ref 1 1 1 1 2 6 6 1 1 8 1 1 1 1 1 1 1 1 1 1

2 3 4 5 6 7 8 9 10 11

276109 940281 982211 900236 983518 274686 276311 973574 945032 274581 276024 276623 276621 900037 986239 940101 954036 274569 941 220 900419 982096 983403 900341 900445

Screw, Spline, SocKet Cap, M8 x 45 mm Paste, Teflon Washer, Flat, 0.53 in. ID x 0.32 in. ID
Manifold Assembly

Manifold Plug, O-Ring, 9/16 -18, Str. Thd. O-Ring, Viton, 0.38 in. Tube Plug Filter Assembly* Valva, Drain Body, Orain Valve

Tip, Orajn Valve Ball, 440SS, 0.25 in. Dia.

Ring, Retaining O-Ring, Viton Ring, Backup

12 13 14 15 16 17 18 19

Adapter, Filler Bung Q-Ring, Viton, 1.13 in. ID x 1.31 Adhesive, Loctite 620 Screw, Pan Head, M4 x 8 mm Lockwasher, Split, M4 Never Seez Sealant, RTV

In.

OD

1 1

See the Filter Assembly parts lisl.

P/N 1044458

41.2300 8193

Nordsol1 Corporation 1993

AII Aiyhb Reserved

lfIustrated Parts List

8-17

...

cb
14
19

Figure 8.5 -

Tank/Manifold Assembly.

Nordson Corporalion 1993

AH Righls Reserved

PIN 104 4458 41 . 2300 8193

8-18

lIIustrated Parts List

Figure 8.6 - Filler Assembly.

Filter Assembly Parts Ust

Ilem No. Par! No. 274581 Filler Assembly

Description

Required Rel

1 981 747 Screw, Round Head, 10-32 x 6.25 in. 1 2 274579' Core, Filler 1 274578* Sereen, Filter, 0.006 in. mesh 1 3 274513' Bung, Filler 1 4 941 172 O-Rlng, Viton, 0.81 in. ID x 1.0 in. 00 1 5 6 900 341 Never Seez * Shipped with the unit or filler assembly unless olherwise specifled on the purchase arder. Sea Section 10, Optional Parts and Equipment, far listing of optional tilter screens.

PiN 1044456

Nordson CorporallOn 1993

AU Aighls Reservad

41-2300 8193

I/Iustrated Parts List

8-19

./

Figure 8.7 -

PumplSofenoid Assembly.

Pump/Solenoid Assembly Parts List

Uem No. Par! No. Oescriptlon Required

Pump/Solenoid Assembly

2 2

274669 276872 901 137 901 139 939916 274 568" 971 400 971 151

Pump Assembly Solenoid ValvelWiring Assembly (non-380-Y V units) Solenoid Valve/Wiring Assembly (380-Y V units) Valve, Solenoid, Two-Way. 230 YAC (non-380-Y V units)

Re! 1 1

1 1

Valve, Solenoid, Two-Way, 250 YAC (380-Y V units) Connector, Receptacle Terminal, Pin, 16-18 Gauge Tubing, Aluminum, V4 in. 00 Elbow, Male, 0.25 in. T x ',. in. NPT Connector, Male, 0.25 in. T x 1;8 in. NPT

1 1
2 1 1 1
1

3 4 5 6 7

973007 Nipple, Steel, '" in. NPT x 2.0 in. 900 470 Loctite, No. 272

8 900 341 Lubricant, Never Seez , See the Pump Assembly parts Iisl. "* Items 4 and 5 are required whenever new tubing is installed.

Nordson Corporation 1995 AII Ri\tlls ReseNed

PtN 104 445C 412300 11/95

8-20

lIIustrated Parts List

Pump Assembly Psrts Ust (see Figure 8.8)

lIem No. Par! No. 274996 276500 973402 130545 983409 982146 983503 130639 Description Aequired Aef Aef 1 1 9 2 2 1 1 1 1 1 1 1 2 2 1 2 4 1 2 2 2 2 1 1 1 1

Pump Assembly (Non-380-Y V units)' Pump Assembly (380-YV units)' Plug, Pipe, '". in. NPTF Clamp, Valve Actuator Lockwasher, Split, M6 Screw, Hex Head, M6 x 50 mm Washer, Flat, M6 Stop, Shifter Valve/Spring Assembly Air Control Valve AssemblY**

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

274997 276141 983401 274538 983519 274532 274994 973403 982147 274523 940332 984703 503687 503686 503688 274522 274777 503708 900000 985302

Shifter and Spring Assembly*** Locknut, M5 Lockwasher, Split, M5 Block, Spring Shifter Washer, Flat, 0.20 in. ID x 1.0 in. 00 Gasket, Shifter Valve Bracket, Pump Tower Pipe Plug, '116 in. NPTF Screw, Hex Head, M6 x 120 mm Head, Air Cylinder O-Ring, Viton Nul, Hex, M6 Washer, Cupo Piston Cup, Piston Washer, Seal, Pislon Cylinder, Pislon, Pump Piston Assembly, Pump Pressure Sall and Seat Assembly Seat, Ball, Pressure Ball, 44055, 0.38 in. Pin, RolI Piston, Pump, Hydraulic U-Cup, Viton Mount, Pump Ring, Retainer Washer, 0.80 in.OO x 0.54 in. ID Seal, Pump .. Locknut, PN-Oe Lockwasher, W-06 Body, Hydraulic Pump Siphon Ball and Seat Assembly Cage, Ball, Siphon Ball..500 Oia. Seat, Ball, Siphon Crossover Tube Assembly Tuba, Crossover Ring, Backup, 9/1S in. 00 ORing, 9/1 a in. 00

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

1
1 1 1 1 1 1 1 1 1 1 1 1

952 lOO 986602 273 138 273 139 984534 983 183 273108 503694 503696 900001 276317 954013 940133 900236 900223 900465

1 1
1 1 1 1 1

Paste, Teflan .. Lubricant, Parker Adhesive, Loctite 277

P/N 104 4458

41-2300 8193

e Nordson COrporation 1993 All Rights ReseNed

lIIustrated Parts List

8-21

Pump Assembly Parts List (continued)

Item No.

Part No.

Description

Required

44 45 46 47

982237 982207 900341 900470 900465 982237 982207 900341

Screw, Hex Head, M6 x 35 mm Screw, Hex Head, M6 x 45 mm Lubricant, Never Seez Adhesive, Loctjte 272 Adhesive, Threadlocking (380-YV uni!s) Screw, Hex Head, Cap, M6 x 35 mm (380-Y V uni!s) Screw, Hex Head, Cap, M6 x 45 mm (380-Y V uni!s)

1
2

Lubricant. Never Seez (380-Y V unitsl

",*

* See Service Parts Kits listing for Pump Seal Replacement Kit. See the Air Control Valve Assembly parts Iist. *** See the Shifter and Spring Assembly parts list.

e Nordson COIporation 1993 AII R<ghlS Reserved

P/N 1044458

41-23008193

8-22

lIIustrated Parts List

/1
I
//
/1
/

//

I
I

l/

//

Figure 88 .

Pump Assembly (Drawmg 1 012). .

P/N 104 4458

(e)

4123008193

Nordson Corpofalion 1993 AlI A,ghlS Reserved

lIIustrated Parts List

8-23

1-

. . . - --0)
I

"

"'-

I I I

Figure 8.8 ... Pu mp A ssemb/y (Drawing 2 o( 2).

Nordson COrPO'alioo 1993 AII A,ghts Reservad

P/N 104 58

41-23006193

8-24

lIIustrated Parts List

~---
Figure 8.9 - Air Control Valve Assembly. (200/230 V version shown; 380V version sim/ar)

. I

Air Control Valve Assembly Parts List*

Ilem
Part No.

Description

Required

No.
276861 276928 133980 982206 982206 105519 Air Control Valve Assembly (200/230 V) Air Control Valve Assembly w/Mufflers (220/380 V) Pino Detent Screw, Fillister Head, M4 x 0.7 (200/230 V)
Screw, Fillister Head, M4 x 0.7 (380 V)

1 2 2 3
4

Rel Re! 1 6
4

5 6
7

982275 503737 243512 270 042

Seat, Poppet Body, Air Control Valve Rod. Shifter. Air Valve Screw, Fillister Head, Lock, M4 x 0.7-16 mm Spacer Detent Lubricant, Moly Disulfide Poppet, 4-Way Air Valve Spool, Valve Lubricant, Graphite, Dry Disc, Sintered Mutller Top (380 V) Cap, Mutller (380 V) Disc, Sintered Mutller Bottom (380 V) Adapter, Mutller, Pump (380 V)

2 1
1

2
2 1 2 1

276360 276 359 276 361 135911

1 2 1 1

983 111 Lockwasher. External. Spt. #8 (380 V) 2 * Nordson recommends no repairs to this assembly other than seat replacement. Any damage to the shifter rod may cause the
valva shifter to malfunction.

P/N 104 4458

,e) Nordson COfporalion 1993

412300 8193

AU AiUhls RAS..rv.. (j

JIIustrated Pars List

8-25

THESE ITEMS CONTAINED IN

PUMP
ASSEMBLY

Figure 8 1O ~ Shiffer and Spring Assembly.

Shifter and Spring Assembly

Item No.

Par! No.

Description

Required

274997
1

Shlfler and Spring Assembly Slide Spring Assembly, Valve

1 1

2 3
4

2
4 4

5 6

276 175 983401 276141 900419

Retainer, Spring

Lockwasher, Split, M5 Nut, Lock, M5 Adhesive. Retaining Cylindrical

(C)

Nordson Corporaban 1993 AII Aighls Aeser~ed

P/N 104 4456

41-23008/93

8-26

lIIustrated Parts List

Recommended Spare Parts List

Part No,

Descrip!ion
Manifold and Tank Tank Gasket Filler Assembly Filler Screen O-Ring, Vito n (filter bung) Pressure Relief Valve Backup Ring (drain valve) O-Ring, Viton (drain valve)
Piston Pump Assembly

Req'd

274511 274581

941 172 276 109 954036 940101

274532 503686 952 100 940332 503687 503688 273139 274777 986602 276315 983 183 940 133

Gasket, Shifter Valve Pistan Cup U-Cup, Viton O-Ring, Viton (air cylinder) Piston Cup Washer Piston Seal Washer Pump Seal Pump Pistan Assembly Retainer Ring

2
2 1

2
2 1
1

1
1
1

VaJve/Shifter Replacement Kit

Lockwasher, W-06 O-Ring (crossover tube) Electrical Componen!s Circuit Board Tank RTD Sensor Circui! Breaker, 3-pole, 30-amp Power-On Lamp, 240 YAC Thermostat w/lnsulator, 450F
Fuse, Circuit Board, 6.3 amp (hose channel)

1
1

..
937283 274585 939646 276022 939683 939091 939644

1
1
1

Fusa, lnline, 5-amp Tank Triac, 25-amp

3 4
1

901 254 274669 276872

Pump Alr Supply System 1/ in. NPT Air Gauge 8 Solenoid Valve/Wiring Assembly (non-380-Y V unils) Solenoid Valve/Wiring Assembly (380-Y V unils)

Miscellaneous
900236 900223 900419 900341
Teflon Paste

Parker Lubricant Loctile No. 620 Adhesive

Never Seez Lubricant (16 02. can)

See Section 10 (Optional Parts and Equipment) for list 01 available filter sereen sizes.

** Sea selection charts on page 8-3 for correet circuit board part number.

P/N 1044456

412300 8193

It) Nordson Corporahon 1993

Al! R'ghls Reservad

IlIustrated Parts List Service Parts List

Part No.

8-27

Description Piston Pump Assembly Kits Serviee Kit, 4-Way Air Valve w/Mufflers,

Req'd

276861 274532 130639 276928 274532 130639 503694 503696 900001 503780 900000 276315 130639 274532 127324 900874 900772 134944 243521 503737 133980 982275 136 184 134944 982276 135911 145817 126115 145818 126116 105519

Gasket, Valva Shifter Valva, Air Control Stop, Shifter, Air Control Serviee Kil, 4Way Air Valva w/out Mufflers Gasket, Valva Shifter Valva, Air Control Stop, Shifter, Air Control SelVice Kit, Siphon Seat w/Ball Seat, Ball, Siphon Cage, Ball, Siphon Ball Serviee Kit, Pressure Seat w/Ball Seat, Pressure Sal!
8all

2 1 1

2 1 1

SelVice Kil, Valve/Shifter Assembly Valve, Spring Assembly Stop, Shifter, Air Control
Gasket, Valva Shifter

1 1 2

Serviee Kit, Pump, Eleclrie Shifter

Pump, Eleclrle Shifter Cap/Plug, Tapered Cap, Sleeve, 9/16 OD Tube Serviee Kit, Detent, Series 2300 w/out Muffler
Detent

1 3 1

Spacer Pin, Detent Screw, Fillister Head, Lk, M4 x 0.70-16 mm

1 2 1 2

SelVice Kit, Deten!, Series 2300 w/Muffler SelVice Kit, Detent, Series 2300 w/out Muffler Screw, Fillister Head, Lk, M4 x 0.70-25 mm Adapter, Muffler, Pump SaNiee Kit, Solenoid Valve-1 Solenoid Assembly, Eleclrie Shifler1 Sarviee Kit, Solenoid Valve2 Solenoid Assembly, Eleclric Shifter-2 Sarviee Kit, Poppet Seat Seat, Poppet Tag, Info

1 2 1

2 1

',(' Nordson Corporalion 1993 AII Rlghts Reserved

P/N 104 4458 41 2300 8193

8-28

lIfustrated Parts List

Service Parts Ust

{continued}

Part No,

Description Piston Pump Assembly Kits (continued) Service Kit, Pump Seal Seal, Pump Gasket, Valve Shifter Cup, Pistan
O-ring, Viton O-rlng, Viton

Req'd

276314 273139 274532 503686 940133 940033 952100 954013

U-Cup, Viton Ring, Back-up, Single Tank and Manifold Kits Service Kit, Tank wrrag Tag, Warranty, Tank Gasket, Tank
Strainer, Tank Tank, Machined Adapter, Terminal, Tank Haater

1 2 2 1 2 1 1

276310 274511 276200 276320 900445 276311 274569 276109 900236 900419 940101 940281 941 172 941 220 973574 276312 274511

1 1 1 1 2

Seaiant, RTV, White Service Kit, Manifold Replacement Adapter, Filler Bung Manifold Valve, Reliet, 1,600 psi Sealant, Tenon Paste
Adhesive, Retaining, Cyiindrical

O-rl"g, Viton O-ring, Viton O-ring, Viton O-ring, Viton Plug, O-ring

1 2 1 1 8

Replacement Kit, Tank Caver

Gasket, Tank

Caver Assembly 276317 940133 954013 276313 274612 274625 274631

Serviee Kit, Crossover Tube Tube, Crossover

O-ring, Viton

Ring, Back-up, Single

Replacement Kit, Insulation Insulation, Tank

Insulation, Side, Tank Insulation, Bottom, Tank Electrical Kits Replacement Kit, Terminal Block
Terminal Block, Input Power, 5-station Strip, Marker, 5-statlon

1 1 1

276316 933295 933297

Pft\l104445B
41-23008193

Nordson Corporalion 1993

A11 Alghts Aeserved

lIIustrated Parts List

8-29

Service Parts List

(continued)

Part No. Electrical Kits (continued) Kit, Terminal Adapter, Tank Heater .. Terminal, Flag, Noninsulated

Description

Req'd

276320 933325 139672 940202 100307 981 754 139671 100586

Repair Kit, Hose End, Series 2300 Hose .. Pin, Connector, Holder .. O-ringo Buna N .. Shell, Convertible Connector Screw, Flat Head, Sell-Tapplng, 4-40 .. Connector, Sirain Relief
o

5 5
5 10

5
1 2

Tool, Crimping, Ralchel

.. Extractor

Accessory Group, Unit End, Series 2300 139675 Repair Kit, Gun End, Series 2300 Hose o Culf, Hose w/Connector .. Collar, Caver, Hose Cuff o Collar, Hose Culf o Screw, Fillister Head, Rec, Tap, 6-32 x 0.437 in. o O-ring, Buna N Tool, Crimping, Ralchel .. Extractor
o o

5
5

5
10

981 776 940202 139671 100586

5
1 2

Accessory Group, Unit End, Series 2300

276319 274652 982221 983411 984700 274651 274653 274650 939683

Kit, Unit Hose Wiring Harness .. Connector, Socket, 12-pin .. Wire Group, Hose Power Supply
o o o

1
1
4

Screw, Pan Head, M3 x 0.30 x 10 mm Washer, Flat, Narrow, M3

4
4

Nul, Hex, M3 .. Gasket, Connector .. Caver, Connector, Socket, 12-pin .. Gasket, Connector, Cordset, Unit Fuse, Fast-Aeting, 250 V, 6.3 Amp, 5 x 20 mm

1
1

1
11

\9 Nordson Corporatioo 1993 AII Aighls Aeserved

PIN 104 445B

4123008193

830

lIIustrated Parts List

This Page Intentionally Left Blank

P/N 104 4456

412:lOO8I93

Narclson Corporahon 1993

AII Righls Reserved

## TABSHEET ##

SECTION 9

SECTION9

Specification Summary
1. General

2. Power requirements 3. Calculating system eleetrical power requirements 4. Malerial safely dala information

9-1 9-3 9-5 9-6

List of lIIustrations
Figure 9.1 Series 2300 Dimensions in Inches (Millimelers) 9-2

This Page Intentionally Left Blank

Specification Summary

9-1

Section 9 Specification Surnrnary*

1. General
Viscosity Range Tank Volume** (lo top flange) Tank Capaclly" (to 10p flange) System Mell Rale** Maximum Inslanleous Pumping Rale** Tank Heating Melhod Ambienl Temperalure Range Operating Temperature Range Temperature Control Stabilily Recommended Pump Operating Air Pressure Number 01 Hoses per Unil 2302 2304 2305 2306 Hose and Gun Capacity Maximum Allowable Hose Lenglh Electrical Requirements
Maximum 8ystem Power Requirements***

1,000 lo 30,000 cenlipoise 3 3 520 in (8,521 cm ) 18,7 lbs (8.5 kg) 20.0 Ib/hr (9.1 kg/hr) 72.0 Ib/hr (32,7 kg/hr) Cast-in resistive heating elemenl 32 lo 120F (O lo 50C) 220 to 400F (105 to 205C) 1F (0.5C) 10 to 60 psi (6910414 kPa)

2 Hoses 4 Hoses 5 Hoses 6 Hoses See Tables 9,1 and 9.2 in Ihis Seclion 16 ft (4.9 m) maximum per channel 64 ft (19,5 m) total 01 all hoses 196 lo 254 VAC, 50/60 Hz, l-phase or 3-phase; 380-Y/230 VAC, 50/60 Hz, 3-phase only 3,500 walls al 230 VAC 5,200 walls at 230 VAC See Figure 9,1 Meels IP-54 requiremenls 60 lbs (27.2 kg) 1,500 psi (10.4 MPa) 35-80 psi (207 - 690 kPa) 3,000 cycles per minute 3,000 cycles per minule 3,000 cydes per minule Manual Gun RTD-conlrolled cartridge heater 1 SCFM al 60 psi (414 kPa) and 60 slrokes per minute

2302 and 2304 2305 and 2306 Dimensions Endosure Rating Weight, Empty (approximale) Workmg Hydraulic Pressure (maximum al 125 psi/862 kPa air pressure) Recommended Operaling Air Pressure, Guns Maximum Operaling Speed, Guns H20 H200 AD-24 AD-31 Gun Heating Melhod Alr Consumption

*Due to possible technological and/or quality improvemenls, equipmenl specilications are subjecllo change without notice. **See delinition 01 Ihis lerm in Ihe Glossary allhe end 01 Seclion 2. ***The actual power requirement lor Ihe hol melt syslem is delermined by adding Ihe power requirements 01 Ihe individual components used (tanks, hoses and guns). See Calcufating System Efectricaf Power Requirements in Ihis Section.

'C

Nordson Corporalion 1993

RI!Jh'~

P/N 1044458
412l008/"l:1

Al!

R .. s ..rvfl<l

9-2

Specification Summary

CLEARANCE REQUIRED F"OR OPENING CONTROL PANEL DOOR.

--(254 mm)
~

10.0 In.

.-

\ \

\
\

.
""- ......
.......

I Dn=J=
'F

DLJ=

po=
PCj:=

-- l
CLEARANCE F"OR F"ILTER REMOVAL.

JCl=a
8.& In.

(218 mm)

11.0 In. rOR PUUP ENCLOSURE (279 mm) REWOVAL

CLtARANCE REQUIRED

ClEARANCE REQUIREO
rOR EL[CTRICAL

[NCLOSUREREWOVAL

:S04g mm)

2 1.6 In.

/ /

--(~@'

I---'t:::::::::::==:j~-.~

2.2 In.
(56 mm)

E
1: .

".0 In.
(381 mm)

_'n--j~I'

(297 mm)

11.7 In.

----

-'----'--1--0/ ! 1---(204' mm)---1 9.8 In.

13.8 In. 1-_ _ (351 mm)

@J!I (@l)

1 6 In

(4 mm)

21 ..... 1". (:)44 mm)

-1

FIgure 9.1 Sertes 2300 Dlmenslons (Mi/lime/ero).

In

Inches

P/N 104 4458

11';)

41-23008193

Nordson Corporahon 1993 AIJ Righls ReseNad

Specification Summary

9-3

2. Power requirements
TABLE 9.1 " HEATER ANO ELECTRICAL DATA FOR TANKS ANO HOSES Part No.

Oescription

Wattage

Voltage (VAC) 220/230 200 220/230 220/230 220/230 220/230 220/230 220/230 220/230 220/230 200 200 200 200 200 200 200 220/230 220/230 220/230 220/230 220/230 220/230 220/230 220/230 220/230 220/230 220/230 220/230 220/230 220/230 220/230 220/230 220/230 200 200 220/230 220/230 220/230

Resistance
(in Ohms at 75F/24C)* 29 29 1,119 516 336 240 167 139 104 78 846 390 244 159 127 120 78 1,119 516 336 240 167 78 516 336 240 167 139 104 78 240 167 103 78 159 78 240 193 103

Tank w/Cast-ln Heater Tank w/Cast-In Heater Standard Automatic Hoses Automatic Hose, 2 ft Automatic Hose, 4 ft Automatic Hose, 6 ft Automatic Hose, 8 ft Automatic Hose, 10 ft Automatic Hose, 12 ft Automatic Hose, 16 ft Automatic Hose, 24 ft Automatic Hose, 2 ft Automatic Hose, 4 ft Automatic Hose, 6 ft Automatic Hose, 8 ft Automatic Hose, 10ft Automatic Hose, 12 ft Automatic Hose, 16 ft Water-Res. Automalic Hoses (IP-56 at gun end only) Automatic Hose, 2 ft Automatic Hose, 4 ft Automatic Hose, 6 ft Automatic Hose, 8 ft Automatic Hose, 10ft Automatic Hose, 12 ft Automatic Hoses with High.Flex Construction Automatic Hose, 4 ft Automatic Hose, 6 ft Automatic Hose, 8 ft Automatic Hose, 10ft Automatic Hose, 12 ft Automatic Hose, 16 ft Automatic Hose, 24 ft Handgun Hoses with Corrugated Cover Handgun Hose, 8 ft Handgun Hose, 10ft Handgun Hose, 16 ft Handgun Hose, 24 ft Handgun Hose, 8 ft Handgun Hose, 16 ft Handgun Hose. with Braided Cover Handgun Hose, 8 ft Handgun Hose, 10ft Handgun Hose, 16 ft

1,800 1,360 47 100 153 206 259 313 419 632 47 100 153 206 259 313 419 47 100 153 206 259 419 100 153 206 259 313 419 632 206 259 419 632 206 419 206 259 419

274790 274791 274792 274793 274794 274795 274796 274797 276 150 276 151 276 152 276 153 276 154 276155 276156 276739 276740 276741 276 742 276 743 276744 107288 107286 107287 107289 107310 104008 100832 274798 115833 274799 101 354 276533 276534 133913 138927 132494

K No.-dson Corpmalion 1993 AlI A,ghls Aeserved

P/N 104 44SB 41 -2300 8193

9-4

Specification Summary

2. Power requirements
(continued)

TABLE 9.2 " HEATER ANO ELECTRICAL DATA FOR GUNS Gun Part No. Description Wallage Voltage (YAC)
Resistance

(in Ohms al 75F/24C) 333 - 392 189-222 333 - 392 333 - 392 333 - 392 333 - 392 392 - 465

274702 276096 120664 276954 274728 276778 815 138

H20 Automatic Guns (all with RTD Temperature Control) H20A H20A H20 LBS W'6 in. ID) H20 LBS (!ji. in. ID) H20 w/Micro-Adjust H20W (water-wash) H20 w/Filtered Body

147 180 147 147 147 147 130

220/230 200 220/230 220/230 220/230 220/230 220/230

NOTE: H20B. H20C. H200. H20E and H20F guns are nol available with RTO lemperature control. Other RTD-Temperature-Controlled Guns NOTE: Due to the sheer number ot these guns now available, reter to your Nordson Adhesives and Sealants Equipment Catalog tor data on H200 Automatic Guns, AD-24 Automatic Guns, the A-l Handgun, AD-31 Spray Handguns, AD-31 Swirl Handguns, AD-31 Extrusion Handguns, and CF-200 Conlrolled Fiberization Aulomalic Guns, or contact your Nordson representativa far this information.

P/N 1044456 41-2:l00 8/93

Nordson Corporalion 1993

All Aigh(S Reservea

Specification Summary

9-5

3. Calculating system electrical power requirements

The total power requirements 01 the tank, hoses and guns in lerms 01 lolal watlage must not exceed the maximum power rating 01 the syslem as given in Table 9.3. To determine your systems lotal power requirements, add up the individual tank, hose(s) and gun(s) wattages, lhen compare your total with lhe maximum power rating lor the system given in Table 9.3. Remember " your total must nol exceed the ligure in the table lor your system. Tank and hose data are given in Table 9.1. Some gun data is in Table 9.2, the resl is provided in your Nordson Adhesives and Sealants

Equipment Catalog.

TABLE 9.3 .. SYSTEM MAXIMUM POWER RATINGS IN WATTS' Type 01 Series 2300 Applicator 230 YAC Systems 3,500 5,250 5,250 5,250 200 YAC Systems 2,930 4,360 4,360 4,360 380-YVAC Systems 3,160 4,950 4,950 4,950

Model Model Model Model

2302 2304 2305 2306

(2 (4 (5 (6

hoses hoses hoses hoses

maximum) maximum) maximum) maximum)

Al 350F (177C)

,(j

NordSQn Corporation 1993 AlI Aighls Reserved

P/N 104 4458

41-23006193

96

Specification Summary

4. Material safety data information

I.IDENTITY
Produet Name Nordson Par! No. Nordson Type R Solvent 270 755 (1 Gallon) 270 756 (5 Gallon) 270 757 (55 Gallon) Adipate Polyester Plasticizer

Chemieal Name

11. HAZARDOUS INGREDIENTS

None

/11. PHYSICAL DATA

Boiling Point Vapor Pressure Vapor Density Water Solubility Appearanee and Odor Pereent Volatile by Volume Evaporation Rate Speeilie Gravity >600F (92.2C) <0.01 mm Hg @ 68F (20C)

NA
Negligible Viseous, elear liquid Mild, inoffensive odor 0% Negligible (Butyl Aeetate = 1) 1.09

IV. FIRE AND EXPLOSION HAZARD DATA

Flash Point Extinguishing Media Flammability Limits Speeial Firelighting Procedures Unusual Fire and Explosion Hazards 572F (300C) COC C02. Dry Chemical, Water Fog Not Available Wear MESA/NIOSH-approved, sell-contained breathing apparatus. Use water spray to cool lire-exposed containers. Water may cause Irothing

V. HEALTH HAZARD DATA

Threshold Limit Value Effeets 01 Overexposure Emergency First Aid Procedures: Inhalation Eye Contact Not determined by ACGIH Liquid may cause mild eye irritation. Repeated or prolonged skin contact may cause irritalion. Move subjeet to Iresh airo Remove contact lenses. Hold eyelids away lrom eyeballs to assure thorough rinsing. Flush eyes with large amounts 01 water lor at least 15 minutes. Consult physician il irritaton persists. Wash affeeted skin areas with soap and water.

Skin Contae!

PIN 1044458
41-2300 aro3

Nordsol1 Corporalton 1993 All Aignts Aeserveo

Specification Summary

97

4. Material safety data information

(continued)

VI. REACTlVITY DATA

Stability Conditions to Avoid Incompatability (materials to avoid) Hazardous Decomposition Products Hazardous Polymerization Stable None Strong oxidizers None under normal conditions 01 use. Oxides 01 carbon when burned. Will not occur.

VII. SPILL OR LEAK PROCEDURES

Steps to Be Taken II Material Released or Spilled Dike and contain spill with inert material (sand, earth, Fuller's Earth, etc.) and transler liquid and solid diking materials to separate containers lor recovery and disposal. Wash Iloor with hot water and solution 01 Oakite or equivalent. Remove contaminated clothing and wash belore reuse. Wash affected skin areas with soap and water. Keep spill out 01 sewers and open bodies 01 water. Incinerate liquid in approved equipment. Landlill contaminated diking materials according to current local, state and lederal regulations.

Waste Disposal Method

VIII. SPECIAL PROTECTlON INFORMATION

Resp"atory Protection Ventilation Protective Gloves Eye Protection Other None required for normal operatlons Normal room ventilation Impervious Do not wear contact lenses. Splashgoggles (ANSI Z87.1, 1979) Eyewash lacility Impervious apron

IX. SPECIAL PRECAUTIONS

Precautions to Be Taken in Handling and Storage Stainless steel and alumlnum are acceptable lor storage. Recommended storage temperature is 8DF (27C). Material freezes below 41 F (5C).

X. NFPA 704M RATINGS

Health Hazard Flammability Reactlvity Other Hazards
1

2
D None

.( Nordson Corporabon 1993 AII Aighls Aeserlled

P/N 104 445B

4123008/93

9-8

Specification Summary

This Page Intentlonally Left Blank

P/N 104 4458

412300 8193

Nordson CO'poralion , 993 Al! AightS Reserved

## TABSHEET ##

SECTION 10

SECT/ON 10

Optiona/ Parts and Equipment

1. Inlroduction 10-1 (Listings) 10-1 Field-Installed Options Hoses and Guns 10-1 Gun Nozzles, hose filler screens and miscellaneous fittings 10-1 Handgun Hose Support Bracket . 10-1 Handgun Hose Hanger Kit 10-1 Kits for Special Applications 10-1 Auxiliary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2 Optional Filler Screens . .. 10-3

This Page Intentionally Left Blank

Optlonal Parts and EqulpmBnt

10-1

Section 10 Optional Parts and Equlpment

1. Introduction
Here you wlll find those parts, klts and equipment that are available for use wlth the Series 2300 applicator and associated hoses and guns. Servlce klts, service parts and spare parts are Iisted In 8ectlon 9 01 thls manual. The Iist 01 hoses and guns, as weil as their aecessories. is too long for inclusion here but Is included in your Adhesives and Sea/ants

Equipment Catalog.
Add lo thls Section 10 01 this manual any Instrucllon Sheets lor kits or equlpment ordered laler. Equlpment
Field-lnstalled Options": Parant Machina Interlock

NordlOll Par! No.

274658

Ooocrlptlon
Permits operation 01 the parent machina

only alter Ihe adhesive has ,eachad application temperatura.

Low-Levellndicator Kits: (Flal-Bottomed Tank) (Finned Tank) Unit Temperatura COntrol

Conversian

276176 276334 276587

Previdas warning when tank adhesiva

Kit
See your Adhesives end See/ants Equlpmenl Catalog Sea you, Adhasive. and Sea/ante Equlpmenl Catalog
276318 271 486

level lalls lo relill point. Adds either temperatura setback feature o, both lemperature setbacll and digital readout features.

Hasas and Guns

Gun Nozzles, hose filter scr88ns and miscellaneous finings

Handgun Hosa Support 8,ackel KII

Handgun Hose Hangar Kit

Includes bracket lo prevent excessive

f1exing al ho.e-lo-applicator conneClion.

lncludes overhead support for suspendo

ing hose, Ihus prevenling 11 Imm dragging on floor or kinking.

Kits for Speda/ Applications: Temperatura Setback Interface Kit

276510

AJlows automatic and remote opgration of already-installed temperatura setback featura.

Remole Fault Condition Intertaee K~ Elactrie Shifte, KII

276575 121 224

Allows remote indicatlon (Iight, bell, ele.)

of fault condition.

Replaees the mechnical shifte, and air

valva assamblies on 14:1 Series 2~OO

pump.
Unit Extension Kit SinglePhase Jumper Kits: For 200 o, 230 YAC un~s For 380-Y YAC unlls

276338

Elevates unlt to permlt routing of hoses

undorneath un~.
Required on single-phase Installations.

276084 276236

Parant Machina Interlock, Low-LevaJlndicalor Kit, Tamperature Setback Interface Kit and DigllaJ Readout may also be purehasad as faetOly-installed optlon. Sea Sectlon 8 01 this manual o, your Adhesivos and Sea/anls Equipment Catalog for Sarias 2300 unll par! numbe,s wilh these opllons Installad.

e Nor~on Cotporalion , m
Al Righl. Resetved

PIN 104 4458

.'23008IV3

10-2

Optional Parls and Equipment

Equipmenl
Auxiliary Equipment: Timers
Automatic Standby Controller

Nordson Par! No.

Sea your Adhesives and Sealants
Equipment Catalog 105827

Descriplion

Depending on configuration 01 existing Series 2300 applicator

Slores up to 150 lbs (68 kg) ofsolid ad-

Meller/Feeder for units using only

110663 110772 112133

side-ported hoses Mellar/Feeder far units for unlts with bottomported hasas Mellar/Feeder Conversian Kit

hesive (Sama as aboye) Converts Melter/Feeders for Nordson ModellV and V applicators for use with Series 2300 applicators. Sloras adhesive in clean, dry slate, automatically feeds tank on demand.
Keeps ntragen gas blanket over tank to reduce oxidation or charrjng o, easily
degradable materials.

Automatic Hopper/Feeder Nitrogen Blanket Kit

101 906 815157

111 346
High-Capacity Tank Screen

For a higher mell rale, beyond lhal altained with standard tank screen.

Oplions Interface Board

276893

AUows 1ar remote monitoring 01 power on/off, over/under setpoint indication, low materiallevel indication, temp setback en/off indication (it already installed); also previdas PMI capability and remote control 01 temp setback operaban (jI al-

Tank Calibralion Kit

Hose/Gun Calibration Kit

276633 276635 276632 276862

Field Calibralion Kit

(ineludes both 01 the aboye kits)

readyequipped). For calibrating Series 2300 lemp dials. As aboye. As aboye.

Protects hose electrical connectors al manifold end 01 applicator from external

Hose Connector Cavar Kit

damage.

Over-Voltage Protection Oeviee Kit

109703

Electrical Une Noise Filter Kit

809507

For protection 01 the unt where the un! was connectedJ.o a higher voltage input than specified. For applications where repeated oc~ curence of abnormally high voltage spikes can cause loss of temperature control or damage to the unit circuit board. Has plug connectors at each end.

Extension Cordsets:

2 ft (0.61 m) long 6 ft (0.1.83 m) long 12 ft (3.66 m) long 18 ft (5.49 m) long 24 ft (7.32 m) long 30 ft (9.14 m) long Cordset Assembly, 8 ft (2.44 m) long

115576 115577 115578 115579 115580 115581 810004

Far use in special applications where plug connector required at one end. five wires loase al olher end.

PiN 104 4458 412300 8193

(() Nordson Corporalion 1993 AlI A,ghls Aeserved

Optonal Parts and Equpment

10-3

Equipment
Optional Filler Screens

Nordson Part No.

276 139 274578 276138 276 137 276136

Description
0.004 in. mesh 0.006 in. mesh** 0.009 in. mesh 0.012 in. mesh 0.015 in. mesh 0.020 in. mesh

Sereen, Filler Sereen, Filler Sereen. Filler Sereen, Filler Screen, Filter

Screen. Filler
1<

276 135

Selee! Ihe largesl sereen mesh sjze that is smaller than the gun nozzle diameler.

** This size shipped with the applicator or filter assembly unless specified otherwise on purchase arder.

oc; Nordson Corporat,on 1993 AII R,gnts Reservea

P/N 104 4458

41 2300 8193

Part B, Section 5

Parts
This section covers the following unit configurations Model Voltage Pump Manifold 3500 1.2 Piston (E, F or G) 4-Port (A) 6-Port (B or C) 2-Port (S or T) MultiScan

Control

E 2000Nordson Corporation All rights reserved

413000 Issued 11/00

B5EN-05-[3-PARTS]-4

B 5-0

Parts

B5EN-05-[3-PARTS]-4

413000 Issued 11/00

E 1999 Nordson Corporation All rights reserved

Parts

B 5-1

Section B 5 Parts
1. Introduction
To order parts, call the Nordson Customer Service Center or contact your Nordson representative. Use the parts lists and accompanying illustrations in this section to locate and describe parts correctly.

Overview of the Parts Lists

This section contains parts lists for each major assembly of the melter. Each set of parts lists includes a list of component parts, a detailed illustration, lists of service kits, and other parts lists as appropriate. This section is organized as follows:

S control system parts S pump assembly parts, including the air pressure regulator S melter assembly parts, including the tank, frame, and ground stud
assemblies

S manifold assembly parts, including the manifold filter

E 2000Nordson Corporation All rights reserved

413000 Issued 11/00

B5EN-05-[3-PARTS]-4

B 5-2

Parts
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 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.

Using the Illustrated Parts Lists

Item 1 2

Part 000 000 000 000 000 000 Assembly S Subassembly S S Part

Description

Quantity 1 2 1

Note

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 melter, 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.

B5EN-05-[3-PARTS]-4

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Parts

B 5-3

2. Recommended Spare Parts and Supplies

Major Assemblies
Nordson Uptime Plus packs provide parts for fast repair of your applicator. Major parts can be quickly replaced, resulting in maximum productive operation. The following packs are recommended for your applicator. Recommended Quantity for:
1 system Pumps (select appropriate pump): P/N 161 424 P/N 164 683 P/N 164 684 Uptime Plus pack for Pump E (14:1) replacement Uptime Plus pack for Pump F (21:1) replacement Uptime Plus pack for Pump G (6:1) replacement 0 0 0 1 1 1 2 2 2 5 systems 10 systems

Description

Manifolds (select appropriate manifold): P/N 105 463 P/N 105 467 P/N 105 470 P/N 120 320 P/N 120 348 Controller P/N 105 675 P/N 105 674 Uptime Plus pack for UniScan controller Uptime pack for UnSscan controller 1 1 2 2 4 4 Uptime Plus pack for Manifold A Uptime Plus pack for Manifold B Uptime Plus pack for Manifold C Uptime Plus pack for Manifold S Uptime Plus pack for Manifold T 1 1 1 1 1 2 2 2 2 2 4 4 4 4 4

Complete Service Assemblies

Description

The following assemblies require less frequent servicing than consumables and wear items. Recommended Quantity for:
1 system 5 systems 10 systems

Power Modules P/N 105 647 P/N 105 646 P/N 105 649 Circuit Breaker P/N 105 625 Circuit breaker assembly 0 1 2 4 channel board with heat sink 1 channel board with heat sink Main control board 0 0 0 2 2 1 3 3 2

E 2000Nordson Corporation All rights reserved

413000 Issued 11/00

B5EN-05-[3-PARTS]-4

B 5-4

Parts

Consumables and Wear Items

Description

Recommended Quantity for:

1 system 5 systems 10 systems

Fuses P/N 107 470 Fuse service kit. Contains: Ten 6.3 amp fuses, P/N 939 683 Four 15 amp fuses, P/N 939 113 Three 1 amp fuses, P/N 939 708 Tank P/N 105 582 O-rings Manifold A: P/N 105 526 P/N 105 521 P/N 105 527 P/N 105 524 Manifold B or C: P/N 105 526 P/N 105 521 P/N 109 720 P/N 105 523 P/N 105 522 Manifold S or T: P/N 105 526 P/N 105 521 P/N 109 720 P/N 105 523 P/N 105 522 P/N 120 297 Pump: P/N 940 332 P/N 940 133 P/N 503 686 P/N 952 100 P/N 986 331 P/N 954 013 Filter Screen Manifold A or B: P/N 274 578 Manifold C, S, or T: P/N 288 092 Filter screen, 0.006 in. Filter screen, 0.006 in. 2 2 6 6 12 12 Viton o-ring, 2.000 x 2.125 x 0.063 in. Viton o-ring, 0.438 x 0.563 x 0.063 in. SP Piston cup Viton cup Push-on retaining ring Single back-up ring 2 1 2 1 1 1 4 2 4 2 2 2 10 10 10 10 10 10 Viton o-ring, 0.38 in. tube (eight of 945 032) Viton o-ring, 0.250 x 0.375 x 0.063 in. (four of 940 101) Viton o-ring, 1.000 in. tube (four of 945 037) Viton o-ring, 1.375 x 1.50 x 0.063 in. (four of 940 281) O-ring for filter assembly (four of 941 201) Viton o-ring, 0.750 in. tube 2 1 1 1 2 1 4 2 2 2 4 2 6 3 3 3 6 3 Viton o-ring, 0.38 in. tube (eight of 945 032) Viton o-ring, 0.250 x 0.375 x 0.063 in. (four of 940 101) Viton o-ring, 1.000 in. tube (four of 945 037) Viton o-ring, 1.375 x 1.50 x 0.063 in. (four of 940 281) O-ring for filter assembly (four of 941 201) 2 1 1 1 2 4 2 2 2 4 6 3 3 3 6 Viton o-ring, 0.38 in. tube (eight of 945 032) Viton o-ring, 0.250 x 0.375 x 0.063 in. (four of 940 101) Back-up ring, 0.25 x 0.38 in. (four of 954 036) O-ring for filter assembly (four of 941 172) 2 1 1 2 4 2 2 4 6 3 3 6 RTD & Thermostat 1 2 3 1 1 2

Pump (other than o-rings):

Regulator/filter assembly P/N 165 870 Element filter 1 5 10

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Parts

B 5-5

System Components
Description Recommended Quantity for:
1 system Applicator (unit) Guns (assuming 1 gun per applicator) Hoses (assuming 1 hose per applicator) Timers 0 0 0 0 5 systems 0 1 1 0 10 systems 1 2 2 1

Supplies and Tools

P/N
900 236 900 223 900 419 900 341 902 514 901 515 901 915 270 755

Item
Teflon paste (for tank seals, NPT threads as directed) Parker Lubricant (for Viton o-rings) Loctite Adhesive #620 (for non-removable washers and screws) Never Seez (for removable washers and screws) Protective gloves Filter for air supply to pump Nozzle cleaning kit Type R fluid

E 2000Nordson Corporation All rights reserved

413000 Issued 11/00

B5EN-05-[3-PARTS]-4

B 5-6

Parts
The control system determines how the melter functions and the temperatures at which the heated zones operate.

3. Control System Parts

Control System Parts List

Item 1 2 Part 105 663 105 659 105 660 110 022 3 4 5 6 7 8 105 650 120 439 183 838 120 437 121 590 105 658 110 040 110 039 9 10 11 12 13 14 15 16 17 NOTE A: B: 183 837 121 007 105 626 105 647 121 008 105 646 163 034 142 445 -----------

See Figure B 5-1.

Description Quantity 1 1 1 1 1 1/2/3 1/2/3 1/2/3 1 1 1 1 1 2 9/11/13 1/2/3 4/8/12 2 2 2 2 1 D D B, C B A A A Note

Door assembly Control-end frame, 2 hose Control-end frame, 4 hose Control-end frame, 6 hose Bracket, door latch Ribbon cable, 20 position Board, hose/gun control, 2/4/6 hose, w/control panel Ribbon cable, 16 position Ribbon cable, 10 position Board, display, standard, w/control panel Board, display, setback, w/control panel Board, display, monitor/setback, w/control panel Board, main control Fuse, 1 A, 250 VAC (pkg of 4) Screw, hi-lo, pan-head, recessed, cut, 6-19 x 0.50 in. (pkg of 10) Hose/gun power module and board, 4 channel, w/heat sink Fuse, 6.3 A, 250 VAC (pkg of 4) Tank power module and board, 1 channel, w/heat sink Fuse, 12 A, 250 VAC (pkg of 4), 3100 and 3400 melters Fuse, 25 A, 250 VAC (pkg of 4), 3500 melters Bracket, heat sink, hose/gun power modules Bracket, heat sink, tank power module

This part is a service kit that includes items 3 and 11. Note quantity, more than one package is needed.

C: This is the fuse for the hose/gun power module boards. D: This is the fuse for the tank power module board.

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Parts

B 5-7

12 13 1 16 14

6 5 4 17 11 7

15

8 2

11 3 Fig. B 5-1 Control System Parts 10

4130945A

E 2000Nordson Corporation All rights reserved

413000 Issued 11/00

B5EN-05-[3-PARTS]-4

B 5-8

Parts
See Figure B 5-1. Service kits contain groups of related replacement parts.
Description Fuse replacement Main control board replacement Item 9 Contains Fuses for items 9, 12, and 14

Control System Service Kits

Part 107 470 183 837

Control System UpTime Packs

UpTime packs contain a selection of service kits and are available at a substantial price discount. Each service kit may also be ordered individually. For an illustration that shows the indicator lights, the RTD, and the thermostat, refer to Melter Assembly Parts.
Contains Service kit 105 583, indicator light replacement Service kit 105 582, RTD/thermostat replacement Service kit 107 470, fuse replacement

Part 105 674

Description Service kit, MultiScan, UpTime pack

105 676

Service kit, MultiScan, UpTime Plus pack

Service kit 105 583, indicator light replacement Service kit 105 582, RTD/thermostat replacement Service kit 107 470, fuse replacement Service kit 183 837, main control board replacement

B5EN-05-[3-PARTS]-4

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Parts

B 5-9

4. Pump Assembly Parts

The pump assembly includes the piston pump and the actuator. This section also includes a parts list for the air pressure regulator. See Figure B 5-2.

Item 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

Part 161 424 1005247 982 059 983 402 983 403 1006027 900 493 333 560 155 057 166 880 164 606 155 068 155 067 986 714 155 059 985 302 900 000 503 709 900 470 503 696 288 031 900 344 954 013 940 133 503 695 900 001 288 028 973 402 288 030 983 184 984 545 982 135 983 410 940 332 952 100 986 331 309 822 984 092 333 137 983 445 Pump, piston, 14:1, SP-30

Description S Bracket, cover, pump, SP, 14:1, 6:1 S Screw, socket-head, M4 x 8 S Washer, flat, narrow, M4 S Washer, lock, split, M4 S Valve assembly, SP S Lubricant, Parker, hi-temp S Spring, wave, SP pump S Detent, upper, SP S Fork, magnetic, assembly S Actuator, magnetic, assembly, SP S Can, SP S Detent, lower, SP S Retaining ring, internal, 156, bowed S Piston pump, 14:1, SP S Pin, roll, 0.125 x 0.500 in. S Ball, 440 stainless, 0.375 in., 50 S Seat, ball, pressure S Adhesive, threadlocking, Loctite 272 S Cage, ball, siphon S Tube, crossover, pump S Lubricant, Never Seez, 8 oz can S Backup ring, single, 7/16 x 9/16 in. S O-ring, Viton, 0.426 ID x 0.070 in. wide S Seat, ball, siphon S Ball, 440 stainless, 0.500 in., 50 S Body, pump, hydraulic S Plug, pipe, socket, flush,
1/ 8

Quantity 1 2 2 2 1 AR 1 1 1 1 1 1 1 1 1 1 1 AR 1 1 AR 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1

Note

in.

S Mount, pump, machined, 6:1 and 14:1 S Washer, lock, bearing, W-08, S Nut, lock, bearing, PN-08 S Screw, hex-head, cap, M6 x 30 S Washer, flat, narrow, M6 S O-ring, Viton, 2.000 x 2.125 x 0.063 in. S U-cup, Viton S Retaining ring, internal, 100, push-on S Manifold, air, SP S Nut, hex, lock, torque, M6, class 10 S Head, cylinder, SP, machined S Washer, piston seal, SP

Continued on next page

E 2000Nordson Corporation All rights reserved

413000 Issued 11/00

B5EN-05-[3-PARTS]-4

B 5-10
Item 40 41 42 43 44 45 46 47 48 49

Parts

Part 983 446 163 039 986 602 273 138 273 139 982 147 983 409 982 028 211 228 982 308 S Washer, piston cup, SP S Cup, piston, SP

Description

Quantity 2 2 1 1 1 4 4 4 AR 2

Note

S Retaining ring, internal, inverted S Washer, 0.799 OD x 0.543 ID x 0.034 in. thick S Seal, pump S Screw, hex-head, cap, M6 x 120 S Washer, lock, split, M6 S Screw, socket-head, M5 x 20 S SP lubricating oil S Screw, pan-head, M4 x 10

AR: As Required

38

45 33 46

42 43 44

47

1 48 5 6

36 27 37 40 26

7 49 8 2 33 10 35 3 4 41

41 39 22 20 21 23

40

31 32 6 14

34

47

30

28

9 16

15

11 12 13

17 29 19 25 24

18

4601190A

Fig. B 5-2

Pump E Parts

B5EN-05-[3-PARTS]-4

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E 1999 Nordson Corporation All rights reserved

Parts UpTime Pack

B 5-11

See Figure B 5-3. The UpTime pack for pump E provides the parts that should be replaced as part of routine maintenance.

Item NS 2 3 4 5 6 7 8 9 10 11 NS NOTE A: NS: Not Shown

Part 164 601 940 111 940 332 984 092 163 039 986 331 952 100 986 602 273 138 273 139 940 133 940 181 211 228

Description UpTime pack, pump E, SP 30, 14:1 S O-ring, Viton, 0.301 x 0.70 in. S O-ring, Viton, 2.00 x 2.125 x 0.063 in. S Nut, hex, lock, torque, M6, class 10 S Cup, piston S Retaining ring, internal, 100, push-on S Cup, U, Viton S Retaining ring, internal, 81, inverted S Washer, 0.799 OD x 0.543 ID x 0.034 in. S Seal, pump S O-ring, Viton, 0.426 ID x 0.70 in. S O-ring, Viton, 0.0.739 ID x 0.70 in. wide S SP lubricating oil

Quantity 4 2 1 2 1 1 1 1 1 1 4 1

Note A

Not used with this pump.

7 2 8 9 11

3 4 4 2 5 6 10

4131136A

Fig. B 5-3

Pump E UpTime Pack Parts

E 2000Nordson Corporation All rights reserved

413000 Issued 11/00

B5EN-05-[3-PARTS]-4

B 5-12

Parts
See Figure B 5-4.

Air Pressure Regulator Parts List

Item 1 2 2 3 4 5 Part 165 871 165 872 165 735 973 490 973 491 901 258 165 870 165 878

Description Regulator/filter assembly, 90 psi (4 hose melters) Regulator/filter assembly, 90 psi (6 hose melters) S Regulator, filter, air, S Nipple, brass, 40, S Nipple, brass, 40, S Gauge, air,
1/ 8 1/ 4

Quantity 1 1 1 1 1 1

Note

NPT

1/ 4 1/ 4

in., 2.50 in. (4 hose melters) in., 5.00 in. (6 hose melters)

NPT, 90 psi

Service kit, filter element Service kit, filter bowl

1 3

4103139

Fig. B 5-4

Air Pressure Regulator Parts

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Parts
The melter assembly includes the tank, frame, and ground stud assemblies. See Figures B 5-5 and B 5-6.

B 5-13

5. Melter Assembly Parts List

Item 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 NOTE A: B: Part ----------120 816 ----------120 815 ------------------------------121 103 120 417 120 388 -----274 667 338 368 108 907 121 104 103 825 ---------------274 669 132 384 -----120 814 105 614 Tank

Description Insulation, tank Gasket, tank Insulation, hose-end frame Cover, tank Gasket, tank cover, (pkg of 2) Base Tag, hot Tag, circuit breaker Tag, warning Spacer, manifold Spacer, tank Screw, hex-head, M8 x 70 mm (pkg of 4) Screw, hex-head, M8 x 30 mm (pkg of 4) Washer, lock, split, M8 (pkg of 4) Manifold Plate, retainer, RTD Screw, pan-head, cross recessed, M3 x 5 mm RTD, tank Screw, pan-head, slotted, M5 x 10 mm (pkg of 4) Screw, pan-head, recessed, M3 x 6 mm (pkg of 5) Frame, center Control system Frame, hose-end Solenoid valve, pumps E and G Solenoid valve, pump F Pump assembly Cover, front Lid, electrical enclosure

Quantity 1 1 1 1 1 1 1 1 1 1 2 1 1 2 3 1 4 1 6 10 1 1 1 1 1 1 1

Note A A A A

A A A A A

C C A D A

Refer to Melter Assembly Service Kits. Refer to Manifold Assembly Parts.

C: Note quantity, more than one package is needed. D: Refer to Control System Parts.
Continued on next page

E 2000Nordson Corporation All rights reserved

413000 Issued 11/00

B5EN-05-[3-PARTS]-4

B 5-14

Parts

5. Melter Assembly Parts List (contd)

Item 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 NOTE A: B: Part 120 813 120 801 -----121 105 120 388 133 915 120 800 111 804 121 422 -----120 424 -----105 626 275 115 105 628 108 908 105 594 982 246 120 413 120 414 120 415 982 119 -----Cover, rear Cover, pump Pan, pump Screw, hex-head, cap, M8 x 30 mm (pkg of 4) Washer, lock, split, M8 (pkg of 4) Lid assembly, tank Strainer, tank, small Strainer, tank, large Washer, flat, 0.156 x 0.375 x 0.049 in. Breaker, circuit Cover, circuit breaker Insulation, center frame Screw, pan-head, 6-19 x 10 mm (pkg of 10) Adapter, air line, 1/4 NPTF Harness, hose/gun (2 hose/4 hose) Thermostat, tank, 26 in. leads Screw, hi-lo, hex-head, wash, cut, Screw, pan-head, M6 x 10 mm Neon lamp, white (pkg of 2) Neon lamp, red (pkg of 2) Neon lamp, green (pkg of 2) Screw, pan-head, M5-08 x 10 mm Ground stud assembly
1/ -15 4

Description

Quantity 1 1 1 3 3 1 1 1 4 1 1 1 5 1 2/4 1

Note

B B

x 0.62 in.(pkg of 4)

6 2 1 1 1 2 1

Refer to Pump Assembly Parts. Refer to Melter Assembly Service Kits.

C: Note quantity, more than one package is needed. D: Refer to Ground Stud Assembly Parts List.

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Parts

B 5-15

30

32 26 28 33

31

29

23 B C

4131083A

Fig. B 5-5

Melter Assembly Parts (1 of 2)

E 2000Nordson Corporation All rights reserved

413000 Issued 11/00

B5EN-05-[3-PARTS]-4

B 5-16

Parts

5. Melter Assembly Parts List (contd)

34

40 36

6 20 49 A 5 1 3 4 45 16 19 17 25 41 35 42

24

38 B

C 21 15 13 46 47 48

Fig. B 5-6

B5EN-05-[3-PARTS]-4

12 11 50 43 9 37 44 14 15 Melter Assembly Parts (2 of 2)

18

8 10 8

22 27

4131084A

413000 Issued 11/00

E 1999 Nordson Corporation All rights reserved

Parts Melter Assembly Service Kits

Part 105 591 120 818 105 582 105 592 105 593 105 619 105 625 120 817 120 798 105 610 105 611 105 583 Tag replacement Insulation replacement RTD and thermostat replacement Manifold spacer replacement Center frame replacement Pump pan replacement Circuit breaker replacement Tank replacement Tank cover replacement Hose-end frame replacement (2-hose) Hose-end frame replacement (4-hose) Lamp replacement

B 5-17

See Figures B 5-5 and B 5-6. Service kits contain all the parts typically required for the complete replacement of an assembly.
Service Kit Description 8, 9, 10, 21 2, 4, 39 17, 18, 19, 43 11, 12, 13, 14, 15 22, 44 31, 32, 33 37, 38 1, 3 3, 5 24, 40, 45, 49 24, 40, 45, 49 46, 47, 48 Contains Items

E 2000Nordson Corporation All rights reserved

413000 Issued 11/00

B5EN-05-[3-PARTS]-4

B 5-18

Parts
See Figure B 5-7.

Ground Stud Assembly Parts List

Item 1 2 3 4 5 6 7 NOTE A: Part 984 129 271 221 983 120 240 674 983 048 982 938 ------

Description Nut, hex-head, machine, #10-32 Lug, 45_, double, 0.250 in., 0.438 in. Washer, lock, split, #10 Tag, ground Washer, lock, external, #10 Screw, round-head, #10-32 x 1.500 in. Base

Quantity 5 7 5 1 1 1 1

Note

Base shown for reference purposes only.

1 2

7 Fig. B 5-7 Ground Stud Assembly Parts

B5EN-05-[3-PARTS]-4

6
413000 Issued 11/00

4130420

E 1999 Nordson Corporation All rights reserved

Parts

B 5-19

6. Manifold Assembly Parts

The manifold assembly includes the manifold block, manifold filter, pressure relief valve, and drain valve. See Figure B 5-8.

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 NOTE A: B:

Part 105 413 120 324 983 414 288 023 973 574 940 101 954 036 276 024 982 096 983 403 -----274 569 941 220 940 281

Description Manifold A, 4-port, noncirculating, standard filter Valve, pressure relief, 1600 psi, 3.5 in. Washer, flat, narrow, M8 Screw, hex-head, special, M8-1.25 Plug, O-ring, straight thread, 9/16-18 O-ring, Viton, 0.239 ID x 0.070 in. Backup ring, single, 1/4 x 3/8 in. Drain valve assembly Screw, pan-head, slotted, M4 x 8 mm Washer, lock, split, M4 Manifold filter assembly Adapter, filter bung O-ring, Viton, 1.125 x 1.313 x 0.094 in. O-ring, Viton, 1.375 x 1.500 x 0.063 in.

Quantity 1 1 5 5 8 1 1 1 1 1 1 1 1 2

Note A

B B

B B B, C B, D E E

This part is a complete manifold assembly and includes items 1, 2, 3, and 13. Apply anti-seize lubricant, part 900 341.

C: Refer to Manifold Filter Parts List. D: Apply retaining cylindrical adhesive, part 900 419. E: Apply O-ring lubricant, part 900 223.

13 12 11 10 8 7 6 Fig. B 5-8 Manifold Assembly Parts 5

4131058A

2 3 4

E 2000Nordson Corporation All rights reserved

413000 Issued 11/00

B5EN-05-[3-PARTS]-4

B 5-20

Parts
See Figure B 5-9.

Manifold Filter Parts List

Item 1 2 3 4 5 NOTE A:

Part 105 432 274 578 981 747 274 513 941 172 274 579 Manifold filter assembly

Description S Screen, 0.006 mesh, 5.38 in. long S Screw, round-head, 10-32 x 6.250 in. S Bung S O-ring, Viton, 0.813 x 1.000 x 0.094 in. S Core, 5.718 in. long

Quantity 1 1 1 1 1 1

Note

Apply anti-seize lubricant, part 900 341.

4 2 3

Fig. B 5-9

Manifold Filter Parts

B5EN-05-[3-PARTS]-4

413000 Issued 11/00

1
4130043A E 1999 Nordson Corporation All rights reserved

Fusores DuraBluet
Modelos D4L, D10L y D16L
Manual P/N 213 716 A Spanish
Edicin 09/02

NORDSON CORPORATION DULUTH, GEORGIA USA www.nordson.com

Nmero de pedido P/N = Nmero de pedido de artculos Nordson

Advertencia La presente publicacin de Nordson Corporation est protegida por los derechos de autor. Copyright E 2002. Se prohibe cualquier reproduccin parcial o total del presente manual y su traduccin a otro idioma sin el previo consentimiento por escrito de Nordson. Nordson se reserva el derecho a realizar modificaciones sin previo aviso. 2002 Reservados todos los derechos

Marcas comerciales AccuJet, AquaGuard, Asymtek, Automove, Autotech, Blue Box, CF, CanWorks, Century, Clean Coat, CleanSleeve, CleanSpray, Compumelt, Control Coat, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, Durafiber, Durasystem, Easy Coat, Easymove Plus, Econo-Coat, EPREG, ETI, Excel 2000, Flex-O-Coat, FlexiCoat, Flexi-Spray, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Helix, Horizon, Hose Mole, Hot Shot, Hot Stitch, Isocoil, Isocore, Iso-Flo, JR, KB30, Little Squirt, Magnastatic, MEG, Meltex, MicroSet, Millennium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson, OmniScan, Opticoat, OptiMix, Package of Values, Patternview, PluraFoam, Porous Coat, PowderGrid, Powderware, Prism, ProBlue, DuraBlue, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, PRX, RBX, Rhino, S. design stylized, Saturn, SC5, Seal Sentry, Select Charge, Select Coat, Select Cure, Slautterback, Smart-Coat, Spray Squirt, Spraymelt, Super Squirt, Sure Coat, System Sentry, Tela-Therm, Trends, Tribomatic, UniScan, UpTime, Veritec, Versa-Coat, Versa-Screen, Versa-Spray, Walcom, Watermark y When you expect more. son marcas comerciales registradas de Nordson Corporation. ATS, AeroCharge, Auto-Flo, AutoScan, BetterBook, Chameleon, CanNeck, Check Mate, Colormax, Control Weave, Controlled Fiberization, Coolwave, CPX, Dry Cure, E-Nordson, EasyClean, Eclipse, Equi=Bead, Fill Sentry, Fillmaster, Gluie, Heli-flow, Ink-Dot, Iso-Flex, Kinetix, Lacquer Cure, Maxima, MicroFin, Minimeter, Multifil, Origin, PermaFlo, PluraMix, Powder Pilot, Powercure, Primarc, Process Sentry, PurTech, Pulse Spray, Ready Coat, Select Series, Sensomatic, Shaftshield, SheetAire, Spectral, Spectronic, Spectrum, Summit, Sure Brand, Sure Clean, Sure Max, Swirl Coat, Tempus, Tracking Plus, Trade Plus, Universal, Vista, Web Cure y 2 Rings (Design) son marcas comerciales de Nordson Corporation.

P/N 213716A

Manual 41-DURABLUE-MA-02

E 2002 Nordson Corporation

Introduction

O-1

Nordson International
Europe
Country
Austria Belgium Czech Republic Denmark

Phone
43-1-707 5521 31-13-511 8700 4205-4159 2411 45-43-66 0123 45-43-66 1133 358-9-530 8080 33-1-6412 1400

Fax
43-1-707 5517 31-13-511 3995 4205-4124 4971 45-43-64 1101 45-43-66 1123 358-9-530 80850 33-1-6412 1401 49-211-254 658 49-4131-894 149 49-211-3613 527 39-02-9078 2485 31-13-511 3995 47-22 68 3636 47-22-65 8858 48-22-836 7042 351-22-961 9409 7-812-11 86 263 4205-4124 4971 34-96-313 2244 46-40-932 882 46 (0) 303 66959 41-61-411 3818 44-1844-21 5358 44-161-428 6716 44-1753-558 100

Hot Melt Finishing

Finland France Germany

Erkrath Lneburg Dsseldorf Nordson UV

49-211-92050 49-4131-8940 49-211-3613 169 39-02-904 691 31-13-511 8700

Italy Netherlands Norway

Hot Melt Finishing

47-23 03 6160 47-22-65 6100 48-22-836 4495 351-22-961 9400 7-812-11 86 263 4205-4159 2411 34-96-313 2090

Poland Portugal Russia Slovak Republic Spain Sweden

Hot Melt Finishing

46-40-680 1700 46 (0) 303 66950 41-61-411 3838

Switzerland United Kingdom

Hot Melt Finishing Nordson UV

44-1844-26 4500 44-161-495 4200 44-1753-558 000

Distributors in Eastern & Southern Europe

DED, Germany

49-211-92050

49-211-254 658

E 2002 Nordson Corporation All rights reserved

NI_EN_K0702

O-2

Introduction

Outside Europe / Hors dEurope / Fuera de Europa

S For your nearest Nordson office outside Europe, contact the Nordson
offices below for detailed information.

S Pour toutes informations sur reprsentations de Nordson dans votre

pays, veuillez contacter lun de bureaux ci-dessous.

S Para obtenir la direccin de la oficina correspondiente, por favor

dirjase a unas de las oficinas principales que siguen abajo.

Contact Nordson
Africa / Middle East
DED, Germany

Phone
49-211-92050

Fax
49-211-254 658

Asia / Australia / Latin America

Pacific South Division, USA

1-440-988-9411

1-440-985-3710

Japan

Japan

81-3-5762 2700

81-3-5762 2701

North America

Canada USA

1-905-475 6730

1-905-475 8821 1-770-497 3500 1-440-985 1417 1-440-985 4593

Hot Melt Finishing Nordson UV

1-770-497 3400 1-440-988 9411 1-440-985 4592

NI_EN_K0702

E 2002 Nordson Corporation All rights reserved

Tabla de materias

Tabla de materias
Avisos de seguridad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seales de alerta de seguridad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Responsabilidades del propietario del equipo . . . . . . . . . . . . . . . . . . . Informacin de seguridad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrucciones, requerimientos y estndares . . . . . . . . . . . . . . . . . . Cualificaciones del usuario . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prcticas de seguridad industriales aplicables . . . . . . . . . . . . . . . . . . Uso previsto del equipo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrucciones y mensajes de seguridad . . . . . . . . . . . . . . . . . . . . . . Prcticas de instalacin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normas de manejo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normas de mantenimiento y reparacin . . . . . . . . . . . . . . . . . . . . . Informacin de seguridad del equipo . . . . . . . . . . . . . . . . . . . . . . . . . . Desconexin del equipo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eliminacin de la presin hidrulica del sistema . . . . . . . . . . . . Separacin de la corriente en el sistema . . . . . . . . . . . . . . . . . . Desactivacin de pistolas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Avisos de seguridad generales y precauciones . . . . . . . . . . . . . . . Otras precauciones de seguridad . . . . . . . . . . . . . . . . . . . . . . . . . . Primeros auxilios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Etiquetas y rtulos de seguridad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduccin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Otras fuentes de informacin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gua del usuario . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Asistencia online . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CD de recursos del producto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Descripcin del producto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Uso propuesto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Restricciones de uso . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modos de funcionamiento . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identificacin del fusor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Componentes clave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipamiento opcional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-2 1-2 1-2 1-3 1-4 1-4 1-4 1-5 1-5 1-6 1-7 1-7 1-7 1-7 1-8 1-9 1-12 1-12 1-13 2-1 2-2 2-2 2-2 2-2 2-3 2-3 2-4 2-4 2-5 2-6 2-8

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Tabla de materias

Instalacin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Datos tcnicos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Informacin adicional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tareas de instalacin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Experiencia del personal de instalacin . . . . . . . . . . . . . . . . . . . . . . Requerimientos de instalacin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distancias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tensin elctrica . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Otras consideraciones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Desembalaje del fusor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contenido del kit de instalacin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Materiales suministrados por el cliente . . . . . . . . . . . . . . . . . . . . . . Montaje del fusor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuracin del servicio elctrico . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conexin de mangueras y pistolas . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuracin del fusor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuracin rpida . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parmetros de funcionamiento . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seleccin de parmetros de funcionamiento . . . . . . . . . . . . . . . Lectura o edicin de parmetros de funcionamiento . . . . . . . . Temperatura de punto de referencia del tanque, mangueras y pistolas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revisin de cambios en parmetro y temperatura de punto de referencia . . . . . . . . . . . . . . . . . . . . . . . . . Instalacin de equipamiento opcional . . . . . . . . . . . . . . . . . . . . . . . . . . Conexin de un accionador de pistola, un controlador de encolado o un temporizador . . . . . . . . . . . . . . . . . . Purga del fusor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ajuste de la vlvula de control de presin . . . . . . . . . . . . . . . . . . . . . . Manejo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Informacin adicional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ms acerca de los componentes calefactados . . . . . . . . . . . . . . . Llenado del tanque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Puesta en marcha del fusor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vigilancia del fusor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Confirmar que el fusor est funcionando correctamente . . . . . . . . Control de temperaturas de componente . . . . . . . . . . . . . . . . . . . . Control de fallos del fusor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ajuste de temperaturas de componente . . . . . . . . . . . . . . . . . . . . . . . Utilizacin de las teclas de funcin del fusor . . . . . . . . . . . . . . . . . . . Tecla de calefactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tecla de bomba . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tecla de ajuste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tecla de reloj programador semanal . . . . . . . . . . . . . . . . . . . . . . . . . Tecla de reposo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Desconexin del fusor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mantenimiento . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eliminar la presin del sistema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limpieza del fusor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sustitucin del filtro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limpieza del tanque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1 3-1 3-1 3-2 3-2 3-4 3-4 3-6 3-6 3-7 3-7 3-7 3-8 3-10 3-12 3-14 3-14 3-16 3-16 3-17 . 3-20 3-22 3-24 3-24 3-24 3-25 4-1 4-1 4-2 4-3 4-4 4-6 4-6 4-7 4-9 4-13 4-17 4-17 4-17 4-18 4-18 4-19 4-20 5-1 5-2 5-2 5-4 5-6

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III
A-1 B-1 B-2 B-5 B-8 B-17

Clculo de requerimientos de tensin del fusor . . . . . . . . . . . . . . Parmetros de funcionamiento . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Estndar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control de temperatura . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reloj programador semanal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seleccin PID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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P/N 213716A

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Seccin 1

Avisos de seguridad
Leer esta seccin antes de utilizar el equipo. Esta seccin contiene las recomendaciones y normas aplicables para instalacin, operacin y mantenimiento seguros (a partir de aqu denominados uso) del producto descrito en este documento (a partir de aqu denominado equipo). Ms informacin de seguridad, en forma de mensajes de alerta de seguridad especficos, aparece a lo largo de este documento segn sea necesario. AVISO: Si se hace caso omiso de los mensajes de seguridad, las recomendaciones y los procedimientos para evitar peligros proporcionados en este documento, pueden originarse lesiones personales, incluso la muerte, o daos en el equipo o la propiedad.

Seales de alerta de seguridad

La siguiente seal de alerta de seguridad y las palabras de aviso se utilizan a lo largo de este documento para alertar al lector de los peligros para la seguridad personal o para identificar condiciones que pueden provocar daos en el equipo o la propiedad. Cumplir toda la informacin de seguridad que acompaa a la palabra de aviso. AVISO: Indica una situacin potencialmente peligrosa que, si no se evita, puede provocar lesiones personales, incluso la muerte.

PRECAUCION: Indica una situacin potencialmente peligrosa que, si no se evita, puede provocar lesiones personales menores o moderadas.

PRECAUCION: (Usada sin la seal de alerta de seguridad). Indica una situacin potencialmente peligrosa que, si no se evita, puede provocar daos en el equipo o la propiedad.

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Avisos de seguridad

Responsabilidades del propietario del equipo

Los propietarios del equipo son responsables de gestionar la informacin de seguridad, asegurndose de que se cumplen todas las instrucciones y requerimientos para el uso del equipo, as como de cualificar a todos los usuarios potenciales.

Informacin de seguridad
S Investigar y evaluar la informacin de seguridad de todas las fuentes
pertinentes, incluyendo normas de seguridad especficas del propietario, las mejores prcticas industriales, reglamentos vigentes, informacin de producto del fabricante del material, as como el presente documento.

S Proporcionar informacin de seguridad a los usuarios del equipo segn

los reglamentos vigentes. Contactar con la autoridad con competencia sobre la informacin.

S Mantener la informacin de seguridad, incluyendo las etiquetas de

seguridad fijadas al equipo, en condiciones legibles.

Instrucciones, requerimientos y estndares

S Asegurarse de que el equipo se utiliza de acuerdo con la informacin
proporcionada en este documento, los cdigos y reglamentos vigentes, as como las mejores prcticas industriales.

S Si es aplicable, obtener la aprobacin del departamento de ingeniera o

de seguridad, o de algn departamento similar dentro de su organizacin, antes de instalar u operar el equipo por primera vez.

S Proporcionar un equipo de emergencia y de primeros auxilios

apropiado.

S Realizar inspecciones de seguridad para asegurarse de que se siguen

los procedimientos requeridos.

S Volver a evaluar los reglamentos y procedimientos de seguridad cuando

se realizan cambios en el proceso o en el equipo.

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Cualificaciones del usuario

Los propietarios del equipo son responsables de que los usuarios:

S Reciban la formacin en seguridad apropiada para la funcin que

desempean segn lo indican los reglamentos vigentes y las mejores prcticas industriales.

S Estn familiarizados con las normas y procedimientos de prevencin

de accidentes y de seguridad del propietario del equipo.

S Reciban formacin especfica del equipo y de tareas de otra

persona cualificada. OBSERVACION: Nordson puede ofrecer formacin en la instalacin especfica del equipo, en operacin y en mantenimiento. Contacte con su representante Nordson para obtener ms informacin.

S Posean cualificaciones especficas para la industria y el comercio

as como un nivel de experiencia apropiado a la funcin que desempean.

S Sean capaces fsicamente de desempear su funcin de trabajo y

no estn bajo la influencia de ninguna substancia que degrade su capacidad mental o fsica.

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Avisos de seguridad

Prcticas de seguridad industriales aplicables

Las siguientes prcticas de seguridad se refieren al uso del equipo segn la forma descrita en este documento. La informacin proporcionada aqu no pretende incluir todas las prcticas de seguridad posibles, sino que representa las mejores prcticas de seguridad para el equipo de un potencial de peligros similar utilizado en industrias similares.

Uso previsto del equipo

S Utilizar el equipo nicamente para los fines descritos y dentro de los
lmites especificados en este documento.

S No modificar el equipo. S No utilizar materiales incompatibles o dispositivos auxiliares no

homologados. Contacte con su representante Nordson si tiene alguna pregunta acerca de la compatibilidad del material o de la utilizacin de dispositivos auxiliares no estndar.

Instrucciones y mensajes de seguridad

S Leer y seguir las instrucciones proporcionadas en este documento y en
otros documentos de referencia.

S Familiarizarse con la localizacin y el significado de las etiquetas y los

rtulos de aviso de seguridad fijadas al equipo. Ver Etiquetas y rtulos de seguridad (en caso de que exista) al final de esta seccin.

S Si no est seguro de cmo utilizar el equipo, contactar con el

representante Nordson para obtener asistencia.

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Prcticas de instalacin
S Instalar el equipo de acuerdo con las instrucciones proporcionadas en
este documento y en la documentacin proporcionada con los dispositivos auxiliares.

S Asegurarse de que el equipo est preparado para el entorno en que

ser utilizado, y que las caractersticas de procesamiento del material no crearn un entorno peligroso. Ver la hoja de datos de seguridad del material (HDSM) para el material.

S Si la configuracin de instalacin necesaria no coincide con las

instrucciones de instalacin, contactar con el representante Nordson para obtener asistencia.

S Posicionar el equipo para una operacin segura. Tener en cuenta los

requerimientos de distancia entre el equipo y otros objetos.

S Instalar desconectadores de tensin bloqueables para separar de las

correspondientes fuentes de tensin tanto el equipo como todos los dispositivos auxiliares con alimentacin elctrica independiente.

S Conetcar a tierra todo el equipo apropiadamente. Contactar con el

organismo de seguridad local acerca de disposiciones de construccin para conocer los requerimientos especficos.

S Asegurarse de que estn instalados los fusibles del tipo y valor

correctos en el equipo de fusibles.

S Contactar con la autoridad con competencia para determinar el

requerimiento de permisos o inspecciones de instalacin.

Normas de manejo
S Familiarizarse con la localizacin y el manejo de todos los dispositivos e
indicadores de seguridad.

S Confirmar que el equipo, incluyendo todos los dispositivos de seguridad

(protecciones, interbloqueos, etc.), est en buen estado de trabajo y que se cumplen las condiciones ambientales requeridas.

S Utilizar el equipo de proteccin personal (EPP) especificado para cada

tarea. Ver Informacin de seguridad del equipo o las instrucciones del fabricante de material y la HDSM para el EPP.

S No utilizar un equipo que no funciona correctamente o que muestra

signos de un malfuncionamiento potencial.

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Avisos de seguridad

Normas de mantenimiento y reparacin

S Realizar las actividades de mantenimiento programadas en los
intervalos descritos en este documento.

S Eliminar la presin hidrulica y neumtica antes de manipular el equipo. S Separar la corriente del equipo y de todos los dispositivos auxiliares
antes de manipular el equipo.

S Utilizar slo piezas de repuesto nuevas o de reconstruccin autorizadas

por la fbrica.

S Leer y cumplir las instrucciones del fabricante y la HDSM proporcionada

con los compuestos de limpieza del equipo. OBSERVACION: Las HDSM para los compuestos de limpieza que Nordson vende estn disponibles en www.nordson.com o llamando a su representante Nordson.

S Confirmar el correcto funcionamiento de todos los dispositivos de

seguridad antes de volver a poner el equipo en funcionamiento.

S Desechar los compuestos de limpieza y los materiales residuales segn

los reglamentos vigentes. Ver la HDSM pertinente o contactar a la autoridad competente para obtener informacin.

S Mantener limpias las etiquetas de aviso de seguridad del equipo.

Reemplazar las etiquetas gastadas o daadas.

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Informacin de seguridad del equipo

Esta informacin de seguridad del equipo es aplicable a los siguientes tipos de equipos Nordson:

S Equipo de aplicacin de adhesivos termofusibles y adhesivos fros, y

todos los accesorios relacionados.

S Controladores de encolado, temporizadores, sistemas de deteccin

y verificacin, y todos los dems dispositivos de control de proceso opcionales.

Desconexin del equipo

Para llevar a cabo muchos de los procedimientos descritos en este documento, debe desconectarse previamente el equipo. El nivel de desconexin requerido vara segn el tipo de equipo que se utilice y segn el procedimiento que se realice. En caso necesario, las instrucciones de desconexin se especifican al inicio del procedimiento. Los niveles de desconexin son:

Eliminacin de la presin hidrulica del sistema

Eliminar completamente la presin hidrulica del sistema antes de desconectar cualquier conexin o junta hidrulicos. Ver el manual de producto especfico del fusor para obtener instrucciones acerca de la presin hidrulica del sistema de eliminacin.

Separacin de la corriente en el sistema

Separar el sistema (fusor, mangueras, pistolas y dispositivos opcionales) de todas las fuentes de alimentacin antes de acceder a alguna conexin elctrica de alta tensin o a algn punto de conexin. 1. Apagar el equipo y todos los dispositivos auxiliares conectados al (sistema del) equipo. 2. Para evitar que el equipo reciba tensin de forma accidental, bloquear y tapar el (los) interruptor(es) de desconexin o el (los) disyuntor(es) de circuito que proporciona(n) tensin elctrica entrante al equipo y a los dispositivos opcionales. OBSERVACION: La legislativa estatal y los estndares industriales dictan los requerimientos especficos para el aislamiento de fuentes de energa peligrosas. Ver la legislativa o el estndar apropiado.

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Avisos de seguridad

Desactivacin de pistolas
Deben desactivarse todos los dispositivos elctricos o mecnicos que proporcionan una seal de activacin a las pistolas, a la(s) electrovlvula(s) de pistola o a la bomba de fusor antes de realizar alguna tarea en una pistola, o alrededor de la misma, que est conectada a un sistema sometido a presin. 1. Apagar o desconectar el dispositivo accionador de pistola (controlador de encolado, temporizador, PLC, etc.). 2. Desconectar la conexin elctrica de seal de entrada a la(s) electrovlvula(s) de pistola. 3. Reducir a cero la presin de aire a la(s) electrovlvula(s) de pistola, despus eliminar la presin de aire residual entre el regulador y la pistola.

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Avisos de seguridad generales y precauciones

La tabla 1-1 contiene los avisos de seguridad generales y las precauciones referentes al equipo de adhesivo termofusible y de adhesivo fro de Nordson. Revisar la tabla y leer detenidamente todos los avisos o precauciones que se refieren al tipo de equipo descrito en este manual. Los tipos de equipo se designan en la tabla 1-1 de la siguiente manera: HM = Hot Melt = Adhesivo termofusible (fusores, mangueras, pistolas, etc.) PC = Process control = Control de proceso CA = Cold adhesive = Adhesivo fro (bombas de aplicacin, contenedor sometido a presin y pistolas) Tab. 1-1 Avisos de seguridad generales y precauciones Tipo de equipo Aviso o precaucin AVISO: Vapores peligrosos! Antes de procesar cualquier material termofusible reactivo al poliuretano (PUR) o con base disolvente en un fusor compatible Nordson, leer y cumplir la HDSM de material. Asegurarse de que no se excede la temperatura de procesamiento ni los puntos de inflamacin del material, y de que se cumplen todos los requerimientos para el manejo seguro, la ventilacin, primeros auxilios y el equipo de proteccin personal. El incumplimiento de los requerimientos de HDSM puede provocar lesiones personales, incluso la muerte.

HM

HM

AVISO: Material reactivo! No limpiar nunca un componente de aluminio, ni enjuagar el equipo Nordson con disolventes derivados de hidrocarburos halogenados. Los fusores y pistolas Nordson contienen componentes de aluminio que pueden reaccionar de forma violenta con hidrocarburos halogenados. El uso de compuestos de hidrocarburo halogenado en el equipo Nordson puede causar lesiones personales, incluyendo la muerte.

HM, CA

AVISO: Sistema sometido a presin! Eliminar la presin hidrulica del sistema antes de desconectar cualquier conexin o junta hidrulicas. Si no se elimina la presin hidrulica del sistema, puede originarse una liberacin incontrolada de adhesivo termofusible o de adhesivo fro y causar lesiones personales.

HM

AVISO: Material fundido! Ponerse proteccin para los ojos y la cara, un traje que proteja la piel expuesta y guantes aislantes del calor durante la manipulacin del equipo que contiene el adhesivo termofusible fundido. Incluso solidificado, el adhesivo termofusible puede causar quemaduras. Si no se lleva puesto un equipo de proteccin personal adecuado, pueden originarse lesiones personales.
Contina...

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Avisos de seguridad generales y precauciones (cont.)

Tab. 1-1 Avisos de seguridad generales y precauciones (cont.) Tipo de equipo Aviso o precaucin AVISO: El equipo se inicia automticamente! Los dispositivos de accionamiento a distancia se utilizan para controlar las pistolas de termofusin automticas. Antes de trabajar en una pistola en funcionamiento (o cerca de la misma), desactivar el dispositivo de accionamiento de pistola y extraer el suministro de aire a la(s) electrovlvula(s) de la pistola. Si no se desactiva el dispositivo de accionamiento de pistola ni se extrae el suministro de aire a la(s) electrovlvula(s), pueden originarse lesiones personales.

HM, PC

HM, CA, PC

AVISO: Peligro de electrocucin! Incluso una vez desconectado y aislado elctricamente en el interruptor de desconexin o disyuntor de circuito, puede que el sistema todava est conectado a dispositivos auxiliares con tensin. Desconectar y separar de la alimentacin todos los dispositivos auxiliares antes de manipular el equipo. Si no se separa correctamente la tensin elctrica del equipo auxiliar antes de manipular el equipo, pueden originarse lesiones personales, incluso la muerte.

CA

AVISO: Peligro de incendio o explosin! El equipo de adhesivos fros de Nordson no est preparado para su uso en ambientes explosivos y no debera utilizarse junto con adhesivos con base disolvente que pueden crear una atmsfera explosiva cuando se utilizan. Ver la HDSM del adhesivo para determinar sus caractersticas y limitaciones de procesamiento. La utilizacin de adhesivos con base disolvente incompatibles o el procesamiento incorrecto de adhesivos con base disolvente puede provocar lesiones personales, incluyendo la muerte.

HM, CA, PC

AVISO: Encomendar la operacin o manipulacin del equipo nicamente a personal con formacin y experiencia apropiadas. La utilizacin de personal no formado o inexperto en la operacin o el servicio del equipo puede provocar lesiones, incluso la muerte, al propio personal o a otros, as como daar el equipo.
Contina...

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Tipo de equipo

Aviso o precaucin PRECAUCIN: Superficies calientes! Evitar el contacto con las superficies metlicas calientes de las pistolas, mangueras y con ciertos componentes del fusor. Si no se puede evitar el contacto, ponerse guantes aislantes al calor y un traje de proteccin al trabajar alrededor del equipo expuesto al calor. Si no se evita el contacto con las superficies metlicas calientes, pueden originarse lesiones personales.

HM

HM

PRECAUCIN: Algunos fusores Nordson estn especficamente diseados para procesar el adhesivo termofusible reactivo al poliuretano (PUR). Si se intenta procesar PUR en un equipo no diseado especficamente para este fin puede daarse el equipo y causar una reaccin prematura del adhesive termofusible. En caso de inseguridad acerca de la capacidad del equipo para procesar PUR, contactar con el representante Nordson para obtener asistencia.

HM, CA

PRECAUCIN: Antes de utilizar algn compuesto de limpieza o lavado en el equipo, o dentro de ste, leer y cumplir las instrucciones del fabricante y la HDSM suministrada con el compuesto. Algunos compuestos de limpieza pueden reaccionar de forma imprevisible con el adhesivo termofusible o el adhesivo fro, causando daos en el equipo.

HM

PRECAUCIN: El equipo de adhesivo termofusible de Nordson ha sido probado en la fbrica con el disolvente de tipo R de Nordson, el cual contiene plastificante de polister. Algunos materiales termofusibles pueden reaccionar con el disolvente de tipo R y formar una goma slida que puede obstruir el equipo. Antes de utilizar el equipo, confirmar que el adhesivo termofusible es compatible con el disolvente de tipo R.

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Otras precauciones de seguridad

S No utilizar una llama abierta para calentar los componentes del sistema
de termofusin.

S Comprobar diariamente las mangueras de alta presin por si existieran

signos de desgaste excesivo, daos o fugas.

S No dirigir nunca una pistola manual de aplicacin hacia s mismo o

hacia otros.

S Sujetar las pistolas manuales de aplicacin por el punto de suspensin

adecuado.

Primeros auxilios
Si el adhesivo termofusible fundido entra en contacto con la piel: 1. NO intentar quitar el adhesivo termofusible fundido de la piel. 2. Sumergir inmediatamente el rea afectada en agua limpia y fra hasta que el se enfre. 3. NO intentar quitar el adhesivo termofusible solidificado de la piel. 4. En caso de quemaduras graves, atender la conmocin. 5. Buscar inmediatamente ayuda mdica experta. Proporcionar la HDSM del adhesivo termofusible al personal mdico que proporciona el tratamiento.

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Etiquetas y rtulos de seguridad

La figura 1-1 muestra la localizacin de las etiquetas o rtulos de seguridad del producto fijados al equipo. La tabla 1-2 proporciona el texto de cualquier mensaje de seguridad que aparece en cada etiqueta o el significado de los smbolos que aparecen sin mensaje de seguridad. El kit de instalacin proporcionado con el fusor puede contener hojas superpuestas de etiqueta impresas en varios idiomas. Si los reglamentos de seguridad vigentes as lo indican, aplicar la hoja superpuesta adecuada al trozo de texto de las etiquetas mostradas en la figura 1-1.

Fig. 1-1

Localizacin de etiquetas y rtulos de seguridad

Tab. 1-2 Etiquetas y rtulos de seguridad Pieza

1

Descripcin
AVISO: Tensin peligrosa. Desconectar todas las conexiones de suministro de tensin antes de la manipulacin. PRECAUCIN: Peligro de quemaduras. Superficies calientes! AVISO: Tensin peligrosa. Desconectar todas las conexiones de suministro de tensin antes de la manipulacin. PRECAUCIN: Peligro de quemaduras. Superficies calientes!

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Seccin 2

Introduccin
Este manual describe la instalacin y el uso de los fusores de adhesivo DuraBlue 4L (D4L), DURABLUE 10L (D10L) y DuraBlue 16L (D16L). En caso necesario, se remite al lector para que vea la documentacin proporcionada con otros productos Nordson o productos proporcionados por terceros. A diferencia de la capacidad del tanque, la capacidad de la manguera/ pistola y el aspecto externo, todos los fusores DuraBlue son idnticos en cuanto a funciones. Para simplificar la presentacin de la informacin en este manual, se utilizan de forma genrica dibujos del modelo D10L a travs de todo el manual para representar todos los fusores DuraBlue.

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Introduccin

Otras fuentes de informacin

Ver los siguientes recursos adicionales para obtener informacin de referencia rpida, asistencia tcnica e informacin acerca de cmo obtener el mximo rendimiento del fusor DuraBlue.

Gua del usuario

La gua del usuario enviada con el fusor proporciona una referencia rpida visual de las tareas a nivel de operario ms comunes. La gua es resistente al agua y est diseada de tal manera que puede mantenerse con el fusor en el rea de produccin.

Asistencia online
Visite www.Nordson.com y siga los enlaces a recursos de asistencia para el producto, preguntas ms frecuentes, pedido online de piezas de repuesto e impresin bajo demanda de documentacin.

CD de recursos del producto

El CD de recursos enviado con el fusor contiene una versin electrnica de este manual as como recursos de asistencia de formacin.

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Descripcin del producto

Ver la figura 2-1. Los fusores DuraBlue de Nordson se utilizan junto con las mangueras y pistolas de termofusin de Nordson para crear un sistema de aplicacin de adhesivo termofusible. El fusor convierte en lquido el adhesivo termofusible en forma slida y mantiene el mismo a la temperatura deseada. Cuando se activan las pistolas, el fusor bombea el adhesivo termofusible licuado a travs de las mangueras y hacia las boquillas de la pistola, que lo aplican de forma usual sobre la superficie de un producto.

3 Figure 2-1 Componentes del sistema 3. Manguera de termofusin

1. Fusor DuraBlue 2. Pistola de termofusin

Uso propuesto
Los fusores DuraBlue estn especialmente diseados para:

S Fundir y bombear materiales termofusibles en forma slida que

estn diseados para hacerse lquidos y extrudos a temperaturas por debajo de los 230_C (450_F) para fusores 240 VAC or por debajo des los 200_C (400_F) para fusores 120 VAC.

S Ser utilizados con mangueras y pistolas de termofusin compatibles

fabricadas por Nordson Corporation.

S Ser utilizados en ambientes no explosivos.

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Introduccin

Restricciones de uso
Utilizar los fusores DuraBlue slo para los fines para los que han sido diseados. Los fusores DuraBlue no deben usarse:

S Para fundir o bombear materiales termofusibles reactivos al

poliuretano o cualquier otro material que genere un peligro para la salud o la seguridad cuando se calienta.

S En entornos en los que sea necesario limpiar el fusor con lavados

de agua o rociadores.

Modos de funcionamiento
Los fusores DuraBlue funcionan en los siguiente modos: Exploracin automtica: El fusor comprueba y muestra automticamente la temperatura actual del tanque, las mangueras y las pistolas para confirmar que estn dentro del rango de temperatura predefinido. Por defecto, el fusor se encuentra siempre en el modo de exploracin automtica a no ser que se ajuste a otro modo de funcionamiento. Reposo: La temperatura del tanque, las mangueras y las pistolas se reduce de la temperatura de funcionamiento (a partir de aqu denominada temperatura de punto de referencia) en un nmero predefinido de grados. Ajuste: El modo de ajuste se utiliza para configurar las opciones y caractersticas de control del fusor y para revisar los datos de funcionamiento almacenados. Fallo: El fusor alerta al operario cuando se produce una condicin de fallo, como por ejemplo un fallo RTD o una temperatura fuera del rango.

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Identificacin del fusor

Ver la figura 2-2. Es necesario el modelo y el nmero de pieza del fusor cuando se solicita un servicio o se piden piezas de repuesto y equipamiento opcional. El modelo y el nmero de pieza estn indicados en la placa de identificacin del equipo localizada en la parte delantera del fusor.

Figure 2-2

Placa de identificacin del equipo

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Introduccin

Componentes clave
La figura 2-3 proporciona el nombre y la localizacin de los componentes clave del fusor.

Figure 2-3 1. 2. 3. 4.

Componentes clave 5. 6. 7. 8. Tanque Receptculos de manguera/pistola Distribuidor Vlvula de control de presin 9. 10. 11. 12. Filtro Bomba Soporte de montaje Motor

Puerta del armario elctrico Panel de control (ver la figura 2-4) Tapa del tanque Paneles laterales

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0.201

6 Figure 2-4 Panel de control 4. Interruptor de control 5. Pantalla derecha y teclas de desplazamiento 6. Pantalla izquierda y teclas de desplazamiento 7. Teclas de funcin

1. LED de fallo 2. LED de listo 3. Teclas/LEDs de componente

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Introduccin

Equipamiento opcional
El siguiente equipamiento puede pedirse para ampliar la funcionalidad y la capacidad de los fusores DuraBlue:

S S S S S S S

Tarjeta de ampliacin de entrada/salida (I/O) Tarjetas de comunicacin Control de presin automtico Manmetro Interruptor de pie Kit de control de aire Gancho de pistola manual

Ver la seccin 7, Piezas de repuesto para obtener informacin acerca de cmo pedir equipamiento opcional.

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Seccin 3

Instalacin
AVISO: Riesgo de lesiones personales o daos en el equipo! Ver la informacin de seguridad proporcionada en la seccin 1, Avisos de seguridad, antes del manejo o manipulacin del equipo. El incumplimiento de la informacin de seguridad proporcionada puede provocar lesiones personales, incluyendo la muerte.

Datos tcnicos
Los fusores DuraBlue vienen configurados de fbrica para cada pedido y slo necesitan las tareas de montaje y preparacin descritas en esta seccin. Si su fusor fue pedido como un sistema completo, el contenedor de envo tendr tambin una o ms mangueras y pistolas de termofusin. Se enva el fusor desde la fbrica con un kit de instalacin que contiene componentes que el cliente debe montar en el fusor. El cliente deber suministrar algunos materiales adicionales para completar la instalacin. Si se ha pedido equipamiento opcional con el fusor, ver la documentacin suministrada con el equipamiento opcional para su instalacin e instrucciones de manejo. Las ilustraciones que acompaan a los procedimientos en esta seccin describen el fusor D10L. A no ser que se indique de otra manera, las instrucciones se aplican tambin a los fusores D4L y D16L.

Informacin adicional
Esta seccin presenta los procedimientos de instalacin en su forma ms habitual. Las variaciones en el procedimiento o las consideraciones especiales se explican en la tabla de informacin adicional que acompaa a la mayora de los procedimientos. En caso necesario, algunas entradas de tabla contienen tambin informacin con referencias cruzadas. Las tablas de informacin adicional se indican con el smbolo que se muestra a la izquierda.

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Instalacin

Tareas de instalacin
A continuacin, la secuencia general para las tareas de instalacin: 1. Verificar que existen las condiciones de instalacin y los servicios requeridos. 2. Desembalar e inspeccionar el fusor. 3. Montar el fusor sobre la mquina principal o estructura de soporte. 4. Configurar el servicio elctrico. 5. Conectar las mangueras y pistolas de termofusin. 6. Preparar el fusor para que funcione con el proceso de fabricacin. 7. Instalar equipamiento opcional. 8. Conectar un accionador de pistola, un controlador de encolado o un temporizador (si se utilizan). 9. Purgar el fusor. 10. Ajustar la vlvula de control de presin.

Experiencia del personal de instalacin

Se pretende que las instrucciones proporcionadas en esta seccin sean llevadas a cabo por personal experimentado en las siguientes materias:

S S S S

Procesos de aplicacin de adhesivo termofusible Energa industrial y cableado de control Prcticas de instalacin mecnica industriales Control de proceso bsico e instrumentacin

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Esta pgina est en blanco intencionadamente.

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Instalacin

Requerimientos de instalacin
Antes de instalar el fusor, asegurarse de que la localizacin de instalacin deseada ofrece las distancias, las condiciones ambientales y los servicios requeridos.

Distancias
La figura 3-1 ilustra las distancias mnimas requeridas entre el fusor y los objetos que lo rodean. La tabla 3-1 describe cada distancia.

Figure 3-1

Distancias de instalacin mnimas

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Table 3-1 Distancias de instalacin Distancia requerida Pieza Descripcin

Anchura del fusor en la parte exterior de los soportes de montaje. Distancia requerida entre el fusor y el objeto ms cercano para la extraccin del filtro. Distancia requerida entre el extremo frontal del fusor (panel de control) y el objeto ms cercano para poder abrir completamente la puerta del armario elctrico. Espacio mnimo requerido horizontalmente para el fusor cuando la puerta del armario elctrico y la tapa del tanque estn completamente abiertas. Espacio vertical mnimo requerido para el fusor cuando la tapa del tanque est en su punto ms alto.

D10L D16L
441 mm (17,36 in.) 203 mm (8,00 in.)

D4L
334 mm (13,14 in.) 203 mm (8,00 in.)

330 mm (13,00 in.)

279 mm (11,00 in.)

1.12 m (44,23 in.)

907 mm (35,73 in.)

853 mm (33,59 in.)

649 mm (24,54 in.)

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Instalacin

Tensin elctrica
Antes de instalar el fusor, asegurarse de que ste no ser sobrecargado y de que el servicio elctrico de planta est preparado para manejar la tensin requerida por el fusor y las mangueras y pistolas que van a utilizarse en la planta. Si el representante Nordson no ha verificado todava la tensin requerida, o si se tiene pensado aadir o cambiar las mangueras o pistolas, deber calcularse la tensin elctrica requerida. Ver el apndice A, Clculo de requerimientos de tensin del fusor. Si se necesitara asistencia, contactar al representante Nordson. Los fusores DuraBlue deben instalarse con un interruptor de desconexin de tensin bloqueable que asle al fusor de su fuente de alimentacin.

Otras consideraciones
Tener en cuenta los siguientes factores adicionales al evaluar dnde instalar el fusor.

S El requerimiento de tensin de cada manguera dicta la distancia

mxima entre el fusor y cada pistola. Ver el apndice A, Clculo de requerimientos de tensin del fusor, para obtener informacin acerca de cmo calcular la longitud mxima permitida de la manguera.

S El operario debe poder llegar al panel de control de forma segura y

controlar con precisin los indicadores del mismo.

S El operario debe poder observar de forma segura el nivel del adhesivo

termofusible dentro del tanque.

S El fusor debe estar instalado lejos de reas con fuertes corrientes de

aire o donde se produzcan repentinos cambios de temperatura.

S Debe instalarse el fusor donde est en conformidad con los

requerimientos de ventilacin especificados en la hoja de datos de seguridad del material para poder utilizar el adhesivo termofusible.

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Desembalaje del fusor

Antes de iniciar la instalacin, extraer el fusor del palet, localizar el kit de instalacin e inspeccionar el fusor por si tuviera piezas daadas o por si faltara alguna pieza. Informar al representante Nordson acerca de cualquier problema.

Contenido del kit de instalacin

El kit de instalacin suministrado con el fusor contiene los componentes mostrados en la figura 3-2. El kit de instalacin contiene tambin un paquete de hojas superpuestas de etiqueta de seguridad impresas en varios idiomas. Si as lo indican las regulaciones locales, deber aplicarse la hoja superpuesta de etiqueta en el idioma apropiado sobre la versin en ingls de la misma etiqueta. Ver Etiquetas y rtulos de seguridad en la seccin 1, Avisos de seguridad para conocer la localizacin de cada etiqueta de seguridad.

Materiales suministrados por el cliente

Los siguientes materiales adicionales se requieren tambin para instalar el fusor:

S (Fusores de 240 VAC) Un cable de alimentacin, algunos

prensaestopas y un conducto elctrico rgido o flexible que sean del tamao y grado adecuados para el servicio elctrico que va a suministrar tensin al fusor.

S Pernos roscados de 8 mm (5/16 pulgadas) y material de sujecin

para montar el fusor.

Figure 3-2

Installation kit components 4. Fusible, rpido, 5 A, 250 VAC 5. Fusible, 6.3 A, 250 VAC (2)

1. Racor de manguera recto 2. Fusible, rpido, 10 A, 250 VAC 3. Fusible, lento, 2 A, 250 VAC

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Instalacin

Montaje del fusor

Antes de montar el fusor, asegurarse de que la mquina principal o estructura de soporte est nivelada respecto al suelo, ofrece una superficie de montaje lisa, no est expuesta a grandes vibraciones y es capaz de soportar el peso del fusor, un tanque lleno de adhesivo termofusible y las mangueras y pistolas. Ver la seccin 8, Datos tcnicos, para conocer el peso del fusor. Ver los datos tcnicos proporcionados por el fabricante del adhesivo termofusible para obtener informacin acerca del peso volumtrico del adhesivo termofusible.

Para montar el fusor Ver la Figura 3-3. Utilizar pernos roscados de 8 mm (5/16 pulgadas) y material de sujecin para fijar los soportes de montaje del fusor a la superficie de montaje. OBSERVACIN: El encolado de montaje de perno de los fusores DuraBlue puede adaptarse al de otros muchos fusores Nordson. Ver la tabla 3-2.

Orificios de montaje

Figure 3-3

Encolados de montaje de perno (ver la tabla 3-2)

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Table 3-2 Comparacin de las dimensiones del fusor DuraBlue con las dimensiones de otros fusores Dimensin 3100 3400 3500 3700 3830 3930 LS10 KB10 KB20

A B C D E F

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Configuracin del servicio elctrico

Los fusores DuraBlue se envan de fbrica en una de las siguientes formas:

S Con un cable de alimentacin adjunto S Sin un cable de alimentacin adjunto. Para configurar este tipo de
fusor de forma que funcione en sus instalaciones debe conectarse un cable de alimentacin. Conexin de tensin a fusores con cable de alimentacin adjunto 1. Conectar el cable de alimentacin a un enchufe elctrico hembra. La intensidad de unidad mxima de los fusores DuraBlue 120 VAC es 20 A. Ver la tabla 3-3 para conocer las intensidades mximas de los fusores de 200240 VAC. OBSERVACIN: Los fusores DuraBlue con cable de alimentacin adjunto no estn destinados al uso particular. 2. Ver Connexon de mangueras y pistolas. No se requiere configuracin de servicio elctrico adicional.

Conexin de tensin a fusores sin cable de alimentacin adjunto 1. Seleccionar un cable de alimentacin preparado para la mxima intensidad requerida por el fusor. Asegurarse de que el cable de alimentacin cumple con los cdigos elctricos y los estndares aplicables. Las intensidades mximas de los fusores DuraBlue que funcionan a 200240 VAC se muestran en la tabla 3-3.

Table 3-3 Intensidades mximas para los fusores de 200240 VAC Tensin (VAC)
200240, monofsico ,

Modelo
D4L D10L D16L

Intensidad mxima
14 17 19

AVISO: Peligro de electrocucin! Los fusores DuraBlue deben instalarse con un interruptor de desconexin de tensin bloqueable que desconecte la circulacin de corriente del fusor por completo aislndolo de su fuente de alimentacin. Si no se desconecta la alimentacin de corriente del fusor cuando se solicite, pueden originarse lesiones personales, incluso la muerte. AVISO: Peligro de descarga elctrica o cortocircuito. Utilizar un conducto rgido o flexible o un prensaestopas del tamao apropiado para proteger el cable de alimentacin del borde afilado de la penetracin del conducto.

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2. Abrir la puerta del armario elctrico. 3. Encaminar el cable de alimentacin entre el interruptor de desconexin de tensin y el fusor a travs de la penetracin del conducto PG-21 o de 1 pulgada en la base del compartimento elctrico. Ver la figura 3-4. 4. Conectar cada conector de cable de alimentacin al terminal XT1. 5. Conectar el conductor a tierra del cable de alimentacin al pilar de tierra localizado en el chasis. El pilar de tierra est marcado con PE/G.

Apertura de la puerta del armario elctrico

XT1

L2/N L1

PE/G

Figure 3-4

Conexin del cable de alimentacin y del conductor a tierra en un fusor de 200240 VAC

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Conexin de mangueras y pistolas

Los fusores DuraBlue utilizan mangueras y pistolas Nordson estndar y aceptan la conexin de hasta dos pares de manguera/pistola. Los fusores vienen previstos de un racor de manguera recto (tapado) preinstalado en el distribuidor. AVISO: Peligro de incendio o de daos en el equipo. Antes de conectar las mangueras y pistolas al fusor, confirmar que la tensin requerida por las mangueras y pistolas no excede el vatiaje mximo especificado en el apndice A, Clculo de requerimientos de tensin del fusor.

Para conectar las mangueras Ver la figura 3-5. Observar las siguientes directrices:

S Conectar las mangueras a cualquiera de los puertos de manguera en el

distribuidor.

S Para obtener informacin acerca de la eleccin de manguera de

termofusin correcta de Nordson para su proceso de fabricacin, ver la ltima edicin del equipo de aplicacin de adhesivo termofusible Catlogo de piezas de repuesto o ponerse en contacto con el representante Nordson.

Puertos de manguera en el distribuidor (se muestran los distribuidores filtrados y no filtrados

S Ver la gua del usuario proporcionada con cada manguera Nordson. La

gua contiene importante informacin acerca del tendido y la instalacin de la manguera.

S Guardar todos los conectores de puerto extrados del distribuidor. Si se

extrae ms adelante una manguera, ser necesario volver a instalar en el distribuidor un conector de puerto.

S Si se utiliza una manguera de pistola manual por conmutacin, conectar

el latiguillo de conmutacin en la manguera al receptculo de conmutacin en el fusor.

Receptculo de conmutacin

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Figure 3-5

Conexin de una manguera

Para conectar las pistolas Observar las siguientes directrices:

S Para obtener informacin acerca de la eleccin de pistola de

termofusin Nordson ms apropiada para su proceso de fabricacin, ver la ltima edicin de equipo de aplicacin de adhesivo termofusible Catlogo de piezas de repuesto o ponerse en contacto con el representante Nordson. Ver el apndice A, Clculo de requerimientos de tensin del fusor, para obtener informacin acerca de cmo calcular la tensin requerida por las pistolas de termofusin Nordson.

S Ver la gua del usuario enviada con cada pistola para obtener
informacin acerca de la instalacin de la pistola y de la conexin de la manguera a la pistola. OBSERVACIN: Los fusores DuraBlue se envan con un filtro de termofusin de malla 100 (0,15 mm) instalado en la bomba. Tambin estn disponibles filtros de pantallas de malla 50 y 200. Pedir el filtro adecuado segn el tamao ms pequeo de la boquilla.

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Configuracin del fusor

Despus de instalar fsicamente el fusor, ste debe configurarse para que soporte el proceso de fabricacin. La configuracin del fusor consiste en ajustar o realizar cambios en los parmetros de operacin configurados en fbrica que afectan al uso y el funcionamiento del fusor. La temperatura de funcionamiento (punto de referencia) del tanque y de cada manguera y pistola tambin se establece durante la configuracin del fusor. El fusor se enva de fbrica con los parmetros de funcionamiento de uso ms frecuente ya ajustados. La configuracin de fbrica puede modificarse en cualquier momento para que se ajuste al proceso de fabricacin en cuestin.

Configuracin rpida
La tabla 3-4 describe los parmetros de funcionamiento de uso ms frecuente y sus ajustes de fbrica. Revisar la tabla para determinar si los ajustes de fbrica para cada parmetro soportarn su proceso de fabricacin. Si los valores predeterminados de cada uno de estos parmetros de funcionamiento son apropiados para su proceso de fabricacin, entonces no necesita preparar el fusor. Ir directamente a Temperatura de punto de referencia del tanque, mangueras y pistolas, ms adelante en este manual, para completar el proceso de instalacin. Si resulta necesario realizar cambios en la configuracin de fbrica o si quieren conocerse otros parmetros de funcionamiento, ir a Parmetros de funcionamiento.

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Table 3-4 Parmetros de funcionamiento comunes Parmetro Nombre de parmetro Fines

Temporizador que retarda la activacin del LED de listo por un periodo de tiempo predefinido despus de que el tanque, las mangueras y las pistolas estn a la temperatura deseada de punto de referencia correcta. El temporizador de retardo de listo se activar slo si la temperatura del tanque, en el momento en que se enciende el fusor, se encuentra 27C (50F) o ms por debajo de su temperatura de punto de referencia asignada. Si se utiliza el receptculo de conmutacin, este parmetro determina el tiempo que el motor permanecer encendido despus de apagar el dispositivo de conmutacin. Determina si puede activarse la bomba (no poner en marcha) antes de que todos los componentes estn a la temperatura de punto de referencia deseada (activado) o si slo puede ponerse en marcha pulsando la tecla de bomba despus de que todos los componentes hayan alcanzado su temperatura de punto de referencia deseada (desactivado). Fija las unidades de la pantalla de temperatura a grados Celsius (C) o a grados Fahrenheit (F). Establece el nmero de grados que cualquier componente calefactado puede sobrepasar respecto a su temperatura de punto de referencia antes de que se produzca un fallo de sobretemperatura. Establece el nmero de grados por debajo de los que cualquier componente calefactado puede caer respecto a su temperatura de punto de referencia antes de que se produzca un fallo de temperatura baja. Ajusta el nmero de grados de temperatura a los que bajarn todos los componentes calefactados cuando se pone el fusor en modo de reposo. Establece el tiempo que el fusor permanecer en modo de reposo despus de pulsar la tecla de reposo. Grupo de parmetros que controla el reloj del fusor. El reloj se utiliza para encender y apagar automticamente los calefactores y para poner el fusor en modo de reposo.

Valor predeterminado

Tiempo de retardo de listo

0 minutos

Retardo de motor apagado

0 segundos

Encendido automtico de bomba

Activado

20

Unidades de temperatura

21

Delta de sobretemperatura

15C (25F)

22

Delta de temperatura baja

25C (50F)

23

Delta de reposo

50C (100F)

26

Tiempo de reposo manual Reloj programador semanal

Desactivado

50 a 77

Desactivado

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Parmetros de funcionamiento
El fusor utiliza parmetros de funcionamiento para almacenar valores no editables y valores editables. Los valores no editables son aqullos que proporcionan informacin acerca del historial de rendimiento del fusor. Los valores editables son bien un punto de referencia numrico o un ajuste de opcin de control. Los ajustes de opciones de control afectan a la visualizacin de la informacin o al funcionamiento del fusor. Los parmetros de funcionamiento estn almacenados en la microprogramacin del fusor (firmware) en forma de una lista numerada secuencialmente. La lista est organizada en los grupos lgicos descritos en la tabla 3-5.

Table 3-5 Grupos de parmetros Grupo Nmeros de parmetro

0 a 11 20 a 26 50 a 77

Descripcin de grupo
No editables y otros parmetros usados con frecuencia Controlar calefactores Configurar la funcin de reloj

Estndar Control de temperatura Reloj programador semanal

Adems de poder leer y editar valores de parmetro, tambin pueden revisarse los diez ltimos cambios que se han realizado en los parmetros editables.

Seleccin de parmetros de funcionamiento

La tabla 3-6 proporciona una lista completa de los parmetros de funcionamiento. Revisar la lista para determinar qu parmetros de funcionamiento soportarn mejor el proceso de fabricacin en cuestin. Ver el apndice B, Parmetros de funcionamiento, para obtener informacin detallada acerca de cada parmetro. El apndice B contiene una descripcin completa de cada parmetro, incluyendo su influencia sobre el fusor, el valor predeterminado y la sintaxis. OBSERVACIN: Los parmetros que se utilizan para configurar equipamiento opcional, o que si no estn reservados a la microprogramacin (firmware), estn excluidos de la tabla 3-6 y del apndice B.

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Lectura o edicin de parmetros de funcionamiento

Sin tener en cuenta si el valor de parmetro es editable o no, el procedimiento para acceder a cada parmetro con el fin de leer o editar su valor actual es el mismo.

Para leer o editar un parmetro 1. Conectar el fusor. El fusor ejecuta una comprobacin inicial. 2. Pulsar la tecla de ajuste.
Interruptor de control

En la pantalla izquierda aparece el parmetro 1. 3. Utilizar la tecla de desplazamiento de la pantalla izquierda para desplazarse al nmero de parmetro deseado. Ver la tabla 3-6 para obtener una lista completa de parmetros.

Tecla de ajuste

Cuando se haya acabado de introducir los nmeros de parmetro de uno o dos dgitos, la pantalla derecha indica el valor actual del parmetro. 4. Realizar una de las siguientes acciones:

S Si el valor no es editable, ver Vigilancia del fusor en la seccin 4,

Manejo.

S Si el valor es editable, ir al paso 5.

5. Pulsar una tecla de desplazamiento en la pantalla derecha. La pantalla derecha parpadea.

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Para leer o editar un parmetro (cont.)
6. Utilizar la tecla de desplazamiento de la pantalla derecha para introducir el punto de referencia numrico deseado o la opcin de control en la pantalla derecha. Ver el apndice B, Parmetros de funcionamiento para obtener informacin acerca del valor numrico o de las elecciones de la opcin de control para cada parmetro. 7. Pulsar la tecla de desplazamiento en la pantalla izquierda. El fusor comprueba que el nuevo valor u opcin de control es aceptable.

S Si se acepta el punto de referencia numrico o la opcin de control,

las pantallas derecha e izquierda indican el siguiente nmero y valor de parmetro secuencial.

S Si no se acepta el punto de referencia numrico u opcin de control,

la pantalla derecha mostrar guiones (----) durante tres segundos y despus volver al valor original. 8. Repetir los pasos 5 a 7 para leer o cambiar el siguiente nmero de parmetro secuencial o pulsar la tecla de ajuste para salir del modo de ajuste.

Table 3-6 Parmetros de funcionamiento Parmetro

Estndar
1 2 3 4 7 8 Horas totales con calefactores encendidos (no editable) Registro de fallos (no editable) Registro de historial de cambios (no editable) Tiempo de retardo de listo Retardo de motor apagado Encendido automtico de bomba 9999 0 a 60 minutos 0 a 360 segundos 0 (desactivado) o 1 (activado) 0 _-F0 (vaco) P-_ (vaco) 0 minutos 0 segundos 1 (activado)

Nombre

Rango de valores

Valor predeterminado

Control de temperatura
20 21 22 23 24 25 26 Unidades de temperatura (grados _C o _F) Delta de sobretemperatura Delta de temperatura baja Delta de reposo Temporizacin de puesta en reposo automtica Tiempo de apagado automtico de calefactores Tiempo de reposo manual C (grados Celsius) o F (grados Fahrenheit) 5_C (10_F) a 60 _C (110_F) 5_C (10_F) a 60 _C (110_F) 25_C (50_F) a 190 _C (350_F) 0 a 1440 minutos 0 a 1440 minutos 0 a 180 minutos C (grados Celsius) 15_C (25_F) 25_C (50_F) 50_C (100_F) 0 (desactivado) 0 (desactivado) 0 (desactivado)

Continued on next page

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Table 3-6 Parmetros de funcionamiento (contd) Parmetro

Reloj programador semanal
50 51 55 56 57 58 60 61 62 63 65 66 67 68 71 72 73 74 75 76 77 Da actual Hora actual Programa 1 calefactores encendidos Programa 1 calefactores apagados Programa 1 entrar en reposo Programa 1 salir del reposo Programa 2 calefactores encendidos Programa 2 calefactores apagados Programa 2 entrar en reposo Programa 2 salir del reposo Programa 3 calefactores encendidos Programa 3 calefactores apagados Programa 3 entrar en reposo Programa 3 salir del reposo Programa para los lunes Programa para los martes Programa para los mircoles Programa para los jueves Programa para los viernes Programa para los sbados Programa para los domingos 1 a 7 (1 = lunes) 0000 a 2359 0000 a 2359 0000 a 2359 0000 a 2359 0000 a 2359 0000 a 2359 0000 a 2359 0000 a 2359 0000 a 2359 0000 a 2359 0000 a 2359 0000 a 2359 0000 a 2359 07 (ver observacin) 07 (ver observacin) 07 (ver observacin) 07 (ver observacin) 07 (ver observacin) 07 (ver observacin) 07 (ver observacin) 06:00 17:00 : : : : : : : : : : 2 (programa 2) 2 (programa 2) 2 (programa 2) 2 (programa 2) 2 (programa 2) 2 (programa 2) 2 (programa 2)

Nombre

Rango de valores

Valor predeterminado

OBSERVACIN:

Para obtener una explicacin detallada de cada parmetro de funcionamiento ver el apndice B Parmetros de funcionamiento.

Puede abandonarse el modo de ajuste en cualquier momento pulsando la tecla de ajuste. Los nmeros de parmetro que no son pertinentes se pasan por alto al desplazarse a travs de la lista de parmetro de funcionamiento en la pantalla izquierda. Si durante el modo de ajuste no se pulsa ninguna tecla durante dos minutos, el fusor volver al modo de exploracin automtica.

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Temperatura de punto de referencia del tanque, mangueras y pistolas

El fusor se enva de fbrica con una temperatura de punto de referencia para el tanque de 175C (350F) y las temperaturas de punto de referencia de la manguera y pistola a 0 grados (apagadas). Antes de poder utilizar el fusor, debe asignarse una temperatura de punto de referencia al tanque, a las mangueras y a las pistolas. Las temperaturas de punto de referencia se asignan utilizando uno de los siguientes mtodos:

S Global: El tanque y todas las mangueras y pistolas se ajustan a la

misma temperatura de punto de referencia.

S Global-por-grupo de componente: Todas las mangueras o todas las

pistolas se ajustan a la misma temperatura de punto de referencia.

S Componente individual: La temperatura de punto de referencia del

tanque y de cada manguera y pistola se ajusta de forma individual. Debido a que la mayora de los procesos de fabricacin requerirn que el tanque, las mangueras y las pistolas funcionen a la misma temperatura, en esta seccin slo se describe el mtodo global de las temperaturas de punto de referencia asignadas. Para obtener ms informacin acerca de los otros dos mtodos de asignacin de temperaturas de punto de referencia, ver Ajuste de temperaturas de componente en la seccin 4, Manejo. Al igual que con los parmetros de funcionamiento, pueden revisarse los cambios pasados que se han hecho a las temperaturas de punto de referencia.

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Para asignar una temperatura de punto de referencia global 1. Pulsar durante tres segundos la tecla de tanque. En la pantalla izquierda parpadea 1.
Tecla de tanque

2. Desplazarse por la pantalla izquierda hasta 0. La pantalla derecha muestra todos los guiones (----) y los LED en las teclas del tanque, manguera y pistola se vuelven verdes. 3. Pulsar una tecla de desplazamiento en la pantalla derecha. La pantalla derecha parpadea. 4. Utilizar las teclas de desplazamiento de la pantalla derecha para introducir la temperatura de punto de referencia recomendada por el fabricante del adhesivo termofusible. Ver la hoja de datos tcnicos suministrada por el fabricante del adhesivo termofusible para determinar la temperatura de punto de referencia ptima. 5. Pulsar la tecla de tanque. Cada componente empieza a calentar o enfriar a la nueva temperatura de punto de referencia global y el fusor vuelve al modo de exploracin automtica. Cuando todos los componentes alcanzan la temperatura de punto de referencia global, el LED de listo se enciende (verde).

Pantalla izquierda y tecla de desplazamiento

LED de listo

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Revisin de cambios en parmetro y temperatura de punto de referencia

El fusor almacena en un registro de historial de cambios un registro de los diez ltimos cambios que se han hecho a los parmetros de funcionamiento o a las temperaturas de punto de referencia. Debido a que el registro slo almacena diez cambios, las entradas de registro antiguas se sobreescribirn comenzando por la primera entrada de registro, por la entrada once y siguientes.

Para revisar el registro de historial de cambios 1. Pulsar la tecla de ajuste.

Tecla de ajuste

El parmetro de funcionamiento 1 parpadea en la pantalla izquierda. 2. Pulsar la tecla de desplazamiento de la pantalla izquierda para cambiar la pantalla al parmetro 3 (el registro de historial de cambios). Sucede lo siguiente:

S Si el ltimo cambio se ha realizado en un parmetro editable, todos

Pantalla izquierda y tecla de desplazamiento

los LED de teclas de componentes permanecen apagados.

S Si el ltimo cambio que se ha realizado ha sido a una temperatura

de punto de referencia, el LED de la(s) tecla(s) de componente asociada(s) se enciende(n).

S La pantalla derecha indica la entrada de registro de cuatro dgitos

asociada con el ltimo cambio realizado.
LED de tecla de componente

La tabla 3-7 proporciona el significado, de izquierda a derecha, de cada dgito en la entrada de registro. Tras la tabla aparecen dos ejemplos de entradas de registro. 3. Pulsar una tecla de desplazamiento de la pantalla derecha para revisar cada una de las nueve entradas de registro restantes. Cada vez que se presiona una tecla de desplazamiento aparece una entrada de registro anterior. 4. Pulsar la tecla de ajuste para volver al modo de exploracin automtica.

Desplazamiento por el registro

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Table 3-7 Registro de historial de cambios Primer dgito Segundo dgito Tercer y cuarto dgito
Indica el nmero del parmetro que se ha cambiado Se utilizan junto con los LED en las teclas de componente para indicar la localizacin y el mtodo de un cambio en la temperatura de punto de referencia.
Cuando este LED est encendido... Tecla de tanque Y el cuarto dgito indica... 1 1 6 1 6 0 El cambio se ha realizado en... El tanque Una manguera sola Una pistola sola Todos los componentes Todas las mangueras Todas las pistolas Y el mtodo de cambio ha sido... Individual Individual Individual Global Global-porcomponente Global-porcomponente

P (Parmetro)

S (Punto de
referencia)

Tecla de manguera Tecla de pistola Todas las teclas

Tecla de manguera

Tecla de pistola

Ejemplos del registro de historial de cambios Ejemplo 1:

El parmetro 4 (retardo de listo) ha cambiado.

Ejemplo 2:

Si el LED en la tecla de pistola est encendido, entonces esta pantalla indicar que se ha utilizado el mtodo global-por-componente para cambiar la temperatura de las pistolas.

Las entradas del registro sin utilizar en el registro del historial de cambios se indican en la pantalla derecha mediante P-_.

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Instalacin de equipamiento opcional

El siguiente equipamiento opcional puede pedirse para su fusor DuraBlue:

S Tarjetas ampliacin de entrada/salida (I/O) que permiten ampliar el

nmero de entradas de control disponibles.

S Tarjetas de comunicacin que permiten al fusor comunicarse con

otro equipamiento de proceso o controlador utilizando protocolos de red estndar.

S Control de presin automtico que permite al fusor aumentar

automticamente la salida de adhesivo basndose en los requerimientos de produccin.

S Manmetro que proporciona una lectura de presin hidrulica del

distribuidor.

S Interruptor de pie que permite una activacin de la bomba manual. S Kit de control de aire que controla el aire que interviene en el
mdulo de una pistola montada sobre el distribuidor o de una pistola rociadora manual.

S Gancho de pistola manual

Se enva cada pieza del equipamiento opcional con instrucciones para la instalacin y funcionamiento del equipamiento. Ver la seccin 7, Piezas de repuesto, para obtener los nmeros de pieza del equipo.

Conexin de un accionador de pistola, un controlador de encolado o un temporizador

En caso necesario, completar la instalacin del fusor conectando las pistolas al accionador de pistola, el controlador de encolado o el temporizador deseados. Ver el manual de producto suministrado con el dispositivo para obtener informacin acerca de cmo instalar y operar el equipo.

Purga del fusor

Antes de utilizar el fusor para produccin, debera purgarse para eliminar cualquier residuo dejado en la prueba de fbrica. La purga del fusor se realiza procesando un mnimo de volumen de un tanque de adhesivo termofusible a travs de los fusores, mangueras y pistolas. Ver la seccin 4, Manejo, para obtener informacin acerca del llenado del tanque y del funcionamiento del fusor.

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Ajuste de la vlvula de control de presin

Antes de poner el fusor a funcionar de forma normal, ajustar la vlvula de control de presin para alcanzar la cantidad de salida de adhesivo deseada para el proceso de fabricacin. Cuando la lnea est en funcionamiento y las pistolas estn aplicando adhesivo, girar el tornillo de ajuste en la vlvula de control de presin.

S En el sentido de las agujas del reloj para aumentar la salida de

adhesivo

S En el sentido contrario al de las agujas del reloj para disminuir la

Ajuste de la vlvula de control de presin

salida de adhesivo

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Seccin 4

Manejo
AVISO: Riesgo de lesiones personales o daos en el equipo! Ver la informacin de seguridad proporcionada en la seccin 1, Avisos de seguridad, antes del manejo o manipulacin del equipo. El incumplimiento de la informacin de seguridad proporcionada puede provocar lesiones personales, incluyendo la muerte. Esta seccin proporciona informacin acerca de las siguientes tareas a nivel de operario:

S S S S

Llenado del tanque del fusor Puesta en marcha del fusor Control de manejo del fusor Ajuste de la temperatura de funcionamiento de los componentes calefactados

S Utilizacin de las teclas de funcin del fusor S Desconexin del fusor

La mayora de los controles descritos en esta seccin estn localizados en el panel de control detrs de la puerta del teclado. Ver Componentes clave en la seccin 2, Introduccin, para conocer la localizacin del panel de control.

Informacin adicional
Esta seccin presenta los procedimientos de manejo en su forma ms habitual. Las variaciones en el procedimiento o las consideraciones especiales se explican en la tabla de informacin adicional que acompaa a la mayora de los procedimientos. En caso necesario, algunas entradas de tabla contienen tambin informacin con referencias cruzadas. Las tablas de informacin adicional se indican con el smbolo que se muestra a la izquierda.

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Manejo

Ms acerca de los componentes calefactados

El fusor contiene tres grupos de componentes calefactados. stos son: el grupo del tanque, que contiene el tanque y la bomba; el grupo de la manguera y el grupo de la pistola. Los grupos de componente estn representados en el panel de control por las teclas de componente mostradas a la izquierda. Los componentes calefactados dentro de cada grupo estn identificados por su nmero de posicin. La posicin del tanque y de la bomba est fijada en 1. Los nmeros de posicin de la manguera y pistola se asignan automticamente segn el receptculo de manguera/pistola al que estn conectadas. Por ejemplo, los nmeros de posicin de un par de manguera/pistola conectado al segundo receptculo ser posicin de manguera 2 y posicin de pistola 2. Los fusores tienen dos receptculos de manguera/pistola. OBSERVACIN: En algunas instalaciones, puede haber dispositivos auxiliares (como un distribuidor de aire caliente) conectados a un receptculo de manguera/pistola. En tales casos, debe etiquetarse (o identificarse de alguna forma) el dispositivo auxiliar con el nmero de posicin de la manguera o pistola que representa el dispositivo. El panel de control identificar estos dispositivos como una manguera o una pistola, independientemente del tipo de dispositivo que sea.

Teclas de componente (tanque, manguera y pistola)

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Llenado del tanque

Antes de llenar el tanque, confirmar que el material termofusible es compatible con el fusor. Ver Uso propuesto en la seccin 2, Introduccin para obtener informacin acerca de los materiales termofusibles que no deberan emplearse en los fusores DuraBlue.

Para llenar el tanque AVISO: Caliente! Peligro de quemaduras! Utilizar un cubo para llenar el tanque con el adhesivo termofusible. No realizar nunca esta accin con las manos desprotegidas. La utilizacin de las manos al descubierto para llenar el tanque puede provocar lesiones personales. 1. Abrir la tapa del tanque. 2. Utilizar un cubo para llenar el tanque con adhesivo termofusible. La tabla 4-1 enumera la capacidad del tanque en cada fusor DuraBlue. OBSERVACIN: Nordson Corporation recomienda mantener el tanque al menos con la mitad del depsito lleno mientras el fusor est funcionando. 3. Cerrar la tapa del tanque cuando haya terminado de llenar el tanque. Table 4-1 Capacidad del tanque
Llenado del tanque

Modelo
D4L D10L D16L

Capacidad* Litros
4 10 16

Kilos
4 10 16

Libras
9 22 35

*Supone un adhesivo termofusible con una gravedad especfica de 1

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Puesta en marcha del fusor

Antes de poner en marcha el fusor por primera vez, confirmar que:

S El fusor est instalado completamente incluyendo entradas y

salidas requeridas y accionadores de pistola, controladores de encolado o temporizadores.

S Los parmetros de funcionamiento del fusor estn configurados

para soportar el proceso de fabricacin actual. Ver la seccin 3, Instalacin, si alguno de los componentes listados anteriormente no est completo.

Para poner en marcha el fusor 1. Conectar el fusor. El fusor:

Interruptor de control del fusor (conectado/desconectado)

S Comprueba los LED del panel de control S Enciende los calefactores (el LED de los calefactores se pone
verde)

S Empieza a explorar automticamente y mostrar la

temperatura actual del tanque y de cada manguera y pistola que tenga una temperatura de funcionamiento (a partir de aqu denominada temperatura de punto de referencia) superior a cero grados. La secuencia de la exploracin automtica es: Tanque, cada par de manguera y pistola y despus de nuevo el tanque.
LED de calefactores

S Enciende el LED de listo (verde) cuando el tanque y todas las

mangueras y pistolas se encuentran a 3_C (5_F) de la temperatura de punto de referencia asignada. 2. Pulsar la tecla de bomba para activar la bomba.

S Si el sistema no ha alcanzado el estado de sistema listo cuando se

pulsa la tecla de bomba, el LED en la tecla de bomba se volver amarillo indicando que la bomba est activada pero no puesta en marcha. La bomba se pondr en marcha automticamente cuando se haya alcanzado el estado de sistema listo.
Secuencia de exploracin automtica

S Si el sistema ha alcanzado el estado de sistema listo cuando se

pulsa la tecla de bomba, la bomba se pondr en marcha y el LED en la tecla de bomba se volver verde indicando que la bomba est en funcionamiento.

S Si se ajusta el fusor para una activacin manual de la bomba, el

LED de listo

LED de la bomba no se encender ni la bomba se pondr en marcha hasta que sta se ponga en marcha de forma manual mediante el dispositivo de conmutacin. OBSERVACIN: Puede cambiarse el modo en que la tecla de bomba funciona cambiando el parmetro 8 (encendido automtico de bomba). Ver el apndice B, Parmetros de funcionamiento.

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Si el fusor est conectado cuando la temperatura del tanque es de 27_C (50_F) o ms por debajo de su temperatura de punto de referencia asignada (condicin de arranque en fro), el LED de listo no se encender hasta que el retardo de listo (definido cuando se configur el fusor) haya desaparecido. El tiempo restante en el retardo de listo (en minutos) aparece en la pantalla derecha al final del cada ciclo de exploracin. Cuando slo queda un minuto en el tiempo de retardo de listo, la pantalla derecha realiza una cuenta atrs en segundos. Puede pasarse por alto el tiempo de retardo de listo pulsando la tecla de calefactores dos veces La aparicin de F4 en la pantalla derecha inmediatamente despus de conectar el fusor indica un problema con el procesador o el cuadro principal del fusor. La aparicin de F1 en la pantalla derecha inmediatamente despus de poner en marcha el fusor indica que puede haber un latiguillo de manguera o pistola desprendido o desconectado. Si se ajusta el fusor para una activacin de bomba manual y se ha cambiado el preajuste del parmetro 7 (retardo de motor apagado), la bomba no se parar hasta que haya transcurrido un tiempo especificado por el usuario. La condicin de una o ms entradas puede prevenir que los calefactores se enciendan. Si se ha ajustado la funcin del reloj programador semanal y se ha encendido la ltima vez que se ha desconectado el fusor, el reloj se encender automticamente la prxima vez que se conecte el fusor.

Apndice B, parmetro 4

Apndice B, parmetro 4

Control de fallos del fusor

Seccin 6, Localizacin de averas

Apndice B, parmetro 7

Instalacin de entradas de fusor en la seccin 3, Instalacin Utilizacin de las teclas de funcin del fusor

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Vigilancia del fusor

El fusor dispone de indicadores que permiten:

S Confirmar rpidamente que el fusor est funcionando

correctamente.

S Vigilar la temperatura actual del grupo del tanque y de cada

manguera y pistola.

S Identificar los fallos del fusor.

El fusor determina automticamente el nmero y la localizacin de todas las mangueras y pistolas que estn conectadas al mismo. Ver el apartado Ms acerca de los componentes calefactados, anteriormente en esta seccin, para obtener informacin acerca de la capacidad de manguera/pistola y de la identificacin de los componentes calefactados.

Confirmar que el fusor est funcionando correctamente

El LED de listo se enciende (verde) cuando todos los componentes calefactados se encuentran a 3_C (5_F) de la temperatura de punto de referencia. El LED de listo no se encender, ni apagar, si sucede algo de lo siguiente:
LED de listo

S S S S

El retardo de listo sigue realizando la cuenta atrs. El operario o una entrada remota pone el fusor en modo de reposo. El reloj programador semanal pone el fusor en modo de reposo. Existe un fallo (el LED de fallo se enciende):

Ver el apartado Control de fallos del fusor y Utilizacin de las teclas de funcin del fusor, ms adelante en esta seccin, para obtener informacin acerca de los fallos del fusor y la utilizacin del reloj programador semanal y las funciones de reposo. Ver el apndice B, Parmetros de funcionamiento, para obtener informacin acerca del retardo de listo.

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Los componentes calefactados con una temperatura de punto de referencia de cero grados se pasan por alto durante el ciclo de exploracin automtica. La temperatura de punto de referencia del tanque y de la bomba no pueden ajustarse de forma independiente. El tiempo restante en el retardo de listo aparece en la pantalla derecha al final de cada ciclo de exploracin. Puede anular el reloj programador semanal en cualquier momento. Si el temporizador ha apagado los calefactores, puede pulsarse la tecla de calefactores para volver a encenderlos. Si el temporizador ha puesto el fusor en modo de reposo, puede pulsarse la tecla de reposo para volver a poner los componentes calefactados a su temperatura de punto de referencia asignada. Apndice B, parmetro 4

Utilizacin de las teclas de funcin del fusor

Control de temperaturas de componente

Puede comprobar la temperatura actual de cada componente calefactado (el tanque y cada manguera y pistola) utilizando el modo de exploracin automtica o seleccionando manualmente y comprobando cada componente. De forma predeterminada, el fusor permanece en modo de exploracin automtica excepto cuando:

S El fusor est ajustado en modo de ajuste. S La temperatura de punto de referencia de todas las mangueras y
pistolas est establecida en cero grados.

S Ocurre un fallo.
Para comprobar las temperaturas de componente con el modo de exploracin automtica 1. Cuando el LED de listo est encendido, observar los LED en las teclas de componente. 2. Cuando el LED de la tecla que representa el grupo de componente deseado (tanque, manguera o pistola) se enciende, observar la pantalla izquierda hasta que sta indica el nmero de posicin del componente especfico que se desea comprobar. 3. Cuando el nmero de posicin del componente deseado aparece en la pantalla izquierda, observar la pantalla derecha para determinar la temperatura actual del componente.

LEDs en teclas de componentes

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Para comprobar una temperatura de componente de forma manual 1. Pulsar la tecla (tanque, manguera o pistola) que representa el grupo de componentes que se quiere comprobar. La exploracin automtica se para y la pantalla izquierda indica el nmero del primer componente secuencial en el grupo de componente seleccionado. La pantalla derecha indica la temperatura actual del componente. OBSERVACIN: Cuando se pulsa la tecla de tanque, no se muestra a la izquierda ningn nmero de componente (pantalla en blanco). 2. Si el primer componente secuencial no es el componente que quiere comprobarse, utilizar la tecla de desplazamiento de la pantalla izquierda para corregir el nmero de componente. La pantalla derecha indica la temperatura actual del componente seleccionado. 3. Pulsar dos veces la tecla de ajuste para volver al modo de exploracin automtica.

Pantalla izquierda y tecla de desplazamiento

Pantalla de temperatura de componente

Al desplazarse por la pantalla izquierda, pasar el nmero del ltimo componente secuencial en un grupo de componente. En la pantalla izquierda aparece el nmero del primer componente secuencial en el siguiente grupo de componente. El fusor volver al modo de exploracin automtica dos minutos despus de pulsar la ltima tecla. Cuando se pulsa la tecla de tanque, aparece concretamente la temperatura de la bomba en la pantalla derecha. Para comprobar la temperatura actual del tanque, pulsar simultneamente la tecla de tanque y la tecla de desplazamiento de la pantalla izquierda. La unidad predeterminada para mostrar la temperatura es grados Celsius (C). sta puede cambiarse a grados Fahrenheit utilizando el parmetro de funcionamiento 20. Los LED en cada tecla de componente cambiarn de verde a amarillo si algn componente en el grupo de componente baja ms de 3_C (5_F) por debajo de su temperatura de punto de referencia asignada. Apndice B, parmetro 20

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Control de fallos del fusor

El fusor alerta al operario de las siguientes condiciones de fallo:

S Cualquier componente est por encima o por debajo de su

temperatura de punto de referencia.

S Un RTD falla S El procesador central falla S El cuadro principal falla

Cuando se produce un fallo, el fusor: 1. Enciende el LED de fallo (rojo). 2. Apaga el LED de listo.
LED de fallo (rojo)

3. Apaga los calefactores y la bomba (los LED en la tecla de calefactor y bomba se apagan):
LED de listo

4. Detiene la exploracin automtica de la siguiente manera:

S Para los fallos de sobretemperatura, temperatura baja y fallos RTD,

el LED en la tecla de componente que representa el componente con fallo se pone amarillo.

S Para los fallos del procesador y del cuadro principal, se apagan

todos los LED de las teclas de componente. 5. Indica el nmero del componente fallido en la pantalla izquierda. OBSERVACIN: Si el LED de tecla de tanque est en amarillo, la pantalla izquierda mostrar un 1 para el tanque y un 2 para la bomba. 6. Indica el cdigo de fallo (F1, F2, F3 o F4) en la pantalla derecha. La tabla 4-3 describe cada cdigo de fallo.
Pantalla tpica de cdigo de fallo

Antes de poder volver a encender los calefactores, el fallo deber ser corregido y el fusor reiniciado. El fusor mantiene un registro de los diez ltimos fallos en un registro de fallos. Puede revisarse el registro de fallos en cualquier momento.

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Para reiniciar el fusor 1. Corregir la condicin de fallo y volver a establecer el fusor en modo de exploracin automtica. Ver la seccin 6, Localizacin de averas, para obtener informacin acerca del anlisis y la correccin de fallos. 2. Desconectar el fusor y volver a conectarlo. El fusor se reinicia. 3. Pulsar la tecla de calefactor para encender los calefactores. 4. Reanudar el funcionamiento normal.

Tecla de calefactor

Table 4-2 Cdigos de fallo Cdigo de fallo

F1

Tipo de fallo
RTD

Descripcin
El RTD para el componente indicado en la pantalla derecha ha fallado o el componente ha sido desconectado del fusor. La temperatura actual del componente indicada en la pantalla derecha ha cado por debajo del delta de temperatura baja, que ha sido ajustado con el parmetro 22. La temperatura actual del componente indicada en la pantalla derecha ha aumentado por encima del delta de sobretemperatura, que ha sido ajustado con el parmetro 21. Existe un problema con el procesador central o cuadro principal.

F2

Temperatura baja

F3

Sobretemperatura

F4

Fallo de control

Para ver la temperatura de un componente calefactado al tiempo que se produce un fallo F2 o F3, pulsar simultneamente y mantener las dos teclas de desplazamiento de la pantalla derecha. Cuando aparece un cdigo de fallo F1, puede determinarse si el fallo fue causado por un RTD abierto o abreviado, pulsando simultneamente las dos teclas de desplazamiento en la pantalla derecha. Si en la pantalla derecha aparece OP, el RTD est abierto; si aparece SH, se ha abreviado el RTD. Cuando se produce un fallo F4, escribir el subcdigo que aparece en la pantalla izquierda. El departamento de servicios tcnicos de Nordson necesitar el subcdigo si llama solicitando apoyo tcnico.

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Para revisar el registro de fallos 1. Pulsar y mantener la tecla de ajuste. La exploracin automtica se para y el parmetro de funcionamiento 1 aparece en la pantalla izquierda.
Tecla de ajuste

2. Desplazarse por la pantalla izquierda al parmetro 2 (el registro de fallos). La pantalla derecha indica el ltimo fallo que se produjo de la siguiente manera:

S Si el ltimo fallo ha sido un fallo F1, F2 o F3, entonces el LED en la

tecla de componente afectada se vuelve amarillo.

S Si el ltimo fallo que se ha producido ha sido un fallo F4, entonces

los LED en todas las teclas de componente se apagan.

S La pantalla derecha muestra la entrada de registro para el ltimo

Pantalla izquierda y tecla de desplazamiento

fallo ocurrido. La tabla 4-4 proporciona el significado de cada dgito en la entrada de registro. Despus de la tabla aparecen dos ejemplos de entradas de registro de fallos. 3. Pulsar una tecla de desplazamiento de la pantalla derecha para revisar cada una de las nueve entradas de registro restantes. Cada vez que se presiona una tecla de desplazamiento aparece una entrada de registro anterior. OBSERVACIN: El registro de fallos almacena nicamente los diez ltimos fallos. Despus de producirse diez fallos, las entradas de registro existentes se sobreescriben, empezando por la entrada ms antigua, por la once y las siguientes entradas de registro. 4. Pulsar la tecla de ajuste para volver al modo de exploracin automtica.

Desplazamiento por el registro de fallos

Table 4-3 Registro de fallos Primer dgito

Componente:
1 = Tanque o manguera/pistola 1 2 = Bomba o manguera/pistola 2 3 = Manguera 3 o pistola 3 4 = Manguera 4 o pistola 4 5 = Manguera 5 o pistola 5 6 = Manguera 6 o pistola 6

Segundo y tercer dgito

Cuarto dgito
Tipo de fallo:
0 = Entrada de registro sin usar 1 = RTD (abierto o abreviado) 2 = Temperatura baja de componente 3 = Sobretemperatura de componente

-F

Subcdigo para fallo F4:

Asignado por Nordson

Tipo de fallo:
4 = Procesador o fallo elctrico

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Ejemplos de registro de fallos Ejemplo 1:

Una entrada de registro sin usar. Ejemplo 2:

Si el LED en la tecla de tanque estuviera encendido, esta entrada de registro indicara que el tanque est a temperatura baja. Si el LED en la tecla de manguera estuviera encendido, esta entrada de registro indicara que la manguera 1 est a temperatura baja.

Para ver el nmero de horas que los calefactores han estado encendidos cuando se cre una entrada de registro, pulsar simultneamente las dos teclas de desplazamiento bajo la pantalla derecha. El nmero de horas aparece en la pantalla derecha. Si el registro de fallos se deja abierto por un periodo de dos minutos sin pulsar ninguna tecla, el fusor volver al modo de exploracin automtica. Cuando un fallo F1 es el resultado de la desconexin del fusor de un par de manguera/pistola, se crean dos entradas de registro de fallos. La primera entrada es para la pistola y la segunda para la manguera.

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Ajuste de temperaturas de componente

Puede ajustarse la temperatura de punto de referencia del componente calefactado utilizando los siguientes mtodos:

S Global: El tanque y todas las mangueras y pistolas se ajustan a la

misma temperatura de punto de referencia.

S Global-por-grupo de componente: Todas las mangueras o todas

las pistolas se ajustan a la misma temperatura de punto de referencia.

S Componente individual: La temperatura de punto de referencia del

tanque y de cada manguera y pistola se establece de forma individual. Antes de ajustar las temperaturas de punto de referencia, confirmar que cada par de manguera/pistola est conectado al receptculo de manguera/pistola. Por ejemplo, el par de manguera/pistola 1 deber estar conectado al receptculo 1. Ver Ms acerca de los componentes calefactados tratado con anterioridad en esta seccin para obtener informacin acerca de las posiciones de manguera/pistola.

Para ajustar las temperaturas de punto de referencia utilizando el mtodo global 1. Pulsar durante tres segundos la tecla de tanque. En la pantalla izquierda parpadea 1. 2. Desplazarse por la pantalla izquierda hasta 0 (parpadeando).
Tecla de tanque

La pantalla derecha muestra todos los guiones (----) y los LED de todas las teclas de componente se vuelven verdes. 3. Pulsar una tecla de desplazamiento en la pantalla derecha. La pantalla derecha parpadea. 4. Utilizar las teclas de desplazamiento de la pantalla derecha para introducir la temperatura de punto de referencia recomendada por el fabricante del adhesivo termofusible. Ver la hoja de datos tcnicos suministrada por el fabricante del adhesivo termofusible para determinar la temperatura de punto de referencia ptima. 5. Pulsar la tecla de tanque. Todos los componentes empiezan a calentarse o enfriarse a la nueva temperatura de punto de referencia global. Cuando todos los componentes alcanzan su temperatura de punto de referencia, el LED de listo se enciende (verde).

Tecla Enter

Pantalla izquierda y tecla de desplazamiento

LED de listo

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Para ajustar la temperatura de punto de referencia utilizando el mtodo global por componente 1. Pulsar y mantener la tecla de manguera o la tecla de pistola durante tres segundos. La pantalla izquierda indica el nmero de la primera manguera o pistola secuencial. La pantalla derecha indica la temperatura de punto de referencia actual de la manguera o la pistola. 2. Desplazarse por la pantalla izquierda hasta 0.
Teclas de tanque, manguera y pistola

La pantalla derecha muestra todos los guiones (- - - -). 3. Pulsar una tecla de desplazamiento en la pantalla derecha. La pantalla derecha parpadea. 4. Utilizar las teclas de desplazamiento de la pantalla derecha para introducir la temperatura de punto de referencia recomendada por el fabricante del adhesivo termofusible. Ver la hoja de datos tcnicos suministrada por el fabricante del adhesivo termofusible para determinar la temperatura de punto de referencia ptima. 5. Pulsar la tecla de desplazamiento en la pantalla izquierda. Las mangueras o pistolas comienzan a calentarse o enfriarse a su nueva temperatura de punto de referencia. Cuando todas las mangueras o pistolas alcanzan su temperatura de punto de referencia, el LED de listo se enciende (verde).

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Para ajustar la temperatura de punto de referencia de un componente individual 1. Pulsar durante tres segundos la tecla de tanque, la tecla de manguera o la tecla de pistola. Si se ha pulsado la tecla del tanque, la pantalla izquierda muestra 1. Si se ha pulsado una tecla de manguera o pistola, la pantalla izquierda muestra el nmero de la primera manguera o pistola secuencial. La pantalla derecha muestra la temperatura de punto de referencia actual del componente indicado en la pantalla izquierda. 2. Desplazarse por la pantalla izquierda hasta el nmero de componente deseado. La pantalla derecha muestra todos los guiones (parpadeando), y el LED de la tecla del grupo de componente se vuelve verde. 3. Pulsar una tecla de desplazamiento en la pantalla derecha. La pantalla derecha parpadea. PRECAUCIN: La reduccin de la temperatura de punto de referencia de algn componente en una cantidad mayor que el delta de sobretemperatura (parmetro 21) causar un fallo de sobretemperatura (F3). 4. Utilizar las teclas de desplazamiento de la pantalla derecha para introducir la temperatura de punto de referencia recomendada por el fabricante del adhesivo termofusible. Ver la hoja de datos tcnicos suministrada por el fabricante del adhesivo termofusible para determinar la temperatura de punto de referencia ptima. 5. Realizar una de las siguientes acciones:

S Para registrar la nueva temperatura de punto de referencia y

moverse despus para cambiar la temperatura de punto de referencia del siguiente componente secuencial, pulsar la tecla Enter y repetir despus los pasos 4 y 5.

S Para registrar la nueva temperatura de punto de referencia y volver

al modo de exploracin automtica ir al paso 6. 6. Pulsar cualquier tecla de componente (tanque, manguera o pistola). El componente seleccionado empieza a calentarse o enfriarse a la nueva temperatura de punto de referencia. Cuando el componente alcanza su temperatura de punto de referencia, el LED de listo se enciende (verde).

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Si se introduce una temperatura de punto de referencia vlida para una manguera/pistola que no est conectada al fusor o si se introduce una temperatura de punto de referencia que est fuera del rango, la pantalla derecha mostrar guiones (----) durante tres segundos y despus volver a la temperatura de punto de referencia original. Si se utiliza el mtodo global o global por componente del ajuste de temperatura de punto de referencia y despus se elimina o aade una manguera/pistola, deber ajustarse o configurarse la temperatura de punto de referencia de la manguera o pistola afectada. Cuando se elimina una manguera o pistola, utilizar el mtodo de componente individual para ajustar la temperatura de punto de referencia del componente eliminado a cero grados (apagado). Esto evitar un fallo F1. Cuando se aade una manguera o pistola, utilizar el mtodo de componente individual para ajustar la temperatura deseada. La temperatura de punto de referencia de fbrica del tanque es de 175_C (350_F). La temperatura de punto de referencia de fbrica de todos los dems componentes es de cero grados (apagados). Cuando se establecen las unidades de temperatura en grados Celsius, las temperaturas de punto de referencia mnimas y mximas son de 40_C y 230_C. Cuando las unidades de temperatura se establecen en grados Fahrenheit, las temperaturas de punto de referencia mnimas y mximas son de 100_F y 450_F. Tambin pueden utilizarse las teclas de desplazamiento de la pantalla derecha para ajustar una temperatura de punto de referencia. Cuando se utilizan las teclas de desplazamiento, la pantalla derecha aumenta de forma automtica entre 0, 175 y 230_C o entre 0, 350 y 450_F. El fusor saldr del modo de ajuste y volver al modo de exploracin automtica dos minutos despus de pulsar la ltima tecla. Una temperatura de punto de referencia global de cero grados (Celsius o Fahrenheit) apaga todos los componentes. Al desplazarse por los nmeros de componente en la pantalla izquierda, se pasan por alto los nmeros de componente asociados a receptculos de manguera/pistola no utilizados. El fusor almacena un registro de los diez ltimos cambios realizados en las temperaturas de punto de referencia (y parmetros de funcionamiento) en el registro de historial de cambios.

Revisin de cambios en parmetro y temperatura de punto de referencia en la seccin 3, Instalacin

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Utilizacin de las teclas de funcin del fusor

El panel de control ofrece las siguientes teclas estndar y teclas de funcin especiales:

Teclas de funcin estndar

S Calefactor S Bomba S Ajuste

Teclas de funcin especiales

S Reloj programador semanal S Reposo

PRECAUCIN: La activacin accidental de las teclas de funcin puede, en ciertas circunstancias, tener efectos no deseados en el fusor o en el proceso de fabricacin. nicamente el personal familiarizado con la preparacin del fusor y con su conexin con el proceso de fabricacin debera utilizar las teclas de funcin. El uso indebido de las teclas de funcin puede provocar un comportamiento errneo del proceso o lesiones personales.

Tecla de calefactor
La tecla de calefactor se utiliza para encender y apagar de forma manual los calefactores de componente. Al pulsar la tecla de calefactor se anula el control (encendido o apagado) de los calefactores, bien por la funcin del reloj programador semanal, bien por una entrada remota. El LED en la tecla de calefactor se enciende cuando los calefactores estn encendidos. Cuando se produce un fallo (ver Control de fallos del fusor, anteriormente en esta seccin) los calefactores se apagan automticamente. La tecla de calefactor se utiliza para volver a encender los calefactores despus de corregir una condicin de fallo.

Tecla de calefactor

Tecla de bomba
La tecla de bomba se utiliza para activar, poner en marcha y parar la bomba. El LED de la tecla de bomba est amarillo cuando la bomba est activada (no en funcionamiento) y verde cuando la bomba est en funcionamiento. El encender o apagar la bomba no afecta al control de los calefactores. Si la caracterstica de encendido automtico de bomba (parmetro 8) est desactivada, entonces la tecla de bomba debe utilizarse para poner en marcha la bomba cuando el fusor est listo. Si se establece alguna de las entradas para utilizar la opcin de control activar/desactivar de la bomba, el LED de tecla de bomba debe estar encendido antes de encender la bomba.

Tecla de bomba

E 2002 Nordson Corporation

Manual 41-DURABLUE-MA-02

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4-18 Manejo

Tecla de ajuste
La tecla de ajuste se utiliza para poner y quitar el fusor en el modo de ajuste. Cuando se pone el fusor en modo de ajuste, la exploracin automtica se para y las pantallas izquierda y derecha se utilizan para seleccionar y leer o editar los parmetros de funcionamiento.
Tecla de ajuste

Tecla de reloj programador semanal

La tecla de reloj programador semanal enciende y apaga la funcin de reloj del fusor. Cuando el reloj est encendido, la temperatura de cada componente calefactado es regulada automticamente basndose en un grupo de programas definidos por el usuario.
Tecla de reloj programador semanal

Para adaptar el trabajo por turnos diario y los das no laborables pueden establecerse programas de cuatro relojes. Tres de los programas se utilizan para especificar cundo deben encenderse y apagarse los calefactores o cundo debe el fusor entrar o salir del modo de reposo. El cuarto programa se utiliza para los das en los que el fusor debe estar apagado. Cuando un programa de reloj llama a los calefactores para que se enciendan, los calefactores estn regulados por sus temperaturas de punto de referencia asignadas previamente. Cuando el reloj activa el modo de reposo, la temperatura de punto de referencia de cada componente se reduce temporalmente por un delta de reposo predeterminado. Ver Configuracin del fusor en la seccin 3, Manejo, as como el apndice B, Parmetros de funcionamiento para obtener informacin acerca del ajuste del reloj programador semanal y del delta de reposo.

Si el fusor est desconectado mientras el reloj est encendido, el reloj volver a encenderse automticamente la prxima vez que vuelva a conectarse el fusor. Si se apagan los calefactores manualmente cuando un programa de reloj los llama para que se enciendan, stos no volvern a encenderse hasta la prxima vez que el programa de reloj los llame para encenderse. El reloj funcionar incluso si el fusor tiene fallos o est en modo de ajuste.

P/N 213716A

Manual 41-DURABLUE-MA-02

E 2002 Nordson Corporation

Manejo

4-19

Tecla de reposo
La tecla de reposo se utiliza para poner y sacar manualmente el fusor del modo de reposo. La utilizacin del modo de reposo en periodos de tiempo en los que el fusor est inactivo ayuda a conservar energa y permite a los componentes calefactados volver rpidamente a sus temperaturas de punto de referencia cuando se vuelva a necesitar el fusor. Cuando el fusor est puesto en el modo de reposo, un delta de reposo preajustado reduce las temperaturas de todos los componentes desde su temperatura de punto de referencia. El fusor permanecer en el modo de reposo hasta que se pulse la tecla de reposo o hasta que la funcin de uno de los parmetros de funcionamiento saque el fusor del modo de reposo. Si el fusor se ajust para utilizar el temporizador de reposo manual (parmetro 26), la utilizacin de la tecla de reposo pondr al fusor en el modo de reposo por un periodo de tiempo especificado por el temporizador. Despus de haber transcurrido el tiempo de reposo manual, el fusor volver a empezar a calentar todos los componentes a su temperatura de punto de referencia asignada. La utilizacin de la tecla de reposo anula el control del fusor (encendido o apagado) por el reloj programador semanal o una entrada remota Ver Configuracin del fusor en la seccin 3, Manejo, as como el apndice B, Parmetros de funcionamiento para obtener informacin acerca del ajuste del delta de reposo y del temporizador de reposo.

Tecla de reposo

El fusor puede volver a ajustarse para que entre de forma automtica en el modo de reposo utilizando una variedad de parmetros de funcionamiento.

Apndice B, parmetros 25, 26, 3033, 57, 62 y 67

E 2002 Nordson Corporation

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4-20 Manejo

Desconexin del fusor

Desconectar el fusor cuando no se va a utilizar durante un periodo de tiempo prolongado.

Para desconectar el fusor 1. Desconectar el fusor. 2. Desactivar las pistolas como sigue:

S Pistolas manejadas por aire: Apagar el suministro de aire a las

pistolas.

S Pistolas elctricas: Apagar el accionador de pistola, el controlador

Interruptor de control del fusor (conectado/desconectado)

de encolado o el temporizador.

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E 2002 Nordson Corporation

Mantenimiento

5-1

Seccin 5

Mantenimiento
AVISO: Riesgo de lesiones personales o daos en el equipo! Ver la informacin de seguridad proporcionada en la seccin 1, Avisos de seguridad, antes del manejo o mantenimiento del equipo. El incumplimiento de la informacin de seguridad proporcionada puede provocar lesiones personales, incluyendo la muerte. La tabla 5-1 describe las tareas de mantenimiento preventivo requeridas para mantener los fusores DuraBlue funcionando dentro sus lmites establecidos y para prevenir el malfuncionamiento del equipo. Para obtener informacin acerca del mantenimiento de equipamiento opcional suministrado por Nordson, ver las instrucciones proporcionadas con el equipo. Si el fusor deja de funcionar o si funciona incorrectamente, ver la seccin 6 Localizacin de averas, para obtener informacin acerca de cmo diagnosticar problemas comunes y realizar el mantenimiento correctivo.

Table 5-1 Tareas de mantenimiento preventivo Tarea

Eliminar la presin del sistema

Frecuencia
Antes de llevar a cabo alguna tarea de mantenimiento que requiera la apertura de una conexin hidrulica o puerto Diaria

Referencia
Eliminar la presin del sistema

Limpieza del exterior del fusor, mangueras y pistolas Sustitucin del filtro OBSERVACIN: Algunos fusores DuraBlue no tienen filtro.

Limpieza del fusor

S S S S

Cuando sea necesario Cuando se cambia el tipo o el grado del adhesivo termofusible Cuando se cambia el tipo o el grado del adhesivo termofusible Cuando se produce una carbonizacin excesiva

Sustitucin del filtro

Hoja de instrucciones proporcionada con filtro de repuesto

Limpieza del tanque

Limpieza del tanque

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Mantenimiento

Eliminar la presin del sistema

Antes de desconectar algn racor hidrulico o abrir algn puerto sometido a presin, completar siempre previamente el siguiente procedimiento para eliminar de forma segura la presin hidrulica que puede estar atrapada dentro del fusor, las mangueras y pistolas.

Para eliminar la presin del sistema 1. Pulsar la tecla de bomba para parar la bomba. 2. Accionar las pistolas hasta que no salga ms adhesivo termofusible de las mismas.
Tecla de bomba

Limpieza del fusor

Para evitar el sobrecalentamiento de los componentes debido a la acumulacin de calor o a la falta de circulacin de aire, eliminar regularmente el adhesivo termofusible que se deposite en el exterior del fusor, mangueras y pistolas. Si de forma inadvertida entra adhesivo termofusible en los espacios interiores del fusor, los paneles exteriores pueden extraerse para limpiar el adhesivo termofusible cado. AVISO: Peligro de electrocucin y fuego! No limpiar el fusor con un chorro directo de agua o vapor. Utilizar nicamente agua o una solucin de limpieza apropiada no inflamable que se aplicar con un trapo limpio. La limpieza del fusor con un chorro directo de agua o vapor, o con un disolvente inflamable puede provocar daos materiales o lesiones personales, incluyendo la muerte.

Para limpiar el exterior del fusor

S Utilizar nicamente compuestos de limpieza compatibles con polister. S Aplicar compuestos de limpieza con un trapo suave. S No utilizar herramientas punzantes o afiladas para limpiar la superficie
exterior.

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E 2002 Nordson Corporation

Mantenimiento

5-3

Para extraer y sustituir los paneles exteriores Ver la figura 5-1. 1. Desconectar la circulacin de corriente del fusor. Ver la seccin 1, Avisos de seguridad. 2. Utilizar una llave de cabeza hexagonal de 4 mm (5/32 pulgadas) para girar el pasador de 1/2 vuelta localizado en el centro de cada panel lateral en el sentido contrario al de las agujas del reloj. 3. Sacar el panel fuera del marco del fusor. 4. Realizar en orden inverso los pasos 2 y 3 para volver a instalar cada panel.

Figure 5-1

Extraccin de los paneles exteriores

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5-4

Mantenimiento

Sustitucin del filtro

Algunos fusores DuraBlue estn equipados con un filtro de termofusin desechable de malla 100 (0,15 mm). El filtro elimina restos y carbonilla del adhesivo termofusible cuando ste fluye desde el tanque. El adhesivo termofusible fluye desde dentro hacia fuera del filtro, atrapando los contaminantes dentro del filtro. No es necesario volver a purgar o limpiar el filtro. Cuando el filtro llega al final de su vida til, deber reemplazarse. Los factores que determinan la vida til del filtro son:

S El tipo, grado y pureza del adhesivo termofusible en forma slida. S La temperatura de punto de referencia del tanque. S El periodo de tiempo que el adhesivo termofusible permanece en el
tanque. El filtro debera ser reemplazado tambin cuando se cambie a un tipo o grado diferente de adhesivo termofusible. Para determinar la vida til ptima para el filtro, controlar y comparar el nmero total de horas que los calefactores estn encendidos, teniendo en cuenta:

S La pureza del adhesivo termofusible aplicado. S Aumentos en la presin de trabajo S La frecuencia de sustitucin o limpieza de la boquilla de pistola.
Ruta de flujo del adhesivo termofusible

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E 2002 Nordson Corporation

Mantenimiento

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Para sustituir el filtro 1. Eliminar la presin del sistema. Ver Eliminacin de la presin del sistema en la primera parte de esta seccin.
Tecla de bomba

2. Utilizar una llave de cabeza hexagonal de 8 mm (5/16 pulgadas) o una llave ajustable para aflojar (en el sentido contrario al de las agujas del reloj) y despus extraer el filtro. 3. Desechar el filtro antiguo de la forma apropiada. 4. Confirmar que la junta trica en el nuevo filtro est en buenas condiciones. 5. Atornillar el filtro en el cuerpo de bomba y despus apretar el filtro a 4,5 Nm (40 pulgadas-libras). 6. Reanudar el funcionamiento normal.

Aflojar el filtro

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Mantenimiento

Limpieza del tanque

Para evitar los problemas que pueden producirse cuando se mezclan diferentes materiales termofusibles o cuando se forma carbonilla en el tanque, limpiar el tanque cuando:

S Se cambie a un tipo de adhesivo termofusible diferente. S Se genera demasiada carbonilla dentro del tanque.
OBSERVACIN: Los procedimientos del tanque del limpiar en esta seccin requieren la utilizacin de material purgante adecuado. El material purgante deber ser compatible con el adhesivo antiguo y con el nuevo adhesivo, en caso necesario.

Para limpiar el tanque al cambiar el adhesivo termofusible 1. Funcionar normalmente con el fusor hasta que se vace el tanque. 2. Pulsar la tecla de bomba para parar la bomba. 3. Permitir que el fusor se caliente o enfre a la temperatura recomendada por el fabricante del material purgante.
Tecla de bomba

4. Limpiar cualquier resto de adhesivo termofusible de dentro del tanque siempre llevando el equipo de proteccin apropiado.

PRECAUCIN: Para evitar daos en el equipo, el material purgante utilizado debe ser compatible con el adhesivo usado previamente y, en caso necesario, con el nuevo adhesivo que se va a utilizar. 5. Aadir el tipo y la cantidad apropiados de material purgante al tanque. 6. Pulsar la tecla de bomba para arrancar la bomba. 7. Bombear todo el material purgante desde el tanque y a travs de las mangueras y bombas. 8. Volver a poner el fusor en funcionamiento normal y bombear un mnimo de volumen de un tanque de adhesivo termofusible nuevo a travs del tanque, las mangueras y las pistolas.

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E 2002 Nordson Corporation

Mantenimiento

5-7

Para limpiar el tanque de carbonilla excesiva 1. Extraer el adhesivo termofusible usado y eliminar la carbonilla de la siguiente manera: a. Funcionar normalmente con el fusor hasta que se vace el tanque. b. Pulsar la tecla de bomba para parar la bomba.
Tecla de bomba

c. Permitir que el fusor se caliente o enfre a la temperatura recomendada por el fabricante del disolvente de termofusin. d. Limpiar cualquier resto de adhesivo termofusible y eliminar la carbonilla de dentro del tanque siempre llevando el equipo de proteccin apropiado. e. Extraer el prensaestopas del tanque, limpiarlo con un disolvente adecuado y volver a instalarlo. 2. Aadir el tipo y la cantidad apropiados de disolvente de termofusin al tanque. 3. Desconectar una manguera de una pistola y desechar la manguera en un recipiente de desecho. 4. Cerrar la vlvula de control de presin girando la misma completamente en el sentido de las agujas del reloj.

Prensaestopas del tanque

AVISO: Peligro de quemaduras. Llevar equipo de proteccin tener cuidado el bombear material caliente a un recipiente de desecho. 5. Pulsar la tecla de bomba para arrancar la bomba. 6. Cuando el tanque est vaco, parar la bomba. 7. Llenar el tanque con adhesivo nuevo. 8. Repetir los pasos 5 y 6 para bombear todo el adhesivo fuera del tanque. 9. Volver a conectar la manguera desconectada a la pistola correspondiente. 10. Sustituir el filtro. Vea Sustitucin del filtro anteriormente en esta seccin. 11. Llenar el tanque con adhesivo nuevo y purgar todas las mangueras y pistolas con el mismo. 12. Restablecer el funcionamiento normal del sistema.

Cierre de la vlvula de control de presin

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Mantenimiento

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E 2002 Nordson Corporation

Clculo de requerimientos de tensin del fusor

A-1

Apndice A

Clculo de requerimientos de tensin del fusor

Antes de ubicar el fusor en el rea de produccin o de ajustar mangueras y pistolas al mismo, debe calcularse la tensin elctrica requerida por las mangueras y pistolas y confirmar que la tensin requerida no excede el vatiaje mximo admitido. El clculo apropiado de los requerimientos de tensin del fusor previene daos en el fusor e identifica la distancia mxima admitida entre el fusor y el punto en el que se aplica el adhesivo termofusible. Hay tres vatiajes mximos que deben considerarse al calcular los requerimientos de tensin del fusor. Se trata de los siguientes:

S Mximo de componente individual: El vatiaje de cualquier

manguera o pistola individual

S Mximo de par de manguera/pistola: El vatiaje combinado de

cualquier manguera y pistola (par de manguera/pistola)

S Mximo de dos pares de manguera/pistola: El vatiaje combinado

de los pares de manguera/pistola 1 y 2 Si su representante Nordson ha calculado ya los requerimientos de tensin de la manguera/pistola y confirmado que no se sobrepasarn los vatiajes mximos admitidos, entonces no es necesario realizar ningn clculo ms. Sin embargo, deberan volver a evaluarse los requerimientos de tensin de la manguera y pistola antes de:

S Aadir una nueva manguera o pistola al fusor que no se ha tenido

en cuenta en la evaluacin de vatiaje original.

S Sustituir una manguera existente por una manguera ms larga o

una pistola existente por una pistola mayor.

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A-2

Clculo de requerimientos de tensin del fusor

Para evaluar los requerimientos de tensin de la manguera/pistola 1. Identificar todos los pares de manguera/pistola con base en el receptculo de manguera/pistola a los que stos estn conectados. 2. Examinar el rtulo o la placa de identificacin de cada manguera y pistola y registrar el vatiaje de cada uno en la columna A de la tabla A-1. Introducir un cero por cada manguera o pistola que no estn instalada. 3. Aadir los vatiajes de cada par de manguera/pistola y colocar la suma en la columna B de la tabla A-1. 4. Aadir los vatiajes de los pares de manguera/pistola 1 y 2 y colocar la suma en la columna C de la tabla A-1. 5. Comparar cada uno de los vatiajes introducidos en las columnas A, B y C de la tabla A-1 con los vatiajes mximos admitidos asociados en la tabla A-2 para los fusores 240 VAC o la tabla A-3 para los fusores 120 VAC. 6. Realizar una de las siguientes acciones:

S Si los vatiajes calculados en el paso 5 no exceden los vatiajes

mximos admitidos asociados, que aparecen en la tabla A-2, entonces la tensin requerida por las mangueras y pistolas se encuentra dentro de los lmites aceptables.

S Si alguno de los vatiajes calculados en el paso 5 excede un vatiaje

mximo admitido asociado que aparece en la tabla A-2 y A-3, entonces la configuracin o la posicin de los pares de manguera/pistola deben volver a organizarse, deben utilizarse mangueras ms cortas o deben utilizarse pistolas de tensin ms baja con el fin de reducir el requerimiento de tensin.

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Clculo de requerimientos de tensin del fusor

A-3

Table A-1 Vatiajes de manguera/pistola A Componente Nmero Tipo/tamao Vatiaje de componente B Vatiaje de par de manguera/pistola C Vatiaje de dos pares de manguera/pistola

Manguera 1 Pistola 1 Manguera 2 Pistola 2

Table A-2 Vatiajes mximos admitidos de pistola/manguera para fusores 240 VAC Columna en tabla A-1 A B C Componente Cualquier manguera o pistola individual Cualquier par de manguera/pistola Suma de los pares de manguera/pistola 1 y 2 Vatiaje mximo

1000 W 1200 W 2000 W

Table A-3 Vatiajes mximos admitidos de pistola/manguera para fusores 120 VAC Columna en tabla A-1 A B C Componente Cualquier manguera o pistola individual Cualquier par de manguera/pistola Vatiaje mximo

500 W 600 W

Suma de los pares de manguera/pistola 1 y 2 en un...

S D4L con motor de 1/16 hp* S D4L con motor de 1/6 hp* S D10L con motor de 1/6 hp* S D10L con motor de 1/4 hp* S D16L con motor de 1/4 hp*
*Refer to the motor identification plate.

1125 W 1045 W 1045 W 985 W 985 W

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Clculo de requerimientos de tensin del fusor

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Parmetros de funcionamiento

B-1

Apndice B

Parmetros de funcionamiento
Los parmetros de funcionamiento estn organizados en este apndice segn los grupos lgicos listados en la tabla B-1. Para obtener informacin acerca de la seleccin y la edicin de parmetros de funcionamiento ver el apartado Configuracin del fusor en la seccin 3, Instalacin. OBSERVACIN: Los nmeros de parmetro reservados o que no se utilizan no aparecen en este apndice.

Table B-1 Grupos de parmetros Grupo

Estndar Control de temperatura Reloj programador semanal Seleccin PID

Parmetros
0 a 11 20 a 26

Descripcin
Parmetros utilizados con frecuencia Funcin de calefactor de control

50 a 77 8091

Configurar la funcin de reloj Cambiar ajustes PID predeterminados

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B-2

Parmetros de funcionamiento

Estndar
1 Horas totales con calefactores encendidos
(no editable)
Descripcin: Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:
Un valor no editable que indica el nmero total de horas durante las cuales los calefactores han estado encendidos. 9999 (panel de control) y 999,999 en el explorador web. 1 hora 0 La pantalla registra hasta 9999 horas y despus vuelve a 0000. En el explorador web, el registro vuelve a cero al llegar a 999,999 horas.

Registro de fallos
(no editable)
Descripcin: Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:
Almacena un registro de los diez ltimos fallos. _-F0 (entrada de registro no utilizada) F1, F2, F3 y F4 Utilizar las teclas de desplazamiento de la pantalla derecha para revisar las entradas de registro para los diez ltimos fallos. Las entradas de registro vacas estn indicadas por _-F0. Ver Vigilancia del fusor en la seccin 4, Manejo.

Registro de historial de cambios

(no editable)
Descripcin: Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:
Registra los ltimos diez cambios hechos en las temperaturas de punto de referencia o en los parmetros de funcionamiento. P-_ (entrada de registro no utilizada) Ver Revisin de cambios en parmetro y temperatura de punto de referencia en la seccin 3, Instalacin. Utilizar la tecla de la pantalla derecha para revisar las entradas de registro de los diez ltimos cambios realizados a los parmetros de funcionamiento o a las temperaturas de punto de referencia. Las entradas de registro vacas estn indicadas por P-_.

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Parmetros de funcionamiento

B-3

Tiempo de retardo de listo

Descripcin:
El tiempo que debe transcurrir despus de que todos los componentes han alcanzado su temperatura de punto de referencia y antes de que se encienda el LED de listo. El tiempo de retardo de listo funciona nicamente cuando la temperatura del tanque, cuando el fusor est encendido, es superior a 27C (50F) respecto a su temperatura de punto de referencia. El tiempo de retardo de listo comienza cuando todos los componentes se encuentran a 3C (5F) de sus respectivas temperaturas de punto de referencia. 0 a 60 minutos 1 minuto 0 minutos El retardo de listo permite calentar el contenido del tanque durante un periodo de tiempo adicional antes de que se encienda la bomba. OBSERVACIN: El tiempo restante en el retardo de listo se indica en minutos en la pantalla derecha al final de cada ciclo de exploracin automtico. Cuando el tiempo de retardo llega a 1 minuto, el tiempo restante aparece en segundos.

Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:

Retardo de motor apagado

Descripcin: Valor:
Determina el tiempo que el motor permanecer encendido despus de que se apague el dispositivo de conmutacin. 0 a 360 segundos O - - - - (infinito)

Resolucin: Valor predeterminado: Sintaxis: Uso:

segundos 0 segundos Este parmetro se aplica slo cuando existe un dispositivo de conmutacin conectado al receptculo de conmutacin en el fusor.

Encendido automtico de bomba

Descripcin: Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:
Determina si puede activarse la bomba antes de que el fusor est listo. 0 = desactivado o 1 = activado 1 (activado) Si est activado, puede activarse la bomba antes de que el fusor est listo. Una vez activado, la bomba se pondr en marcha automticamente cuando el fusor est listo. Si est desactivado, debe ponerse en marcha la bomba pulsando la tecla de bomba despus de que el fusor est listo. OBSERVACIN: Si el encendido automtico de bomba est desactivado (0) estando la misma en funcionamiento, la bomba permanecer encendida hasta que se pulse la tecla de bomba.

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B-4

Parmetros de funcionamiento

Estndar (cont.)
12 Zona uno canal de manguera: Funcin de pistola elctrica
Descripcin:
Cambia la posicin de la manguera del receptculo de manguera/pistola 1 de control de temperatura de manguera a actuacin de la pistola elctrica en la tensin de lnea. 0 (desactivado) 1 (activado)

Valor:

Resolucin: Valor predeterminado: Sintaxis: Uso:

0 (desactivado) nicamente para uso con pistolas elctricas montadas en el distribuidor Nordson. Ver el manual de la pistola para obtener ms informacin.

13

Zona dos canal de manguera: Funcin de pistola elctrica

Descripcin:
Cambia la posicin de la manguera del receptculo de manguera/pistola 2 de control de temperatura de manguera a actuacin de la pistola elctrica en la tensin de lnea. 0 (desactivado) 1 (activado)

Valor:

Resolucin: Valor predeterminado: Sintaxis: Uso:

0 (desactivado) nicamente para uso con pistolas elctricas montadas en el distribuidor Nordson. Ver el manual de la pistola para obtener ms informacin.

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Control de temperatura
20 Unidades de temperatura
Descripcin: Valor: Resolucin:
Establece las unidades para mostrar la temperatura. C (grados Celsius) o F (grados Fahrenheit) 0 = Celsius 1 = Fahrenheit

Valor predeterminado: Sintaxis: Uso:

21

Delta de sobretemperatura
Descripcin:
El nmero de grados que la temperatura de cualquier componente puede aumentar por encima de su temperatura de punto de referencia asignada antes de que se produzca un fallo de sobretemperatura (F3). 5_C (10_F) a 60_C (110_F) 1_C 1_F

Valor: Resolucin:

Valor predeterminado: Sintaxis: Uso:

15_C (25_F)

22

Delta de temperatura baja

Descripcin:
El nmero de grados que la temperatura de cualquier componente puede caer por debajo de su temperatura de punto de referencia asignada antes de que se produzca un fallo de temperatura baja (F2). 5_C (10_F) a 60_C (110_F) 1_C 1_F

Valor: Resolucin:

Valor predeterminado: Sintaxis: Uso:

25_C (50_F)

E 2002 Nordson Corporation

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Parmetros de funcionamiento

Control de temperatura (cont.)

23 Delta de reposo
Descripcin: Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:
El nmero de grados que bajarn todos los componentes calefactados cuando se pone el fusor en modo de reposo. 25_C a 190_C (50_F a 350_F) 1_C 1_F 50_C (100_F) Debe seleccionarse un delta de reposo que d lugar a un balance entre el ahorro de energa del fusor en periodos de inactividad, la cantidad de tiempo y energa requeridos para volver a poner el fusor a la temperatura de punto de referencia y una temperatura en la que el adhesivo termofusible pueda mantenerse en el tanque por periodos largos de tiempo sin que se produzca carbonizacin. Ver Utilizacin de las teclas de funcin del fusor en la seccin 4, Manejo. OBSERVACIN: El delta de reposo no afecta al delta de temperatura baja (parmetro 22).

24

Temporizacin de puesta en reposo automtica

Descripcin:
El tiempo que debe transcurrir despus de enviar la ltima seal (accionador de pistola) a la entrada 1 y antes de que el fusor entre en el modo de reposo. La funcin de temporizacin de puesta en reposo automtica ahorra energa al permitir que el fusor entre automticamente en modo de reposo si el fusor detecta que las pistolas ya no disparan ms. 0 a 1440 minutos (24 horas) 1 minuto 0 (desactivado) 1. Cambiar el parmetro 23 en caso necesario. 2. Ajustar la opcin de control para el parmetro 30 (entrada 1) a opcin 10 (reposo automtico) OBSERVACIN: Activar el parmetro 24 slo cuando haya una seal de tensin de 24 VDC conectada a la entrada 1. Si no hay tensin en los contactos de entrada cuando el fusor est listo, el fusor entrar en modo de reposo despus del tiempo de reposo automtico.

Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:

25

Tiempo de apagado automtico de calefactores

Descripcin:
El tiempo que debe transcurrir despus de haber transcurrido el tiempo de reposo automtico (parmetro 24) y antes de que se apaguen los calefactores. 0 a 1440 minutos (24 horas) 1 minuto 0 (desactivado)

Valor: Resolucin: Valor predeterminado:

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B-7

Sintaxis: Uso:

Ajustar el parmetro 24 (temporizacin de puesta en reposo automtica) al valor deseado antes de ajustar el parmetro 25.

26

Tiempo de reposo manual

Descripcin: Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:
El tiempo que el fusor permanecer en el modo de reposo despus de pulsar la tecla de reposo. 0 a 180 minutos 1 minuto 0 Ajustar el tiempo de reposo cuando se quiere que el operario pueda poner el fusor en modo de reposo por un periodo de tiempo limitado (descanso, comida, etc.). Ajustar el delta de reposo (parmetro 23) al valor deseado antes de ajustar el parmetro 26.

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B-8

Parmetros de funcionamiento

Reloj programador semanal

Antes de ajustar el reloj, ver Utilizacin de las teclas de funcin del fusor en la seccin 4, Manejo, para familiarizarse con el funcionamiento y el uso de la funcin de reloj. Si no se est familiarizado con el procedimiento de acceso y edicin de parmetros de funcionamiento, ver Configuracin del fusor en la seccin 3, Instalacin.

Para ajustar el reloj 1. Utilizar el parmetro 50 para seleccionar el da en curso de la semana. 2. Utilizar el parmetro 51 para seleccionar la hora actual del da. 3. Crear programa 1: a. Ajustando los parmetros 55 y 56 a la hora del da a la que los calefactores deben encenderse y apagarse. b. Ajustando los parmetros 57 y 58 a la hora del da a la que el fusor debe entrar y salir del modo de reposo. 4. Utilizar los parmetros 60 a 68 para crear los programas 2 y 3 repitiendo el paso 3. 5. Utilizar los parmetros 71 a 77 para asignar uno de los cuatro programas que deben utilizarse cada da de la semana. Pueden asignarse a cada da hasta tres programas (compatibilidad con tres turnos de trabajo). Cada una de las ocho opciones de control (0 a 7) que estn disponibles en los parmetros 71 a 77 asigna una combinacin diferente de los tres programas. La opcin 0 se utiliza para mantener el fusor en el estado ordenado por la ltima transicin de reloj hasta que ocurra la prxima transicin de reloj.

Para que el reloj funcione de continuo durante la

semana, debe asignarse un programa vlido a cada da de la semana (parmetros 71 a 77). Para prevenir una activacin accidental del reloj, la configuracin predeterminada para los parmetros 71 a 77 es el programa 2, el cual no tiene valores temporales asignados. Con el ajuste predeterminado en el programa 2, la activacin accidental de la tecla de reloj no afecta al fusor.

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B-9

50

Da actual
Descripcin: Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:
Se utiliza para ajustar el da en curso de la semana. 1 a 7 (1 = lunes, 2 = martes, etc.) 1 Ver Utilizacin de las teclas de funcin del fusor en la seccin 4, Manejo, para obtener informacin acerca del uso y las consecuencias de la funcin de reloj programador semanal.

51

Hora actual
Descripcin: Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:
Se utiliza para ajustar la hora local del da. 0000 a 2359 (formato europeo de hora) 1 minuto (Hora ajustada en fbrica)

hora, hora: minuto, minuto

Slo es necesario realizar este ajuste una vez para todos los programas diarios.

55

Programa 1 calefactores encendidos

Descripcin: Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:
Se utiliza para ajustar la hora a la que el reloj encender los calefactores durante el programa 1. 0000 a 2359, - - - 1 minuto 0600

hora, hora: minuto, minuto

Ajustar la hora deseada para que se enciendan los calefactores. Para desactivar este parmetro, ajustar el valor del parmetro a - - - -.

56

Programa 1 calefactores apagados

Descripcin: Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:
Se utiliza para ajustar la hora a la que el reloj apagar los calefactores durante el programa 1. 0000 a 2359 1 minuto 1700

hora, hora: minuto, minuto

Para desactivar este parmetro, ajustar el valor del parmetro a - - - -.

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B-10 Parmetros de funcionamiento

Reloj programador semanal (cont.)

57 Programa 1 entrar en reposo
Descripcin: Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:
Se utiliza para ajustar la hora a la que el fusor entrar en modo de reposo durante el programa 1. 0000 a 2359, - - - 1 minuto ----

hora, hora: minuto, minuto

Ajustar la hora a la que el aplicador entrar en modo de reposo durante el programa 1. Para desactivar este parmetro, ajustar el valor del parmetro a - - - -. Observacin: No ajustar una hora de entrada en reposo que se encuentre fuera del periodo de tiempo definido por el tiempo de calefactor encendido y apagado del programa. El fusor no puede entrar en el modo de reposo cuando los calefactores estn apagados.

58

Programa 1 salir del reposo

Descripcin: Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:
Se utiliza para ajustar la hora a la que el fusor saldr del modo de reposo durante el programa 1. 0000 a 2359, - - - 1 minuto ----

hora, hora: minuto, minuto

Ajustar la hora a la que el aplicador saldr del modo de reposo durante el programa 1. Para desactivar este parmetro, ajustar el valor del parmetro a - - - -. Observacin: No ajustar una hora de salida del reposo que se encuentre fuera del periodo de tiempo definido por el tiempo de calefactor encendido y apagado del programa. El fusor no puede entrar en el modo de reposo cuando los calefactores estn apagados.

60

Programa 2 calefactores encendidos

Descripcin: Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:
Se utiliza para ajustar la hora a la que el reloj encender los calefactores durante el programa 2. 0000 a 2359, - - - 1 minuto ----

hora, hora: minuto, minuto

Ajustar la hora deseada para que se enciendan los calefactores. Para desactivar este parmetro, ajustar el valor del parmetro a - - - -.

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61

Programa 2 calefactores apagados

Descripcin: Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:
Se utiliza para ajustar la hora a la que el reloj apagar los calefactores durante el programa 2. 0000 a 2359, - - - 1 minuto ---

hora, hora: minuto, minuto

Para desactivar este parmetro, ajustar el valor del parmetro a - - - -.

62

Programa 2 entrar en reposo

Descripcin: Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:
Se utiliza para ajustar la hora a la que el fusor entrar en modo de reposo durante el programa 2. 0000 a 2359, - - - 1 minuto ----

hora, hora: minuto, minuto

Ajustar la hora a la que el aplicador entrar en modo de reposo durante el programa 2. Para desactivar este parmetro, ajustar el valor del parmetro a - - - -. Observacin: No ajustar una hora de entrada en reposo que se encuentre fuera del periodo de tiempo definido por el tiempo de calefactor encendido y apagado del programa. El fusor no puede entrar en el modo de reposo cuando los calefactores estn apagados.

63

Programa 2 salir del reposo

Descripcin: Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:
Se utiliza para ajustar la hora a la que el fusor saldr del modo de reposo durante el programa 2. 0000 a 2359, - - - 1 minuto ----

hora, hora: minuto, minuto

Ajustar la hora a la que el aplicador saldr del modo de reposo durante el programa 2. Para desactivar este parmetro, ajustar el valor del parmetro a - - - -. Observacin: No ajustar una hora de salida del reposo que se encuentre fuera del periodo de tiempo definido por el tiempo de calefactor encendido y apagado del programa. El fusor no puede entrar en el modo de reposo cuando los calefactores estn apagados.

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Reloj programador semanal (cont.)

65 Programa 3 calefactores encendidos
Descripcin: Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:
Se utiliza para ajustar la hora a la que el reloj encender los calefactores durante el programa 3. 0000 a 2359, - - - 1 minuto ----

hora, hora: minuto, minuto

Ajustar la hora deseada para que se enciendan los calefactores.

Para desactivar este parmetro, ajustar el valor del parmetro a - - - -.

66

Programa 3 calefactores apagados

Descripcin: Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:
Se utiliza para ajustar la hora a la que el reloj apagar los calefactores durante el programa 3. 0000 a 2359, - - - 1 minuto ---

hora, hora: minuto, minuto

Para desactivar este parmetro, ajustar el valor del parmetro a - - - -.

67

Programa 3 entrar en reposo

Descripcin: Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:
Se utiliza para ajustar la hora a la que el fusor entrar en modo de reposo durante el programa 3. 0000 a 2359, - - - 1 minuto ----

hora, hora: minuto, minuto

Ajustar la hora a la que el aplicador entrar en modo de reposo durante el programa 3. Para desactivar este parmetro, ajustar el valor del parmetro a - - - -. Observacin: No ajustar una hora de entrada en reposo que se encuentre fuera del periodo de tiempo definido por el tiempo de calefactor encendido y apagado del programa. El fusor no puede entrar en el modo de reposo cuando los calefactores estn apagados.

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68

Programa 3 salir del reposo

Descripcin: Valor: Resolucin: Valor predeterminado: Sintaxis: Uso:
Se utiliza para ajustar la hora a la que el fusor saldr del modo de reposo durante el programa 3. 0000 a 2359, - - - 1 minuto ----

hora, hora: minuto, minuto

Ajustar la hora a la que el aplicador saldr del modo de reposo durante el programa 3. Para desactivar este parmetro, ajustar el valor del parmetro a - - - -. Observacin: No ajustar una hora de salida del reposo que se encuentre fuera del periodo de tiempo definido por el tiempo de calefactor encendido y apagado del programa. El fusor no puede entrar en el modo de reposo cuando los calefactores estn apagados.

71

Programas para los lunes

Descripcin: Valor:
Se utiliza para seleccionar el (los) programa(s) que se utilizar(n) los lunes. 0 Permanecer en la ltima transicin de reloj 1 Utilizar slo el programa 1 2 Utilizar slo el programa 2 3 Utilizar slo el programa 3 4 Utilizar programas 1 y 2 5 Utilizar programas 2 y 3 6 Utilizar programas 1 y 3 7 Utilizar programas 1, 2 y 3 1 2 Selecciona el (los) programa(s) activo(s) para el da. OBSERVACIONES: Si se utiliza la opcin de programa 0, los calefactores no volvern a encenderse hasta que no llegue la prxima hora programada de calefactores encendidos.

Resolucin: Valor predeterminado: Sintaxis: Uso:

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Reloj programador semanal (cont.)

72 Programas para los martes
Descripcin: Valor:
Se utiliza para seleccionar el (los) programa(s) que se utilizar(n) los martes. 0 Permanecer en la ltima transicin de reloj 1 Utilizar slo el programa 1 2 Utilizar slo el programa 2 3 Utilizar slo el programa 3 4 Utilizar programas 1 y 2 5 Utilizar programas 2 y 3 6 Utilizar programas 1 y 3 7 Utilizar programas 1, 2 y 3 1 2 Selecciona el (los) programa(s) activo(s) para el da. OBSERVACIONES: Si se utiliza la opcin de programa 0, los calefactores no volvern a encenderse hasta que no llegue la prxima hora programada de calefactores encendidos.

Resolucin: Valor predeterminado: Sintaxis: Uso:

73

Programas para los mircoles

Descripcin: Valor:
Se utiliza para seleccionar el (los) programa(s) que se utilizar(n) los mircoles. 0 Permanecer en la ltima transicin de reloj 1 Utilizar slo el programa 1 2 Utilizar slo el programa 2 3 Utilizar slo el programa 3 4 Utilizar programas 1 y 2 5 Utilizar programas 2 y 3 6 Utilizar programas 1 y 3 7 Utilizar programas 1, 2 y 3 1 2 Selecciona el (los) programa(s) activo(s) para el da. OBSERVACIONES: Si se utiliza la opcin de programa 0, los calefactores no volvern a encenderse hasta que no llegue la prxima hora programada de calefactores encendidos.

Resolucin: Valor predeterminado: Sintaxis: Uso:

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74

Programas para los jueves

Descripcin: Valor:
Se utiliza para seleccionar el (los) programa(s) que se utilizar(n) los jueves. 0 Permanecer en la ltima transicin de reloj 1 Utilizar slo el programa 1 2 Utilizar slo el programa 2 3 Utilizar slo el programa 3 4 Utilizar programas 1 y 2 5 Utilizar programas 2 y 3 6 Utilizar programas 1 y 3 7 Utilizar programas 1, 2 y 3 1 2 Selecciona el (los) programa(s) activo(s) para el da. OBSERVACIONES: Si se utiliza la opcin de programa 0, los calefactores no volvern a encenderse hasta que no llegue la prxima hora programada de calefactores encendidos.

Resolucin: Valor predeterminado: Sintaxis: Uso:

75

Programas para los viernes

Descripcin: Valor:
Se utiliza para seleccionar el (los) programa(s) que se utilizar(n) los viernes. 0 Permanecer en la ltima transicin de reloj 1 Utilizar slo el programa 1 2 Utilizar slo el programa 2 3 Utilizar slo el programa 3 4 Utilizar programas 1 y 2 5 Utilizar programas 2 y 3 6 Utilizar programas 1 y 3 7 Utilizar programas 1, 2 y 3 1 2 Selecciona el (los) programa(s) activo(s) para el da. OBSERVACIONES: Si se utiliza la opcin de programa 0, los calefactores no volvern a encenderse hasta que no llegue la prxima hora programada de calefactores encendidos.

Resolucin: Valor predeterminado: Sintaxis: Uso:

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Reloj programador semanal (cont.)

76 Programas para los sbados
Descripcin: Valor:
Se utiliza para seleccionar el (los) programa(s) que se utilizar(n) los sbados. 0 Permanecer en la ltima transicin de reloj 1 Utilizar slo el programa 1 2 Utilizar slo el programa 2 3 Utilizar slo el programa 3 4 Utilizar programas 1 y 2 5 Utilizar programas 2 y 3 6 Utilizar programas 1 y 3 7 Utilizar programas 1, 2 y 3 1 2 Selecciona el (los) programa(s) activo(s) para el da. OBSERVACIONES: Si se utiliza la opcin de programa 0, los calefactores no volvern a encenderse hasta que no llegue la prxima hora programada de calefactores encendidos.

Resolucin: Valor predeterminado: Sintaxis: Uso:

77

Programas para los domingos

Descripcin: Valor:
Se utiliza para seleccionar el (los) programa(s) que se utilizar(n) los domingos. 0 Permanecer en la ltima transicin de reloj 1 Utilizar slo el programa 1 2 Utilizar slo el programa 2 3 Utilizar slo el programa 3 4 Utilizar programas 1 y 2 5 Utilizar programas 2 y 3 6 Utilizar programas 1 y 3 7 Utilizar programas 1, 2 y 3 1 2 Selecciona el (los) programa(s) activo(s) para el da. OBSERVACIONES: Si se utiliza la opcin de programa 0, los calefactores no volvern a encenderse hasta que no llegue la prxima hora programada de calefactores encendidos.

Resolucin: Valor predeterminado: Sintaxis: Uso:

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B-17

Seleccin PID
8083 Seleccin PID para los receptculos de manguera/pistola 1, 2, 3 y 4
Descripcin:
Utilizado para cambiar las selecciones PID predeterminadas. Utilizar el parmetro 80 para seleccionar el valor de la manguera 1, el parmetro 81 para seleccionar el valor de la pistola 1, y as sucesivamente. 0 = Manguera 1 = Pistola estndar 2 = Pistola grande 3 = Calefactor de aire 0 o 1 dependiendo del tipo de canal (manguera o pistola) Consulte a su representante Nordson antes de cambiar los ajustes PID.

Valor:

Resolucin: Valor predeterminado: Sintaxis: Uso:

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DECLARACIN DE CONFORMIDAD
(Equipo de aplicacin de adhesivo/pegamento de certificado CE) PRODUCTO: Fusor DuraBluet, Modelo D10, D16, D4L, D10L, D16L REGLAMENTOS APLICABLES: 98/37/EC (Maquinaria) 73/23/EEC (Reglamento de baja tensin) 89/336/EEC (Reglamento de compatibilidad electromagntica) ESTNDARS UTILIZADOS PARA VERIFICAR LA: EN292 EN60204-1 EN563 EN61000-6-2 EN55011 PRINCIPIOS: Este producto est fabricado de acuerdo con la buena prctica de la ingenieria.

El producto especificado cumples los reglamentos y estndares descritos arriba.

Fecha: 14 agosto 2002 Donald J. McLane, Senior Vice President

Nordson Corporation S Duluth, Georgia

DOC034

Bulletin No. CUB1/2-F Drawing No. LP0001 Revised: 12/00 Tel +1 (717) 767-6511 Fax +1 (717) 764-0839 www.redlion-controls.com

MODELS CUB 1 & CUB 2 COUNTERS

OPEN UP NEW COUNTING HORIZONS, FROM COUNTING SIMPLE SWITCH CONTACT CLOSURES
!

CUB 1 MINIATURE ELECTRONIC COUNTER

!

TO HIGH SPEED PULSES FROM TTL, CMOS, OR OTHER ELECTRONIC SOURCES AT A PRICE LESS THAN EQUIVALENT E.M.[ELECTROMECHANICAL] COUNTERS

CUB 2 GENERAL PURPOSE INDUSTRIAL COUNTER

The heart of the CUB is a tiny custom silicon chip developed by Red Lion Controls. This chip contains all of the counting and display circuits in an area less than 0.02 (0.5 mm) square inches. Via micro-assembly, the chip and other peripheral parts are attached to a substrate with the electrical connections being made ultrasonically - using wire approximately 1/3 the diameter of a human hair. The result is an entirely new concept in counting, that is not only cost effective, but opens the door to counting applications that until now were not economically feasible.

AND HERE ARE SOME MORE ADVANTAGES:

SELF POWERED Self-Contained batteries eliminate the need for external power and prevent loss of count if power fails. Also provides for remote or portable applications. Battery operation also means elimination of shock hazard and allows the use of 2-conductor bell wire for count signals and micro-power input signals. Batteries are easily replaceable (2 N Cells, alkaline) and average battery life is four years. HIGH SPEED The 5 KHz count speed is at least 100 times faster than high performance E.M. counters. This opens up vast new application areas that previously were impossible, or at best, accommodated by expensive electronic counters costing 5 to 10 times as much. FLEXIBILITY Various count inputs allow use with switch contacts or high speed pulse outputs from electronic sensors and circuits. The reset function can be disabled, set up for front panel reset, remote reset, or both. NO-WEAR, NO-NOISE The CUBs micro-circuits can accurately and silently accumulate enough counts in one hour to completely wear out an ordinary E.M. counter. More over, it can repeat this performance 3500 times (4 years) with just one set of batteries. RELIABILITY Internal micro-assembly construction withstands many times the G force of shock and vibration compared to conventional construction. CUB counters also feature elastomeric contacts. This eliminates long term problems associated with contact corrosion. Battery operation, a high degree of input filtering, plus an inherent common mode rejection ratio of more than 120 dB @ 50/60 Hz, provides ultra-high immunity from electrical noise interference. RUGGED, SEALED FRONT-PANEL CONSTRUCTION Housed in a die-cast metal case, CUB counters are front panel sealed and designed to meet NEMA 4/IP65 specifications, for wash-down and/or dust when properly installed.

SPECIFICATIONS
1. DISPLAY: 6-digit LCD CUB 1: 0.2" (5 mm) high CUB 2: 0.35" (9 mm) high 2. POWER SOURCE: No external power required. Operates from 2 N type alkaline batteries (supplied separately). Battery life up to 4 years or more. (See Note, at right.) 3. COUNT & RESET INPUT SIGNALS: Adapts to Count-Switch Contact Signals, Open-Collector Transistor Outputs, and Bi-Polar Drive Outputs as shown in the diagrams on the following page. Counter increments and resets on negative going (pull down) transition of count or reset signal. 4. OPERATING TEMPERATURE RANGE: 0 to 50C (32 to 122F) 5. STORAGE TEMPERATURE RANGE: -20 to +60C (-4 to +140F) 6. COUNT SPEED: Up to 50 Hz with switch contact input (counters have internal de-bounce circuits) or up to 5 KHz with solid-state electronic input (See diagrams on following page). Note: Only Alkaline Cells are recommended for use with CUB Counters. DO NOT USE CARBON-ZINC BATTERIES since they have short life times and can leak electrolyte causing internal corrosion damage. When using switch contacts for count input or remote reset, normally open contact circuits are recommended. Switch contacts that remain normally-closed and are opened only briefly to signal a count, can reduce battery life to somewhat less than 4 years.

USE CUB COUNTERS WITH:

VCM VOLTAGE CONVERTER MODULES for isolated, A.C., control voltage count inputs to 270 VAC, LCM LOGIC CONVERTER MODULES for interface with standard logic voltages & outputs, PSMA POWER SUPPLY & INTERFACE MODULE for operation with electronic sensors. [See Accessory Section Of The Catalog] 1

APPLICATION FLEXIBILITY VIA RECONNECT OPTIONS

Selection of desired operating modes is easily done by adding or moving terminal leads in the Input Connector Body. The connector body is polarized to prevent incorrect insertion, and locked in place by the battery cover to avoid accidental disengagement. Connectors are supplied with the 3 leads installed as shown below. A spare blue lead is supplied in the hardware pack. TO REMOVE TERMINAL, insert blade of a small screwdriver into slot of connector body, and gently push in to disengage lock pawl. Pull terminal out. WHEN INSERTING TERMINAL into connector body, make sure the lock pawl is toward the slot in the body. Push terminal in until lock pawl snaps into slot.

LOW SPEED COUNT INPUT, 50 Hz MAX. [For 250 Hz see note in text]

Pulling the L.S. CNT. Input to Common with a mechanical or solid-state switch increments the counter. The low pass filter (1meg resistor and 4700 pf cap) used with a Schmidt trigger circuit debounces mechanical switch signals. The switch load is 14 A (max. voltage drop 0.5 V) when ON. OFF-state leakage current must be less than 2 A.

Reed switches, mercury wetted contacts, snap action limit switches, and silver alloy relay contacts with wiping action are usually satisfactory for generating count input signals. Motor starter contacts, tungsten contacts, and brush-type contacts should NOT be used. Note: By parallel connecting both H.S. CNT. and L.S. CNT. inputs, count speed can be increased to 250 Hz if de-bounce is not needed.
TTL OR CMOS OUTPUT PNP O.C. TRANSISTOR OR BI-POLAR OUTPUT NPN O.C. TRANSISTOR

HIGH SPEED COUNT INPUT, 5 KHz MAX.

Moving the white wire to the H.S. CNT. Input allows the CUB Counter to operate at speeds up to 5 KHz when driven by bi-polar outputs or external circuits having an output impedance of 3.3 K or less. Input drive voltage must be limited to 3.0 V maximum to avoid a charging current into the batteries which can cause premature battery failure or leakage. CMOS and TTL Logic outputs can be loaded with a resistor (RL) to limit drive voltage, or a voltage divider can be used as shown for the PNP O.C. Transistor output.

INPUT PULSE EXCURSION LIMITS VIN (High) = +2.7 V min. +3.3 V max. VIL (Low) = +0.5 V max. Note: The PSMA Power Supply and Interface Module used for powering RLC sensors with CUB Counters, has proper interface output for direct drive to H.S. CNT.

RESET OPTIONS
Connecting the RST. EN. (Reset Enable) Input to Common activates the front panel Reset button. When the front panel Reset button is to be deactivated, remove the yellow wire from the RST. EN. Input. When Remote Reset is required, the blue wire in the hardware pack is inserted in the REM. RST. Input. Pulling this input low causes the counter to reset. The REM. RST. can be pulled low by either a mechanical switch or solid-state transistor switch. Switch load and leakage are the same as for L.S. CNT. Input above. Note: The RC protection circuit on the REM. RST. Input causes a delay of approximately 6 msec in Reset response.

DIMENSIONS, INSTALLATION, & BATTERY INSERTION

After cutting opening in panel, slide the panel gasket over the rear of the counter body to the back of the bezel. Then slide counter through the panel cutout. Install mounting clips on each side of counter body with mounting screws. CUB 1 Make sure the side rails or tabs of the clips fit into the recesses in the side of the counter body so that the Tang Ends or Tabs wedge between the panel opening and body as the screws are tightened. CUB 2

DIMENSIONS In inches (mm)

BATTERY COVER REMOVAL & BATTERY INSERTION

CUB 1 The battery cover is held in place by upper and lower clasps that capture mating lock ramps on the cover. To remove, insert thumbnail and index finger nail in the gaps between the upper and lower clasps and the battery cover, and deflect the clasps slightly to clear the edges of the ramps while pulling out on the cover. To replace cover, simply push into place until both clasps snap into engagement with lock ramps. CAUTION: Do not deflect clasps more than necessary to clear lock ramps. Excessive deflection can cause clasps to break off. CUB 2 Slide battery cover to the left until the right hand lip disengages and pops out. To reinstall cover, insert left hand lips into case first, push cover to the left until right hand lip drops down and cover snaps back into place. Install batteries as shown below observing proper polarity. Note: Push battery spring clips to the left (toward connector) to completely free the batteries when removing or installing batteries. Conductive rubber battery contacts can be torn from their retaining pins if batteries are forced in.

ELECTRICAL CONNECTIONS
There are certain considerations that shoud be observed when running the count and control signal wires. A length of wire can act like an antenna and the closer it is to a source of electrical noise, the more it becomes susceptible to that noise. There are a few rules that should be followed when running these wires. 1. Never run count or control signal wires in the same conduit or raceway with AC power lines, conductors that feed motors, solenoids, SCR controls, heaters, etc. 2. Signal wires within enclosures should be routed as far away as possible from contactors, control relays, transformers, and other noisy components. 3. When shielded wire is used, connect the shield to the common of the CUB unit, and leave the other end of the shield disconnected and insulated from machine ground. 4. Mount the CUB in a panel that is grounded to the machine frame. 5. When using accessory devices such as LCMs or PSMs into the H.S. CNT. Input, the accessory devices should be mounted near the CUB Counter.

ORDERING INFORMATION
MODEL NO. DESCRIPTION PART NUMBERS

CUB 1 CUB 1 Miniature Electronic Counter CUB10000 CUB 2 CUB 2 Gen. Purpose Industrial Electronic Counter CUB20000 BNA N Type Alkaline Batteries (Note 1) BNA00000 HWK 1 CUB 1 Spare Hardware Kit (Note 2) HWK10000 HWK 2 CUB 2 Spare Hardware Kit (Note 2) HWK20000 ICA Spare Input Connector & Terminal Wires (Note 3) ICA00000 For more information on Pricing, Enclosures & Panel Mount Kits refer to the RLC Catalog or contact your local RLC distributor.

NOTES 1. Batteries NOT supplied with counters, order separately. 2 required per unit. 2. Counters supplied with required hardware. Includes 2 mounting clips & screws, panel gasket, 2-wire nuts & blue terminal wire. 3. Counters supplied with connector body & white, yellow, & black wires. Kit ICA includes connector body & one each of black, white, blue, & yellow terminal wires.

NT 6 Contrast scanners
Dimensional drawing 56 25 9 28 1 2

Scanning distance 9 mm
Contrast scanners

21

s s s

5 15.4 52 40 4 10 13 28 3 3

80
Adjustments possible NT 6-03022 NT 6-04018 NT 6-13022 NT 6-03012 NT 6-04022 NT 6-03018 NT 6-13012 NT 6-04012 1 2

Blind screw can be replaced by Item 2 Lens can be replaced by Item 1 3 M 5 threaded mounting hole, 5.5 mm deep 4 Function signal indicator 5 Cover for adjuster 6 4-pin, M 12 plug or 2m cable with T3104/1 plug or 2m cable 7 Control for switching threshold 8 Switch for operating mode X Light-switching q Dark-switching

8
J J

Connection types

NT 6-03022 NT 6-13022 NT 6-04022

NT 6-03018 NT 6-04018

NT 6-03012 NT 6-13012 NT 6-04012

Accessories Cable receptacles Lens

page 496 556

6 x 0.34 mm2
red gra blu blk grn yel

4-pin, M 12
brn blk blu wht gra

cable + plug

L+ Q M PE NC QA

1 4 3 2 5

L+ Q M PE QA

2 1 6 4 3

412

SENSICK CATALOGUE

64
L+ Q M PE NC QA

LED light source with two switchselectable spectral ranges Lens position selectable Light- or dark-switching selectable Rapid response times

6
M5

30.4

M5

NT 6
Technical data Scanning distance from front edge of lens Light type/light spot dimension 9 mm 2 mm Green/1.5 x 5 mm Red/1.5 x 4 mm LED, red, green selectable Longitudinal Transverse 10 . . . 30 V DC 2) <5V < 80 mA Light-/dark-switching, selectable B: HIGH = VS < 2 V/LOW = < 2 V PNP: HIGH = VS < 2 V/LOW = 0 V 200 mA 50 s To 10 kHz 0.15 . . . 6 V Cable 7) with T 3104/1 plug Cable 7) without plug Plug NT 603012 03022 03018 13012 13022 04012 04022 04018

Light source 1), light type Light spot direction

Supply voltage VS Ripple 3) Current consumption 4) Switching outputs

Output current lA max. Response time 5) Max. switching frequency 6) Analogue output QA Connection types

VDE protection class 8) Enclosure rating Circuit protection 9) Ambient temperature TA Shock load Weight Housing material
1) Average service life 100,000 h at TA = + 25 C 2) Limit values

V
IP 67 A, B, C Operation 10 C . . . + 50 C Storage 25 C . . . + 75 C To IEC 68 Approx. 540 g Cast metal
3) May not exceed or fall short of VS tolerances 4) Without load 5) Signal transit time with resistive load 6) With light/dark ratio 1:1 7) Do not bend below 0 C 8) Reference voltage 50 V DC 9) A = VS connections reverse-polarity protected B = Outputs Q and QA short-circuit protected C = Interference pulse suppression

Scanning distance 120

Order information Type NT 6-03012 NT 6-03022 NT 6-03018 NT 6-13012 80 1 NT 6-13022 NT 6-04012 NT 6-04022 60 Relative sensitivity in % NT 6-04018 Part no. 1 005 821 1 005 822 1 006 367 1 005 823 1 005 824 1 006 474 1 006 475 1 007 478

100

40

20

(mm)

10

15

20

25

30 9 mm

1 Scanning distance

SENSICK CATALOGUE

413

ENGLISH
Contrast Scanner Operating Instructions

A
8 005 235.0699 HJS KE

Safety Specifications
Read the operating instructions before starting operation. Connection, assembly, and settings only by competent technicians. Protect the device against moisture and soiling when operating. No safety component in accordance with EU machine guidelines.

Proper Use
The NT 6 contrast scanner is an optoelectronic sensor and is used for optical, non-contact detection of contrast marks.

Starting Operation

1 2 3 4

5 6

Connect and secure cable receptacle tension-free.The following apply for connection in B: brn=brown, blu=blue, blk=black, gra=gray, wht=white, red=red, yel=yellow, grn=green. Outputs: QPNP or QB (corresponding to type label, see below). QA: Analog output; output current proportional to received light. Connect the scanner according to the B connection chart. Timing element (corresponding to type label, see below): Select light emission side; replace the lens with a dummy screwed connection if necessary. Mount the sensor with mounting holes at the place (e.g., deflection roller) where the test object has the least horizontal and vertical movement. Pay attention to the scanning range when doing this (see the technical data at the end of these operating instructions and the chart: x=scanning range; y= relative sensitivity). Align the horizontal and vertical movements of the test object using correspondingly long markings. Make sure that sensor movement does not influence the scanning distance. In the case of objects with reflective or shiny surface, tilt sensor by 10o to 15o relative to surface. Connect cables. Connect photoelectric switch to operating voltage (see type label). Switching threshold setting: Operating panel: A=switching threshold adjustor; B=dark-switching green light; C=light-switching green light; D=green light adjustment; E=dark-switching red light; F=light-switching red light; G=red light adjustment; H=status indicator Open the safety hood. Select the color light source and set >light-switching<. Red or green component of a color not clear: Determine the contrast of both light sources. Select the light source that creates the greater difference in brightness. Place the lighter object to be detected in the light spot. a) The status indicator lights: turn the adjusting device until the indicator switches off. b) The status indicator does not light: turn the adjusting device counter-clockwise until the indicator lights, then proceed with step a). Set the operating mode switch to >light- or dark-switching< according to C Close the safety hood. only: NT 6- _ _ 2 _ _ only: The switching threshold is set remotely via the voltage level 0...10V.
3 Output B PNP PNP + 50 ms Off Delay PNP + 15 ms Off Delay PNP + 3.5 ms Off Delay | 3 4 o 7 8 9 _ 1 Lens / TW 1, 2 3, 4 5, 6 7, 8 # 211 / 9 mm # 213 / 18 mm # 214 / 50 mm # 25 / 25 mm _

NT 6
SICK AG Schiess-Strae 56 D-40549 Dsseldorf 02 11 53 01-0 Fax: 02 11 53 01-1 00 www.sick.de Australia Erwin Sick Optic-Electronic Pty. Ltd. Ivanhoe 03 94 97 41 00 Austria SICK GmbH 2355 Wiener Neudorf 0 22 36 622 88-0 Belgium/Luxembourg Sick nv/sa Asse (Relegem) 02 4 66 55 66 Brazil SICK Indstria & Comrcio Ltda. So Paulo 011 55 61 26 83 China/Hong Kong SICK Optic-Electronic Co., Ltd. Kowloon 20 27 63 69 66 Czech Republic SICK spol. sro. Praha 5-Radotin 02 578 10 561 Denmark SICK A/S Birkerd 45 82 64 00 Finland SICK Optic-Electronic Oy Helsinki 09 7 28 85 00 France SICK Marne la Valle 1 64 62 35 00 Great Britain Erwin Sick Ltd. St. Albans 0 17 27 83 11 21 Italy SICK S.p.A. Cernusco sul Naviglio -MI02 92 14 20 62 Japan SICK Optic-Electronic K.K. Tokyo 03 33 58-13 41 Netherlands SICK B. V. AD Bilthoven 0 30 2 29 25 44 Norway SICK AS Gjettum 67 81 50-0 Poland SICK Optic-Electronic Sp. z. o. o. Warszawa 022 8 37 40 50 Singapore SICK Optic-Electronic Pte. Ltd. Singapore 387 383 65 7 44 37 32 Spain SICK Optic-Electronic S. A. Sant Just Desvern 93 4 80 31 00 Sweden SICK AB Vrby 08 6 80 64 50 Switzerland SICK AG Stans 041 6 19 29 39 Taiwan SICK Optic-Electronic Co., Ltd. Taipei 02 23 65 62 92 USA SICK, Inc. Bloomington, MN 55438 (952) 9 41-67 80

4 B

We reserve the right to make changes without prior notification nderungen vorbehalten Sous rserve de modifications Reser vam-se alteraes Ret til ndringer forbeholdes Con riserva di modifiche Wijzigingen voorbehouden Reservado el derecho a introducir modificaciones

5 6

NT6 - 0 LED / Light spot 0 1 2 3 red/grn red/grn red/grn red

Maintenance
SICK contrast scanners do not require any maintenance. We recommend that you clean the optical interfaces and check the screw connections andplug-in connections at regular intervals.

DEUTSCH
Kontrasttaster Betriebsanleitung

(s. technische Daten am Ende dieser Betriebsanleitung und siehe Diagramm, x=Tastweite, y=relative Empfindlichkeit). Seiten- und Hhenbewegungen des Prfobjektes durch entsprechend lange Markierungen ausgleichen. Bewegungen des Sensors mit Tastweiteneinflu ausschlieen. Bei spiegelnden oder glnzenden Objektoberflchen Sensor um 10o bis 15o zur Materialoberflche neigen. Leitungen anschlieen. Sensor an Betriebsspannung legen (s.Typenaufdruck). Einstellung Schaltschwelle: Bedienfeld: A=Schaltschwelleneinsteller, B=Dunkelschaltend Grnlicht, C=Hellschaltend Grnlicht, D=Justage Grnlicht, E=Dunkelschaltend Rotlicht, F=Hellschaltend Rotlicht, G=Justage Rotlicht, H=Funktionsanzeige. Schutzhaube ffnen. Farbe Lichtsender whlen und >hellschaltend< einstellen. Rot- oder Grnanteil einer Farbe unklar: Kontraste beider Lichtsender ermitteln. Den Lichtsender whlen, der den greren Helligkeitsunterschied bewirkt. Hellere Tastgutflche im Lichtfleck positionieren. Betriebsartenschalter auf >I< stellen. Dunklere Tastgutflche im Lichtfleck positionieren. a) Funktionsanzeige leuchtet: Einsteller drehen, bis Anzeige eben erlischt. b) Funktionsanzeige leuchtet nicht: Einsteller erst gegen Uhrzeigersinn drehen bis Anzeige aufleuchtet, dann weiter mit a). Betriebsartenschalter nach C auf >hell- oder dunkelschaltend< stellen. Schutzhaube aufsetzen. Nur NT 6- _ _ 2 _ _: Schaltschwelle wird ber Spannungspegel 0...10V ferneingestellt.
3 Ausgang B PNP PNP + 50 ms Off Delay PNP + 15 ms Off Delay PNP + 3.5 ms Off Delay _ 1 Objektiv / TW 1, 2 3, 4 5, 6 7, 8 # 211 / 9 mm # 213 / 18 mm # 214 / 50 mm # 25 / 25 mm _

Sicherheitshinweise
Vor der Inbetriebnahme die Betriebsanleitung lesen. Anschlu, Montage und Einstellung nur durch Fachpersonal. Gert bei Inbetriebnahme vor Feuchte und Verunreinigung schtzen. Kein Sicherheitsbauteil gem EU-Maschinenrichtlinie.

NT6 - 0 LED / Lichtfleck 0 1 2 3

Bestimmungsgeme Verwendung
Der Kontrasttaster NT 6 ist ein opto-elektronischer Sensor und wird zum optischen, berhrungslosen Erfassen von Kontrastmarken eingesetzt.

red/grn | 3 red/grn 4 red/grn o 7 red 8 9

Wartung
SICK-Kontrasttaster sind wartungsfrei. Wir empfehlen, in regelmigen Abstnden - die optischen Grenzflchen zu reinigen, - Verschraubungen und Steckverbindungen zu berprfen.

Inbetriebnahme

1 2 3 4

Leitungsdose spannungsfrei aufstecken und festschrauben. Fr Anschlu in B gilt: brn=braun, blu=blau, blk=schwarz, gra=grau, wht=wei, red=rot, yel=gelb, grn=grn. Ausgnge: QPNP oder QB (entspr.Typenschlssel, s.u.) QA: Analogausgang, Ausgangsstrom propotional Lichtempfang. Taster laut Anschluschema B anschlieen. Zeitglied (entspr.Typenschlssel, s.u.): Lichtaustrittsseite whlen, ggf. Objektiv gegen Blindverschraubung austauschen. Sensor mit Befestigungsbohrungen an Stelle (z. B. Umlenkrolle) montieren, an der das Prfobjekt die geringsten Seitenund Hhenbewegungen ausfhrt. Dabei Tastweite beachten

FRANAIS
Dtecteur de contrastes Instructions de Service

Conseils de scurit
Lire les Instructions de Service avant la mise en marche. Installation, raccordement et rglage ne doivent tre effectus que par du personnel qualifi. Lors de la mise en service, protger lappareil de lhumidit et des salets. Nest pas un composant de scurit au sens de la directive europenne concernant les machines.

Utilisation correcte
Le dtecteur de contraste est un capteur opto-lectronique qui sutilise pour la saisie optique sans contact de repres lumineux contrasts.

Mise en service

1 2

3 4

5 6

Enficher la bote conducteurs sans aucune tension et la visser. Pour le raccordement dans B on a: brn=brun, blu=bleu, blk=noir, gra=gris, wht=blanc, red=rouge, yel=jaune, grn=vert. Sorties: QPNP o QB (conformment au code des modles, voir ci-dessous). QA: Sortie analogique, courant de sortie proportionel la lumire reue. Raccorder le dtecteur conformment au schma de circuit B. Relais temporisateur (conformment au code des modles, voir ci-dessous): Choisir le ct de sortie de la lumire, remplacer ventuellement lobjectif par un embout viss dobturation. Installer le capteur, muni de trous de fixation, lendroit (par ex. poulie de renvoi) o lobjet examiner excute les mouvements latraux et verticaux les plus faibles. Ce faisant, tenir compte de la distance de dtection (voir les caractristiques techniques la fin de ces Instructions de Service et voir le diagramme, x=distance de dtection, y=sensibilit relative). Compenser les mouvements latraux et verticaux de lobjet examiner au moyen de repres de longueur approprie. Exclure tout mouvement du capteur pouvant influer sur la distance de dtection. Dans le cas dobjets surface brillante ou rflchissante incliner le capteur de 10o 15o par rapport la surface du matriau. Raccorder les conducteurs. Appliquer la tension de service au capteur (voir inscription indiquant le modle). Rglage Seuil de commutation: Panneau de commande: A=Bouton rgulateur du seuil de commutation, B=Commutation sombre Lumire verte, C=Commutation claire Lumire verte, D=Ajustement Lumire verte, E=Commutation sombre Lumire rouge, F=Commutation claire Lumire rouge, G=Ajustement Lumire rouge, H=Affichage de fonction. Ouvrir le capot de protection. Choisir la couleur metteur de lumire et rgler sur >commutation claire<. Proportion incertaine de rouge ou de vert dans une couleur: Dterminer la puissance de contraste des deux metteurs de lumire. Choisir lmetteur qui produit la plus grande diffrence de luminosit. Positionner la face la plus claire du matriel dtecter dans la tache de lumire. Placer le commutateur de mode sur >I<. Positionner la face la plus sombre du matriel dtecter dans la tache de lumire. a) Le tmoin de fonctionnement sallume: tourner le bouton rgulateur jusqu ce que le tmoin steigne. b) Le tmoin de fonctionnement ne sallume pas: tourner le bouton rgulateur tout dabord dans le sens contraire des aiguilles dune montre jusqu ce que le tmoin sallume, continuer ensuite suivant a). Placer le commutateur de mode conformment C sur >commutation claire ou sombre<. Mettre le capot de protection en place. NT 6- _ _ 2 _ _ uniquement: On rgle distance le seuil de commutation par lintermdiaire du niveau de tension variant de 0 10V.
3 Sortie B PNP PNP + 50 ms Off Delay PNP + 15 ms Off Delay PNP + 3.5 ms Off Delay _ 1 Objektif / TW 1, 2 3, 4 5, 6 7, 8 # 211 / 9 mm # 213 / 18 mm # 214 / 50 mm # 25 / 25 mm _

Montar o sensor executando perfuraes no lugar (por ex. rolo de inverso), em que o objeto de controle executa os menores movimentos laterais e de elevao. Atender, durante este processo, ao raio de explorao (ver dados tcnicos no fim das presentes instrues de servio e ver diagrama, =raio de explorao, y=sensibilidade relativa). Compensar os movimentos laterais e de elevao do objeto de controle atravs de marcaes de comprimento adequado. Excluir movimentos do sensor, influenciando o raio de explorao. Tratando-se de superfcies de objetos que refletem ou brilham inclinar o sensor por 10o o at 15o com relao superfcie do material. Fazer a cablagem eltrica. Ligar o sensor tenso operacional (ver identificao do tipo). Regulao nvel de ligao. Campo operacional. A= regulador do nvel de ligao, B= luz verde ligao a escuro, C= luz verde ligao a claro, D= regulao luz verde, E= luz vermelha ligao a escuro; F= luz vermelha ligao a claro; G= regulao luz vermelha; H= lmpada de funcionamento. Abrir a tampa de proteo. Selecionar Cor emissor de luz e regular para ligao a claro. Averiguar contrastes dos dois emissores. Selecionar o emissor de luz, que produz a maior diferena. Posicionar a rea mais clara do objeto de explorao no ponto de luz. Colocar o interruptor de servio em >I<. Posicionar a rea mais escura do objeto de explorao no ponto de luz. a) A lmpada de funcionamento acende: Rodar o regulador, at que a lmpada apague. b) A lmpada de funcionamento no acende: Rodar o regulador s no sentido contra os ponteiros do relgio, at que a lmpada acenda. Depois continuar com o procedimento indicado em a). Colocar o interruptor dos tipos de funcionamento a seguir a C em ligao a claro ou a escuro. Colocar a tampa de proteo. S NT 6- _ _ 2 _ _: O nvel de ligao regulado por telecomando atravs do nvel de voltagem 0....10V
3 Sada B PNP PNP + 50 ms Off Delay PNP + 15 ms Off Delay PNP + 3.5 ms Off Delay _ 1 Objetivo / TW 1, 3, 5, 7, 2 4 6 8 # 211 / 9 mm # 213 / 18 mm # 214 / 50 mm # 25 / 25 mm _

Kun NT 6- _ _ 2 _ _: Koblingstrskel fjernindstilles via spndingsniveau 0...10V.

NT6 - 0 LED / Lysplet 0 1 2 3 3 Udgang B PNP PNP + 50 ms Off Delay PNP + 15 ms Off Delay PNP + 3.5 ms Off Delay _ 1 Objektiv / TW 1, 2 3, 4 5, 6 7, 8 # 211 / 9 mm # 213 / 18 mm # 214 / 50 mm # 25 / 25 mm _

NEDERLANDS
Contrastsensor Gebruiksaanwijzing

Veiligheidsvoorschriften
Lees voor de ingebruikneming de gebruiksaanwijzing. Aansluiting, montage en instelling alleen door vakbekwaam personeel laten uitvoeren. Apparaat voor ingebruikneming tegen vocht en verontreiniging beschermen. Geen veiligheidscomponent conform EU-machinerichtlijn.

red/grn | 3 red/grn 4 red/grn o 7 red 8 9

Vedligeholdelse
SICK-kontrasttaster krver ingen vedligeholdelse.Vi anbefaler, at - de optiske grnseflader rengres - forskruninger og stikforbindelser kontrolleres med regelmssige mellemrum.

Gebruik volgens bestemming

De drukmerkentaster NT 6 is een optisch-elektronische sensor en wordt gebruikt voor het optisch, contactloos registreren van drukmerken.

5 6

Ingebruikneming

1 2 3 4
ITALIANO
Sensore di contrasto Instruzioni per l'uso

Avvertimenti di sicurezza
Leggere prima della messa in esercizio. Allacciamento, montaggio e regolazione solo da parte di personale qualificato. Durante la messa in esercizio proteggere da umidit e sporcizia. Non componente di sicurezza secondo la Direttiva macchine EN.

5 6

Impiego conforme allo scopo

Il sensore di contrasto NT 6 un sensore opto-elettronico che viene impiegato per il rilevamento ottico a distanza di marchi di contrasto.

NT6 - 0 LED / Ponto luminoso 0 1 2 3

red/grn | 3 red/grn 4 red/grn o 7 red 8 9

Messa in esercizio

1 2

Manuteno
As foto-clulas de contraste SICK no requerem manuteno. Recomendamos que se faa, em intervalos regulares, - a limpeza das superfcies ticas, - e um controle s conexes roscadas e unies de conetores.

3 4

DANSK
Kontrastknap Driftsvejlening

Sikkerhedsforskrifter
Driftsvejledningen skal gennemlses fr idrifttagning. Tilslutning, montage og indstilling m kun foretages af fagligt personale. Apparatet skal beskyttes mod fugtighed og snavs ved idrifttagningen. Ingen sikkerhedskomponent iht. EU-maskindirektiv.

5 6

Beregnet anvendelse
Kontrasttasteren NT 6 er en opto-elektronisk fler, som benyttes til optisk, berringsls registrering af kontrastmrker.

NT6 - 0 LED / Tache lumineuse 0 1 2 3

red/grn | 3 red/grn 4 red/grn o 7 red 8 9

Idrifttagning

1 2 3 4

Maintenance
Les dtecteurs de contraste SICK ne ncessitent pas dentretien. Nous recommandons, intervalles rguliers - de nettoyer les surfaces optiques, - de contrler les assemblages visss et les connexions fiche et prise.

PORTUGUS
Foto-clula de contraste Instrues de operao

Instrues de segurana
Antes do comissionamento dev ler as instrues de operao. Conexes, montagem e ajuste devem ser executados exclusivamente por pessoal devidamente qualificado. Guardar o aparelho ao abrigo de umidade e sujidade. No se trata de elemento de segurana segundo a Diretiva Mquinas da Unio Europa.

5 6

Utilizao devida
A foto-clula de contraste NT 6 um sensor opto-eletrnico que utilizado para a anlise tica, sem contato, de marcas contrastantes.

Comissionamento

1 2 3

Enfiar a caixa de cabos sem tores e aparafus-la. Para a ligao eltrica em B : brn=marron, blu=azul, blk=preto, gra=cinzento, wht=branco, red=vermelho, yel=amarelo, grn=verde. Sadas: QPNP e QB (Conforme cdigo tipo, ver ab.). QA: sada anloga, corrente de sada proporcional recepo. Ligar o sensor conforme o esquema de ligaes B. Elemento temporizador (Conforme cdigo tipo, ver ab.): Selecionar o lado de sada da luz, se for caso disso, substituir a objetiva por unio roscada cega.

Ledningsdse monteres spndingsfri og skrues fast. For tilslutning i B glder : brn=brun, blu=bl, blk=sort, gra=gr, wht=hvid, red=rd, yel=gul, grn=grn. Udgange: QPNP og QNPN (svarer til typengle, se nedenfor). QA: Analogudgang, udgangsstrm proportional lysmodtagelse. Knap tilsluttes iht. tilslutningsskema B. Tidsled (svarer til typengle, se nedenfor): Lysudtrdningsside vlges hhv. objektiv udskiftes med blindskrue. Sensor monteres med montagehuller p et sted (f.eks. styrerulle), hvor kontrolobjektet udfrer de mindste side- og hjdebevgelser.Vr opmrksom p tastvidde (se tekniske data i slutningen af nrvrende driftsvejledning og se diagram, x=tastvidde, y=relativ modtagelighed). Kontrolobjektets side- og hjdebevgelser udlignes med tilsvarende lange markeringer. Sensorens bevgelser udelukkes med tastviddepvirkning. Ved spejlende eller glimrende objektoverflader skal fleren have en hldning p 10o til 15o i forhold til materialets overflade. Ledninger tilsluttes. Fler forbindes med driftsspnding (se typebetegnelse). Indstilling af koblingstrskel: Kontrolpanel: A=Koblingstrskelindstiller, B=Skift til mrkegrnt lys, C=Skift til lysegrnt lys, D=Justering af grnt lys, E= Skift til mrkerdt lys, F=Skift til lyserdt lys, G=Justering af rdt lys, H=Funktionslysdiode. Tag beskyttelseskappen af. Vlg farve Lysgiver og indstil >skift til lyst<. Ml de to lysgiveres kontrast.Vlg den lysgiver, der giver den strste lysstyrkeforskel. Positioner aftastningsemnets lyseste flade i lyspletten. Stil driftsmdevlgeren p >I<. Positioner aftastningsemnets mrkeste flade i lyspletten. a) Funktionslysdioden lyser: Drej indstilleren, indtil lysdioden lige netop gr ud. b) Funktionslysdioden lyser ikke: Drej frst indstilleren mod uret, indtil lysdioden lyser, herefter videre med a). Stil driftsmdevlger mod C p >skift til lys eller mrk<. St beskyttelseskappen p.

Inserire scatola esente da tensione e avvitare stringendo. Per collegamento B osservare: brn=marrone, blu=blu, blk=nero, gra=grigio, wht=bianco, red=rosso, yel=giallo, grn=verde. Uscite: QPNP o QB (secondo codice modello, v. sotto). QA: Uscita analogica, corrente di uscita proporzionale a ricezione di luce. Collegare il sensore secondo lo schema B. Temporizzatore (secondo codice modello, v. sotto): Scegliere il lato di uscita luce, sullaltro lato sostituire lobiettivo con un tappo a vite. Montare il sensore con i fori di fissaggio nel punto (ad es. carrucola di rinvio) in cui loggetto effettua meno movimenti orizzontali e verticali.Tenere conto della distanza di ricezione (cf. Scheda tecnica alla fine di queste Istruzioni e v. diagramma, x=distanza di ricezione, y=sensibilit relativa). Compensare i movimenti orizzontali e verticali delloggetto tramite demarcazioni di lunghezza adeguata. Escludere movimenti del sensore che possano influenzare la distanza di ricezione. Con superfici riflettenti oppure brillanti inclinare di 10o - 15o rispetto alla superficie delloggetto. Collegare i cavi. Allacciare sensore a tensione di esercizio (cf. stampigliatura). Impostazione limite di commutazione: Quadro comandi: A=impostazione limite di commutazione, B=commutazione a scuro luce verde, C=commutazione a chiaro luce verde, D=regolazione luce verde, E=commutazione a scuro luce rossa, F=commutazione a chiaro luce rossa, G=regolazione luce rossa, H=indicatore di funzionamento. Aprire la copertura di protezione. Selezionare il colore emettitore e impostare >commutazione a chiaro<. Componente rossa/verde di un colore incerta: Determinare il contrasto dei due emettitori e scegliere quello che produce il contrasto maggiore. Posizionare sul punto luminoso una superficie chiara. Mettere il selettore del modo operativo su >I<. Posizionare sul punto luminoso una superficie scura. a) lindicatore di funzionamento si accende: ruotare la manopola fino al punto esatto in cui si spegne. b) lindicatore di funzionamento non si accende: ruotare la manopola in senso antiorario finch lindicatore si accende, proseguire con il punto a). Mettere il selettore del modo operativo su >commutazione a chiaro o a scuro< come indicato in C. Richiudere la copertura di protezione. Solo NT 6- _ _ 2 _ _: Il limite di commutazione viene impostato a distanza tramite il livello di tensione 0...10V.
3 Uscita B PNP PNP + 50 ms Off Delay PNP + 15 ms Off Delay PNP + 3.5 ms Off Delay _ 1 Obiettivo / TW 1, 2 3, 4 5, 6 7, 8 # 211 / 9 mm # 213 / 18 mm # 214 / 50 mm # 25 / 25 mm _

Connector spanningsloos monteren en vastschroeven.Voor de aansluiting in B geldt: brn=bruin, blu=blauw, blk=zwart, gra=grijs, wht=wit, red=rood, yel=geel, grn=groen. Uitgangen: QPNP o QB (voor de betr. typesleutel, z.o.). QA: Analoge uitgang, uitgangsstroom proportioneel lichtontvangst. Fotocel volgens aansluitschema B aansluiten. Tijdelement (voor de betr. typesleutel, z.o.): Lichtuitstraalzijde kiezen, indien nodig objectief vervangen door een blinde schroefverbinding. Systeem met bevestingsgaten daar (bijv. leidschijf) bevestigen, waar het proefobject de minste horizontale en verticale bewegingen maakt. Houd rekening met de tastafstand (zie technische gegevens op het einde van deze gebruiksaanwijzing en zie diagram, x=tastafstand, y=relatieve gevoeligheid). Compenseer horizontale en verticale bewegingen van het proefobject met overeenkomstig lange markeringen. Vermijd bewegingen van het systeem met tastafstandeninvloed. Bij spiegelende of glanzende oppervlakken de sensor met 10o tot 15o t.o.v. het oppervlak laten hellen. Kabels aansluiten. Sensor onder spanning zetten (z.Typeplaatje). Instelling schakeldrempel: Bedieningsveld: A=schakeldrempelinstelling, B= donkerschakelend groen licht, C= helderschakelend groen licht, D= uitrichten groen licht, E= donkerschakelend rood licht, F= helderschakelend rood licht, G= uitrichten rood licht, H= functieaanduiding. Beschermkap openen. Kleur lichtzender kiezen en >helderschakelend< instellen. Rood of groen aandeel van een kleur vaag: Contrasten van beide lichtzenders berekenen. De lichtzender kiezen die het grootste helderheidsverschil teweegbrengt. Helder objectoppervlak in de lichtvlek positioneren. Bedrijfsmodusschakelaar op >I< zetten. Donker objectoppervlak in de lichtvlek positioneren. a) Functieaanduiding licht op: insteller draaien tot de aanduiding dooft. b) Functieaanduiding licht niet op: insteller eerst linksom draaien tot de aanduiding oplicht, dan verder zoals onder a) vermeld. Bedrijfsmodusschakelaar naar C op >helder- of donkerschakelend< zetten. Beschermkap opzetten. Alleen NT 6- _ _ 2 _ _: Schakeldrempel wordt via spanningsniveau 0 ... 10 V op afstand ingesteld.
3 Uitgang B PNP PNP + 50 ms Off Delay PNP + 15 ms Off Delay PNP + 3.5 ms Off Delay _ 1 Objectief / TW 1, 2 3, 4 5, 6 7, 8 # 211 / 9 mm # 213 / 18 mm # 214 / 50 mm # 25 / 25 mm _

tipos, ver abajo): Seleccionar el lado de salida de la luz, en caso dado, recambiar el objetivo por atornilladura ciega. Montar el sensor con las perforaciones de fijacin en el lugar (p. ejem., polea de reenvo) donde los objetos a controlar ejecuten el menor movimiento lateral y de altura.Tener en cuenta aqu el alcance de exploratin (ver caractersticas tcnicas al final del Manual de Servicio y el diagrama, x=alcance de exploratin, y=sensibilidad relativa). Compensar los movimientos laterales y de altura de los objetos a controlar mediante marcas correspondientemente largas. Excluir movimientos del sensor con influencia de aplitud de exploratin. Con superficies de objetos reflectantes o brillantes inclinar el sensor entre 10o y 15o hacia la superficie del material. Conectar los conductores. Poner el sensor en tensin de servicio (ver impresin tipogrfica). Ajuste del umbral de conexin: Campo de mando: A=Ajustador del umbral de conexin, B=conexin en oscuro luz verde, C=conexin en claro luz verde, D=ajuste de la luz verde, E=conexin en oscuro luz roja, F=conexin en claro luz roja, G=ajuste de la luz roja, H=indicador de funcin. Abrir la caperuza de proteccin. Seleccionar el color Emisor de luz y ajustar >conexin en claro<. Relacin de rojo o de verde de un color no est clara: Determinar el contraste de ambos emisores de luz. Elegir el emisor de luz que produzca la mayor diferencia de claridad. Posicionar en la mancha de luz la superficie ms clara del producto a explorar. Colocar en >I< el interruptor de tipo de servicio. Posicionar en la mancha de luz la superficie ms oscura del producto a explorar. a) Se enciende el indicador de funcin: Girar el ajustador justamente hasta que se extinfa el indicador. b) No se enciende el indicador de funcin: Girar el ajustador primeramente contra el sentido del reloj hasta que se encienda el indicador y continuar despus con A). Colocar el interruptor de tipo de servicio despus de C en >conexin clara u oscura<. Colocar de nuevo la caperuza de proteccin. Solo NT 6- _ _ 2 _ _: El umbral de conexin es regulado por medio del nivel de tensin 0...10V.
3 Salida B PNP PNP + 50 ms Off Delay PNP + 15 ms Off Delay PNP + 3.5 ms Off Delay _ 1 Objetivo / TW 1, 2 3, 4 5, 6 7, 8 # 211 / 9 mm # 213 / 18 mm # 214 / 50 mm # 25 / 25 mm _

NT6 - 0 LED / Mancha fotoelctrica 0 1 2 3

red/grn | 3 red/grn 4 red/grn o 7 red 8 9

Mantenimiento
Los detectores de contacto SICK estn libres de mantenimiento. Recomendamos a intrvalos regulares - limpiar las superficies pticas limtrofes, - controlar los prensaestopas y las conexiones de enchufe.

NT6 - 0 LED / Lichtvlek 0 1 2 3

red/grn | 3 red/grn 4 red/grn o 7 red 8 9

Onderhoud
SICK-drukmerkentasters zijn onderhoudsvrij.Wij bevelen aan, regelmatig - de optische grensvlakken schoon te maken, - schroef - en connectorverbindingen te controleren.

ESPAOL
Palpador de contraste Manual de Servicio

Observaciones sobre seguridad

Leer el Manual de Servicio antes de la puesta en marcha. Conexin, montaje y ajuste solo por personal tcnico. A la puesta en marcha proteger el aparato contra humedad y suciedad. No es elemento constructivo de seguridad segn la Directiva UE sobre maquinaria.

NT6 - 0 LED - Punto luminoso 0 1 2 3

red/grn | 3 red/grn 4 red/grn o 7 red 8 9

Empleo para usos debidos

El palpador de contraste NT 6 es un sensor opto-electrnico empleado para la deteccin ptica y sin contacto de marcas de contraste.

Puesta en marcha Manutenzione

I sensori di contrasto SICK non richiedono manutenzione. Si consiglia - di pulire regolarmente le superfici limite ottiche, - di controllare regolarmente gli avvitamenti e i collegamenti a spina.

1 2

Insertar y atornillar bien la caja de conexiones sin tensin. Para conectar en B: brn=marrn, blu=azul, blk=negro, gra=gris, wht=blanco, red=rojo, yel=amarillo, grn=verde. Salidas: QPNP y QB (aplicar de acuerdo a la clave de tipos, ver abajo). QA: Salida analgica, corriente de salida proporcional a receptin de luz. Conectar el pulsador de acuerdo al esquema de conexiones B. Elemento temporizador (aplicar de acuerdo a la clave de

Spencer Vortex Regenerative Blowers Installation, Operation and Maintenance Instructions

Serial No: Model No:

VB-007

VB-055

Important
Read and become familiar with this manual prior to uncrating and installing your Spencer Vortex Blower. Following the instructions detailed here will help you realize its full potential of efficient service and extended lifespan. Damage resulting from failure to follow correct procedure will void the warranty. The Spencer Turbine Company Windsor, Connecticut 06095 Form ZZ12.1

Contents
I. General Page Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . 2 II. Installation Locating, Mounting, Connecting . . . . . . . . . . . . . 2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 III. Operation Limits of Operation . . . . . . . . . . . . . . . . . . . . . 4-5 Temperature Rise . . . . . . . . . . . . . . . . . . . . . . . . 5 IV. Disassembly and Reassembly General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Disassembly Procedure . . . . . . . . . . . . . . . . . . . 5 Reassembly Cautions . . . . . . . . . . . . . . . . . . . . . 5 Locknut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 6 V. Vortex Blower Data Assembly Diagrams . . . . . . . . . . . . . . . . . . . . 6-17 Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Performance Curves . . . . . . . . . . . . . . . . . . . 6-17 VI. Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . 18

No assemblies or parts of assemblies will be accepted for repair or replacement under this warranty without prior authorization by The Spencer Turbine Company. For complete warranty information, obtain Spencers Form 706, Terms and Conditions of Sales. Safety Precautions Power sources, protective devices, and grounding provisions must be in accordance with wiring instructions provided in this manual. Blower becomes hot during operation and may cause burns if touched. Do not operate the blower under load conditions which exceed the rated full-load amps on the nameplate. Do not install the blower in any area which may have an explosive atmosphere or which may contain flammable gases or liquids. Always provide proper ventilation. Do not install in any area which may subject the blower to corrosive liquids. Excessive moisture may cause electrical failure; install the blower in areas free from water or rain. Do not operate blower without motor cooling fan cover, or without impeller end cover. Before installing blowers with explosion-proof motors, the buyer must check federal, state and local codes to see if such motors are appropriate for the intended application environment. It is the buyers responsibility to determine the suitability of any product for a particular purpose. Storage If machine is to be stored for an extended period of time, it must be carefully protected from dampness and dirt.

I. General
Scope Information contained in this manual relates to Vortex Blowers standard and explosion-proof motor models VB-001S, VB-001, VB-002S, VB-002, VB-003S, VB-003, VB-004S, VB-004, VB-007S, VB-007, VB-019S, VB-019, VB-030S, VB-030, VB-037S, VB-037,VB-055, VB-075, and VB-110. Limited Warranty We warrant that this product will be free from defects in material and workmanship for a period of 18 months from date of shipment or 12 months from date of startup, whichever comes first. Within the warranty period, we shall repair or replace F.O.B. our Factory such products that are determined by us to be defective. This warranty will not apply to any product which has been subjected to misuse, negligence, or accident, or misapplied or improperly installed. This warranty will not apply to any product which has been disassembled, repaired, or otherwise altered by any persons not authorized by the Spencer Vortex Service Department. On units which include thermal protection, the thermal protection must be connected as recommended. The guarantee of the motor and control manufacturers will govern the extent of our guarantee on such equipment. Warranty work on motors and controls must be authorized by Spencer and must be performed in an authorized shop as designated by the manufacturers. The Spencer Turbine Company reserves the right to invoice all expenses incurred when repairs are made in the field at the specific request of the customer.

II. Installation
Locating, Mounting, Connecting Ambient temperature at the installed location should not be less than -5 F or greater than 104 F. Relative humidity should not exceed 80%. Mount the blower in a horizontal or vertical position as shown in Figure 1. For models VB-055, VB-075 and VB-110, it is recommended to mount in the horizontal position only. Check with factory prior to mounting these models vertically.

Fig. 1 Mounting Positions Remove protective coverings, such as vinyl tape or plastic plugs, from the inlet and outlet ports. For models VB-004 and larger, attach to system piping using threaded connection as provided. Avoid excessive stress caused by pipe connector tightening or by misaligned pipe on the inlet and outlet ports. Support piping by brackets or other means. Models VB-001, VB-002 and

VB-003 are supplied with a patented (U.S. Patent 5,791,870) reversible flange with threaded pipe or tubing connections. In the event the blower is located where dust, fibers, drops of water, or other particulates may be in the airstream, use a filter on the suction side of the piping. If foreign matter enters the impeller, it may clog, jam, or otherwise impair the blower performance. Wiring Caution: Confirm that the power source is the same as that indicated on the units nameplate. Application of incorrect voltage or improper phase connection may cause motor failure or other damage. Use conductors and devices (such as the circuit breakers, starters, and switches shown in Figure 3) that are suitable for the applications shown in Tables 1 and 2 and are in compliance with the National Electric Code and applicable local codes and regulations. Motor terminal connections are shown below Table 1.

Provide protection from overheating of the motor windings. Some models are equipped with built-in thermal protectors (see Table 1). Where applicable, connect the leads from the pilot-duty thermal protector to the magnetic starter as shown in Fig. 3. Check the direction of rotation of the blower. To reverse the direction or rotation: 1) for a single-phase motor, interchange motor leads 5 and 8. 2) for a three-phase motor, interchange any two of the three line connections. Caution: Install a properly-sized overload device and disconnect in accordance with local codes and regulations and dedicated only to the Vortex Blower. Furnish the Vortex Blower and all associated electrical devices with a proper ground in accordance with all local codes and regulations.

Fig. 3 Typical Wiring Diagram

The Spencer Turbine Company 600 Day Hill Road, Windsor, CT 06095-4706 TEL 800-232-4321 x 860-688-8361 x FAX 860-688-0098

Table 1 Three-Phase Motor Data - Typical Values

60 Hertz Operation
Model No. Power (hp) Voltage (V) FL Amp (A) Voltage (V) FL Amp (A) Model No. Power (hp) Voltage (V) FL Amp (A) Voltage (V) FL Amp (A) VB-001 0.13 200-230/460 .5-.48/.24 VB-002 0.25 200-230/460 .86-.73/.37 575 .4 VB-037 5 200-230/460 13.2-12/6 575 4.8 VB-003 0.5 208-230/460 1.8-1.6/.8 575 0.8 VB-055 7.5 200-230/460 19.8-17.2/8.6 575 7 VB-004 0.75 200-230/460 2.3-2.4/1.2 575 0.96 VB-075 10 200-230/460 27.5-27.2/13.6 575 9.6 VB-007 1 200-230/460 2.7-2.8/1.4 575 1.4 VB-110 15 200-230/460 39-37/18.5 575 13.5 VB-019 2.5 200-230/460 7.2-6.6/3.3 575 2.1

VB-030 4 200-230/460 10.6-10.2/5.1 575 3

50 Hertz Operation
Model No. Power (hp) Voltage (V) FL Amp (A) Model No. Power (hp) Voltage (V) FL Amp (A) VB-001 0.13 190-220/380-415 .5-.52/.25-.26 VB-030 3.4 190/380-415 10.2/5.2-5.1 VB-002 0.21 190-220/380-415 .74-.66/.37-.34 VB-037 4.2 190/380-415 11.8/5.9-5.6 VB-003 0.5 190/380-415 2/1-.9 VB-055 6.25 190/380-415 17.6/8.8-8.2 VB-004 0.63 190/380-415 2.4/1.2-1.3 VB-075 8.33 190/380-415 27/13.5-14.5 VB-007 .83 190/380-415 2.8/1.4-1.5 VB-110 12.5 190/380-415 36/18-17 VB-019 2.1 190/380-415 6.6/3.3-3.1

NOTE: Thermostats are provided on the VB-004 and larger models.

MOTOR WIRING
Three-Phase High Voltage Low Voltage Single-Phase High Voltage Low Voltage Single-Phase Single Voltage

THERMOSTATS VB-004 AND LARGER

Volts Amps Wiring

5 1

4 8

Line

Line

Line

Line

Line

NOTES:

(1) For three-phase, interchange any two line connections to reverse shaft rotation (2) For single-phase, interchange motor leads 5 and 8 to reverse shaft rotation

Table 2 Single-Phase Motor Data - Typical Values

60 Hertz Operation
Model No. Power (hp) Voltage (V) FL Amps (A) VB-001S 0.13 115/230 1.25/.63 VB-002S 0.25 115/230 2.3/1.15 VB-003S 0.5 115/230 5.2/2.6 VB-004S 0.75 115/208-230 9.6/5-4.8 VB-007S 1 115/208-230 12.4/6.5-6.2 VB-019S 2.5 115/208-230 22/11.5-11 VB-030S 4 115/208-230 34.8/18.5-17.4 VB-037S 5 230 20.8

50 Hertz Operation
Model No. Power (hp) Voltage (V) FL Amps (A) VB-001S 0.13 110/220 1.34/.67 VB-002S 0.21 110/220 2.1/1.05 VB-003S 0.5 110/220 5.6/2.8 VB-004S 0.63 100-110/220 9.9-11.6/5.8 VB-007S 1 100-110/220 12.7-12.4/6.2 VB-019S 2.1 100-110/220 22-21/10.5 VB-030S 3.3 100-110/220 42-38.6/19.3 VB-037S 4.2 220 19

The Spencer Turbine Company 600 Day Hill Road, Windsor, CT 06095-4706 TEL 800-232-4321 x 860-688-8361 x FAX 860-688-0098

IV. Disassembly and Reassembly

A. General 1. Precautions should be taken when disassembling or reassembling the blower. See Warranty Terms. 2. Keep all parts clean. 3. Do not overtighten bolts and screws.
MOTOR C FACE IMPELLER HUB SHAFT THREADED PLATE

Year of Production

Fig. 4 Typical Nameplate

BOLT SHIM BLOCK

III. Operation
Limits of Operation Operation at flows less than those indicated by the solid line on the applicable performance curve will cause overheating of the unit and is to be avoided. Maximum pressure and vacuum are indicated on the nameplate (see Fig. 4). These represent conditions at which the minimum allowable airflow (CFM) occurs. Check the operating pressure or vacuum to assure that the pressure or vacuum remains less than maximum. For continuous operation at low air volume (on the dotted portion of the performance curve), provide a bypass in the piping and operate at a lower pressure than maximum operating pressure. See Performance Curves, Section V. Caution: Low flow conditions may produce heat levels which may cause burns. Do not touch the blower in operation. Temperature Rise A NEMA Class F insulation system is used in the motor. Maximum allowable winding temperature is 265F. If a thermal protector or thermal relay activates because the temperature rise of the motor is higher than usual, investigate and correct the problem. Explosion-proof motors use a NEMA Class B insulation. Typical causes of motor overheating are given in Section VI, Troubleshooting Guide.

Fig. 5 Impeller Puller B. Disassembly Procedure (Reassembly is performed in reverse order) Caution: Shims are used to adjust the gap between the impeller and casing. When disassembling, take care to note the quantity of shims and their thickness. The shim stack replacement must be the correct thickness to assure proper clearance and to avoid degradation of performance. 1. Remove impeller cover; remove screws, pull cover away from case. 2. Unfasten lock washer; remove nut and washer. 3. Remove impeller from shaft by one of the following methods: a. manually pull the impeller outward, OR b. screw two bolts into tapped holes and pull on the bolts, OR (if the fit is tight) c. use a puller assembly (not furnished) as shown in Fig. 5. 4. Remove motor shaft key. 5. Remove case from motor; if necessary remove screws holding case to base and motor to case. 6. Remove shims from motor shaft if necessary; do not discard them. See Note above. Caution: Motors are heavy. Lift motor on models larger than VB002 by the eyebolt on the motor with an aid from a lifting device. C. Reassembly Guidance 1. The gap between the impeller and case is essential for proper performance of the unit. The shims between the shaft collar and impeller hub establish the spacing of this gap. In reassembly, before installing the impeller cover, check the gap between the impeller and case to assure that the measurement conforms to the gap specification on the assembly drawing (on the following pages) for your unit.

The Spencer Turbine Company 600 Day Hill Road, Windsor, CT 06095-4706 TEL 800-232-4321 x 860-688-8361 x FAX 860-688-0098

2. For models VB-004 to VB-110, remove the plug at the bottom of the case and check the gap with a feeler gage. Remove impeller and adjust shims if necessary to change gap. When adjustments and checks are complete, replace plug tightly to prevent air leakage. a. For models VB-001 to VB-003, check gap anywhere along the periphery of the case to impeller mating surface. 3. Fasten impellers using lockwashers and locknuts. Torque locknut to recommended torque values in Table 3. Bend a lockwasher tab down into a lockwasher slot. 4. Reattach the impeller cover.

V. Vortex Blower Data

Pages 7 through 17 present information about the various blower models. This information is important in understanding your blowers performance, in using the blower in the proper operating range, and in ordering parts that might be needed. A. Assembly Diagrams At the top of each page is an assembly diagram of the unit. Items are identified by circled numbers around the diagram. Above each diagram is the gap specification. B. Parts Lists At the lower left of each diagram is a table giving the item number (shown on the Assembly Diagram), the Part No. for that item and the corresponding part description. In ordering parts, provide the model number, the part number and the description. C. Performance Curves At the lower right of each diagram are performance curves for 50Hz and 60Hz operation. The curves present the following information: The upper line of each curve is pressure performance while the lower line is vacuum performance. The dashed portion at the left end of some of the curves indicates an intermittent-only operating area. See Operation Section on page 5. D. Estimated Acoustical Noise Level at 1.5M, 60Hz

Catalog No. VB001, VB001S, VB002 VB002S, VB003, VB003S VB004, VB004S VB007, VB007S VB019, VB019S VB030, VB030S VB037, VB037S VB055 VB075 VB110

Recommended Torque (Ft-Lb) 22 31 36 36 44 44 77 90 90

Table 3 Locknut Torque

Model VB001S VB001 VB002S VB002 VB003S VB003 VB004S VB004 VB007S VB007 VB019S VB019 VB030S VB030 VB037S VB037 VB055 VB075 VB110

dba 62 61 61 61 66 66 63 63 70 64 70 73 71 73 74 76 82 81 80

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Spencer Vortex Regenerative Blowers

VB001S, VB001
Assembly Diagram
in. mm.

VB001S, VB001 Performance Curves

Parts List
DESCRIPTION: VORTEX BLOWER ASSEMBLY VB001S & VB001 ITEM PART NO. DESCRIPTION 1 VBC90101 Case, Unibody 2 VBI90101 Impeller 3 VBE90101 Cover, Impeller 4 NUT90219 Locknut, Shaft 5 WSH90184 Lockwasher, Shaft 6 WSH90185 Shim, Shaft to Impeller (as required) 7 MOT90210 Motor 42C 1/8 HP, 1 Ph 7A MOT90215 Motor 42C 1/8 HP, 3 Ph 8 SCR90901 M4 x 0.7 Pan Head Phillips Screw x .31 [8] Long 10 SCR90307 1/4-20 x .625" Long Socket Cap Screw 11 GSK90168 Gasket, Flange 12 FLC90013 Flange 13 SCR90888 M5 x 0.8 Hex Head Bolt x .63 [16] long 16 INS90014 Absorber 17 KEY90083 Key 18 N/A Impeller to case gap specification QTY. 1 1 1 1 1 1 1 1 4 4 1 1 6 2 1 N/A

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Spencer Vortex Regenerative Blowers

VB002S, VB002
Assembly Diagram

in.

mm.

VB002S, VB002 Performance Curves

Parts List
DESCRIPTION: VORTEX BLOWER ASSEMBLY VB002S & VB002 ITEM PART NO. DESCRIPTION 1 VBC90201 Case, Unibody 2 VBI90201 Impeller 3 VBE90201 Cover, Impeller 4 NUT90219 Locknut, Shaft 5 WSH90184 Lockwasher, Shaft 6 WSH90185 Shim, Shaft to Impeller (as required) 7 MOT90211 Motor 42C, 1/4 HP, 1 Ph 7A MOT90212 Motor 42C, 1/4 HP, 3Ph 8 SCR90901 M4 x 0.7 Pan Head Phillips Screw x .31 [8] Long 10 SCR90307 1/4-20 x .625" Long Socket Cap Screws 11 GSK90169 Gasket, Flange 12 FLC90014 Flange 13 SCR90888 M5 x 0.8 Hex Head Bolt x .63 [16] Long 16 INS90015 Absorber 17 KEY90085 Key 18 N/A Impeller to case gap specification QTY. 1 1 1 1 1 1 1 1 4 4 1 1 6 2 1 N/A

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Spencer Vortex Regenerative Blowers

VB003S, VB003
Assembly Diagram
in. mm.

VB003S, VB003 Performance Curves

Parts List
DESCRIPTION: VORTEX BLOWER ASSEMBLY VB003S & VB003 ITEM PART NO. DESCRIPTION 1 VBC90301 Case, Unibody 2 VBI90301 Impeller 3 VBE90301 Cover, Impeller 4 NUT90219 Locknut, Shaft 5 WSH90184 Lockwasher, Shaft 6 WSH90185 Shim, Shaft to Impeller (as required) 7 MOT90213 Motor 48C, 1/2 HP, 1 Ph 7A MOT90214 Motor 48C, 1/2 HP, 3 Ph 7B MOT90229 Motor 48C, 1/2 HP, 3 Ph, 575 Volt 8 SCR90901 M4 x 0.7 Pan Head Phillips Screw x .31 [8] Long 10 SCR90307 1/4-20 x .625" Long Socket Cap Screw 11 GSK90170 Gasket, Flange 12 FLC90015 Flange 13 SCR90888 M5 x 0.8 Hex Head Bolt x .63 [16] Long 16 INS90016 Absorber 17 KEY90085 Key 18 N/A Impeller to case gap specification QTY. 1 1 1 1 1 1 1 1 1 4 4 1 1 6 2 1 N/A

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Spencer Vortex Regenerative Blowers

VB004S, VB004
Assembly Diagram
in. mm.

VB004S, VB004 Performance Curves

Parts List
DESCRIPTION: VORTEX BLOWER ASSEMBLY VB004S & VB004 ITEM PART NO. DESCRIPTION 1 VBC90401 Case 2 VBI90401 Impeller 3 VBB90401 Base 4 VBE90401 Cover, Impeller 5 NUT90212 Locknut, Shaft 6 WSH90170 Lockwasher, Shaft 7 WSH90177 Shim, Shaft to Impeller (as required) 8 MOT90193 Motor 48C, 3/4 HP, 1 Ph 8A MOT90192 Motor 48C, 3/4 HP, 3 Ph 8B MOT90230 Motor 48C, 3/4 HP, 3 Ph, 575 Volt 9 SCR90887 M6 x 1.0 Hex Head Bolt x .63 [16] Long 10 WSH90142 Lock washer, M5 11 WSH90166 Flat Washer, M5 12 SCR90888 M5 x 0.8 Hex Head Bolt x .63 [16] Long 13 WSH90181 Flat Washer, M5 14 SCR90877 M5 x 0.8 Pan Head Phillips Screw x .39 [10] Long 15 WSH90138 Lockwasher, M5 16 WSH90139 Flat Washer, M5 17 SCR90307 1/4-20 x .625" Long Socket Cap screw 18 GSK90165 Gasket, Case 19 GSK90163 Gasket, Flange 20 FLC90007 Flange 21 SCR90931 M6 x 1.0 S.H.C.S. x .98 [25] Long 23 PLG90037 Plug, 1/4 NPT x .43 [11] Long 25 INS90017 Absorber 27 KEY90076 Key 28 SEL90108 Lip Seal 29 N/A Impeller to case gap specification QTY. 1 1 1 1 1 1 1 1 1 1 4 4 4 2 2 4 4 4 4 1 2 2 4 1 4 1 1 N/A

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10

Spencer Vortex Regenerative Blowers

VB007S, VB007, VB007SXP, VB007XP
Assembly Diagram
in. mm.

(See Bulletin 417, pages 34 and 35 for specifics on models with explosionproof motors.)

VB007S, VB007 Performance Curves

Parts List
DESCRIPTION: VORTEX BLOWER ASSEMBLY VB007S, VB007, VB007SXP, VB007XP ITEM PART NO. DESCRIPTION QTY. 1 VBC90701 Case 1 2 VBI90701 Impeller 1 3 VBB90701 Base 1 4 VBE90701 Cover, Impeller 1 5 NUT90210 Locknut, Shaft 1 6 WSH90171 Lockwasher, Shaft 1 7 WSH90160 Shim, Shaft to Impeller (as required) 1 8 MOT90195 Motor, 56C, 1 HP, 1 Ph 1 8A MOT90194 Motor, 56C 1 HP, 3 Ph 1 8B MOT90231 Motor, 56C, 1 HP, 3 Ph, 575 Volt 1 8C MOT90225 Motor, 56C, 1-1/2 HP, 3 Ph, XP 1 8D MOT90358 Motor, 56C, 1-1/2 HP, 1 Ph, XP 1 9 SCR90887 M6 x 1.0 Hex Head Bolt x .63 [16] Long 4 10 WSH90142 Lockwasher, M6 4 11 WSH90166 Flat Washer, M6 4 12 SCR90888 M5 x 0.8 Hex Head Bolt x .63 [16] Long 2 13 WSH90181 Washer, Flat M5 2 14 SCR90877 M5 x 0.8 Pan Head Phillips Screw x .39 [10] Long 4 15 WSH90138 Lockwasher, M5 4 16 WSH90139 Flat Washer, M5 4 17 SCR90867 3/8-16 x .75" Long Socket Cap Screw 4 18 GSK90164 Gasket, Case 1 19 GSK90163 Gasket, Flange 2 20 FLC90008 Flange, 1 1/2 FNPT 2 21 SCR90931 M6 x 1.0 S.H.C.S. x .98 [25] Long 4 23 PLG90037 Plug, 1/4 NPT x .43 [11] Long 1 25 INS90018 Absorber 4 27 KEY90076 Key 1 28 SEL90107 Lip Seal 1 30 N/A Impeller to case gap specification N/A

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Spencer Vortex Regenerative Blowers

VB019S, VB019, VB019SXP, VB019XP
Assembly Diagram
in. mm.

(See Bulletin 417, pages 36 and 37 for specifics on models with explosionproof motors.)

VB019S, VB019 Performance Curves

Parts List
DESCRIPTION: VORTEX BLOWER ASSEMBLY VB019S, VB019, VB019SXP, VB019XP ITEM PART NO. DESPCRIPTION QTY. 1 VBC91901 Case 1 2 VBI91901 Impeller 1 3 VBB91901 Base 1 4 VBE91901 Cover, Impeller 1 5 NUT90210 Locknut, Shaft 1 6 WSH90171 Lockwasher, Shaft 1 7 WSH90160 Shim, Shaft to Impeller (as required) 1 8 MOT90254 Motor, 145TC, 2-1/2 HP, 1 Ph 1 8A MOT90249 Motor, 145TC, 2-1/2 HP, 3 Ph 1 8B MOT90347 Motor, 145TC, 2-1/2 HP, 3 Ph, 575 Volt 1 8C MOT90224 Motor, 145TC, 2-1/2 HP, 3 Ph, XP 1 8D MOT90359 Motor, 145TC, 2-1/2 HP, 1 Ph, XP 1 9 SCR90887 M6 x 1.0 Hex Head Bolt x .63 [16] Long 4 9ALT SCR90876 M6. x 1.0 Hex Head Bolt x .98 [25] Long (Cast Motor) 4 10 WSH90142 Lockwasher, M6 4 11 WSH90166 Flat Washer, M6 4 12 SCR90943 M5 x 0.8 Hex Head Bolt x .79 [20] Long 2 13 WSH90181 Flat Washer, M5 2 14 SCR90877 M5 x 0.8 Pan Head Phillips Screw x .39 [10] Long 4 15 WSH90138 Lockwasher, M5 4 16 WSH90139 Flat Washer, M5 4 17 SCR90867 3/8-16 x .75" Long Socket Cap Screw 4 18 GSK90162 Gasket, Case 1 19 GSK90163 Gasket, Flange 2 20 FLC90008 Flange, 1 1/2 FNPT 2 21 SCR90931 M6 x 1.0 S.H.C.S. x .98 [25] Long 4 23 PLG90037 Plug, 1/4 NPT x .43 [11] Long 1 25 INS90019 Absorber 4 27 KEY90077 Key 1 28 SEL90107 Lip Seal 1 30 N/A Impeller to case gap specification N/A

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12

Spencer Vortex Regenerative Blowers

VB030S, VB030, VB030XP
Assembly Diagram
in. mm.

(See Bulletin 417, pages 38 and 39 for specifics on models with explosionproof motors.)

VB030S, VB030 Performance Curves

Parts List
DESCRIPTION: VORTEX BLOWER ASSEMBLY VB030S, VB030, VB030XP ITEM PART NO. DESCRIPTION 1 VBC93001 Case 2 VBI93001 Impeller 3 VBB93001 Base 4 VBE93001 Cover, Impeller 5 NUT90209 Locknut, Shaft 6 WSH90172 Lockwasher, Shaft 7 WSH90157 Shim, Shaft to Impeller (as required) 8 MOT90370 Motor, 184TC, 4 HP, 1 Ph 8A MOT90250 Motor, 182TC, 4 HP, 3 Ph 8B MOT90348 Motor, 182TC, 4 HP, 3 Ph, 575 Volt 8C MOT90223 Motor, 182TC, 4 HP, 3 Ph, XP 9 SCR90879 M8 x 1.25 Hex Head Bolt x .98 [25] Long 10 WSH90148 Lockwasher, M8 11 WSH90182 Flat Washer, M8 12 SCR90876 M6 x 1.0 Hex Head Bolt x .98 [25] Long 13 WSH90166 Flat Washer, M6 14 SCR90877 M5 x 0.8 Pan Head Phillips Screw x .39 [10] Long 15 WSH90138 Lockwasher, M5 16 WSH90139 Flat Washer, M5 17 SCR90335 1/2 -13 x 1.0 Long Socket Cap Screw 18 GSK90161 Gasket, Case 19 GSK90155 Gasket, Flange 20 FLC90009 Flange, 2 FNPT 21 SCR90878 M6 x 1.0 Hex Head Bolt x 1.57 [40] Long 23 PLG90037 Plug, 1/4 NPT x .43 [11] Long 25 INS90020 Absorber 27 KEY90078 Key 28 SEL90104 Lip Seal 30 N/A Impeller to case gap specification QTY. 1 1 1 1 1 1 1 1 1 1 1 4 4 4 2 2 4 4 4 4 1 2 2 4 1 4 1 1 N/A

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13

Spencer Vortex Regenerative Blowers

VB037S, VB037, VB037XP
Assembly Diagram
in. mm.

(See Bulletin 417, pages 40 and 41 for specifics on models with explosionproof motors.)

VB037S, VB037 Performance Curves

Parts List
DESCRIPTION: VORTEX BLOWER ASSEMBLY VB037S, VB037, VB037XP ITEM PART NO. DESCRIPTION 1 VBC93701 Case 2 VBI93702 Impeller 3 VBB93700 Base 4 VBE93701 Cover, Impeller 5 NUT90209 Locknut, Shaft 6 WSH90172 Lockwasher, Shaft 7 WSH90157 Shim, Shaft to Impeller (as required) 8 MOT90361 Motor, 184TC, 5 HP, 1 Ph 8A MOT90181 Motor, 184TC, 5 HP, 3 Ph 8B MOT90234 Motor, 184TC, 5 HP, 3 Ph, 575 Volt 8C MOT90222 Motor, 184TC, 5 HP, 3 Ph, XP 9 SCR90879 M8 x 1.25 Hex Head Bolt x .98 [25] Long 10 WSH90148 Lockwash, M8 11 WSH90182 Flat Washer, M8 12 SCR90878 M6 x 1.0 Hex Head Bolt x 1.57 [40] Long 13 WSH90166 Flat Washer, M6 14 SCR90877 M5 x 0.8 Pan Head Phillips Screw x .39 [10] Long 15 WSH90138 Lockwasher, M5 16 WSH90139 Flat Washer, M5 17 SCR90335 1/2-13 x 1.0 Long Socket Cap Screw 18 GSK90154 Gasket, Case 19 GSK90155 Gasket, Flange 20 FLC90009 Flange, 2 FNPT 21 SCR90878 M6 x 1.0 Hex Head Bolt x 1.57 [40] Long 23 PLG90037 Plug, 1/4 NPT x .43 [11] Long 25 INS90021 Absorber 26 SCN90056 Absorber Screen 27 KEY90079 Key 28 SEL90104 Lip Seal 29 SPR90088 Spacer, Washer (Case to Base) 30 N/A Impeller to case gap specification 31 PLC90027 Plate, Case QTY. 1 1 1 1 1 1 1 1 1 1 1 4 4 4 2 2 4 4 4 4 1 2 2 4 1 4 2 1 1 2 N/A 1

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14

Spencer Vortex Regenerative Blowers

VB055, VB055XP
Assembly Diagram
in. mm.

(See Bulletin 417, pages 42 and 43 for specifics on models with explosionproof motors.)

VB055 Performance Curves

Parts List
DESCRIPTION: VORTEX BLOWER ASSEMBLY VB055, VB055XP ITEM PART NO. DESCRIPTION 1 VBC95501 Case 2 VBI95502 Impeller 3 VBB95501 Base 4 VBE95501 Cover, Impeller 5 NUT90211 Locknut, Shaft 6 WSH90173 Lockwasher, Shaft 7 WSH90154 Shim, Shaft to Impeller (as required) 8 MOT90182 Motor, 213TC, 7-1/2 HP, 3PH 8A MOT90205 Motor, 213TC, 7-1/2 HP, 3 Ph, 575 Volt 8B MOT90221 Motor, 213TC, 7-1/2 HP, 3 Ph, XP 9 SCR90881 M8 x 1.25 Hex Head Bolt x 1.18 [30] Long 10 WSH90148 Lockwasher, M8 11 WSH90182 Flat Washer, M8 12 SCR90895 M8 x 1.25 Hex Head Bolt x 1.57 [40] Long 13 WSH90182 Flat Washer, M8 14 SCR90876 M6 x 1.0 Hex Head Screw x .98 [25] Long 15 WSH90143 Lockwasher, M6 16 WSH90142 Washer, Flat M6 17 SCR90335 1/2-13 x 1.0 Long Socket Cap Screw 18 GSK90156 Gasket, Case 19 GSK90157 Gasket, Flange 20 FLC90010 Flange, 2-1/2 FNPT 21 SCR90878 M6 x 1.0 Hex Head Bolt x 1.57 [40] Long 23 PLG90037 Plug, 1/4 NPT x .43 [11] Long 25 INS90022 Absorber 26 SCN90057 Absorber Screen 27 KEY90080 Key 28 SEL90105 Lip Seal 30 N/A Impeller to case gap specification 31 PLC90028 Case Plate QTY. 1 1 1 1 1 1 1 1 1 1 4 4 4 2 2 8 8 8 4 1 2 2 4 1 4 2 1 1 N/A 1

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15

Spencer Vortex Regenerative Blowers

VB075, VB075XP
Assembly Diagram
in. mm.

(Contact factory for specifics on models with explosion-proof motor.)

VB075 Performance Curves

Parts List
DESCRIPTION: VORTEX BLOWER ASSEMBLY VB075, VB075XP ITEM PART NO. DESCRIPTION 1 VBC97501 Case 2 VBI97502 Impeller 3 VBB97501 Base 4 VBE97501 Cover, Impeller 5 NUT90213 Locknut, Shaft 6 WSH90174 Lockwasher, Shaft 7 WSH90179 Shim, Shaft to Impeller (as required) 8 MOT90199 Motor, 215TC, 10 HP, 3 PH 8A MOT90235 Motor, 215TC, 10 HP, 3 Ph, 575 Volt 8B MOT90220 Motor, 215TC, 10 HP, 3 Ph, XP 9 SCR90881 M8 x 1.25 Hex Head Bolt x 1.18 [30] Long 10 WSH90148 Lockwasher, M8 11 WSH90182 Flat Washer M8 12 SCR90881 M8 x 1.25 Hex Head Bolt x 1.18 [30] Long 13 WSH90182 Flat Washer M8 14 SCR90876 M6 x 1.0 Hex Head Screw x .98 [25] Long 15 WSH90143 Lockwasher, M6 16 WSH90142 Flat Washer M6 17 SCR90335 1/2-13 x 1.0 Long Socket Cap Screw 18 GSK90158 Gasket, Case 19 GSK90159 Gasket, Flange 20 FLC90011 Flange, 3 FNPT 21 SCR90883 M8 x 1.25 Hex Head Bolt x 2.165 [55] Long 23 PLG90037 Plug, 1/4 NPT x .43 [11] Long 25 INS90023 Absorber 26 SCN90058 Absorber Screen 27 KEY90081 Key 28 SEL90106 Lip Seal 29 SPR90089 Spacer, Washer (Case to Base) 30 N/A Impeller to case gap specification 31 PLC90029 Case Plate QTY. 1 1 1 1 1 1 1 1 1 1 4 4 4 2 2 8 8 8 4 1 2 2 4 1 4 2 1 1 2 N/A 1

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16

Spencer Vortex Regenerative Blowers

VB110, VB110XP
Assembly Diagram
in. mm.

(Contact factory for specifics on models with explosion-proof motor.)

VB110 Performance Curves

Parts List
DESCRIPTION: VORTEX BLOWER ASSEMBLY VB110, VB110XP ITEM PART NO. DESCRIPTION 1 VBC91101 Case 2 VBI91102 Impeller 3 VBB91101 Base 4 VBE91101 Cover, Impeller 5 NUT90213 Locknut, Shaft 6 WSH90174 Lockwasher, Shaft 7 WSH90179 Shim, Shaft to Impeller (as required) 8 MOT90200 Motor, 254-6TC, 15 HP, 3PH 8A MOT90236 Motor, 254-6TC, 15 HP, 3 Ph, 575 Volt 8B MOT90219 Motor, 254TC, 15 HP, 3 Ph, XP 9 SCR90882 M10 x 1.5 Hex Head Bolt x 1.57 [40] Long 10 WSH90137 Lockwasher, M10 11 WSH90183 Flat Washer M10 12 SCR90881 M8 x 1.25 Hex Head Bolt x 1.18 [30] Long 13 WSH90182 Flat Washer M8 14 SCR90876 M6 x 1.0 Hex Head Screw x .98 [25] Long 15 WSH90143 Lockwasher, M6 16 WSH90142 Flat Washer M6 17 SCR90335 1/2-13 x 1.0 Long Socket Cap Screw 18 GSK90160 Gasket, Case 19 GSK90159 Gasket, Flange 20 FLC90011 Flange, 3 FNPT 21 SCR90883 M8 x 1.25 Hex Head Bolt x 2.16 [55] Long 23 PLG90037 Plug, 1/4 NPT x .43 [11] Long 25 INS90024 Absorber 26 SCN90061 Absorber Screen 27 KEY90082 Key 28 SEL90106 Lip Seal 29 SPR90089 Spacer, Washer (Case to Base) 30 N/A Impeller to case gap specification 31 PLC90030 Case Plate QTY. 1 1 1 1 1 1 1 1 1 1 4 4 4 2 2 8 8 8 4 1 2 2 4 1 4 2 1 1 2 N/A 1

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17

VI. Troubleshooting Guide

Trouble Possible Cause Corrective Action

Blower Does Not Turn and there is A Humming Sound One phase of power line disconnected One phase of stator line open Bearing(s) defective Impeller jammed by foreign material Impeller jammed against casing or side cover Rubbing of rotor core and stator core Capacitor open (single-phase models) Two phases of power line disconnected Two phases of stator winding open Faulty switch connection Fuse blown Connect power leads properly Contact factory Change defective bearing(s) Clean impeller Adjust gap Contact factory Change capacitor Connect power leads properly Contact factory Change switch Change fuse

No Sound

Blower Turns, but Fuse Blows Fuse capacity insufficient, wiring fault Short circuit Terminals shorted Excessive load Inspect wiring Repair Improve insulation and check connections Increase air flow

Overheats or Thermal Protector Activates

Power source unbalance; possible voltage drop Operating in single-phase condition Excessive friction due to defective bearings Impeller contaminated by foreign material Impeller rubbing against casing or side cover Operation at less than minimum rated flow

Check voltage; phases must be balanced within 5% and voltage must be within 10% of rated Check connections Replace bearings Clean impeller Adjust gap Increase air flow

Makes Abnormal Sound

Impeller rubbing against casing or side cover Impeller rubbed by foreign material Bearing(s) defective There is a leak or air passages are clogged Loose cap screw

Adjust gap Clean impeller Replace bearings Repair or clean Tighten screw

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18

Customer Maintenance Log

DATE PROCEDURE COMMENTS INITIALS

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19

Products & Services

Industrially rated products offering effective solutions for air and gas moving problems:
Modular central vacuum systems Mobile or stationary integrated vacuum units Dust collectors and separators Multi-stage centrifugal blowers Single stage centrifugal blowers Regenerative blowers Gas boosters Custom-engineered products with special materials for extreme temperatures and pressure

Complementary accessories with single source convenience and compatibility:

Standard and custom electrical control panels - UL, CUL and C.E. Listed available Comprehensive selection of tubing, fittings, vacuum hoses, valves and tools Valves, gauges, couplings, shrink sleeves, vibration isolators and other system components

Comprehensive engineering and other customer support services:

The industrys largest complement of technical specialists in air and gas moving technology Worldwide parts and service organization Application research and testing facility Product selection process aided by internal computer program

Worldwide organization of sales representatives and distributors offering:

Product selection, installation and operation assistance Comprehensive system design services Follow-up services and troubleshooting For the name and telephone number of your local Spencer Representative, call 1-800-232-4321 or email marketing@spencer-air.com.

Since 1892 moving air and gas for a cleaner environment

The

Turbine Company, 600 Day Hill Road, Windsor, CT 06095-4706

TEL 800-232-4321 x 860-688-8361 x FAX 860-688-0098 x www.spencerturbine.com
Form ZZ12.1, Copyright 2006 The Spencer Turbine Company 806PM4.0

819-9027

INSTALLATION &

OPERATION MANUAL

Tension Control System MCS-166, MCS-203, MCS-204

WARNER ELECTRIC"

TABLE OF CONTENTS
Introduction Specilications Installation Control Housings Sensor System Wiring MCS-166/MCS-203 MCS-166/MCS-204 3 3-4

4-7 7

:............................................................................................. :

89 10-12

System Start-Up & Adjustmnts MCS-166/MCS-203 MCS-166/MCS-204 System Troubleshooting MCS-166/MCS-203 MCS-166/MCS-204 Replacement Parts Lisling Lisling 01 Figures and lIIuslralions

13-16 17-20

21-22 23 24 24

Notes:

Inslallalion musl be made in accordance wilh Ihe inslruclions lound in Ihis manual. Failure lo do so may damage Ihe conlrols and void their warranly.

Warning: Conlacl wilh Ihe eleclrical vollages presenl in the conlrols covered in Ihis manual can cause injury or dealh. To avoid Ihese consequences, make sure all power is off during inslallalion.

?-257

TensionControl System Installation and Operating Instructions

MCS-166/MCS-203/MCS-204
lNTRODUCTION
AII Warner Electric Tension Control Systems are comprised 01 an electric tension brake, a power supply module, an electronic control module, and a sensor or input control device. This manual has been designed to cover the lull range 01 installation, start-up, operation, and maintenance 01 your tension control system. System selection and brake information can be lound in Warner Electric's Tension Control Systems Catalog, P-771. Power Supply The MCS-t 66 Power Supply Module is designed to operate either the MCS-203 Dancer Control or the MCS-204 Remote\Analog Control. The MCS-166 accepts either 120 VAC or 220/240 VAC input power and provides 26-28 VDC output power lor operation 01 the control modules and a brake. Controls The MCS-203 Dancer Control Module is a solid state eiectronic control that receives asignai lrom adancer pivot-point sensor and transmits the appropriate current to the brake to maintain astable .dancer posttion. The MCS-203 is a closed loop control. lI'he MCS-204 Remote/Analog Control Module is asolid state electronic control that will accept a variety 01 input signals and provide an output curren! proportional to the input. This system is open loop andany change in outputto the brake must be inputtothe control Irom the signal source. The MCS-204 can be operated by the local torque knob on tts face or remotely by external potentiometer, vollage input, or current loop input. The MCS-60S-1 or TCS-60S-S Pivot Point Sensors provide the dancer posttion signal to the MCS-203 Dancer Control. The MCS60S-1 is coupled to the dancer pivot when rotation is no more than 60 degrees, while the TCS-60S-S covers rotation up to 300 de grees. Fuslng: 3/8 amp, 2S0V last-acting, type 3AG, AC input. 6910-448-014 26-28VDC 10% 1.S amps maximum with single brake, 3.0 amps with dual brake. From single or dual MCS-166 power supplies. +32 F to +120 F (O Cto +49 C) (Forward direction) 0-24VDC, pulse width modulated 3 amps maximum (Reverse direction) Antiresidual mode, Oto 1.8VDC into 10 ohm load, or Oto 180 ma. maximum 3 amp, 120V, last acting, type 3AG, DC input

MCS-203 Pancer Control Modyle

Par! Number:

Input Power:

Amblent Temperature: Output:

Fuses:

Control Input: From MCS-60S-1 or TCS-60S-S pivot point sensor Protectlon: Internal short circutt protection on driver output stage. Reverse polartty protection on DC input power connections. Brake On - Applies lull output, 24VDC, to brake. Active low. Brake Off Removes brake power and applies anli-residual current (reverse voltage) to brake. Active low. Aotj-prjlt Provides integrator reset lunction. Active low. Switch inputs can be controlled by switch closure between input and DC common or open collector, NPN transistor to DC common. Switch or transistor rating: 20VDC minimum, .02 amps maximum raling. Adjustments: Front Panel: Dancer Pasition: sets dancer operating posilion. Gain - controls overall system response

Auxiliary Inputs:

SPECIFICATIONS
MCS-166 Power Supply Module Part Number: Input Power: Ambient Temperature: Jf1utput: 6910-448-013 120VAC or 220/240VAC, SO\60 Hz, 10% swttch selectable +32 Fto +120 F (O Cto +49 C) 26-28VDC, unregulated, 10% 1.S amps maximum. Over voltage protected.

?~251

MCS-204 Remote/AnaloR Control Module Par! Number: Input Power: 6910-448-017 26-28VDC, 10%, 1.S amps maximum wilh single brake, 3.0 amps maximum with dual brake. From single or dual MCS-166 power supplies. +32F to +120F (OC to +49C) (Forward direction) 0-24VDC pulse wldth modulated 3 amps maximum. (Reverse direction) Anti-residual mode, Oto 1.8 VDC into 10 ohm load, or Oto 180 ma. maximum. 3 amp, 120V, last-acting, type 3AG, DC input Internal short circuit protection on driver output slage. Reverse poiarity protection on DC input power connections.

Generallnlormatlon Control chassis must be considered NEMA 1and should be kept clear 01 all areas where loreign material, dust, grease, or oil might aflect the operation 01 the control. Control chassis should be electrically grounded. Neilher sensor nor brake wires are at ground potential and should be considered '110ating" unless both sides of the AC input power to the MCS-166 are disconnected. Plvot Polnt Sensors MCS60S1, TCS-BOSS Part Numbers: MCS-60S-1, 7330-448-002, single turn TCS-SOS-S, 7330-448-003, S-turn Control Element: Cable: General: Tension Brakes Data and technical specilications lor the TB style tension brakes can be lound in Warner Electric's Master Catalog, P-137, or Tension Control Catalog, P-771. For detailed brake installation, reler to manual P-23S.
INSTALLATION INSTRUCTIONS

Amblent Temperature: Output:

Fuses: Protectlon:

Precision potentiometer, 1000 ohms, 2 watts, S% tolerance. 1S ft. long, shielded, with connector The tension sensor should be kept Iree Irom loreign materiai, dust, grease and oil.

Control Input: Via terminal strip connections in control housing, dependent on type 01 input control function. (Manual, remote, voltage source, current source.) Auxllary Inputs: Brake 00 - Applies lull output, 24VDC, to brake. Active low. Brake Qjl - Removes brake power and applies anti-residuai current (reverse voltage) to brake. Active low. Switch inputs can be controlled by switch ciosure between Input and DC common or open collector, NPN transistor to DC como mono Switch or transistor rating: 20VDC minimum, 0.02 amps maximum rating. Ad]ustments: Frant Paoel: Zera Adjusl: Provides lor adjustment 01 minimum input to correspond to minimum output level. Torque AdjustlSpan: Provides lor either manual adjust or span adjustment when in all other modes 01 operation.
4

Installatlon Thls Installation and Operating Manual has been arranged ter the systematic installation and start-up 01 your Tension Control Systemo Please check off each step In the space provided before proceeding to the nexl step. Sample O Check box alter completion ot each step.
Remove controllogic assembly by loosening two(2) captive screws on the laceplale and slide the assembly out 01 ils housing.

'ns\alatlon

Control HOllSII1qs

t:l o;'Using Ihe dimensions shownin Figure 1,page 5, drlll four

(4) 13164' mounling holes lor each housing lo provide clearance lor #10 boils.
O c. Apply Ihe lerminal slrip label supplied with Ihe oonlrol logic module loIhe PC Board as shown In Figure 2, page

A. WalVSheff Mounljng lhe longue and groove joinls on Ihe sides 01 each housing module allow any number 01 Ihem lo be joined logetherlo form one housing. 1. Connecljng Ihe Housjngs

6.
CAUlION: Be sure lo apply Ihe labelln Ihe proper posllion wllh Ihe brake (+) terminal at Ihe lop. O d. Mounl Ihe rear seclions loosely lo Ihe mounllng surtace. Do nol connecl Ihe fronl seclions ye!. lhe oonlrols are now ready lo be wlred. Preceed lo Ihe wiring seclion al Ihis manual lar Ihe appropriale wiring inslruclions. 3. Shen Mounling

o a. Remove Ihe PC Board assemblies lrom the housings. iI

inslalled by loosening Ihe Iwo caplive screws on each Ironl panel and sliding Ihe assemblies out.

o b. Loasen Ihe lalches hoiding Ihe Iwo part housings 10gelher and separate Ihe Iwo pieces. lhe lalches are 10caled on Ihe inside lops and bottoms of Ihe housing. O c. Working from righl lo left, join Ihe rearsections 01 each housing by sliding Ihem logelher. Repeat the precess for Ihe lronl sections, bul do not fasten Ihem together yet. 2. wall Mounllng O a. ff bottomenlry conduil enlrance is required, remove lhe L-shaped brackel and discard i!. Reinsert lhe screws inlo Ihe conlrol alter Ihe brackel has been removed.

O a. ff bottom oonduit.enlraoce is required remove Ihe lwo (2) screws attaching Ihe brackels lo Ihe housing. Rolale Ihe brackels lo lace away frem the housings and reinsert and lighlen Ihe screws. O b. Using Ihe dimensions shown in Figure1 ,page 5, drill your (4)13164' mounling holes lar each housing to previde clearance lor #10 boils. O c. Apply lhe lermlnal slrip label supplled wllh Ihe oontrel logic moduie lo Ihe PC Board as shown in Figure 2, page

.r :

6.
CAUlION: Be sure to apply the labelln Ihe proper positian wlth Ihe brake (+) terminal al the lop. O d. Mounl Ihe rear seclions loosely lo Ihe mounting surlace. Do not connecl lhe frenl sections ye\. lhe conlrols are now ready lo be wired. Proceed to Ihe wiring seclion al lhis manual for Ihe appropriale inslruclions.
7.82 MAX. 6,69 MAX

:1 l
+
,-:11
r-

rr::
.... ,.
,

812~=r, 45 (2) PLCS .6

.12

J -- , ", , , , , , , , ,

~
/'

3 .00

11.-_: ,
.-\.

"

, r--1- , , ,

, ,

~7

~\

u
.=

4.00

, --

LJo - -

, "', J

~.45

,-

L.

L--$

"'\ \ T
FRONT BRACKET MAy BE MOUNTED

\L BRACKET BASE MOUNT MAY BE MOUNTED

EITHER WAY AS SHOWN FOR SHELVE MOUNT REMOVED ENTIRELY FOR WALL MQUNT

E1THER WAY AS SHOWN

Figure 1. Wall/shelf enclosure dlmenslons 5

r==

.JI
o o o o
rR;TRACER

MCS -203
BRK. BRK

MCS -204
1. BRAKE+ 2. BRAKE
POWER SUPPlV

,e<,

1. BRAKE+

BR'.

2. BRAKE3. +24 VD L.1C-..........- MUSTBE

POWER SUPPLY
CONNECTED TO

," 00"

,,.
'o

3. + 24 V ~ MUST BE CONNECTED TO 4. COM PINS3&4

,"

5. + 15 VOC
6. DANCER 7. DANCERCOM
B. ANTI-DRIFT

,,.
IN",

4. COM

----./

PINS3&4

5. + 15 VDC 6. INPUT

ONe

o o o

I
~
~

00" 00" 00"

'R' OFF 'R'

00" INT
POT
S",

00

7. DC COMMON
B. INT. POT
9. SHUNT RESISTOR
10. CoM 11. BRAKE OFF 12. BRAKEON

9. COM
10. COM 11. BRAKE OFF 12. BRAKEON

00"

R'"

Figure 2. Terminal strip label orienlatlon

B.

panel Mountjng 04. Slide lhe houslng assemblies Into the mounling panel eutouts. Seeurely fasten the housings to the mounting panel wKh the four nuts on eaeh housing.

NOTE: Panel mount housings cannot be oined togelher.

01. Insure the pe Board Assemblies have been removed from lhe housings ~ installed by loosening the two captive screws on the front panels and sliding the assemblies out.
02. Using the dimensions shown in Figure~, page 6, cut an opening 3 5/16" x 6 1/16" intD the mounting panel for each housing assembly.

o 5. Apply the terminal strip label to the housing panel near

the terminal block as shown in Figure 5, page 7. CAUTION: Be sure to apply the labelln the proper positlon wlth the brake (+ terminal at the topo The controls are now ready lo be wired. Proceed to the wiring seetion of this manual for the appropriale instruetions.

03. Using the dimensions shown in Figures 3, page 6, drill four (4) 13/64" mounling holes for each housing to provide clearanee for the #10 mounting sluds.
1.05~

3.50

-o
5.60 MAX.

3.31 .360,
13/6

DISTANCE REQUIRED FOR THE MOUNTING OF

ADDITIDNAL UNITS

Dla

24~9 Si"':
I I

't,'o.....

.17..... 1 4 .62 i.~o

--

3.25 2.50

1-- le

- -l"

--

6.06 6 .75

f!

- ,
I I I I I I I I I I I I I I I

!J
f-"""

7 .25
6.00 6.50

, ,
I
I I I

,
I I

f-r
J

'-

-;:,-------4 PLCS

:"

4>'

10- 32 x 51e 4 PLCS (STUD)

fO\

Figure 3. Panel mounl culoul dlmensions

6

Figure 4. Panel mounl houslng dlmenslons

o
REO

FRONT

"''''EA

....
M'

1. +BRAKE

BR'" BRl(.

,.

.BRAKE
POWER SUPf'Ly

2
3

FRONT
"EUT

...
De

2. - BRAKE
3.

+ 24 voc
.

:::U
PlNSU4

PPlY

....
""" ."
DHC

2. BRAKE

3. +24V~MUSTB~

4 5
6

COM

4 COM:J- COMNEm-EDTO
5. +1SVOC

4. COM 5. + 15VDC
6. OANCER

:':3~TO

L1NE

.1&

REOTRACER

GRN

'HFT

6. INPUT
7. DCCOMMON

,oo'

7
6

e
10
11 12

'"'

a.

INT.POT

""" A. """ """

BR'

7. OANCERCQM
8. ANllORIFT

BHT

9. SHUNT RESISfOR

e.

COM

COM

1D.COM
11. BRAKE OFF
12. BRAKEoN

10.COM

M' OFF M'

o",

11. BRAKE OFF

12. BRAKE. ON

BR'

o
Figure 5. Terminal strip label orlenlallon

MCS6Q51 Senslng Potentlometer

o 6. While holding the sensor and brackel in Ihis posilion,

mark Ihe centers 01 the bracket holes on Ihe machine.

o 1. Using a No. 2 drill, dril! a 1/2 "deep hale in Ihe cenler

01 Ihe dancer pivol shalt.

o 7. Drill and lap Ihree (3) holes lar 832 screws in Ihe ma .
chine.

o 2. Drivelhesupplied pin inlolhe hale inlhe shaft until hall

ils lenglh remains exposed.

o 8. Connect Ihe sensor shaft lo Ihe pin with Ihe supplied

universal coupling. The index mark onlhe sensorshaft musl be aligned wilh Ihe index mar\< on Ihe sensor lace when Ihe dancer arm is al the midpoinl posilion.

o 3. Assemble Ihe Iwo brackets supplied wilh the Iwo 1Q.

32 screws.

o 4. Mounllhe sensor lo Ihe brackets using Ihe Ihree 832

screws.

o 9. Mount Ihe sensor and brackello Ihe machine wilh

Ihree (3) 832 screws. 01 Q.The sensor is now ready lo be wired. Refer lo Ihe wir ing section slarting on page 8 01 Ihis manual lar como plele inslructions.
BRACKET ISEE NOTE 11

o 5. Posllion Ihe sensor and brackel so Ihallhe sensor

shaft and pin are aligned and separaled by 5/16".

1 - - - - - - - 43/8 ------+1j '-1'/16

NOM.--
t,

/'

r--;------,--------rt,

2DIA.
OANCER

COUPLlNG SUPPLIED

i!'1-""--7-,

2500 :2534 DIA.

1 f2 OEEP

5/16

1S' JACKET NDTES, 1. TWO BRACKETS ARE SUPPLIED W!TH EACH UNlT so THAT THE CUSTOMER CAN MOUNT THE MCS60S1 ACCORDINGLY. 2. BRACKETS ARE MADE FROM 14 GAUGE 1.07471 STEEL.

~~9~~L-:~~~---_-__:~~~~~~~~"~,~---.SHAFT rr-'- U~~' ~~~~~SHED :-J --' I

/ ,.
832 seR EWS (3 SUPPl.IEDJ / I

PIVOT

"

~~~=c~s:: 71

10-32 SCREWS WASHERS & NUTS (2 SUPPLlEDI ----3 HOLEs 3/16 OlA. ON - - 1.50 B.C. EaUALl y SPACED

:
I
,j

1I1

~l

'1
1 I

Figure 6 MC5-605-1 & TCS605-S Mounllng Detalls

7

SYSTEM WIRING
System Wiring Precautions WARNING: Contaet wlth the electrlcal voltages present In the controls covered In thls manual can cause InJury or death. To avold these cnsequences, make sure all power Is off durlng installatlon. . These wiring precautions will help you properly install and wire a trouble-Iree system. 1. Use proper gauge wire lor all circus. 2. 1I possible, segregate AC and OC power Iines. brake output Iines, signai lines, and sw~ch wiring. 3. Shieided cable is recommended for sensor connections and externai swilching circuits. 4. Do not operate external accessories from the MCS-166, MCS-203, or MCS-204 controls. CCWO b. For CCW rotalion, connect sensor wires as tollows: Red to Terminal 5, green to Terminal 6, black to Terminai 7. Shleld lead should be connected to Terminal 7. O 5. External
Sw~ch

Connections (optional)

Da. Antl-Drift or integrator Swch Connect swching circuit betwean termlnals 8 and 9 01 MCS-203 terminal strip. NOTE: The anti-drift inpul can be aIimit swch which closes based on dancer arm positlon or ~ can be a ralay circuit activated by the machine start cycle. CAUTION: The switch or relay used lor the antl-drlft Input should be open durlng normal runnlng operallon to prevent unpredlctable reactlons. O b. Brake-0ff Switch Connectsw~ch contacts between Terminals 10 and 11 of MCS-203 terminal strip. O c. Brake-on Swch Connect sw~ch contacts between Terminais 10 and 12 01 MCS-203 terminal strip. NOTE: For single brakeofflunction only, use aSingle Pole-Single Throw, maintained conlact switch. For bolh lunctions, alhree pos~ion switch as shown in Figures 7and 8, page 9, is recommended. O 6. Double check all wiring connectlons per Figure 7 or 8. Insure all terminals are tight. O 7. Reconnect the front housing 01 eher wall or she~ mounting and secure the latches~ ff shelf mounting is used, secure the housing wh the lour (4) bolts tor each section. O 8. Do not insert the control modules at lhis lime. Proceed to the MCS-166/MCS-203 start-upsection ofthis manual.

5. Do not use controls lor purposes other than those intended. Such use could damage the control and void the warranly.
MCS-166/MCS-203 Reter to connection diagrams, Figures 7 and 8, page 9, for wiring connections.

o 1. Wire AC input power lo terminals 1, 2, and 3 01 the

MCS-166terminalblock: Terminal 1neutral, Terminal 2 hot, Terminal 3 earth ground. 02. Wire DCoutpullrom MCS-166Terminal Blockto Input Power Terminals on MCS-203 as lollows: MCS-166 OC Common Terminal 4to MCS-203 OC Common Terminal 4. MCS-186 (+) OC Terminal 5 01 MCS-166to (+) Terminal3 01 MCS-203. O 3. Connect wiring Irom brake magnets to Terminals 1 and 2 01 the MCS-203 terminal block. O 4. Sensor Wiring Determine the direction 01 polentiometer shaft rotalion as viewed Irom the connector end 01 the pivot-poinl sensor. CWO a. For CW rotation, connect sensor wires as follows: Black to Terminal 5. green to Terminal 6. red to Terminal 7. Shield lead should be connected to Terminal 7.

MCS-203 BRAKE (+) BRAKE

24 VDC TENSION BRAKE

MCS-166

(+)r2t\::l----~ I

(1jH--~J

Q)H--_N}
:; (2 ~
G

AC INPUT

+ DC IN
DC COMMON DANCER (+) DANCER IN DANCER COMMON

\13~+-----------'
~

CtH---(4 tt;~~~~~~1==Er.~4)~ DCCOMMON (5"':;:: RED OR BlK ~., (5)

(6 GRN

+ 28 VDC OUT

(7
8

ANTI-DRIFT DCCOMMON

9' H=:o:-'- DCCOMMON (1~I-0FF

BRAKEOFFI (11 BRAKEON

BlK OR RE SHlD -::: -v l-_ ..... RUN

I I

;.

\ I PIVOT - POINT
SENSOR

lS1
ON _

~W-=-'X'f" 12

S2

Figuro 7 MCS-' 661MCS-203 Wlrlng - Singlo Brako

MCS-203
BRAKE (+) BRAKE (+) +DC IN DCCOMMON DANCER (+) DANCER IN DANCER COMMON ANTI-DRIFT DCCOMMON DCCOMMON BRAKEOFF BRAKEON

#2 =, v #1
v

v '--

24 VDC TENSION BRAKE

#1 MCS-166

#2' MCS-166

(1'
2 3

(1' (2) (3)

\.J

'1'

'CV
/3"' '-~

:}'NAp~,
DC COMMON

4
(5 REDOR Bl GRN BlKOR REC SHlD ......
~,

,
1

,-,,5..1

4)

6 7
8

I!
I

+ 28 VDC OUT

RUN

I I PIVOT - POINT SENSOR ' REQUIRED WHEN DUAL BR AKES, TB - 500 OR LARGER, ARE USED FR OM A SINGLE

(9'
10)G1 ([2 _ OFF

IS1

~X""

ON

MCS - 203 NOTE: NO MORE THAN TWO (2) BRAKES CAN BE USED ON A S INGLE MCS - 203.

J~S2

Figura 8 MCS-'66IMC5-203 Wlrlng - Dual Braka.

9

System Wiring
MCS166IMCS-204 Reler to Figures 9, 10, 11, 12, pages 11 & 12, lor actual wiring connectlons.

O C. Vonaae Source Input Connect (+) side al external vonage source to terminal 6 and (.) side (or common) 01 external vonage source to MCS-204 terminal 7, per Figure 110, page 12. CAUTION: The Input level Irom en external voltage souree must not exeeed 14.5 VDC. Voltege levels hlgher then 14.5 VDC wlll damage the eontrol's Input eireults.
O d. Curren! Source Input O 1. Determine the current rangelrom the external current source and select ashunt resistor Irom the chart In Figure 11 E, page 12. Connect the shunt resistor between MCS204 terminals 7 and 9. O 2. Connect the (+) side 01 the external current source to MCS-204 terminal 6 and the (-) slde (common) to terminal 7 , per Figure 11E, page 12.
O e. Analog photoelectric Sensor Input

o 1. Wlre AC Input to terminals 1, 2 and 3 01 the MCS-166

terminal block: terminal 1to be AC neutral, terminal 2 AC hot, and terminal 3 earth ground. 02. Wire MCS-166 OC output to MCS204 input: MCS166 OC common terminal 4 to MCS-204 DC common terminal 4. MCS-166 (+) OC terminal 5to MCS-204 (+) input terminal 3. 03. Connect brake magnet(s) wires to terminals 1and2 01 MCS-204 Terminal Block.

o 4. External Switch Connections (optional)

O a. Brake-0ff Switch Connect switch contacts between terminals 10 and 11 01 MCS-204 terminal strip. O b. Brake-0n Swijch Connect switch contacts between terminals 10 and 12 01 MCS-204 terminal strip.

Reler to Figure 12, page 12 lor connection informatlon.

O 1. Make sure the MCS-166 and MCS-204,

NOTE: 1I only a single brake-oll lunction Is used, an SPST maintained contact swijch may be used. 1I both lunctions are used, a three posltion swijch Is recommended, as shown In Figure 9 and 10, pl1ge 11.
O 5. Control Input Connections

power, and brake are connected per Figure 12, if not already done.
O 2. Connect sensorto MCS-204, 15 VDC power source: Sensor blue lead to DC common terminal 7, and sensor brown lead to +15 VDC terminal 5. O 3. Connect sensor output (black lead) to (+) input on Iso-verter, terminal 7.
O 4. Connect (+) output 01 Iso-verter terminal 2

Relerto Figures 11 and 12, page 12, lorvarlous inputconnection conligurations. O a. Local TOCQue Must Moda Connect jumper between MCS-204 terminals 6 and 8, per Figure 11 B, page 12.
O b. Remote TorQue AdjustlRolI Follower pot

to input 01 MCS-204 terminal 6. Connect remote potentiometer or roll lollower potentiometer to MCS-204 terminals 5, 6, and 7, per Figure 11 C, page 12. NOTE: Wiper will always be connected to terminal 6. End points should be connected so that turning the remote pol CCW or moving the roll lollower pot toward the core wlll decrease vonage at terminal 6.
O 5. Connect MCS-204 terminal 7 (DC como

mon) to both input and output (-) terminals 1 and 8 01 the Iso-verter.
O 6. Connect ashunt resistor between terminals

7 and 9 01 MCS-204 terminal strip. NOTE: To prevent pick-up 01 stray electrical nolse, connect the shield wire to terminal 70nly. Use 01 shielded cable Is strongly recommended lor sensor pot, vonage or current source input, and connection 01 the Iso-verter to the MCS-204 nputs.

10

el 6. Double check all wiring connections per Figures 9, 10, 11, or 12 lar accuracy and lighlness. el 7. Reconnect Ihe Ironl housings il eilher wall or shelf mounting is used. Secure Ihe lalches. Hshell mounling is used, secure Ihe housings wilh Ihe four (4) bolts lor each section.
MCS-204
BRAKEI+) BRAKE 1+) +OCIN

el 8. Do nol nsertIhe conlrol modules al Ihis lime. Proceed lo Ihe MCS-166IMCS-204 slart-up section of Ihis manual.

~
~

~\-I~

24 VOC TENSION BRAKE

MCS-166
'--(/3C--

H~t== N}
~

2:

I:;UT

oc COMMON ll~4t:t--------t--j::! ~

~ oc COMMON --.2:...I-I--+'
';::::::::

+l5VOUT 5 INPUT 1(~6tL-1

L-u~~+ 28 VDC OUT

OC COMMON

SEE INPUT CONFIGURATIONS

FIGURE 11. PAGE 12

INTERNAL POT ~ SHUNT RESISTOR

oc COMMON
BRAKE OFF BRAKE ON

f-;;;=i<o 1
11

(l-l---=.J
l - OFF

~~,< ~ e
~

RUN ""ON

--1

51

Figure 9MCS 166/MCS 204 Wlrlng slngl. brak.

#2

MCS-204
BRAKE 1+> BRAKE(+) +OCIN

24 VOC TENSION BRAKES

#1

(i)
~

#~
-

MCS-166

(2'.
J

~05~1~--1'---~1? 1-- N} AC : G ~~(2*t==E1"2*t==H INPUT

3 3

#2' MCS-166

oc COMMON
+15VOUT INPUT

~
~

H---------+--+,....-{;:~--_1~4~
~
SEE INPUT CONFIGURATIONS FIGURE 11. PAGE 12 RUN

DC COMMON 5 +2BVDCOUT L::2..~--T~J

OCCOMMON INTERNAL POT SHUNT RESISTOR

t~~7~=~
(B (

t-%
9

61+--1

oc COMMON
BRAKE OFF BRAKE ON

(10)- 1- OFF
.

~'i''''''''

ON

REQUIRED WHEN TB-500 OR LARGER DUAL BRAKES ARE USED FROM A SINGLE MCS 204. NOTE: NO MORE THAN (2) BRAKES CAN BE CONNECTED TO A SINGLE MCS - 204.

(1

=!:::J"I
~.-i
51

(1

Figure 10 MC5-166IMCS204 Wlrlng Dual Brak

11

BRAKE(+) BRAKE (-) +DCIN DCCOMMON +15V OUT INPUT DCCOMMON INTERNAL POT SHUNT RESISTOR JUMPER

~
lK -10K POT

VOLTAGE SOURCE MAX.INPUT 14.5 VDC

CURRENT SOURCE

10

DCCOMMON BRAKEOFF BRAKEON

@ @

A. BASIC LABEL

B. LOCAL TORQUE ADJUST

C. EXTERNAL POT OR ROLL FOLLOWER

D. VOLTAGE INPUT

E. CURRENT INPUT

Shunt Reslstor SelocUon

CURRENT
INPUT 1-5 ma

MINlMUM

MAXIMUM

Figure 11. MC5-204lnput Conflguratlon

24 VDC TENSION

4 -.20 ma lO-SOma

RESlSTANCE RESlSTANCE 4700hms l0000hms 100 ohms 220 ohms

470hms

100 ohms

MC5-204
BRAKE (+)

BRAKE

Mes,
;;' N

fr.",

BRAKE (+)
+OCIN
OCCQMMDN

T ~
~
~

./>.AA

l
'--

AC ~~HJINPUT

~ ~ INPUT ~ DCCOMMON
+15VOUT

G DCCOMMON +28V DCOlJT

"""

INTERNAL POT
SHUNT AESISTOR

CQMMON
BRAKE OFF

~l)* m*
~
_

BRAKEON

~
~

OFF~A~N.....ON

SHUNT RESISTOR
1QO -220 ohm FO R4-20 MA INPUT SIGNAL

~~'

'-'

51

Al UF I BROWN

... --,
I I

MeS - 3509 ANALOG PHOTOELECTRIC SENSOR

IcblI~~ I~~

...:...-..:t

OUTPUT

~
i

>

8
N

C\l

ct..,...l

ISO-VERTER MODEL# 116EE - 8278

INPUT

AC INPUT WIRE FOR ErrHER 120VAC OR 240VAC DEPENDING ON UNE VOLTAGE BEING USED.

Figure 12. Analog Photoelectrlc RolI Follower Wlrlng

12

System Start-Up and Adjustment

MCS-166IMCS203 llnce set, most MCS-166/MCS-203 adjustments should require lb lurther attention. Exceptions are the "Dancer Position" and "Gain' controls on the MCS-203 Iront panel. The lollowing start-up and adjustment procedure will provide astable operating system. Relerto Figure 13, page 16, lor the exact location 01 internal adjustment potentiometers.

(NEW STYlE UNITS WITH RIBBON CABLES) Pullthe ribbon cable forward so thatthe connector end is in front ofthe housing assembly. Fasten the ribbon cable connectorto the pin connectoron the control module. Pin 1 (Red Tracer) on the ribbon cable must connect to pin 1on the control module as shown. This "Red Tracer" will AlWAYS be to ward the top of the control. O 6. Set the "Dancer Position'to tts midpoint range and the "Gain' to "S' on the MCS-203 laceplate. O 7.Setthe internal adjustments per Figure 13, page 16, as lollows: O a. O b. O c. O d. Proportional gain, "R32' lully clockwise (CW). Iniegrator gain, ''R24' at 60% clockwise. Differentiator gain, "R16' at 7S% clockwise. Differentiator response swttch 1 'on' and swttches 2 and 3 "off"

A. Preliminary Set-Up

o 1. Set voltage selector switch on MCS-166 lor proper input vottage range. This will be etther 120 VAC or 220/ 240VAC. NOTE: An addttional switch has been added to the MCS-166 lor selecting 220 or 240 VAC operation. This switch is labeled LowHigh. For older style untts wtth a single120/220-240 VAC selector swttch, proceed to step Sbelow. O 2.Set the Low-High Swttch as lollows: O a. For 120 VAC, set to High Posttion. O b. For 240 VAC, set to High Posttion. O c. For 220 VAC, set to Low Posttion. \lOTE: The Low-High swttch is used primarily lor selecting 220 or 240 VAC operation when the line selector swttch is set lor 240 VAC, but it can also be used if low line input voltage exists. O 3.Low line input: For 108 VAC input when set on 120 VAC or 198 VAC input when set on 240 VAC, set the Low-High switch to the Low posttion. O 4. High line input: For 132 VAC input when set on 120 VAC orlor 268 VAC input when setfor240 VAC, setthe Low - High switch to the High Position. CAUTION:lmproperlysettingthe 120/240VAC Selector Switch and the Hlghlow Selector Switch can damage the power supply and/or control Module and vold their Warranties. OS ..Slide the power module nto the housing and secure wilh the two captive lasteners on the laceplate. CAUTlON: (OlO STYlE BACK BOAROS ONl Y) The connectors must mate properly when inserto ing the control modules Into the housings.1f the module does not sllde In smoothly, gently rock the module from side to side until the connectors mate, but do not apply excessive force.

O 8. Slide the control module into the housing and secure with the two captive lasteners on the laceplate. CAUTlON: (OlO STYlE BACK BOAROS ONlY) The connectors must mate properiy when inserto ing the control modules into the housings. If the module does not sllde in smoothly, gently rock the module from side to side until the connectors mate, but do not apply excessive force. (NEW STYlE UNITS WITH RIBBON CABLES) Pull the ribbon cable forward sothat the connector end is in front ofthe housing assembly. Fasten the ribbon cable connector to the pin connectoron the control module. Pin 1 (Red Tracer) on the ribbon cable must connect to pln 1on the control module as shown. This "Red Tracer" will AlWAYS be to ward the top of the control. B. Static Adjustment and Check Out O 1. Apply powerto the tension control system wtth the machine in a non-running or off mode. Check that the "power' indicators on bolh the MCS-166 and MCS203 are iIIuminated. O 2. Move the dancer arm tothe shortest web-Ioop position and note that the "brake' indicator goes "off.' Then move the dancer to the Iongest web-Ioop posttion and note that lhe "brake" indicator illuminates. NOTE: Hthe "brake" indicator is the reverse 01 this, the Pivot-Point Sensor is wired backwards. Reler to the MCS-166IMCS-203 wiring section lor correct connections.

Q3: Brake-onlBrake-Qff Swilch Check (optlonal) Q a. Place Brake-oll swilch In brake-oll mode and note that the "brake" indicator goes out. Q b. Retum the Brake.QII switch to i1s normal run mode. Q c. Hused, turn on the Brake-on swilch and note that the "brake" indicator goes lull on. Q d. Return Brake-on switch to i1s normal running posillon. NOTE: Hoperation 01 the Brake-onlBrake-OII swilches produced the opposile results in 3a and 3cabove, the wiring is reversed. Reler \0 the MCS-166IMCS-203 wiring section lor the proper connectlons. Q 4. AntiResidual Adjustment Q a. Activate the Brake.QII switch (it used) or move the dancer to the shortest webloop position. Q b. Check thatthe brake armature floats away Irom the brake magnet wilh no sticking. Q c. Hthe armature sticks to the magnet, adjust the antiresidual potentiometer CW or CCW until the armature is Iree wilh no sticking. Q d. Reapply the brake eilher by moving the dancer to i1s langest webloopor by returning the brake 011 swilch to its normal run posillon and activat ing the brake-on input. Q a. Rapeat steps 4a through 4d aboye. Q l. Hbrake releases Ireely, make no lurther adjust . menls as the antiresidual is now set. NOTE: CCW rotation decreases the antiresidual output while CW rotation increases i1. Excessive CW rotation can cause brake en gagement. Q 5. Frequency Adjustment The Irequency adjustment changes the modulation Irequency to eliminate brake "hum" or "~owl" when the brake is stationary. The Irequency is lactory set and normally requires no adjustment. Q a. Tum CW Halow pitch hum is present or CCW H hum is high pilched. 'CAUnON: To set the frequency, the control must be un plugged from lis houslng. Do not unplug control unless power Is off. Fallure to turn power off before unplugging wlfl resull In damage to con trol module and/or power module. C. StartUp and Dynamic Adjustments Q 1. VerHy that power is on. 14

Q 2. Start the machine and draw material. Q 3. Afterthe Dancer has stabilized, adjust the Iront panel "Dancer Posilion"potentiometerlorthe desired dancer running posillon. Q 4. II the system Is providing stable dancer operation, increase the "Gain" until the dancer hunts or oscillates. Note the gain posilion number where this oecurs. Q 5. Reduce the "gain" seltingIrom step4 aboye one to two digits. Q 6. Hdancer instabilily is apparentlrom inilial start, reduce the gain until it becomes stable. NOTE: This is only a preliminary gain selting. Afinal gain selting is required at core diameter lor optimum system performance. Q 7. Run the system untilthe unwind roll is wilhin twoto lour inches 01 core diameter. Q 8. 11 the system has been stable, reset the Iront panel "gain" until dancer hunting or oscillation oecurs, noto ing the gain selting number, then reduce the selting one or two digils. NOTE: This is the optimum gain selting. No lurther adjustments are necessary. Q 9. Hsystem stabilily cannot be achieved through Iront panel "gain" adjustment, iI may be necessary to adjust gain lunctlons internally. CAUnON: Internal PID gain adjustments should be made only after all other attempts to achleve system sta bility have failed.These adJustments should be made by quallfled personnel only. NOTE: Internal access is required lor the setup adjustments which lollow. This can be accomplished wilh the TCS-900 setup and diagnostic tester or by removing the side panel plate Irom the housing, or, on new versions wilh ribbon cable connectors. by sliding the control module partially out 01 the housing. CAUnON: If side panel plate on the control houslng Is to be removed, Insure the power Is off before removing the control module from the housing. Failure to disengage power before removlng the modulewill resull in damage to the control and/or power module. IMPORTANT: Foilowthesequence outlined belowto proper l adJust the P-ID clrcuit galns. If the TC8-900 ~ used, foilow the Instruetlons ncluded wllh the TC8-900. Applies only 10 "older style" unils wilhout ribbon cable assemblies.

'P~2t?1

D.

PI-D Gain Adjuslmenls

o 1."Po - Proportional gain adjuslmenl, R32

O a. Jumper Ihe anli-drifl inpul (Ierminal a) lo DC common (lerminaI9) on Ihe MCS-203lerminal block lo disable Ihe inlegralor circuito O b. Inject a Iransienl inlo Ihe syslem by rapidly changing Ihe dancer posilion. Suddenly changing dancer air pressure or rapidly depressing Ihe web or dancer arm will provideIhe Iransient. Observe Ihe dancer's response. O C. The dancer should slabilize within one lo two cycles. 1I oscillations do nol subside, reduce Ihe "P" gain polentiomeler, R32, CCW in small increments, observing Ihe effects. O d. Repeat sleps b and c aboye as necessary unlil desired response is oblained. NOTE: "P" gain setlings are alunction 01 brake size. R32 islactory sel at 100% CW. Generally,lhe largerlhe brake, the lowerthe R32 setling. NOTE: 1I response is not obtained wilh "P" gain adjustment, it may be necessary to make "D" gain adjuslments as well. O 2. "D" Dnlerentialor gain adjuslment, R16 O a. Insure anti-drifl (terminal a) is still grounded. O b. Inject a transient nto Ihe web as described in step 1b aboye. O c. 11 dancer slability is achieved wilhin one or two cycles, make no lurther adjystments. O d. 11 stability is nol achieved, adjust R16 aslollows: O 1. 11 response is erratic and dancer is extremely jerky, rolale R16 CCW. O 2. If response is sluggish and dancer hunts, rolale R16 CCW. NOTE: If proper response is not achieved wilh R16 at maximum CW setling, Ihe next higher differenlialor response range should be used. CAUTION: When switchlng to hlgher response ranges, R16 shouId be set full CCW.

O e. Repeal steps b Ihrough d aboye lo insure optimum response. NOTE: To nsure oplimum performance, Ihe syslem should be checked at or near lull roll diameler.

01. Remove jumper on anli-drifl inpul (connecting

lerminal to OC common lerminaI9). O 3. "1" - Integrator gain adjuslmenl, R24. CAUTlON: The "'" galn adjustmentcontrols howlarthe dancer must move to compensate lor unwind roll diame terchanges. Any adjustment mustbe made strictly in accordance with the instructlons below: O a. Wilh the system running and stabilized, observe the amounl 01 dancer movement. O b. IIlhe dancer arc is less than 5degrees and movemenl is smooth, do not make any adjystO C. 11 dancer arc is greater than 10 degrees, bul movement is smoolh, adjusllhe "1" gain polenliomeler CW in small increments, observing the results, until stability is achieved. O d. 11 dancer arc is wilhin 5to 1Odegrees, but move ment is choppy and rough, adjust the "1" gain polentiometer CCW in small increments, observing the resuils, until stabilily is oblained. O 4. Aller completing P-I-D adjuslmenls, recheck main gain ajustments per steps C41hrough ca. This completes the start-slop and adjustment 01 the MCS-166 MCS-203 Dancer Control Syslem. 11 difficuilies are encountered which cannot be resolved using Ihil manual, contact your local Warner Electric Representalive or IhE lactory.
~

FA e. r() /1. ti

S-It:7 1/\/ G :5" /

1'1=>" (R 32) ~
1/

/00% C, WI X" ('R 24-) -'" G 0- 7 O'J . !IV.

(R-/P) _ '/5 ~ e,w S WI reH -it J ()N (oNLr)

/ID"

.D iP

---

R24 ITEGRATOR GAIN

SW1 DIFFERENTIATOR RESPONSE R16 DIFFERENTIATOR GAIN PIN 1

MCS203

I
ANTI-RESIDUAL ADJUSTMENT

o
6.00

o
POWER BRAKE GA1N

......:

.!-E)
,

-N

--
R32 PROPORTIONAL GAIN ~ FREO. ADJUST

-.

.156

1YP

DANCER POSITlON

I
_C--

DANCER CONTROL

TP3=

1.88

OUTPUTIDRIVE BOARD

1 1-'-- 3.00 ......

----1~..1 .
P-I-D - DANCER LOGIC BOARD

NOTE: INTERCONNECT PIN NUMBERING DOES NOT CORRESPOND TO TERMINAL BLOCK NUMBERING.
-~

MC5-166

O
6 .00

POWER

LOW-HIGH SW ITCH .............

LINE SELECT SWITCH

~I:'~~
S21
11111111

PIN 1

POWER SUPPLy

I
1 ...

11

LOW HIGH

J]1.86

1._-.....

3.00 - - -...

~I

3.82 5.28

... 10.46

. 1--

Figuro 13 Control Ad)uslmonILocaUons, MC8-1661MC8-2Q3

16

System Start-Up and Adjustment

MCS166/MCS-204 -lce sel, mosl MCS-166/MCS-204 adjuslmenls require no lur",~er attenlion. The exception is the torque/span adjust which sets the maximum oulput limil. Please lollow the set-up and adjustment procedure below lor trouble Iree start-up. Reler to Figure 14, page 19, lor exact iocation 01 adjuslments and indicators. A. Preliminary Set-Up

(NEW STYLE UNITS WITH RIBBON CABLES) . Pull the ribbon cable lorward so thatthe connector end is in Iront oflhe housing assembly. Fasten the ribbon cable connectorto tite pin connectoron the control module. Pin 1 (Red Tracer) on the ribbon cable must connect to pln 1on the control module as shown. This "Red Tracer"will ALWAYS betoward the top 01 the control. O 6. Slide the MCS-204 Control Module into as housing and secure wah the two captive lasteners on the laceplate. CAUTlON: (OLO STYLE BACK BOAROS ONLY) The connectors must mate properly when inserting the control modules into the housings. If the module does not sUde in smoothly, gently rock the module Irom side to side until the connectors mate, but do not apply excessive lorce. (NEW STYLE UNITS WITH RIBBON CABLES) Pul! the ribbon cable lorward so that the connector end is In Irontoflhe houslng assembly. Fasten the rlbbon cable connector to the pin connectoron the control module. Pin 1 (Red Tracer) on the ribbon cable must connectto pin 1 on the control module as shown. This "Red Tracer" will ALWAYS be toward the top 01 the control. B. Slatic Adjustments and Check Out O 1. Apply pewer to the Tension Control Syslem wah the machine stationary. Check that the "Power" indicalors on both the MCS-166 and MCS'204 are iIIuminated. O 2. Set the Iront panel ''Torque/Span Adjust" petentiome ter to as luli CCW pesaioning. O 3. Brake-<lfflbrake-on swach checks (oplional) O a. Set brake-off swilch to off pesaion and nole thal the 'brake" indicator is off. The 0-100% indlcator may be on al this time. O b. Return thebrake-off swach to as normal running pesaion. O C. Place the brake:on switch (if used) in the brakeon pesition ancfr'lote that the "brake" indicator js on. The 0-1 00% indicator may also be on at this time. O d. Return the brake-on swach to ils normal running pesajon. NOTE: Hoperation 01 the brake-off and brake-<ln is reversed, the wiring is reversed. Reler to MCS-166IMCS-204 wiring section lor proper wiring connections.

o 1. Set votlage selector swilch on MCS-166 lor proper inpul votlage range, either 120 VAC or 220/240 VACo NOTE: An addaional switch has been added to Ihe MCS-166 lor selecting 220 or 240 VAC operation. This switch is iabeled LowHigh. For older style unas wilh asingle120/220-240 VAC selector swilch, proceed to slep 5 below.

o 2.Sel the Low-High Swach as loliows:

O a. For 120 VAC, selto High posaion. O b. For 240 VAC, set to High posaion. O C. For 220 VAC, set to Low posaion. NOTE: The Low-High swach is used primarily lor selecling 220 or ~O VAC operalion when the line selector sw~ch is set lor 240 ~AC, but il can also be used if low line input voltage exists. O 3.Low line input: For 108 VAC inpul when set on 120 VAC or 198 VAC input when set on 240 VAC, sel the Low-High switch to the Low pesajon. O 4. High line input: For 132 VAC inpul when sel on 120 VAC orlor 268 VAC inpul when setfor 240 VAC, setthe Low - High switch to the High Position. CAUTION: Improperlysetllngthe 120/240 VAC SelectorSwltch and the Hlgh-Low Selector Switch can damage the power supply and/or control Module and vold their Warrantles. O 5. Slide pewer module into ~s housing. and secure with the Iwo caplive lasleners on the laceplale. CAUTlON: (OLO STYLE BACK BOAROS ONLY) The connectors must mate properly when insert. ing the control modules Into the houslngs.11 the module does not sUde In smoothly, gently rock the module Irom side to slde until the connectors mate, but do not apply excessive lorce.

o 4. Anti-residual adjustment

O 2. Remote torque adjust O a. Insure that power system is on. O b. Set the remote torque adjust potentiometer to maximum. O c. Set the Iront panel '1orque/span adjust"to maxi. mum output (24VDC). The 0-1 00% indicator will be iIIuminated. O d. Set the remote torque adjust potentiometer to minimum. O e. Set the "zero adjust" potentiometer so the 0100% indicator iIIuminates. O 1. Repeat steps b through e aboye as these two adjustments will interact on each other. NOTE: When the remote torque ad)ust pot is at minimum, the brake should be lully released. When the pot is set to maximum, the brake should be lully on. O g. Alter the proper "span" adjustment is obtained, remove the '10rque/span" knob and inser! the cap plug into the hole to prevent tampering. O 3. Current source adjust O a. Insure that system power is on. O b. Adjust the external current source lor min'mum input current, based on the operating range seleeted. O c. Adjust the "zero adjust" potentiometer so the 0100% indicator is iIIuminated. O d. Set the external current source to maximum input based on the operating range selected. O e. Adjust the '~orque/span" potentiometer lar lull output (24 VDC) and 0-1 00% indicator iIIumination. O 1. Repeat steps b through e to insure there is no nteraetion between adjustments. NOTE: Set-up adjustment is the same lor all three current range inputs. O g. Alterset-up has been completed, the '1orquel span" knob should be removed and the hale plugged with the inser! provided. O 4. Voltage source adjust O a. Insure that system power is on. O b. Set the external voltage source lor maximum input level. WARNING: The maximum input level must notexceed 14.5 VOC or damage may occur to controllogic cir cuits Applies only lo "older slyle" units wilhoul ribbon cable assemblies.

o a.
O b. O c. O d. O e. O 1.

Aetivate the brake-off swttch, nused, or jumper the brake-off terminal to DC common. Check thatthe brake arm ature floats away Irom the magnet wtth no sticking. Hthe armature sticks, adjust the anti-residual potentiometer CW or CCW until the armature is Iree with no sticking. Reapply the brake by etther aetivating the brakeon switch or jumpering the brake-on input to DC common. Brake-off input must be open. Repeat steps 4a through 4d aboye. If brake releases Ireely, the anti-residual is sel.

NOTE: CCW adjustment decreases anti-residual output while CW adjustment increases il. Setting the anti-residual too lar CW can cause brake engagemenl. O 5. Frequency adjust The Irequency adjust changes the modulation Irequency to eliminate brake "hum" or "howl" when the brake is stationary. The Irequency is laetory set and normally requires no adjustmenl. O a. Turn CW il alow pitch hum is present or CCW nthe hum is high pttched. 'CAUTION: To set the frequency, the control must be un plugged Irom its housing. Do not unplug control unless power is off. Failure to turn power 011 be lore unplugging will result in damage to control module and/or power module. C. Input Calibration NOTE: The lollowing calibration procedures assume that the maximum input corresponds to the maximum (24VDC) output to the brake. An accurate digttal voltmeter is required to properly set up this syslem. O 1. Local torque adjust mode O a. Insure power is on and torque adjust/span is set lully CCW. O b. Set the "zero adjust" potentiometer (through Iront panel) so the 0-100% indicator iIIuminates. This is a true zero output to the brake. O c. Now rotate the '~orque/span" potentiometer toward tts maximum setting. As the pot is turned, the 0-100% indicator goes out and the "brake" indicator comes on. At 100% output (24VDC), the 0-100% indicator will come on. NOTE: Depending on the accuracy 01 the inltial "zero" setting, steps a through c aboye may have to be repeated to achieve lull range adjustment 01 the '~orque/span" potentiometer.
18

p~

-;7-C:;1

o c.
O d. O e.
O 1. O g.

Adjustthe "Iorque/span"polentiomelerlor maxi mum outpul (24VDC) as indicaled by Ihe 0100% indicalor iIIuminalion. Adjusllhe external voltage source lor Ihe minimum input levello be used. Sellhe "zero adjusl" potenliomeler or zero oulpul unlillhe 0-100% indicalor i1luminates. Repeal sleps bIhrough e unlil no inleraction is seen belween Ihe two adjuslments. Alter sel up adjuslmenls have been compleled, Ihe '10rque/span" knob should be removed and Ihe hole plugged with Ihe insert provided.

O g. Set Ihe roli loliower arm back lo tts true zero position. O h. Sel the "zero adjust" polenliomeler lor a zero oulpul as indicaled by Ihe 0-100% indicator i1Iu minalion. O i. Repeal sleps eIhrugh h untii no inleraction Is evidenl belween Ihe Iwo adjuslmenls.
NOTE: Al maximum roll diameler, Ihe oulpul 01 Ihe MCS-204 should be sel lor Ihe required lension. This may nol correspond to Ihe lull oulput level 01 Ihe conlrol, depending on lension, speed, and lorque available. D. Dynamic Adjuslmenls
O 1. Remove any meler conneclions, elc., Ihal were made

O 5. Roli loliower adjuslmenl

O a. Insure Ihal syslem power is on.

O b. Connect a DC voltmeter belween Ihe wiper and O c.

during sel-up adjuslmenls.

O d. O e. O l.

OC common on Ihe loliower potenliometer. Adjusllhe roll loliower arm lor atrue zero posilion which corresponds lo Ihe exact cenler oflhe roll shal\. Adjust Ihe roll lollower polentiomeler lo provide a OC inpul reading 01 0.5 VDC C.l VDC. Remove Ihe meler Irom the lollower potentiometer and connect across the brake magne\. Set the roli lollower arm to correspond to Ihe maximum roll diameter. . Adjust the '10rque/span" potentiomeler to pro vide the desired outpullevel to the brake as indicated by Ihe vollmeter.

O 2. Slart syslem and draw web Ihrough Ihe machine.

O 3. Make any adjuslmenl necessary lo provide Ihe re

quired lensions based on Ihe type 01 inpul used. This compleles Ihe slart-up and adjuslmenl 01 Ihe MCS-166/MCS204 Remole/Analog Conlrol Syslem. " any difficullies are encounlered Ihal cannol be resolved Ihrough Ihis manual, conlact your local Warner Electric Represenlalive or Ihe lactory.

19

-.--

MCS2D4

I
ANTI-RESIDUAL ADJUSTMENT

6.00

O O

0POWER BRAKE
O%~100%

TOROUE ADJUST

O
....ADJUST
ZERO FREO. ADJUST

-1

O.......

TP3=

CONTROL

1""'' '11--

3.00 - - - I . .

~I
REMOTElANALOG LOGIC BOARD

3.62 --+-Jl~ 0.46

....,--

5.28 -----,f----.-I OUTPUT/DRIVE BOARD

NOTE: INTERCONNECT PIN NUMBERING DO NOT CORRESPOND TO TERMINAL BLOCK NUMBER)NG.

--

MCS166

O
6 .00

POWER

UNES ELECT TCH ./SWI LOW-HIGH SWITCH '-......

~1:,7J~
S21!!!!!!1

PIN 1

I
'---

POWER SUPPLy

I
~I

1I
]]1.86

LOW HIGH

1. ..

1 - - - 3.00 - - - - I . . I

3.62 5.28

0.46

..

I
I

..

Figure 14 Control Adjustment Locadons, MCS-1661MCS204

20

TROUBLESHOOTING Applles toMCS-203 Control, MCS-166, Power Supply, and MCS-605-1 or TCS-605-5 Plvot Polnt Sensor
lneral: The chart below wil! be helpful when Isolating exact problems which may occur in the control system. The chart will also prove aflpful when encountering problems with the inllial start-up of the system. When the systemhas been running for sorne time, the chart will also be helpful when checking for worn, broken or frayed wires; bent or broken control system parts; blown fuses;' Ioose terminal conneetions and wire conneetions; loose or broken sensor coupllngs; worn or loose mechanical parts for the tension stand (bearing, couplings, etc.); and dust or dirt accumulation inside the control which has caused components to overheat. Symptom A: Dancer wlll not ralse from bottom position. Probable Cause Incorrect Oancer Position setllng Oancer is not free to move because of obstruction. No OC power to the control. Suggested Solutlon Adjust dancer position setling until dancer moves to normal runnlng position. Remove obstruetion, release any holding devices or safety locks. Check for power LEO iIIumination on MCS-20S Check for power LEO iIIumlnation on MCS-166 Check fuses Check proper OC input connections to control (refer to tension control hookup instructions). Check AC power input lo MCS-166 nused. Check to be sure lead wires to the brake are at the brake terminals 1 and 2 DI the control. Check to see if sensor is connected. Using avoltmeter, check for approximately -1.8 to +28VOC between the brake terminals. 11 there is no voltage, check for approximately -1.8 to +28VOC between terminals1 and 20fthe control. Ifthe voltage is present allhe control and not allhe brake, wires to the brake are open. 11 there is no vollage at terminals 1 and 2 of the control, replace the printed circull board assembly. If there is vollage at the brake terminal, check the brake coi! resistance with an ohmmeter for shorted brake magnets or wrong coil vollage. Check for proper pivot sensor allgnment. Terminals 6 and 7 on MCS-20S=7.5VOC 0.1 VOCw/dancer control: 6.1 VOC - shortest web loop. 8.9VOC -Iongest web loop. Check to see Ihal brake is wired properly. Check to see Ihal brake-off input is nol aetivated. Verify Ihal the correct brake was selecled by repeating Ihe selection procedure.

Brake is not engaging.

Brake does nol have the lorque capacity required for the applicalion.

Symptom B: Dancer moves to and remalns at .upper IImlt durlng Inltlal systems start-up. NOTE: Refer lo symplom C if dancer moved lo upper limll alter 11 had been running normal!y at Ihe proper posllion. Probable Cause Incorreet Oancer Posllion setling Rol! shalt nol free lo rolale wilh control off. .Jfnsor incorrecUy conneeted to conlrol lerminals. Suggested Solutlon Adjusl dancer posilion setling unlil dancer moves to normal running posllion. Brake and shalt must be free lo rotate wilh control off. Verify sensor connections.

21

Using avoRmeter, check the DC voRage at the brake terminals as lollows: Slowly raise the dancer and observe thaUhe voRage_decreases- then slowly .Iower the dancer and observe thal the voRage increases. nthe voltage indications are the opposile, reverse the sensor leads al terminals Sand 7 01 the control (see sensor wiring). nno voRage change occurs, check sensor cable connections (check pivot point coupling , connection nMCS-SOS-1 or TCS-SOS-S sensor is used). nno voltage change oecurs, be sure that the brake wires are not grounded to machine. Brake is not releasing as dancer Is raised (even though voRage decreases). Sympton C: Probable Cause Incorrect Dancer Posilion setting Dancer plvot point sensor coupling has slipped Faulty P.C. Board Check the mechancial parts 01 the brake to 'assure they are in good operaling condilion and properly installed. Check to see " Brake-on input is activated. Suggested Solutlon Adjust dancer position setting until dancer moved to normal running posilion.

Dancer moves to and remalns at upper limlt afler operatlng In a normal runnlng posillon 10r a period 01 time.

ndancer posilion adjustment lowers lhe arm near ils normal running position, realign pivot polnt sensor (see sensor mounting).
With dancer posmon and gain at minimum setting, check that the voltage on the brake terminal reduces to less than two volts as the dancer arm is raised. 1I vollage does not reduce to less than lwo volts, replace printed circuit board assembly. Wilh dancer posillon and gain al minimum setting, check that the DC voltage at the brake terminals reduces to Oand reverses polarily as the dancer arm is slowly raised. 1I the voltage reduces and reverses polarily, check to be sure that the brake is in good operating condition and properly installed (see tension brake maintenance-torque loss). Also check to be sure that the unwind stand IricUon is not excessive lor the applicalion. Check the brake selection procedure to be surethe brake being used does nol exceed the minimum allowable torques. nthe voltage did reduce to zero but did not reverse polarily, adjustment 01 the anliresidu~ may be necessary. II adjustment 01 the antiresidual does not cause the brake voltage to reverse polarily in the off state, replace the PC Board Assembly. Suggested Solutlon Adjust dancer gain setting CCW unlil dancer stops hunting.
If the huntlng coincides wilh each revolution 01 the web parent roll, check laulty bearings or

(Problem oecurs near roll core only) Residual torque 01 the unwind stand exceeds the minimum torque allowable lor the application.

Symptom D: Dancer moves erratlcaliy appears to hunt or oselllate. Probable Cause Incorrect Dancer Gain setting Nonunilorm system Iriction Improperly inslalled sensor

misrrounted brake. When an MCS-60S-1 Sensor is being used, check to be sure the index mark on lhe sensor shaft is aligned wilh the index mark on lhe sensor body when the dancer is at the midlravel posilion. Also, be sure lhere is no lag between the movement 01 lhe dancer pivol poinl and the shaft 01 lhe sensor the sensor shaft must move when the dancer pivot moves. Wilh dancer centered, voltage al terminals 6 and 7 should be 7.S VDC O.1 VDC (reler lo lhe sensor mounting section). Check to be sure that all conneclions to the control terminal block and the brake wire connections are secure. Check electrical connector at sensor to be sure it is not loose. Using a DC voRmeter connected between control terminals 6 and 7, check lo be sure the voRage varialion is smooth as the dancer is slowly moved through its travellimils. nthe vollage variation is not relatively smooth, eilher the sensor or cable assembly is laulty. To isolale the lauR to lhe cable or the sensor, turn off power and dis-connect the cable Irom the sensor and connect an ohmmeter between the middle pin and one 01 the remaining pins on the sensor receptable. The resistance indication should vary smoothly as the dancerf', moved through Rs travellimils. nthe indication is erralic, the sensor should be replaced; 1ft indication is not erratic, the cable assembly should be replaced. naboye steps seem normal, recheck dancer arm lenglh (mosl applici;ltions require a dancer arm at least 12'long).

Loose or laulty sensor and cable assembly.

22

TROUBLESHOOTING
Applles lO MCS-204 Control, MCS-166 Power Supply

Wilh Ihe exceplion 01 Ihe dancer inpul, general MCS-166IMCS-204 syslem Iroubleshooling is qu~e similar lo Iroubleshooling Ihe MCS-166IMCS-203. The chart below will be helplul in isolating problems causes. Probable Cause No OC power to the control. Suggested Solutlon Check lar power LEO iIIumination on MCS-204. Check lar power LEO iIIuminalion on MCS-166 Check luses. Check proper OC inpul connections lo conlrol (reler lo lension conlrol hookup inslrucIlons). Check AC power inpul lo MCS-166, nused. Check lo be sure lead wires lo the brake are al Ihe brake lerminals and a! lerminals 1 and 2 01 the conlrol. Check lo see il inpul is properly connected. Using a vo~meter, check lar approxima!ely -1.8 lo +28 VOC belween Ihe brake lerminals. " Ihere is no vo~age, check lar approximalely -1.8 lo +28 VOC belween lerminals 1 and 2 on Ihe conlrol. " Ihe vollage is presenl al Ihe control and nol al Ihe brake, wires lo Ihe brake are open. "Ihere is no vo~age al terminals 1 and 2 01 Ihe conlrol, replace Ihe prinled circu~ board assembly. "there is vollage al Ihe brake lerminal, check Ihe brake coil resistance wilh an ohmmeler lar shorted brake magnetor wrong magnel vottage. Check lar proper input signa!. Check lo see thal brake is wired properly. Check lo see Ihal Brake-Off input is nol activaled. Verify Ihal Ihe correct brake was selected by repealing Ihe seleclion procedure. Check Ihe mechanical parts 01 the brake lo assure Ihe:' 'ire in good operating condilion and properly inslalled. Check lo see if Brake-On input is activaled. Brake and shaft musl be Iree lo rolale wilh conlrol off. Verify inpul connectlons. Using a vo~meler, check Ihe OC voltage al Ihe brake lerminals as lollows. 810wly reduce 1he inpul level and observe Ihal Ihe vo~age decreases - Ihen slowly increase the input level and observe Ihal the vo~age increases. Wilh inpul level al minimum settings, check Ihal Ihe OC vo~age al Ihe brake lerminals reduces lo Oand reverses polar~y. " the vo~age reduces and reverses polar~y, check lo be sure thal the brilke is in good operaling condifion and property Inslalled (see lension brake mainlenance-Iorque loss). Also check lo be sure Iha! Ihe unwind sland Iriction is nal excessive lar the applicalion. Check Ihe brake selection procedure lo be sure Ihe brake being used does nol exceed Ihe minimum allowable torques. 1I lile vo~age did reduce lo zero but did nol reverse polarity, adjuslmenl 01 the antiresidual may be necessary. 1I adjuslmenl 01 Ihe anliresidual does nol cause Ihe brake vo~age lo reverse polarily in the off slale, replace Ihe PC Board Assembly.

Brake is nol engaging.

Brake does nol have Ihe torque capacily required lar the applicalion. Brake is nol releasing as input level decreases RolI shaft nol Iree lo rolale wilh conlrol off. Inputs incorrectly connected lo conlrol lerminals.
If brake LEO off?

(Problem occurs near roll core only) Residual lorque 01 the unwind sland exceeds Ihe mnimum lorque allowable lar Ihe application.

Warranty
Warner Eleetrie, Ine. warrants that it will repair or replaee (whiehever it deerns advisable) any produet manufaetured and sold by it whieh proves to be defeetive in material or workmanship within a periad of one (1) year from the date of original purehase for eonsumer, eommercial or industrial use. This warranty extends only to the original purehaser and is not transferable or assignable without Warner Eleetrie, Ine.'s prior eonsent. Warranty serviee can be obtained in the U.S.A. by returning any defeetive product, transportation eharges prepaid, to the appropriate Warner Eleetrie, Ine. faetory. Additional warranty information may be obtained by writing the Customer Satisfaetion Department, Warner Eleetrie, Ine., 449 Gardner Street, South Beloit, IlIinois 61080, or by ealling815-389-3771. A purehase reeeipt or other proof of original purehase will be required before warranty serviee is rendered. If found defeetive under the terms of this warranty, repair or replaeement will be made, without eharge, together with a refund for transportation eosts. If found not to be defeetive, you will be notified ando with your eonsent, the item will be repaired or replaeed and returned to you at your expense. This warranty eovers normal use and does not eover damage or defeet whieh results from alteration, aeeident, negleet, or improper installation, operation, or maintenanee. Some states do not allow Iimitation on how long an implied warranty lasts, so the above Iimitation may not apply to you. Warner Eleetrie, Ine.'s obligation under this warranty is Iimited to the repair or replaeement of the defeetive produet and in no event shall Warner Eleetrie, Ine. be Iiable for eonsequential, indireet, or incidental damages of any kind ineurred by reason of the manufacture, sale or use of any defeetive produet. Warner Eleetrie, Ine. neither assumes nor authorizes any other person to give any other warranty or to assume any other obligation or Iiability on Its behalf. WITH RESPECT TO CONSUMER USE OF THE PRODUCTo ANY IMPLlED WARRANTIES WHICH THE CONSUMER MAY HAVE ARE L1MITED IN DURATION TO ONE YEAR FROM THE DATE OF ORIGINAL CONSUMER PURCHASE. WITH RESPECT TO COMMERCIAL AND INDUSTRIAL USES OF THE PRODUCT, THE FOREGOING WARRANTY IS IN L1EU OF AND EXCLUDES ALL OTHER WARRANTIES. WHETHER EXPRESS OR IMPLlED BY OPERATION F LAW OR OTHERWISE, INCLUDING, BUT NOT L1MITED TO, ANY IMPLlED WARRANTIES OF MERCHANTABILlTY OR FITNESS. Some states do not allow the exelusion or Iimitation of incidental or eonsequential damages, so the above Iimitation or exelusion may not apply to you. This warranty glves you speeifie legal rights and you may also have other rights whieh vary from state to state. Changes in Dimensions and Specifications AII dimensions and speeifieations shown in Warner Electrie eatalogs are subject to ehange without notiee. Weights do not inelude weight of boxing for shipment. Certified prints will be furnished without eharge on request to Warner Eleetrie.

P257 819-9027

10198 Prlnted In U.S.A.

REPLACEMENT PARTS L1STING

MCS-166 Power Module . 6910-446-013 MCS-166 Housing, Panel Mount . 6910-446-016 6910-446-019 MCS-166 Housing, Wall/She~ Mount.. .. 6910-101-022Rear PIC Board Assy. MCS-166 P1M enel. .. 6910-101-020Rear P/C Board Assye MCS-166 W/S enel. .. Fuse, 1 Amp, 250 Voll, Fast Aeting , . 456-6001-017 MCS203 Dancer Module, Complete .. 6910-446-014 MCS-203 P+D Logie Board .. 6910-446-021 MCS-203 OutputlDriver Board . 6910-446-020 6910-446-015 MCS-203 Housing, Panel Mount... .. 6910-446-016 MCS-203 Housing, Wall/She~ Mount... . Rear P/C Board Assy. MCS-203 PIM enel. . 6910-101-0236910-101-021Rear P/C Board Assy. MCS-203 W/S enel. .. Fuse, 3 Amp, 250 Volt, Fast Acting .. 456-6001-006 MCS-204 Remote/Anaiog Module, Complete 6910-446-017 MCS-204 Remote/Analog Logie Board . 6910-448-022 MCS-204 OutputIDriver Board .. 6910-446-023 MCS-204 Housing, Panel Mount.. .. 6910-446-015 6910-446-016 MCS-204 Housing, Wall/She~ Mount. ,.. 6910-101-023Rear P/C Board Assy. MCS-204 PIM enel. ... Rear P/C Board Assy. MCS-204 W/S enel. .. . 6910-101-021Fuse, 3 Amp, 250 Volt, Fast Acting . 456-6001-006 MCS-605-1 PivotPoint Sensor, Single Turn 7330-446-002 7330-446-003 TCS-605-5 PivotPoint Sensor, 5 Turn ......... Replacement Cable Assy. lor MCS-605-1 , TCS-605-5 .. 7330-101-001 Coupling . 264-8000-003 - New style baek board assembiy w/ribbon cable connector assembly.

L1STING OF FIGURES AND ILLUSTRATIONS

Figure 1 Figure 2 Figure 3 Figure 4 Figure S Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 24 Wall/shelf enclosure dimensions Terminal strip label orientation Panel mounting dimensions Panel mount housing dimensions Terminal strip label orientation MCS-BOS-1 & TCS-BOS-S mounting details MCS-1661MCS-203 wiring . single brake MCS-1661MCS-203 wiring - dual brakes MCS1661MCS-204 wiring . single brake MCS-1661MCS-204 wiring - dual brakes MCS-204 input configurations Analog photoelectrie roll follower wiring Control adjustment locations, MCS1661MCS203 Control adjustmenllocations, MCS-1661MCS-204

Tenslon Control Systems

OOrM;:e Alm Sensors
TCS-605-1 TCS-6052 TCS-605-5
Wurer Electric pMll
poinl senaor 0$ a precision alectr<ric
~d8Yice

Dimensiona

wtloch ia . - l Wltt> lhe t..ICS-203.

01 Tcs-:JlOdar>:oer

- .....
prQWle

~201, T~2'O

1.---,..to..

...

srnooIh oontrol o! .......,.no:j slaflds operallllll at fJJrf speed. '!he 00<1$0/ is mounted al O/Ie e<XI o! lhe dance< J<lI pivoO: oI>aft wt>e<e ~ rnonnor. lIt'IgOJIar potlIIon. direction 01 tra",11Ind relat..... apeec 01 dan:::er 8fftl ~ . TCs-J5..2 uaed ~!h dr..... systems

Intennlttent Mollon SenSOr Coupling

TI-. lnterrriIlen1 MoIion SenIor CoupIno ia lwO f*t coopIinQ llesigned "" ap>Iicationl !he web iI started and SIopped by "'terminent mallon. '-~ccr'~'"~~',~~, TI-. <lesign - . 101 "'" ltdjurtat>ie deltdband 0 0 , " ( l_.m~

Vanslated lO the pivoO: poinl oenso-. TlVa 8Ilowa 101 $tnOOlhef oontrol 01 !he tens<><w>g d8Yice aOO pr.......n.......anted fu'ltl"llllnd ifistabil,ty'" !he S)'Slatn. ~ 'fOOI a~tion rell'-'re$ ltos tvPe 01 <:aJPljng. C<IfIIIlC'I your War..... E~ 1"""",,, speci&~ \O OOle<rrII"I(I ~ ~ is riQl>! 101 yQU.

.....

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Spe<::lflcatlons
_1-' PI" N9.
SInglo ............. '" _

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610-101.001 7)30-101-001

J310l-002 J310l-003

Warner Electrlc 800-825-9050

Operating Instructions
DR 224. Narrow Web Guider with FR 1051 Infra-red Edge Sensor
Notes on Safety Functional characteristics Narrow web guider Positioning drive AG 1011 Infra-red edge sensor FR 1051 Sensor mounting bracket with positioning device VA 1301 Command station RE 4701 Control card RK 1602 Mounting Installation Commissioning Operation Maintenance Narrow web guider Positioning drive AG 1011 Infra-red sensor FR 1051 Sensor mounting bracket and positioning device VA 1301 Special version - Sensor mounting bracket with positioning device VA 1399 Spare parts Technical data 2 4 6 7 8 9 10 14 20 21 23 24 27 27 27 27 30 31 32 33

BEA--084268-E-01

Notes on Safety

Safety must be the primary concern for all those who operate, maintain, or service machines and their components. Moving webs and machines in operation constitute hazards which cannot always be eliminated by design measures. AII personnel must be made aware of these hazards and exercise caution in areas in which machinery is running. Hazards include the following, although it must be remembered that this list cannot be considered complete: Injury from contact with the edge of the moving web Injury due to fingers, jewelry, or clothing becoming caught between the web and the guide roller or control roller Injury due to improper electrical installation Injury from contact with moving machinery parts in general (danger of crushing) Injury resulting from the removal of safety facilities

Due utilisation of equipment The E+L web guider should be used to control the run of textile, paper or foil webs only. The web guider may only be used if it is in perfect condition in accordance with its purpose in accordance with the operating instructions. The operator must be well aware of security regulations and possible risks.

Assembly
When the web guider is being mounted, care must be taken that the safety clearances between the moving and fixed parts of the web guider and the fixed parts of the customer's machinery, for example side panels, steps, ladders, or walkways, are observed in conformity with the locally applicable safety rules and the customary accident prevention regulations. If these parts of the machinery are within reach of the machine operator or other persons, safeguards must be provided in accordance with the accident prevention regulations.

Electrical 5ystem
Electrical components without enclosures, such as switch panels or command stations, must be provided with adequate protection by the customer. When electrical leads are laid, the customer must ensure that the insulation is not damaged and that the leads are fixed in place and protected in the correct manner. The relevant engineering standards must be observed in each case. Wires with black and white markings are used for system ground in E+L products.

Operation
The web guider must always be operated and maintained solely by experts or appropriately instructed personnel.

Emergency operation: should the web guider control frame require adjustment in the event of a malfunktion such as power failure, failure of the actuator or control electronics, this may only be effected once the acuator push rod has been disconnected from the control frame.

Functional characteristics

The DR 224. narrow web guider guides the web as it is running and prevents it from breaking out of its path. Oeslgn The DR 224. narrow web guider is of compact design (see diagram below) and is made up of the following components: the pivoting frame carried in all bearings, the AG 1011 d.c. positioning drive, the FR 1051 infra-red edge sensor, the sensor mounting bracket, the main frame section with the RK 1602 electronic control card and the RE 4701 command station

DR 224. narrow web guider AG 1011

pos~ioning

drive

Pivoting frame

\
~
Sensor mounting braeket

/
~ !In 1" Ir
e-J
1'"'

.\.

"

~
[

Inl
.
r-

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b

J
FR 1051 infrared edge sensor

Main frame seelion w~h RK 1602 eleet ronic control eard and RE 4 711 command station

J
Mode of operatlon

[]ID
lo

CD
e

The DR 224. narrow web guider uses an optoelectronic sensing system and electrical adjustment: guiding method EE. The FR 1051 infra-red edge sensor optically senses the position of a web edge. If the web deviates from its reference line, the sensor produces a signal voltage indicating the magnitude and
4

direction 01 the deviation. The signal voltage is evaluated by the RK 1602 electronic control card and transmitted to the AG 1011 positionning drive. The positioning drive adjusts the guider in accordance with the signal voltage. thereby correcting the position 01 the web. The narrow web guider is operated with the aid 01 the RE 4701 command station. There are three options lor guidance 01 the web: either by the right-hand edge. by the left-hand edge or by the web centre line. The web guider can be adjusted to the midway position lor threading up; the rollers 01 the guider are thus aligned parallel to the press rollers.

Block diagram of DR 224. narrow web gulder

Plvollng lrame

Maln switch 01 tha machina

Power __ connection --

FR 1051 Infrared edge sensor

RE 17..
remote control unn

Lock-out contact

Narrowweb guider

The narrow web guider (see diagram aboye) is mounted on ball bearings and corrects the web run within a short distance. The narrow web guider moves on bearings in U-shaped guideways, and it is driven by the AG 1011 positioning drive. The DR 224. operating instructions apply to two types 01 device, the DR 2240 and DR 2245 narrow web guiders. The two web guiders diller only in terms 01 their roller diameter; reler to the enclosed dimension sheet.

Type DR 2240 DR 2245

Roller diameter "60 mm "80 mm

The positioning drive receives a voltage lrom the electronic control card and converts the voltage into a positioning movemento The positioning movement is transmitted to the web guider via an articulated joint. The AG 1011 positioning drive comprises the lollowing components: a d.c. geared motor a toothed belt drive a ball screw with mechanical spindle stop al the end positions (see diagram below). A toothed bell drive transmits the rolational movement 01 the d.c. motor to a ball screw. A bellow-type cover protects the ball screw against soiling.

AG 1011 positioning drive

D.c. geared motor

Terminals

Toothed ben drive -----f;H-

Ball screw

Bellows

Arliculated joint AG 1011 positioning drive

FR 1051 infra-red edge sensor

The FR 1051 inlra-red edge sensor (see diagram below) senses the position 01 transparent and non-transparent webs by their edge. It indicates the magnitude and direction 01 any deviation to the control electronics in the lorm 01 a signal voltage. The FR 1501 inlra-red edge sensor works according to an optoelectronic principie. The transmission diode emits a pulsed light. The pulses 01 light are shaped by a lens into an almost parallel beam and projected on to the rellector positioned opposite. The rellected Iight is bundled (Iocussed) by the sensor's lens and transmitted via a semi-transparent mirror on to a photodiode. The current Ilowing through the photodiode is proportional to the incoming amount 01 light. The edge 01 the web passes between the sensor and the rellector. Depending on how lar the web protrudes into the Iight beam, the sensor picks up a varying amount 01 the Iight (see diagram on left), and the current Ilowing through the photodiode in the sensor is altered accordingly.

LEO off

LEO green

Web surface and transparency

The sensitivity 01 the sensor is also affected by the sur/ace 01 the web. Shiny sur/aces rellect a great deal 01 light, rough or matt sur/aces rellect less light.
LEO red

The sensor is tilted approximately 20 to the web runo This prevents nter/erence in the lorm 01 the web reflecting the beam 01 light and provides better shielding 01 the light path lor transparent webs.

LEO and the position 01 the web

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A

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FR 1051 infra-red edge sensor

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FR 1051

sensor

The FR 1051 inlra-red edge sensor is mounted on the sensor mounting bracket by way 01 the VA 1301 positioning device (see diagram on right). The positioning device can be adjusted to different positions on the square bar. In order to set up the sensor lor guidance by edge, adjust the VA 1301 positioning device such that the light spot is aimed at the appropriate guidance criterion. Use the knob on the positioning device lor line adjustment (see diagram below). The line adjustment knob on the positioning device adjusts the square bar by 5 mm. A special version 01 the sensor mounting bracket with VA 1399 positioning device is described in the section entitled "Special version".

Sensor mounting bracket with VA 1301 positioning device

Coarse adjustment

\
o

\.~:;;;""-;;FR 1051 infra-

red edge sensor

VA 1301 positioning device Sensor mounting position on the DR 224.

Fine adjustment

o
O

I
O

O O

....
O

..... ..t.
O O
O

Coarse adjustment

D
FR 1051 infra-red edge sensor

O O O
O O

RE 4701 command station

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ED

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@)

@D

-+~.
RE 4701 command station

tE

)-,.

M K \ .

DK 4201

The DR 224. narrow web guider is operated with the aid 01 the RE 4701 command station (see diagram aboye). The lock-out contact and the FR 1051 inlra-red edge sensor are connected to the command station.

~: . .
~. ~\.

J.
~ 11' ~

The rear panel 01 the RE 4701 command station also carries the DK 4201 electronic activation and evaluation card (see diagram on left) for the FR 1051 infra-red edge sensor. A plug-in connection is also filted for an RE 17.. remote control unit for web displacement.

~.

RE 4701 command station

10

LEOs and sensor signal indicator

Positioning motor status LEO ofl positioning motor stationary in end position red positioning motor turning anti-clockwise green positioning motor turning clockwise

End position left right (yeIlOWLEOj

1+--JLh.
Operational state 12 voits (green LEO)

@f)

@f)

@f)

Out 01 range

- - - f - - - (yellow LEO)

I-----;;;;;;;;;;;;;;;;~I
--t-Sensor1Q) Sensor 2(lW Sensor signai indicator

Proteetive caps 01 the potentiometers lor setting the sensors to the transparency lor Sensor 1 (iefthand edge) and lor Sensor 2 (right-hand edge) Part 01 RE 4701 command station

The narrow web guider is ready for operation when the operational state LEO is lit up. In automatic mode, the "Positioning motor status" LEO indicates the motor voltage and its polarity. If the LEO is off, the motor is stationary, for example because the lock-out contact has been opened or the motor is in one of the end positions. The end position lights Iight up when the positioning motor reaches the respective end position and is shut down. The out of range Iight lights up before the web reaches the boundary of the sensors' proportional band (6 V). The output signal from the infra-red edge sensor is shown on the sensor signal indicator (max. 8 V). To enable the infra-red edge sensors to sense transparent webs, the signal amplifier of the edge sensor must be adjusted to match the transparency. The potentiometers for adjusting the edge sensors to the transparency of the web are located under the protective caps. After removing the protective caps, you can use a small screwdriver to reach the trimming screw of the respective potentiometer. Mode switch You can set the operating mode, "Midway position" or "Automatic", with the mode switch (see diagram on right).

Midway position

Automatic

~!~
1

t(

)-~

Mode switch in switch position "Midway position"

11

When set to midway position, automatic web guiding is deactivated; the narrow web guider moves to its midway position. In automatic mode, the web guider operates in accordance with the signals from the sensors.

Amplification knob
The amplification of the control circuit for the narrow web guider can be adjusted with this knob (see diagram on left). Left stop: minimum amplification (sensitivity); right stop: maximum amplification.
Amplilication knob

Web guidance mode switch

You can set the required web guidance mode with the "web guidance mode switch" (see diagram on left). There are three options for guidance of the web: either by the left-hand web edge (Sensor 1, seen in direction of web run), by the righthand web edge (Sensor 2, seen in direction of web run) or by the web centre line.

Web centre line guiding Lelt-hand edge

~.~

I I

Right-hand edge

If you have installed only one sensor, the switch must be set to the corresponding position.
If, for example, your sensor is installed on the left-hand side, you must set the web guidance mode switch to the "web guidance by left-hand edge" position.

Web guidance mode swttch in "Web centre line guiding" position

Jacks
Lockout contact Jack lor edge sensor mounted on left (seen In direction 01 web run)

~
Remote control untt jack for an RE 17.. _ remote control unit

!. 13::.
I

~+-- ~~;:~1:~~0~~~~~~~~

Remote control unit jack

You can use this 7-pin jack for connecting an RE 17.. remote control unit. It is possible to displace the web by approximately 2,5 mm using such a remote control unit.

12

Lock-out contact
The lock-out contact operates only in automatic mode. The lock-out contact allows you to block the positioning drive, for example during interruptions to operation. This prevents malfunction of the narrow web guider with a loose web, for example an oscillating positioning drive, which would result in wear of the motor. The lock-out contact must be opened when the machine is stationary (positioning drive blocked).

Jacks for edge sensors

You must connect your edge sensors to the 7-pin jacks in accordance with their installation location. If, for example, the edge sensor is mounted on the right (seen in the direction the web is running), you must connect it to the jack for "Edge sensor mounted on right" (see diagram on right).

Jack for edge sensor mounted on right (seen in direction of web run)

13

Control card RK 1602

The RK 1602 control card is located in the main frame section of the DR 224. narrow web guider.
Purpose

The control card is a complete control unit for web guidance systems: It receives the sensor signals and control signals, and processes them to generate a common signal for the positioning drive It monitors the motor current and hence the operation of the positioning drive. When the positioning drive reaches one of its end positions the control card (without limit switches) disconnects the motor curren!.
Design

The RK 1602 control card contains the following components: an amplifier for the sensor signals a power amplifier and the disconnection logic for the motor an amplifier for the return-to-centre switch a power pack for the supply of voltage (control voltage and motor voltage)
Component mounting plan: RK 1602

Connector X2

14

Should you ever need to replace the control card, proceed as follows: 1. Set the narrow web guider to its midway position. 2. Switch off the mains voltage and disconnect the FR 1051 infra-red edge sensors etc. at the RE 4701 command station. 3. Remove the screws atlaching the command station to the main frame section and tilt it carefully forwards.
DR 224. narrow web guider

Plvollng lrame
Relurn-to-cenlre switch

Maln switch 01 lhe machina

Power __ connection --

Maln Irame seellon

FR 1051 infrared edge sensor

RE 17.. remote control unil

Lock-oul contact

15

Release the retaining screws on the two connectors on the RK 1602 control card (see diagram on Page 14) and detach the connectors. Unscrew the lour lixing screws on the control card and replace the old card with a new one.

Pin link 53 Set the mode 01 the return-to-center switch with the pin link S3 (see diagram below). The DR 224. narrow web guider operates with an inductive proximity switch as its return-to-centre switch. Position 1. This is set in the lactory.

The switches You can change the direction 01 the positioning drive (anticlockwise/clockwise) with switch 51 (see diagram below). The setting is made during the lunctional test, belore the narrow web guider is delivered. Set the same position on your new control card as on the old one. You can invert the signal Irom the return-to-centre switch with switch 52 (see diagram below).
Part 01 component mounting diagram 01 RK 1602

51

52
f:}

53

j<H<l- -KI--I<I-+<I

! Ri H2 H3 H4 A6 A6!

--@J~
Ie7

-@:::J--

16

The switch position "inverted/not inverted" on S2 is dependent on the mounting position of the return-to-center switch. The setting is made during the functional test, before the narrow web guider is delivered. Set the same position on your new control card as on the old one.

The LEOs

LEO H1 (yellow) indicates that the positioning drive is at its lefthand end position. LEO H2 (yellow) indicates the right-hand end position.
H3 (green) indicates that the operating voltage of 12 volts is available for the electronics and the sensor. LEO H4 (green) indicates that the operating voltage of +24 volts is available for the power amplifiers.

H5 (green) indicates that the motor of the positioning drive is turning clockwise. H6 (red) indicates that the motor of the positioning drive is turning anti-clockwise.
Par! 01 componen! mounting diagram 01 RK 1602

F1

Fuse F1

Fuse F1 (1 AM; see diagram aboye) provides protection against short circuits for the operating voltage of +24 V for the power amplifier. 4. Mount the new control card and plug the two connectors X1 and X2 back in.
17

5. Basic setting
Workjog pojol of Ibe reluro-to-center swilcb
o

Set tbe mode switcb to "midway positioo". Set poteotiometer R24 (see diagram 00 Page 19) to mioimum amplificatioo (after 20 tu ros to Ibe left, mioimum amplificatioo is certaio to be sel). Next defioe tbe workiog poiot of tbe returo-to-ceoter swilcb witb poteotiometer R23 (see diagram 00 Page 19). Tbis poiot sbould be precisely io tbe ceotre. First turo poteotiometer R23 20 tu ros to tbe left aod tbeo about 10 turos to tbe rigb!. Vou will tbeo be io tbe ceotre. Switcb 00 tbe supply voltage. If tbe positiooiog drive moves tbe guider away from tbe midway positioo, you must iovert Ibe sigoal wilb switcb 52. Tbe oarrow web guider is oow electrically io tbe midway posilioo. lo tbis setliog, about a Ibird of tbe reluro-to-ceolre switcb must be covered by tbe sbield (see diagram 00 left). Tbe rollers of Ibe web guider must be parallel lo tbe rollers 00 your system (eotry aod positiooiog rollers). If tbey are oot, you can correct mioor deviatioos (0,5 mm) witb poteotiometer R23, but for larger deviatioos you must adjust tbe sbield. Cooduct fioal fioe adjuslmeot witb poleoliometer R23 agaio.

Zero poinl sensitive area approx. 1/3 covered

Zera poinl: return-lo-centre switch

Ampljfjcatjoo of tbe reluro-to-center swjtcb

o

losert a melallic object, sucb as a screwdriver, betweeo tbe proximity switcb aod tbe sbield, aod take it out agaio. Tbe web guider will be deflected. It sbould returo to Ibe midway positioo rapidly but witbout oversbootiog. If tbis does oot bappeo, turo poteotiometer R24 (see diagram 00 Page 19) to tbe rigbt until tbe guider moves rapidly but witbout oversbootiog to tbe midway posilioo.

18

Amplifjcatioo of the control loop Turn poteotiometer R34 to the left-haod stop (mioimum).

Basic setting of the control card is now completed.

6. Switch off the maios voltage agaio aod screw the RE 4701 commaod statioo to the maio frame sectoo.

The narrow web guider is now ready for operation again.

R34

R 23

R 24

S2

Part 01 componen! mounting diagram 01 RK 1602

19

Mounting

The dimensions for mounting the narrow web guider are given on the enclosed dimension sheet. Note the direction in which the web is to runo This is indicated by an arrow on the side of the pivoting frame (see diagram below).

Centre line 01 roller

Pivoting Irame roller

o
Max.1/3

o
Entry span

-+O

Sensing point

Run-out span

&
Min.2I3

000

Centre line olroller Entry roller Posttioning roller

System geometry Posltlon: Mount the pivoting frame in such a way that the web wraps 90 0 around the entry roller and the positioning roller. Only then can you be sure of the necessary contact for reliable correction. Entry span runout span: The length of the span from the entry roller to the pivoting frame - the entry span - and the distance from the pivoting frame to the positioning roller - the run-out span - should be between approximately 300 mm and 600 mm. A greater distance promotes displaced running 01 the web, while a smaller distance increases the level 01 stress on the web. Posltlonlng rolier: The lirst roller after the web guider should have a surface with good grip.

20

The DR 224. narrow web guider is 01 compact designo The individual components, such as the d.c. positioning drive, the return-to-centre switch and the nlra-red edge sensor are already interconnected. It is only necessary to connect the voltage supply and the lockout contact (see enclosed circuit diagram).

Installation

Connecting the mains voltage

21

Depending on the version of the narrow web guider, the supply voltage may be 110, 12S, 200, 220 or 240 volts (SO or 60 Hz). Make sure that the mains connection of the web guider comes after the main switch of the machi ne.

Lock-out contact The lock-out contact enables you to block the positioning drive, for example during interruptions in operation. This prevents malfunetion of the narrow web guider with a loose web, for example an oscillating positioning drive, which would result in wear of the motor. The lock-out contact must be opened when the machine is stationary (positioning drive blocked). The lock-out contact must have a floating connection. If you ordered the narrow web guider with lock-out, the scope of delivery includes a prepared cable and connector. This must be plugged in at the command station, connecting the lock-out contaet to the control eleetronics (see circuit diagram). If you do not use the lock-out facility, the delivery includes a dummy plug that must then be inserted at the command station instead of the lock-out contacto The narrow web guider cannot be put into operation without this plug.

Jacks for edge sensors You must connect your edge sensors to the 7-pin jacks in accordance with their installation location. If, for example, the edge sensor is mounted on the right (seen in the direction the web is running), you must connect it to the jack for "Edge sensor mounted on righ" (see diagram on Page 23).

22

Lock-out contact

\
Remote control unij jack lor RE 17..

Jack tor edge sensor mounted on left (seen in direction 01 web run)

1
Jack tor edge sensor mounted on right (seen in direction 01 web run)

Jacks on RE 4701 command station

Remate control unit jack

You can use this 7-pin jack lor connecting an RE 17.. remote control unit (see diagram aboye). It is possible to displace the web by approximately 2,5 mm using such a remote control uni!.

The narrow web guider has been checked and set lor nontransparent webs in the lactory belore delivery. You do not need to make any lurther settings. When commissioning the guider, proceed in accordance with the section on "Operation". Check the operation 01 the narrow web guider with the aid 01 various samples 01 material laid across the rollers.

Commissioning

23

Operation

FOllow these instructions for operation of the narrow web guider.

1. Set "midway position" mode (web guidance off)

Midway position Automatic

~~
I

tE )~

Mode switch in switch posnion "Midway position"

Set the mode switch on the RE 4701 command station to "Midway position" (see diagram on left). The web guider then moves to its midway position. The rollers of the pivoting frame are now positioned parallel to the entry roller and positioning roller. This position makes it easier to thread up the web. Web guidance is deactivated in "midway position" mode. The narrow web guider is ready for operation as soon as voltage is connected to the electronics. The guider moves to the position predefined by the return-to-centre switch. If this does not happen and the narrow web guider moves to one or the other end position, check the signal from the returnto-centre switch (see section on the RK 1602 control card).

Web centre lineguiding Left-hand edge Right-hand edge

2. Set web guidance mode

Then set the web guidance mode switch (see diagram on left) to the web guidance mode you wish to use: left-hand edge, web centre line or right-hand edge.
Web guidance mode swnch in "Web centre line guiding" position

3. Position infrared edge sensors

LED off Web

:..::.. :. :. : .

'":9'"....:: . . ..".. . '..:.:.;. :.:.:.:...:.:..:....:....:. .:':":':':':':':': ':':':':':',:,:,:

':':':'::::::::::;:;:;:;:;:'::;::;::';:;:::;:':;:;:;';:::::::::::::::::::::::::~:::::::::::::::::::::::::.:.;

;0.......... .......... .

., .

Infra-red edge sensor: web edge in centre of optical system

Now position the infra-red edge sensor aboye the edge of the web such that the edge is located in the centre of the optical system (see diagram on left). The LED is then off and the sensor signal indicator on the command station indicates O V.

Setting the nfrared edge sensor to the transparency of the web

To be able to sense transparent webs, you have to set the signal amplifier of the edge sensor to the transparency of the web.

24

...............-

- - -

- -

:,

-,

Proceed as lollows: First clean the optical system with a soft, clean cloth. Then remove the protective caps Irom the two potentiometers lor setting the web transparency on the RE 4701 command station (see diagram on right). Position the sensors so that the optical system is completely covered. At the web guidance mode switch, set the web guidance mode "edge guidance by left-hand edge 01 web" (Sensor 1) (see diagram on right). Using the relevant potentiometer tor Sensor 1 on the RE 4701 command station, set a signal 01 -8 V at the sensor signal indicator. When you open up the Iight path again (that s, move Sensor 1 accordingly), the signal must change to +8 V. At the web guidance mode switch, set the web guidance mode "edge guidance by right-hand edge 01 web" (Sensor 2). Using the relevant potentiometer lor Sensor 2 on the RE 4701 command station, set a signal 01 +8 V at the sensor signal indicator. When you open up the light path again (that is, move Sensor 2 accordingly), the signal must change to -8 V.

I
!>

'!ID
@

f+-

-. Lh.
@

!>

@--

~
Protective cap, Sensor 1 potentiometer

,~: ~, \.',1',.,1

. . ..
"

I \

Protective cap, Sensor 2 potentiometer

Par! 01 RE 4701 command station

Web centre line guidlng Lefl-hand edge Right-hand edge

G>.~
Web guldance mode switch in -edge guidance by lefl-hand web edge" positlon

I I

4. Select mode
Set the operating mode, "midway position" or "automatic", that you wish to use. Midway position: Automatic web guidance is switched off and the narrow web guider moves to its midway position.

25

Automatic:
In automatic mode the web guider operates in accordance with the signals from the infra-red edge sensors.

5. Ampllficatlon
You can use the "amplification" knob (see diagram on left) to set the amplification (sensitivity) of the control loop. Turning the knob defines the proportional bando The amplification (sensitivity) of the control loop may be set in each case only so high that the positioning motor and thus the web guider do not oscillate.
AmplWication knob

Set the sensitivity with the control loop closed and the web stationary, proceeding as follows: Position the sensors at the edge of the web. Set the mode switch on the command station to "Automatic". Turn the amplification knob to the right to set maximum sensitivity. Deflect the positioning unit by briefly blocking off the sensor light path. Beware of the moving parts of the installation! The unit must return the edge of the web to the position defin- ed by the sensor, and after overshooting briefly it must come to a steady stop. If the positioning drive does not come to a stop, the sensitivity must be reduced. Turn the amplification knob to the left until the oscillation of the drive dies out. A constantly oscillating drive reduces the life expectation of the motor.

Now allow your web to run at follow-up speed and if necessary check the settlngs you have made once again.

26

1. Pivoting trame The rollers of the pivoting frame are equipped with lubricatedfor-Iife bearings and are therefore maintenance-free.

Maintenance

2. AG 1011 positioning drive The ball screws of the positioning drive should be lubricated at intervals of 5,000 operating hours. To do this, push back the bellows and apply some grease to the screws. Recommended lubricants Grease with the designation K-Y 2 K (according to OIN 51 502) is best suited for lubrication of the screws of the AG 0441 positioning drive. This includes: Castrol Esso Klber Taxaco SEEROLAP 2 ESSONORVA 275 LONGTIME PO 2 High-temperature grease 2 Novatext Grease EP 2 Texando FO 20

3. FR 1051 intrared edge sensor In order to ensure proper operation, you should clean the lens of the edge sensor and the reflector with a clean cloth at regular intervals. Use a household washing-up liquid or similar to remove greasy deposits.

In order to be able to sense transparent films without any problems, clean the sensor optical system and the reflector every day and check the sensor signals.

27

Sensor not covered Sensor covered

Sensor signal 1 approx. +8V approx. -8V

Sensor signal 2 approx. -8V approx. +8V

You must re-adjust the sensor if there is a deviation of ~2 V.

If the reflector shows considerable signs of wear, it must be replaced. To do this, proceed as follows:
o

The reflector comprises a reflective film and a protective film. Remove both films. Clean the base thoroughly, removing any grit, dust and grease. First adhere the reflective film to the base when dry. Make sure that the sensor axis is aligned with the centre of the film. Next adhere the protective film on the reflective film, ensuring that there are no bubbles or creases. The protective film should overlap the reflective film uniformly (see diagram on lelt). Re-adjust the sensor amplifier.

Proteclive film

Reflective film
o

Adjustment of the sensor amplifier Changes to the dislance between the sensor and reflector or replacement of the reflector mean that you have to re-adjust the sensor amplifier. To do this, proceed as follows:
Web cenlre line guiding Left-hand edge Righl-hand edge
o

Set Ihe potentiomeler for web transparency to the lelt-hand stop (non-transparent web). Unscrew Ihe four retaining screws of the front panel and remove the panel. Set Ihe web guidance mode switch lo "Lelt-hand edge" (see diagram on lelt). Wilh the Iighl palh unblocked, use trimming potentiomeler R45 on the DK 4201 card (see diagram on Page 29) lo set the vollage at the sensor signal indicator to +8 V (O,5 V).

Web guidance mode switch in "edge guidance by left-hand web edge" posilion

28

R39

R45

R9

R15

DK4201

RE 4701 command statlon L--

~EI:.=.J
DK 4201

Now block Ihe lighl palh wilh a non-Iransparenl piece of malerial (for example paper). Wilh Ihe Irimming polenliomeler R39 on Ihe DK 4201 card (see diagram aboye), sel Ihe voltage al Ihe sensor signal indicalor lo -8,5 V (+0,5 V). Sel Ihe web guidance mode swilch lo "Righl-hand edge" (see diagram on righl). Wilh Ihe lighl palh unblocked, use Irimming polenliomeler R15 on Ihe DK 4201 card (see diagram aboye) lo sel Ihe vollage al Ihe sensor signal indicalor lo -8 V (0,5 V). Now block Ihe lighl palh wilh a non-Iransparenl piece of malerial (fer example paper). Wilh Ihe Irimming polenliomeler R9 on Ihe DK 4201 card (see diagram aboYe), sel Ihe vollage al Ihe sensor signal indicalor lo +8,5 V (+0,5 V).

Web centre line guiding Left-hand edge Right-hand edge

Web guidance mode switch in "edge guidance by right-hand web edge" posrtion

29

Sall clamping screws

4. Sensor mounting bracket and VA 1301 positioning device

The positioning device (see diagram on lelt) is lactory adjusted Iree lrom play to the square bar 01 the sensor mounting brakket with a ball clamping screw. The setting is secured with Loctite. 1I play develops alter a period 01 time, the device must be set again. Remove the screw, apply Loctite and tighten the screw until the sensor mounting bracket can be adjusted without play. II play develops when the square bar is adjusted, this must also be corrected. Remove the clamping screws (see diagram below), apply Loctite and tighten the screws again until the square bar can be adjusted without play.

VA 1301 positioning device

Fine adjustment

~lamPingS~

Coarse adjustment

Sensor mounting bracket

30

The FR 1051 infra-red edge sensor is mounted on the sensor mounting bracket by means of the VA 1399 positioning device. The positioning device can be moved along the square bar. In order to set up the sensor for guidance by edge, adjust the VA 1399 positioning device such that the Iight spot is aimed at the appropriate guidance criterion. Use the knob on the positioning device for fine adjustment (see diagram on left). The fine adjustment knob on the positioning device adjusts the square bar by 5 mm.

Special version Sensor mounting bracket with VA 1399 positioning device

BaH clamping screw

Coarse adjustment __________

FR 1051

VA 1399 pos~loning devlce ofthe DR 224. special version.

Maintenance
The positioning device is factory adjusted free from play to the square bar of the sensor mounting bracket with a ball clamping screw. The setting is secured with Loctite. If play develops after a period of time, the device must be set again. Remove the screw, apply Loctite and tighten the screw until the sensor mounting bracket can be adjusted without play.

31

Spare parts

We recommend that you stock the following spare parts: 10 mains fuses 0.63 AT, 5 x 20 for 220 - 240 V 10 mains fuses 1.25 AT, 5 x 20 for 110 - 200 V 047475 025980

The following spare parts are obtainable from E+L:

For AG 1011 positioning drive

AG 1011 positioning drive, complete D. c. geared motor Joint Bellows

Part number
086285 205120 107805 083633

Replacement:
In some cases it is possible to obtain a second-hand drive that has been overhauled at E+L, but only If repair of the defective device is still worthwhile. E+L reserves the right to decide if that is the case.

For FR 1051 edge sensor

FR 1051 edge sensor, complete (plug connection) cable length 700 mm Adaptor cable with Connector 1000 mm length 2000 mm length Reflector (comprising signal and protective films; please specify length) 083046 108484 108485 061437

For RE 4701 command station

RE 4701 command station, complete 083039

For the control electronics

RK 1602 control card, complete 083356

32

Narrow web guider -,:,G,-"u",id:.:.in:..:;g:L=:a.=:cc"'u:.:.r.=ac:::.YLCorrection span Correction speed in exit Maximum web tension Transfer span Roller face Input voltage, single-phase
Freguency Maximum power consumption Degree of protection Ambient temperature Dimensions Mounting dimensions

-:+O, 1 :.:.m:..::m"--_ +13 mm approx. 16 mm/sec 300 N 250 mm 200,250,300 mm 110, 125 V / 200,220,240 V +10% 50/60 Hz 50 VA IP 50 oC to 40 oC see enclosed dimension sheet see enclosed dimension sheet

Technical Data

AG 1011 positionlng drive Positioning force Follow-up speed Positioning range Rated motor voltage Rated motor current RK 1602 control card Supply voltage
Power consumption Dimensions W x H x D

max. 50 N max. 7 mm/sec +6 mm 24 V 0,33 A

22 V a.c. 1 A, 2 x 15 V a.c. 0,8 A 50 VA 130 x 158 x 130 mm

FR 1051 intrared edge sensor Operating voltage, stabilized Signal output voltage Proportional band Degree of protection

+12 V +8 V +4mm/10% IP 40

Subject to technical moditications without notice

33

Erhardl + Leimer GmbH Postfach 10 15 40 0-86136 Augsburg Phone (0821) 2435-0 Telefax (0821) 24 35-6 66

I 1::

Description H

Command device RE 1702 for web displacements

1. Function 2. Operation

2 4

1 2 3 4 -5

1 2 3 4 5+

BEA--207640-E-01

Command device RE 1702 Key to symbols performing actions additional important information and hints places in the text worthy of particular note to guarantee the safe operation of command device RE 1702.

1. Function
LED H 1 yellow Sensor range limit

1 0 2 3 4 -5

1 2 3 4 5+

Potentiometer R 1 Web displacement

Lens diameter Set position (sensor zero point) Displaced set position

For web guiding purposes, the sensors should be positioned so that the web edge is located in the center of the sensor measuring range (sensor zero point). If the web edge deviates from this set position in automatic mode, web travel will be corrected. Once the sensors are positioned, the set position is fixed and may only be changed by relocating the sensors. The edge sensors may only be positioned when the machine is at a standstill. Risk of injury! Command device RE 1702 permits the displacement of the web set position during automatic operation by shifting the sensor zero point electronically.

Web

Sensor measuring range Measuring range - web edge set position

Web displacement is set using potentiometer R1. Depending on the potentiometer position, the sensor signal is overlaid by a +5.3 to -5.3 V(20 %) signal. The maximum possible web displacement in "mm" depends on the measuring range of the sensor implemented. It corresponds to approx. 2/3 of the measuring range.

H page 2

Command device RE 1702

1 0 2 3 4 -5 1 2 3 4 5+

Before positioning the sensors on the web, the potentiometer must always be set to "0". Web guiding by the center line

Web displacement range 2/3 of measuring range

Guiding by the center line is only possible with two sensors. If the web set position is in the center of the measuring range, a change in the web width can be detected for the entire measuring range. If the web set position is shifted, the range in which width deviations can be detected and corrected, is reduced. Example: edge sensor FR 08.. The sensors have a measuring range of 8 mm from their zero point. The outer limits of the sensor measuring range begin at 6 mm (3/4 of the measuring range). To ensure failsafe operation, you should reposition the sensors if in this zone. If the potentiometer is set to "0" during center line guiding, width deviations up to 12 mm can be detected. If you shift the set position, this value decreases. If you have a web displacement of 4 mm, it means that a width deviation of up to 4 mm can be corrected.

Outer limits begin at 3/4 of sensor measuring range

LED H1 lights up when the outer limits of the sensor measuring range are reached. When this happens, you must reposition the sensors.

Web displacement range

Web center Correctable width deviation left edge 2 mm Correctable width deviation right edge 2 mm

Outer limit of sensor measuring range 6 mm (3/4 of measuring range) Web

Web displacement +4 mm

Measuring range 8 mm Example: web displacement

H page 3

Command device RE 1702

Erhardt + Leimer GmbH Postfach 10 15 40 D-86136 Augsburg Phone (0821) 24 35-0 Telefax (0821) 24 35-666

2. Operation

You can shift the web set position to the right or left in automatic mode by turning potentiometer R 1. Subject to technical modifications without notice

H page 4

Ersatzteile X Spare Parts X Pices de Rechange X Stellantrieb Drive Unit Entranement AG 1011

066656 107812 107813

044424 066661

208620 205129

083633

6)

061980 002981 002545

013092

075354

107821

ERS--084210-DE/EN/FR-01

Postfach 10 15 40 D-86136 Augsburg Telefon (0821) 24 35-0 Telefax (0821) 24 35-6 66 Internet http://www.erhardt-leimer.com E-mail info@erhardt-leimer.com

Erhardt + Leimer GmbH

104989 107804

107805

Stellantrieb AG 1011
001863 002545 002981 013092 044424 061980 066656 066661 075354 083633 104989 107804 107805 107812 107813 107821 208620 Rillenkugellager 6002 2RS Zyl.-Schraube M 4 x 16 DIN 912 7 ) Rillenkugellager 624 DIN 625 Scheibe 4,3 DIN 433 Runddichtring 24,5 x 3 DIN 3770 Tellerfeder 8,0 x 4,2 x 4 DIN 2093 Zahnriemen Rillenkugellager 62200 DIN 625 Winkel Faltenbalg Spindel, komplett 4 ) 5 ) 6 ) Spindel, komplett 3 ) 5 ) 6 ) Gelenk, komplett Zahnriemenrad, 14 Zhne Zahnriemenrad, 14 Zhne Vierkantstopfen Gleichstrom-Getriebemotor 2 ) 2 stug, 20,25 : 1 205129 Gleichstrom-Getriebemotor 1 ) 1 stug, 6,25 : 1
1) 2) 3) 4) 5)

Drive Unit AG 1011

Deep grouve ball bearing 6002 2RS Cylinder screw M 4 x 16 DIN 912 7 ) Grooved ball bearing 624 DIN 625 Disc 4.3 DIN 433 O-ring seal 24.5 x 3 DIN 3770 Spring washer 8.0 x 4.2 x 4 DIN 2093 Toothed belt Grooved ball bearing 62200 DIN 625 elbow Bellows Ball screw complete 4 ) 5 ) 6 ) Ball screw complete 3 ) 5 ) 6 ) Joint complete Toothed wheel for belt, 14 teeth Toothed wheel for belt, 14 teeth Square plug D.C. geared motor 2 ) double stage, 20.25 : 1 D.C. geared motor 1 ) single stage, 6,25 : 1
1) 2) 3) 4) 5)

Entranement AG 1011
Roulement billes rainur 6002 2RS Vis tte cylindrique M 4 x 16 DIN 912 7 ) Roulement rainur billes 624 DIN 625 Disque 4,3 DIN 433 Joint torique d'tanchite 24,5 x 3 DIN 3770 Rondelle ressort 8,0 x 4,2 x 4 DIN 2093 Courroie dente Roulement rainur billes 62200 DIN 625 Raccord angulaire Soufet accordon Vis complet 4 ) 5 ) 6 ) Vis complet 3 ) 5 ) 6 ) Joint complet Roue dente pour courroie, 14 dents Roue dente pour courroie, 14 dents Bouchon carr Moteur-rducteur courant continu 2 ) deux tages, 20,25 : 1 Moteur-rducteur courant continu 1 ) une tage, 6,25 : 1
1) 2) 3) 4) 5)

Stellgeschwindigkeit 24 mm/sec. Stellgeschwindigkeit 8,9 mm/sec. Stellweg 6 mm Stellweg 25 mm Schmierfett fr Spindel k 2 k DIN 51502 Geklebt mit Loctite Nr. 221 Geklebt mit Loctite Nr. 638

Follow-up speed 24 mmm/sec. Follow-up speed 8.9 mm/sec. Traverse 6 mm Traverse 25 mm For ball screw use grease type k 2 k DIN 51502 or equivalent Sticked with Loctite no. 221 Sticked with Loctite no. 638

Vitesse de raction 24 mm/sec. Vitesse de raction 8,9 mm/sec. Course d'ajustage 6 mm Course d'ajustage 25 mm Graisse pour vis k 2 k DIN 51502 Coll avec Loctite no. 221 Coll avec Loctite no. 638

6) 7)

6) 7)

6) 7)

Technische nderungen vorbehalten

Subject to technical modications without notice

Sous rserve de modications techniques

Connection diagram Z

Web guider with pivoting frame DR 2240/45

Centre line guiding (system 3A) Electronic control panel RK 1602 Version 005 Edge sensor FR 10.. Offset remote control RE 1702

System wiring diagram Circuit diagram

RK 1602-05005ESB sheet 1

Dok.-Nr. SPM-RK_1602-005-E-02.doc 29/03/00 Z

Series 965
User's Manual

96
TOTAL

1/16 DIN Microprocessor-Based Auto-tuning Control

CUSTOMER SATISFACTION
3 Y Warranty ear

ISO 9001
Registered Company
Winona, Minnesota USA

WatlowControls
Watlow Controls, 1241 Bundy Blvd., P.O. Box 5580, Winona, MN 55987-5580, Phone: 507/454-5300, Fax: 507/452-4507

0600-0003-0000 Rev. C July 1998

Supersedes: 0600-0003-0000 Rev. B

$10.00 Made in the U.S.A.

Printed on Recycled Paper

About This Manual Starting Out

How to Use this Manual

We have designed this user's manual to be a helpful guide to your new Series 965. The headlines in the upper right and left corners indicate which tasks are explained on that page.

Notes and Safety Information

NOTE: Details of a "Note" appear here, in the narrow box on the outside of each page. We use notes, cautions and warnings throughout this book to draw your attention to important information. Notes are printed in bold in the margin to alert you to an important detail.

CAUTION: Details of a "Caution" appear here, in the narrow box on the outside of each page. A Caution symbol (an exclamation point in a triangle) appears with information that is important to protect equipment and performance. Read and follow all cautions that apply to your application.

A Warning symbol (a lightning bolt in a diamond) appears with information that is important to protect people and equipment from damage. Pay very close attention to all warnings that apply to your application.

WARNING: Details of a "Warning" appear here, in the narrow box on the outside of each page.

Technical Assistance
If you encounter a problem with your Watlow controller, review all of your configuration information for each step of the setup, to verify that your selections are consistent with your applications. If the problem persists after checking all the steps, call for technical assistance: Watlow Controls at (507) 454-5300, between 7:00 a.m. and 5:30 p.m. Central Standard Time. Ask for an applications engineer. When you call, have the following information ready: the controller's model number ( the 12-digit number is printed on the top of the stickers on each side of the controller's case and on the top or right side of the circuit board); this user's manual; all configuration information; the Diagnostics Menu readings.

Warranty and Returns

For information about the warranty covering the Series 965, see page 37.

Comments and Suggestions

We welcome your comments and opinions about this user's manual and the Series 965. Send them to the Technical Editor, Watlow Controls, 1241 Bundy Blvd., P.O. Box 5580, Winona,MN 55987-5580.Orcall(507)454-5300.Orfaxthemto(507)452-4507. (1459).

WATLOW Series 965 User's Manual

How to Use the Manual

Contents Starting Out

Page Item 31 34 36 37 38 39 40 41 Calibration Procedures Glossary Index Warranty and Returns Specifications Model Number Information Declaration of Conformity Quick Reference

Chapter 1 4 Starting Out With The Watlow Series 965 4 General Description Chapter 2 5 Install And Wire The Series 965 5 Panel Cutout 5 Dimensions 5 Installation Procedure 7 Wiring the Series 965 8 Sensor Installation Guidelines 8 Input Wiring 10 Output 1 Wiring 11 Alarm Wiring 12 System Wiring Example Chapter 3 13 How To Use The Keys And Displays 13 Keys, Displays & LEDs Chapter 4 14 How To Set Up The Series 965 14 Setting the Input Type DIP Switch 15 Entering Setup Menu 16 Setup Parameters 18 Setup Menu Table 19 Operation Parameters 20 Operation Menu Table Chapter 5 21 How To Tune And Operate 21 Auto-tuning 22 Manual Tuning 23 Manual and Automatic Operation 24 Using Alarms 25 Error Code Messages Appendix 1 27 Noise Sources 27 Decreasing Noise Sensitivity 28 Eliminating Noise Appendix 2 29 Entering the Calibration Menu 30 Restoring Factory Calibration 30 Calibration Menu

Figures & Tables Page Figure 4 5 5 6 6 7 7 8 8 9 9 10 10 10 10 11 11 11 12 13 14 15 15 19 21 24 29 30

Item

Series 965 Input & Output Overview 1 Multiple Panel Cutout Dimensions 2 Series 965 Dimensions 3 Mounting, Case Side View & Collar 4 Case, Rear View & NEMA 4X Seal Example 5 High Voltage Power Wiring 6 Low Voltage Power Wiring 7 Thermocouple Sensor Input Wiring 8 0-5V (dc) Process Sensor Input Wiring 9 2- or 3-wire RTD Sensor Input Wiring 10 4-20mA Process Sensor Input Wiring 11 Switched DC Output Wiring 12 5A Mechanical Relay Wiring 13 4-20mA Process Wiring 14 0.5A Solid-state Relay w/o Suppression Wiring 15 Switched DC Output Wiring 16 5A Mechanical Relay Wiring 17 0.5A Solid-state Relay w/o Suppression Wiring 18 System Wiring Example 19 Series 965 Keys and Displays 20 DIP Switch Location & Orientation 21 Entering the Setup Menu 22 The Setup Menu 23 The Operation Menu 24 Auto-tuning at a 200F Set Point 25 Alarm Display Examples 26 Entering the Calibration Menu 27 Calibration Menu 28 Tables

18 Input Ranges 1 18 Setup Menu Prompts/Description 20 Operation Menu Prompts/Description 41 Quick Reference Sheet (Perforated)

2 3

How to Use the Manual

WATLOW Series 965 User's Manual

Starting Out Starting Out

Chapter 1 Starting Out With The Watlow Series 965,

A Microprocessor-Based Control

Single Input Type J, K, T, N or S Thermocouple, RTD or Process

Dual Control OutputPID or on/off, User Selectable Output 1 Heat or Cool Output 2 Heat, Cool, Alarm or None

Figure 1 Series 965 Input and Output Overview Output 1 or 2 Percent Power Auto-tuning for Heat & Cool PID Settings

General Description
Welcome to the Watlow Series 965, a 1/16 DIN microprocessor-based temperature control. The 965 has a single input which accepts type J, K, T, N or S thermocouple, RTD or process input. With dual output, the primary can be heating or cooling while the secondary can be a control output opposite the primary output (heat or cool), alarm or none. Both outputs can be selected as either PID or on/off. PID settings include proportional band, reset/integral, and rate/derivative. Setting the proportional band to zero makes the Series 965 a simple on/off control with switching differential selectable under the HSC parameter. Special 965 features include the NEMA 4X rating, dual four digit displays in either red or green, optional low volt power supply, auto-tuning for both heat and cool outputs, ramp to set point for gradual warm-up of your thermal system, and automatic/manual capability with bumpless transfer. Operator-friendly features include automatic LED indicators to aid in monitoring and setup, as well as a calibration offset at the front panel. The Watlow Series 965 automatically stores all information in a non-volatile memory.

WATLOW Series 965 User's Manual

Getting Started, Chapter 1

Chapter 2 Install and Wire the Series 965

1.77" to 1.79" (44.96mm to 45.47mm)

Installation

Panel Cutout
NOTE: Measurements between panel cutouts are the minimum recommended.
Your Panel Thickness 0.06" to 0.38" (1.5 to 9.7 mm)
1.77" to 1.79" (44.96mm to 45.47mm)

0.38" (9.65mm) Minimum 0.85" (20mm)

Figure 2 Series 965 Multiple Panel Cutout Dimensions

4.7" (119mm)

2.1" (53 mm)

Figure 3 Series 965 Dimensions

4.1" (104mm)

1.76" (45mm)

0.40" (10mm) 1.21" (31mm)

NOTE: For rapid mounting, use Greenlee punch #60020 and die #60021, or hand hydraulic unit, Kit #7306. All available from Grainger.

Installation Procedure
Follow this procedure to mount the Watlow Series 965 temperature control: 1. Make a panel cutout per the dimensions in Figure 2. 2. Remove the 965 chassis from its case. Holding each side of the bezel, press in firmly on the side grips until the tabs release. Pull the chassis out of the case and set aside for later installation. 3. Make sure the rounded side of the external case gasket is facing the panel surface. Check to see that the gasket is not twisted, and is seated within the case bezel flush with the panel. Place the case in the cutout you just made. Make sure the gasket is between the panel cutout and the case bezel. See Figure 4A.
Install and Wire, Chapter 2 WATLOW Series 965 User's Manual

Installation
Figure 4 Mounting, Case Side View & Collar Cross Section

0 to 0.019 space (0 to 0.483 mm)

Panel

Ridges

4A

Bezel Tabs

Mounting Collar External Gasket

4B

Teeth

Mounting Collar Cross Section (notice the offset teeth on each tab)

4. While pressing the front of the case firmly against the panel, slide the mounting collar over the back of the control. The tabs on the collar must line up with the mounting ridges on the case for secure installation. See Figure 4A again. Slide the collar firmly against the back of the panel getting it as tight as possible. Make sure you cannot move the case within the cutout; if you can you do not have a NEMA 4X seal.
NOTE: To guarantee a proper NEMA 4X seal, make sure the gasket between the panel and the rim of the case is not twisted and is seated properly. PRESS FIRMLY.

Now let's make sure we have a tight seal. Use your thumb to lock the tabs into place while pressing the case from side to side. Don't be afraid to apply enough pressure to install the control. The tabs on each side of the collar have teeth which latch into the ridges. See Figure 4B. Each tooth is staggered at a different height, so only one of the tabs on each side are ever locked into the ridges at any time. Looking at Figure 5, you see that the tabs on one side of the collar correspond with those on the opposite side. Make sure that the two corresponding tabs are the only ones locked in the ridges at the same time. If the matching tabs are not holding the case at the same time you will not have a NEMA 4X seal. You can make a visual check, or use your finger nail to pull out on each tab. Only one on each side is engaged, and they must be corresponding as in Figure 5. The space between the bezel and panel must be between 0 and 0.019" (0.48 mm).
Make sure that the two corresponding tabs below are locked in the ridges at the same time.

Figure 5 Case Rear View and NEMA 4X Seal Example

NEMA 4X Seal Example.

When removing the mounting collar, we suggest sliding a thin tool such as a putty knife or screwdriver under all three tabs on each side at once and pulling it back off the case. 5. Insert the control chassis into its case and press the bezel to seat it. Make sure the inside gasket is also seated properly and not twisted. The hardware installation is complete. Proceed to the wiring section from here.

WATLOW Series 965 User's Manual

Install and Wire, Chapter 2

How to Wire the Series 965

The Series 965 wiring is illustrated by model number option. Check the unit sticker on the control and compare your model number to those shown here and also the model number breakdown in the Appendix of this manual. All outputs are referenced to a de-energized state. The final wiring figure is a typical system example. When you apply power without sensor inputs on the terminal strip, the Series 965 displays [----] in the upper display, and a [```0] in the lower display, except for 0-5V (dc) or 4-20mA process input units. Press the A/M key twice, and [ER`7] is displayed for one second. This error indicates an open sensor or A/D error. Remove power to the control and connect the sensor properly, see pages 8 and 9. All wiring and fusing must conform to the National Electric Code and to any locally applicable codes as well.

Power Wiring

WARNING: To avoid potential electric shock, use National Electric Code (NEC) safety practices when wiring and connecting this unit to a power source and to electrical sensors or peripheral devices.

High Voltage
Model # 965A - 3 0 - 00 .
100 to 240 V (ac), nominal (85 to 264 actual)

NOTE: Taking the unit out of the case is not a normal operating condition and should only be done by a qualified maintenance installation technician. Power to the case should be disconnected before removing or installing the controller into its case.

Figure 6 High Voltage Power Wiring

Low Voltage
Model # 965A - 3 1 - 00 .
Figure 7 Low Voltage Power Wiring

12-24V (ac/dc)

WARNING: If high voltage is applied to the low voltage unit, irreversible damage will occur.

Install and Wire, Chapter 2

WATLOW Series 965 User's Manual

Input Wiring

Sensor Installation Guidelines

We suggest you mount the sensor at a location in your process or system where it reads an average temperature. Put the sensor as near as possible to the material or space you want to control. Air flow past this sensor should be moderate. The sensor should be thermally insulated from the sensor mounting. See Chapter 4 for more information on DIP switch location and orientation.

Thermocouple Input
NOTE: When an external device with a nonisolated circuit common is connected to the 420mA or dc output, you must use an isolated or ungrounded thermocouple.

Extension wire for thermocouples must be of the same alloy as the thermocouple itself to limit errors.

DIP Switch Orientation

+ 3

Figure 8 Thermocouple Sensor Input Wiring

T/C 5

CAUTION: Process input does not have sensor break protection. Outputs can remain full on.

0-5V (dc) Process Input

DIP Switch Orientation

Figure 9 0-5V (dc) Process Sensor Input Wiring

Vdc
5

Input impedance: 10K

WATLOW Series 965 User's Manual

Install and Wire, Chapter 2

Input Wiring
RTD, 2- or 3-wire
There could be a + 2F input error for every 1 of lead length resistance when using a 2-wire RTD. That resistance, when added to the RTD element resistance, will result in erroneous input to the instrument. To overcome this problem, use a 3-wire RTD sensor, which compensates for lead length resistance. When extension wire is used for a 3-wire RTD, all wires must have the same electrical resistance (i.e. same gauge, copper stranded, same length).

DIP Switch Orientation

S1 S2 3-wire RTD

2 3 2-wire RTD Jumper Terminals 3 and 5.

S1 S2

2 3

Figure 10 2- or 3-wire RTD Sensor Input Wiring

S3

S3

4 - 20mA Process Input

DIP Switch Orientation

CAUTION: Process input does not have sensor break protection. Outputs can remain full on.

I dc

Figure 11 4-20mA Process Sensor Input Wiring

+ 5

Input impedance: 5

Install and Wire, Chapter 2

WATLOW Series 965 User's Manual

Output 1 Wiring
Figure 12 Switched dc Output Wiring

Switched DC Output Model # 965A - 3 C

- 00

V+ unregulated

9
V

10

Internal Circuitry

NOTE: When an external device with a nonisolated circuit common is connected to the 4-20mA or Switched dc output, you must use an isolated or ungrounded thermocouple. Figure 13 5 Amp Mechanical Relay Wiring

9 10

+ External Load

Mechanical Relay Without Contact Suppression, Form C, 5 Amp Model # 965A - 3 D - 00 .

8 9

NC Fuse COM L1

NOTE: Switching inductive loads (relay coils, solenoids, etc.) with the mechanical relay, switched dc or solid-state relay output options requires using an R.C. suppressor. Watlow carries the R.C suppressor Quencharc brand name, which is a trademark of ITW Pakron. Watlow Part No. 0804-0147-0000. Figure 14 4-20mA Process Wiring

1 0 NO External Load L2

Customer Supplied Quencharc

Process, 4-20mA Model # 965A - 3 F - 00 .

Maximum load resistance: 800

9 10 + External Load

Solid-state Relay Without Contact Suppression, 0.5 Amp Model # 965A - 3 K

Figure 15 0.5 Amp Solid-state Relay Without Contact Suppression Wiring

- 00

.
Custommer Supplied Quencharc

L2

External Load 8 SS1 Fuse 1 0 SS1 L1

10

WATLOW Series 965 User's Manual

Install and Wire, Chapter 2

Output 2 Wiring
Switched DC Output Model # 965A - 3 C - 00
6 7

.
+ External Load

NOTE: For more information on alarms see page 24.

V+ unregulated

Figure 16 Switched dc Output Wiring

6
V

Internal Circuitry

Mechanical Relay Without Contact Suppression, Form C, 5 Amp Model # 965A - 3 D - 00 .

Fuse 1 NC 6 7 COM NO External Load L2 L1

Figure 17 5 Amp Mechanical Relay Wiring

Customer Supplied Quencharc

Solid-state Relay Without Contact Suppression, 0.5 Amp Model # 965A - 3 K - 00 .

NOTE: Switching inductive loads (relay coils, solenoids, etc.) with the mechanical relay, switched dc or solid-state relay output options requires using an RC suppressor. Watlow carries the RC suppressor Quencharc brand name, which is a trademark of ITW Pakron. Watlow Part No. 0804-0147-0000.

1 SS2 Fuse

L1

NOTE: Output is in open State in Alarm Condition.

SS2 External Load L2

Customer Supplied Custommer Supplied Quencharc Quencharc

Figure 18 0.5 Amp Solid-state Relay Without Contact Suppression Wiring

Install and Wire, Chapter 2

WATLOW Series 965 User's Manual

11

Wiring Example

Figure 19 System Wiring Example

WARNING:

All wiring and fusing must conform to the National Electric Code NFPA70. Contact your local board for additional information. Failure to observe NEC safety guidelines could result in injury to personnel or damage to property.

CAUTION:

Watlow mercury relay loads must have a unity power factor. For RESISTIVE LOADS ONLY.

L1 120V (VAC) L2 Earth Ground High Limit Mechanical Controller High Temperature Light Coil Fuse 11 12 SSR-240-10A-DC1 dc Input SSR

Out 1 4 In 2 3

92A3-1DJ1-0000 Limit Control

3 (+) 9 + 5 (-) Red 965A-3CA0-0000 Rear View Process Sensor 10 -

Heater
13 10 + 11 14

Limit Sensor

Optional Normally Open Momentary Switch

120V (VAC) L1

L2

11 1 3 4 (+) 5 (-) 3 5 Series 965 965A-3CA0-0000 Temperature control

12 2

965A-3CA0-0000 1 2 3 4 5 6 7 8 9 10 11 12 Not Used S1, IS2, TC+, V+ Not Used S3, TC-, V-, I+ Not Used Not Used Not Used DC +1 DC -1 L1 L2

9
4

10 7 3-32V (dc) In SSR-240-10A-DC1 DC Input Solid-state Relay Heater 2

(+) 1 CR-1
5

(-)

Out 24-240V (ac)

10

6 7 8 9 10 11 12 13

11 12 13 (+) (-) 14 15

1 13 14 10 11 4

2 Series 92 92A3-1DJ1-0000 Limit Control

3 5

16 1CR 18 R High Temperature Light

2 2

17

12

WATLOW Series 965 User's Manual

Install and Wire, Chapter 2

Keys/Displays

Chapter 3 How to Use the Keys and Displays

After one minute with no key activations, the control reverts to the process value in the upper display and the set point in the lower display.
Figure 20 Series 965 Keys and Displays

Upper Display Red or green, 0.3" (8 mm) high, seven segment, four digit LED display, indicating either process, actual temperature, the operating parameter values or an open sensor. When powering up, the Process display will be blank for five seconds. This display can be blank by setting [`dSP] to [`SEt]. See page 18.

L1 When lit, this LED tells you when Output 1 is energized.

L2 When lit, this LED tells you when Output 2 is active. This output can be configured as a control or alarm output.

Lower Display Red or green, 0.3" (8 mm) high, seven-segment, fourdigit LED display, indicating the set point, output value, parameters for data in the upper display, or error and alarm codes. This display can be blank by setting [`dSP] to [`Pro]. See page 18.

MN Lit when the control is in Manual operation. Press the A/M key twice to enter Automatic operation. When blinking, this indicates that pressing the A/M key toggles between Auto and Manual. After five seconds without pressing the A/M key, the LED stops blinking, and returns to its previous state.

Mode Key Steps the control through the Operating Menu; also, in the Auto mode, new data is self entering in five seconds.

Up-arrow Key Increases the value of the displayed parameter. A light touch increases the value by one. Holding the key down increases the value at a rapid rate. New data is self entering in five seconds.

Down-arrow Key Decreases the value of the displayed parameter. A light touch decreases the value by one. Holding the key down decreases the displayed value at a rapid rate. New data is self entering in five seconds.

Up-arrow/Down-arrow Keys When pressed simultaneously for three seconds, the Setup Menu appears displaying the [`LOC] parameter. Continue to press the Up-arrow/Down-arrow keys, and the Calibration Menu appears.
Keys & Displays, Chapter 3

A/M Key Pressed once, it clears any latched alarms and toggles between Auto and Manual mode. If pressed again within five seconds it will change from Auto to Manual or vice versa. While in Manual mode, percent power is in the lower display.

WATLOW Series 965 User's Manual

13

Setup

Chapter 4 How To Set Up The Series 965

Setting up the Series 965 is a simple process. First set the DIP switches to match your input type. Refer to the orientation below and Page 16 for the In parameter. Next, configure the 965's features to your application in the Setup Menu, then enter values in the Operating Menu. Both tasks use the MODE key to move through the menus and the Up-arrow/Down-arrow keys to select data. Before entering information in the Setup menu, set the dFL parameter. If selected as US: F, proportion band in degrees, reset rate are the defaults. If selected as SI: C, proportional band in % of span, derivative and integral are the defaults. Changing the dFL prompt will set parameters to their factory default. Document all current parameter settings first. See Appendix 2 in the calibration section to change this parameter.

WARNING: Remove power from the control before removing the chassis from the case or changing the DIP switches.

How to Set the Input Type DIP Switch

The Series 965 input type can be user selectable at any time via a Dual In-line Package (DIP) switch inside the control, located on the left (viewed from the bottom). To set the DIP switch, remove the control chassis from the case. Holding each side of the bezel, press in firmly on the side grips until the tabs release. You may need to rock the bezel back and forth several times to release the chassis. The locations of the board and switches appear in Figure 21. Refer to the input types below for DIP switch orientation. DIP switch selection must match the sensor selected under the In parameter in the Setup Menu. Set the software selection for the input type to match. See Page 16.

Figure 21 DIP Switch Location and Orientation

Control Chassis Bottom View

Input Types
Thermocouple RTD Process

14

WATLOW Series 965 User's Manual

Setup, Chapter 4

Setup
Entering the Setup Menu
The Setup Menu displays the parameters that configure the Series 965's features to your application. Enter the Setup Menu by pressing the Up-arrow and Down-arrow keys simultaneously for 3 seconds. The lower display shows the LOC parameter, and the upper display shows its current level. All keys are inactive until you release both keys. You can reach the LOC parameter from anywhere.

Figure 22 Entering the Setup Menu

You will not see all parameters in this menu, depending on the unit's configuration and model number. After stepping through the menu it returns to the control set point parameter under the Operation Menu.

Mode Key

= Parameter may or may not appear depending on your control configuration.

NOTE: While in the Setup Menu, all outputs are off.

LOC In dEC C_F rL rH Ot 1 HSC Ot2

( ( ( ( ( ( ( ( (

) ) ) ) ) ) ) ) )

User lock out Input type Decimal place Celcius__Fahrenheit Range low Range high Output 1 Control hysteresis Output 2

HSA LAt SIL rtd rP rt PL dSP 75

( ( ( ( ( ( ( (

) ) ) ) ) ) ) )

Output 2 alarm hysteresis Output 2 hysteresis Latching for alarm Silence alarm RTD calibration curve Ramp function Ramp rate % Power limiting Display
Control Set Point Figure 23 The Setup Menu

Setup, Chapter 4

WATLOW Series 965 User's Manual

15

Setup
Setup Parameters
When you are at the top of the menu, the Series 965 displays the user level of operation in the upper display, and the LOC parameter in the lower display. Press the MODE key and the value of the next parameter appears in the upper display, and the parameter appears in the lower display. LOC Lock: Selects the level of operator lock-out as defined below. Range: 0 - 4 Default: 0 LOC 0: All operating parameters may be viewed or changed. Manual operation is permitted. When in manual operation, percent power is adjustable. Bumpless transfer to manual mode can occur on sensor break. LOC 1: The set point, actual, and alarm settings are the only visible parameters, set point is adjustable in this level. Manual operation and auto-tune are permitted. When in manual operation, percent power is adjustable. Bumpless transfer to manual mode can occur on sensor break. LOC 2: The set point, actual, and alarm settings are the only visible parameters, set point is adjustable in this level. Manual operation is permitted. When in manual operation, percent power is adjustable. Bumpless transfer to manual mode can occur on sensor break. LOC 3: The set point and actual are the only visible parameters, set point is adjustable in this level. Manual operation is not permitted. Bumpless transfer is defeated and outputs are disabled on sensor break. LOC 4: The set point and actual are the only visible parameters, set point is not adjustable in this level of lock-out. Manual operation is not permitted. Bumpless transfer is defeated and outputs are disabled on sensor break. In Input: Selects the sensor input type. The internal DIP switch must also match the In parameter. See Figure 21 on Page 14 for DIP switch orientation, and see Table 1 on Page 18 for input type temperature ranges. Range: J, K (appears as H), t, n, S, rtd, rt.d, 0-5, 420 Default: J Decimal: Selects the location of the decimal point for all process related data. This parameter only appears if the In parameter is 0-5 or 420. Make sure the internal DIP switch matches the In parameter. Range: 0, 0.0, 0.00 Default: 0 Celsius _ Fahrenheit: Selects the units of temperature measurement for the control. This parameter only appears if the In parameter is a thermocouple or RTD input. The default is dependent on the dFL parameter located in the Calibration menu. Refer to the Appendix. Range: C or F If dFL = US: Default: F If dFL = SI: Default: C Range Low: Selects the low limit of the set point. Also used to set the low end of the process input. 0.0V (VDC) and 4mA represent Range Low (rL) for process input. The process input is linearly scaled between rL and rH. See the model number and specification in the Appendix for range values, or refer to Table 1 on Page 18. Range: Sensor range low to rH Default: Low limit of sensor type/-500 for process input
Setup, Chapter 4

NOTE: Set the LOC parameter value as the final step in programming the Series 965 controller to prevent locking yourself out of the Operations and Setup Menu during initial programming.

NOTE: Process input does not have sensor break protection or bumpless transfer.

dEC

C_F

rL

16

WATLOW Series 965 User's Manual

Setup
Range High: Selects the high limit of the operating range. Also used to set the high end of the process input. 5.0V (dc) and 20mA represent Range High (rH) for process input. The process input is linearly scaled between rL and rH. See the model number and specification information in the Appendix for your range values, or refer to Table 1 on Page 18. Range: Sensor range high to rL Default: High limit of sensor type/9999 for process input Output 1: Selects the action for the primary output. Action in response to the difference between set point and process variable. Select ht (heat) for reverse acting or select CL (cool) for direct acting. Range: ht, CL Default: ht Hysteresis-Control: Selects the switching hysteresis for Output 1 and 2 when you select 0 (ON/OFF) under the Pb1 parameter and Ot2 = Con. Range: 1 to 99, 0.1 to 9.9, 0.01 to 0.99/1 to 55, 0.1 to 5.5, 0.01 to 0.55 Default: 3, 0.3, 0.03F/2, 0.2, 0.02 Output 2: Selects the output action for the secondary output. Range: Con Control mode opposite Output 1 (heat or cool) Default: Con PrA Process alarm with alarm message displayed Pr Process alarm with no alarm message displayed dEA Deviation alarm with alarm message displayed dE Deviation alarm with no alarm message displayed no None Hysteresis - Alarm: Selects the switching hysteresis for Output 2 when Ot2 is an alarm. This parameter only appears if Ot2 Con or no. See Page 19 for the Pb1 parameter. Range: 1 to 9999, 0.1 to 999.9, 0.01 to 99.99/1 to 5555, 0.1 to 555.5, 0.01 to 55.5 Default: 3, 0.3, 0.03/2, 0.2, 0.02 Latching: Selects whether the alarm is latching or non-latching. Latching alarms must be cleared before the alarm output will reset. Non-latching automatically resets the alarm output when the condition clears. This parameter will not appear if Ot2 = Con or no. Range: LAt or nLA Default: nLA Silencing: Selects alarm silencing (inhibit) for the alarm. This parameter appears only when Ot2 = dEA or dE. For more information see Chapter 5, "Using Alarms." Range: On or OFF Default: OFF RTD: Selects the RTD calibration curve for RTD inputs. This parameter will not appear unless In = rtd or rt.d. JIS = 0.003916/C, DIN = 0.003850/C. Range: din or JIS Default: din Ramping: Choose Str, and the set point ramps at the selected rate in /hr from process (actual) temperature to set point, when power is applied to the control (start up). It will not ramp with a set point change. On is the same as Str plus it ramps with a set point change. It ramps from the previous set point to a new one at the selected ramp rate. OFF is for no ramping action. When ramping, the lower display alternately flashes rP. The set point displayed is the desired end set point. The ramping setpoint is not shown. Entering the Setup menu or manual operation disables the outputs and ramp. Once you exit either one, the 965 controls to the last entered set point. Range: Str, On, OFF Default: OFF Rate: Selects the ramping rate in degrees per hour. This parameter will not appear if rP = OFF. Range: 0 to 9999 Default: 100/hr rH

Ot1

HSC

Ot2

HSA

LAt

SIL

rtd

rP

rt

Setup, Chapter 4

WATLOW Series 965 User's Manual

17

Setup
PL Power Limiting: The power limiting function in % power for heat. Range: Dependent on output type. -100 to100 Default: 100 Display: Selects which displays are active or viewable. Five seconds after selected, the appropriate display goes blank. Press MODE, Up-arrow or Down-arrow to override this feature and cause the current value to be displayed for 5 seconds. Range: nor Normal displays Default: nor SEt Set Point - Lower display only Pro Process - Upper display only
Input Type J K (appears as H) t n S rtd (1) rt.d (0.1) 4-20mA 0-5V (dc) Sensor Range Low 32F/0C -328F/-200C -328F/-200C 32F/0C 32F/0C -328F/-200C -199.9/199.9 4mA/-999 units 0V (dc)/-999 units Sensor Range High 1382F/750C 2282F/1250C 662F/350C 2282F/1250C 2642F/1450C 1292F/700C 999.9/700.0 20mA/9999 units 5V (dc)/9999 units

dSP

Table 1 Input Ranges.

Table 2 Setup Menu Prompts and Descriptions.

Setup Menu
Value Do not enter any values here; make photocopies instead. Range Factory Default Appears If:
0-4 J, K (appears as H), t, n, S, rtd, rt.d, 0-5, 420 0, 0.0, 0.00 C or F rL to rH rH to rL ht or CL 1 - 99, 0.1 - 9.9, 0.01 - 0.99 1 to 55, 0.1 to 5.5, 0.01 to 0.55 Con = Control PrA = Process Alarm Pr = Process with no alarm message dEA = Deviation alarm dE = Deviation with no alarm message no = None 1 - 9999, 0.1 - 999.9, 0.01 - 99.99 1 - 5555, 0.1 - 555.5, 0.01 - 55.55 LAt or nLA On or OFF JIS or din Str = Ramping on power up on = Ramping to set point at all times OFF = None 0 to 9999 0 to 100 nor = normal SEt = Set Point (lower only) Pro = Process (upper only) 0 J 0 Dependent on dFL. Input dependent. Input dependent. ht 3, 0.3, 0.03 3, 0.3, 0.03/2, 0.2, 0.02 Con DIP switch selectable. In = 0-5 or 420 In = J,K,t,n,S,rtd,rt.d

Parameter
LOC In dEC C_F rL rH Ot1 HSC Ot2

HSA LAt SIL rtd rP

3, 0.3, 0.03F 2, 0.2, 0.02C nLA OFF din OFF

Ot2 Con or no Ot2 Con or no Ot2 = dEA or dE In = rtd or rt.d

rt PL dSP

100/hr 100 nor

rP OFF

18

WATLOW Series 965 User's Manual

Setup, Chapter 4

Operation
= Prompt appears or not according to control configuration.
M

NOTE:
The upper display will always return to the process value after 1 minute without key strokes.

75 Pb1 ( )

Control Set Point rE2/It2 ( )

Reset 1/Integral 1 Rate 2/Deviative 2 Cycle time 2 Alarm low Alarm high Calibration offset Auto-tune

Proportional band 1 Reset 1/Integral Rate 1/Deviative 1 Cycle time 1 Proportional band 2

rA2/dE2 ( ) Ct2 ALO AHI CAL AUt ( ) ( ) ( ) ( ) ( )

rE1/It1 ( ) rA1/dE1 ( ) Ct1 Pb2 ( ) ( )

Figure 24 The Operation Menu.

Operation Parameters
Set Point: Sets the operating set point for Output 1. Represents the process value the system tries to achieve for Output 1. "SP" does not appear, the control set point value will. The lower display may be blank if dSP = Pro. If in a ramping mode, the lower display alternately flashes the desired end set point and rP. Proportional Band 1 & 2 : A proportional band expressed in degrees or % of span, within which a proportioning function is active for Output 1 or 2. When Pb1 = 0, the unit functions as an on/off control on Output 1 and 2. Pb2 will not appear if Pb1 = 0 or Ot2 Con. The switching differential is determined by the HSC parameter. If dFL = US: Range Pb1: 0 to 999F/0 to 555C/0 to 999 Units; 0.0 to 9.9F/ 0.0 to 5.5C/0.0 to 9.9 units, Pb2: The same as Pb1 except lower limit is 1. Defaults: Pb1 = 25F/2.5F Pb2 = 25 If dFL = SI: Range: 0 to 999.9% of span Defaults: Pb1 = 3.0% Pb2 = 3.0% Reset /Integral 1 & 2: An integral control action for Output 1 or 2 that automatically eliminates offset, or "droop," between set point and actual process temperature. rE1/It1: Will not appear if Pb1 = 0. rE2/It2: Appears if Pb1 0 and Ot2 = Con. Either reset (rE) or integral (It) will appear depending on how the dFL parameter is set in the Calibration menu. See Appendix II. If dFL = US: Range: 0 to 9.99 repeats/minute Default: 0.00 If dFL = SI: Range: 00.1 to 9.99 minutes per repeat Default: 0.00 Rate /Derivative 1 & 2 : The rate (derivative) function for Output 1 or Output 2. Eliminate over shoot on start up, or after the set point changes. rA1/dE1: Will not appear if Pb1 = 0. rA2/dE2: Appears if Pb1 0 and Ot2 = Con. Either rate (rA) or derivative (dE) appears depending on how dFL is set in the Calibration menu. If dFL = US or SI: Range: 0 to 9.99 minutes Default: 0.00 Cycle Time 1 & 2: Time for a controller to complete one time proportioned cycle for Output 1 or Output 2; expressed in seconds. Ct1: Will not appear if Pb1 = 0, or Output 1 is 4-20mA. Ct2: Will not appear if Pb1 = 0 or Ot2 Con. If a mechanical relay or contactor is switching power to the load, a longer cycle time may be desirable to minimize wear on the mechanical components. Typical life of a mechanical relay is 100,000 cycles. Range: 0.1 to 999.9 Default: 5.0
Setup, Chapter 4

[SP ]

Pb1 Pb2

rE1/It1 rE2/It2

rA1/dE1 rA2/dE2

Ct1 Ct2

WATLOW Series 965 User's Manual

19

Operation
ALO Alarm Low: Represents the low process alarm or low deviation alarm. This parameter will not appear if Ot 2 = no or Con. If Ot2 = dEA or dE: Range: -999 to 0 Default: -999 If Ot2 = PrA or Pr: Range: rL to AHI Default: rL Alarm High: Represents the high process alarm or high deviation alarm. This parameter will not appear if Ot2 = no or Con. If Ot2 = dEA or dE: Range: 0 to 999 Default: 999 If Ot2 = PrA or Pr: Range: ALO to rH Default: rH Calibration Offset: Adds or subtracts degrees from the input signal. Range: -180F to 180F/-100C to 100C/-180 units to 180 units; or -18.0F to 18.0F/-10.0C to 10.0C Default: 0 Auto-Tune: Initiates auto-tune. Range: 0 = off, 1 = slow, 2 = medium, 3 = fast

AHI

CAL

AUt

Default: 0

Table 3 Operation Menu Prompts and Descriptions.

Operation Menu
Use this page as a master copy for your Series 965 Operation Parameters. Do not enter any values here; make photocopies instead. Value Range
If dFL = US: 0 - 999F/0 - 555C/0 - 999 Units 0 - 99.9F/0 - 55.5C/0 - 99.9 Units 0=ON/OFF control. HSC =switch diff. If dFL = SI: 0.0 to 999.9% of span 0.00 to 9.99 repeats/minute 0.00 = No Reset. Won't appear if Pb1 = 0 or dFL = SI. 0.0 - 99.9 minutes/rpt. 0.00 = No Integral. Won't appear if Pb1 = 0 or dFL = US. 0.00 to 9.99 minutes 0.00 = No Rate. Will not appear if Pb1 = 0 or dFL = SI. 0.00 - 9.99 minutes. 0.00 = No Derivative. Won't appear if Pb 1 = 0 or dFL = US. 0.1 to 999.9 Won't appear if Pb1 = 0, or 4-20mA. Same as Pb1. Pb2 lower limit = 1, 0.1, 0.01 Same range as rE1. Same range as It1. Same range as rA1. Same range as dE1. Same range as Ct1. -999 to 0 rL to AHI Will not appear if Ot2 = no or Con. 0 to 999 ALO to rH Will not appear if Ot2 = no or Con. 18F/10C/18 Units 0-3

Operation Parameters
Pb1

Factory Default
25F 2.5F

rE1

3% 0.00 repeats/minute

It1 rA1

00.0 minutes/repeat 0.00 minutes

dE1 Ct1 Pb2 rE2 It2 rA2 dE2 Ct2 ALO - Deviation dE Process Pr AHI Deviation dE Process Pr

0.00 minutes 5.0 seconds

-999 rL 999 rH 0 0
Setup, Chapter 4

CAL AUt

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WATLOW Series 965 User's Manual

Tuning

Chapter 5 How to Tune and Operate

Auto-tuning (Heat and/or Cool)
The Series 965 can automatically tune the PID parameters to fit the characteristics of your particular thermal system. The auto-tuning procedure operates on a thermal response value slow, medium, or fast. Use the slow thermal response when your process does not need to reach set point too rapidly, or if it usually does not often exceed set point. A fast thermal response produces a rapid temperature change over a short period of time. Once the auto-tune sequence has begun, the Output 1 heat proportional band is set to 0 and the control goes into an on/off mode of control at 90% of the established set point. The displayed set point remains unchanged. Once the control finishes "learning" the system, it returns to a standard PID control with the PID values automatically set as a result of auto-tuning. See Manual Tuning on the next page to set the cool PID parameters. Any change of the set point, while in auto-tune, re-initiates the auto-tune procedure.
NOTE: Set the HSC parameter under the Setup Menu to 3F/2C before auto-tuning your control.

Auto-tuning at a Set Point of 200F

Auto-tune Begins 200 180

Auto-tune Complete Set Point

Figure 25 Auto-tuning at a Set Point of 200F.

Process 90% of Set Point

Temp

100

Time

In order for the 965 to successfully complete auto-tune, the process must cross 90% of set point four times within 80 minutes after auto-tune has started. If this does not happen within the 80 minute time limit, the Pb remains at 0 and the control functions in an on/off mode.

Tuning and Operating, Chapter 5

WATLOW Series 965 User's Manual

21

Tuning
To start auto-tuning: 1. Press the MODE key until the AUt prompt appears in the data display. 2. Select a thermal response value, 1=slow, 2=medium, and 3=fast, using the Up-arrow/Down-arrow keys. A thermal response value of 2 satisfactorily tunes most thermal systems. Press the MODE key. While the control is in the tuning mode, the lower display alternately displays the normal information and the prompt At. The time between alternations is 1 second. When tuning is complete, the displays return to their previous state and AUt reverts to 0. The 965 installs appropriate PID tuning parameters and saves them in the non-volatile memory. If a mechanical relay or contactor is switching power to the load, a longer cycle time may be desirable to minimize wear on the mechanical components. Typical life of a mechanical relay is 100,000 cycles.

3.

4.

To abort auto-tuning either reset the AUt parameter to 0, press the A/M key twice, or cycle power off and on. In all cases, aborting auto-tune restores all values to those previous to auto-tuning.

Manual Tuning
For optimum control performance, tune the Series 965 to your thermal system. The tuning settings here are for a broad spectrum of applications; your system may have somewhat different requirements. NOTE: This is a slow procedure, taking from minutes to hours to obtain optimum value.
NOTE: Tune heating outputs at a set point above ambient temperature. Tune cooling outputs at a set point below ambient temperature.

1. Apply power to the Series 965 and enter a set point. Begin with these Operation parameters: Pb = 1, rE/It = 0.00, rA/dE = 0.00, Ct = 5.0, CAL = 0, AUt= 0. 2. Proportional Band Adjustment: Gradually increase Pb until the upper display temperature stabilizes to a constant value. The process temperature will not be right on set point because the initial reset value is 0.00 repeats per minute. (When Pb = 0; rE/It and rA/dE1 are inoperative, and the 965 functions as a simple ON/OFF control.) The HSC parameter determines the switching differential value. 3. Reset/Integral Adjustment: Gradually increase rE, or decrease It until the upper display temperature begins to oscillate or "hunt." Then slowly decrease rE or increase It until the upper display stabilizes again near set point. 4. Cycle Time Adjustment: Set Ct as required. Faster cycle times sometimes achieve the best system control. However, if a mechanical contactor or solenoid is switching power to the load, a longer cycle time may be desirable

22

WATLOW Series 965 User's Manual

Tuning and Operating, Chapter 5

Tuning/Operation
to minimize wear on the mechanical components. Experiment until the cycle time is consistent with the quality of control you want. Ct will not appear on units with a process output. 5. Rate/Derivative Adjustment: Increase rA/dE to 1.00 minute. Then raise set point by 20 to 30F, or 11 to 17C. Observe the system's approach to set point. If the load temperature overshoots set point, increase rA/dE to 2.00 minutes. Raise set point by 20 to 30F, or 11 to 17C and watch the approach to the new set point. If you increase rA/dE1 too much, approach to set point is very sluggish. Repeat as necessary until the system rises to the new set point without overshooting or approaching the set point too slowly. 6. Calibration Offset Adjustment: You may want your system to control to a temperature other than the value coming from the input sensor. If so, measure the difference between that temperature (perhaps at another point in the system) and the process value showing in the upper display. Then enter the CAL offset value you want. Calibration offset adds or subtracts degrees from the value of the input signal.

Manual and Automatic Operation

To change from auto to manual operation, press the A/M key twice. Manual operation provides open loop control of the outputs from a range of -100% (full cooling) to 100% (full heating) power. The 965 allows a negative output value only with a Cl (Cool) selection on either Ot1 or Ot2 = Con. Automatic operation provides closed loop on/off or PID control. When the operator transfers from a closed loop to an open loop, the 965 retains the power level from the closed loop control, referred to as bumpless transfer. When the 965 returns to closed loop control, it restores the previous set point temperature. The MN LED indicates auto or manual operation. When the LED is on, the control is in manual operation. When the LED is off, it is in automatic operation. When the LED flashes, press the key again within five seconds to complete the change in operation. When a sensor opens, the 965 switches from automatic to manual operation if LOC = 0, 1 or 2. If LOC = 0, 1 or 2 and the bumpless transfer conditions are met, process has stabilized at a 5% power level for a 2 minute period prior to sensor break provided the power level is less than 75%. The 965 switches to manual operation at the last automatic power level. If LOC = 3 or 4, the 965 switches into manual operation at 0% power (outputs disabled). When transferring from auto to manual operation, the control output(s) remains stable ("bumpless," smooth transition). When transferring from manual to automatic operation, the control output(s) may change significantly. In manual operation, the output value appears in the lower display; in automatic operation, the set point appears.
Tuning and Operating, Chapter 5 WATLOW Series 965 User's Manual

NOTE: Process input does not have sensor break protection or bumpless transfer. Outputs selected as Ht (reverse acting) will be full on if sensor break occurs.

23

Auto/Man-Alarms
Using Alarms
The Series 965 has two alarm types, Process or Deviation. A process alarm sets an absolute temperature. When the process exceeds that absolute temperature limit an alarm occurs. The process alarm set points may be independently set high and low. Under the Setup Menu, select the type of alarm output with the Ot2 parameter. PrA = Process Alarm Pr = Process alarm with no alarm message displayed A Deviation alarm alerts the operator when the process strays too far from set point. The operator can enter independent high and low alarm settings. The reference for the deviation alarm is the set point. Any change in set point causes a corresponding shift in the deviation alarm. dEA = Deviation Alarm dE = Deviation alarm with no alarm message displayed Example: If your set point is 100F/38C, and a deviation alarm is set at +7F/ 4C as the high limit, and -5F/3C as the low limit, the high alarm trips at 107F/ 41.6C, and the low alarm at 95F/35C. If you change the set point to 130F/ 54.4C, the alarms follow the set point and trip at 137F/59C and 125F/51.6C. Under the Setup Menu, select the type of alarm output with the Ot2 parameter. dEA = Deviation Alarm dE = Deviation alarm with no alarm message displayed Both process and deviation alarms can be latching or non-latching. When the alarm condition is removed a non-latching alarm automatically clears the alarm output. You must manually clear a latching alarm before it will disappear. Flashing "LO" or "HI" in the lower display indicates an alarm when Ot2 = PrA or dEA. The lower display alternately shows information from the current parameter and the "LO" or "HI" alarm message at one second intervals. The alarm output is de-energized and the L2 LED is lit. To clear an alarm First correct the alarm condition, then If the alarm is latching Clear it manually; press the A/M key once as soon as the process temperature is inside the HSA parameter alarm limit. If the alarm is non-latching The alarm clears itself automatically as soon as the process temperature is inside the HSA parameter alarm limit.

NOTE: When the alarm output is deenergized, the NO contact is open in the alarm condition.

Figure 26 Alarm Display Examples

Press once Clear a latched and corrected alarm.

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WATLOW Series 965 User's Manual

Tuning and Operating, Chapter 5

Error Codes
Alarm Silencing is available with the deviation alarm. When SIL is selected as "on," the operator must manually disable the alarm by pressing the A/M key once on initial power up (in either the latching or non-latching mode). Alarm silencing disables the alarm output relay. However, the L2 LED (also the lower display when Ot2 = dEA) shows an alarm condition until the process value is within the "safe" region of the deviation alarm band. Once the process value crosses into the "safe" region, both a latching or a non-latching alarm is ready. Any future deviation outside this safe band triggers an alarm.

Error Code Messages

Four dashes, "- - - -", in the upper display indicate a Series 965 error. The error code is visible in the lower display.

NOTE:
An alarm display will be masked by an error condition or when the control is in the Calibration or Setup Menus.

Er 2 - Sensor underrange error (only applies to RTD units)

The sensor input generated a value lower than the allowable signal range, or the A/D circuitry malfunctioned. Enter a valid input. Make sure the In parameter (selected in the Setup menu) and the DIP switch settings both match your sensor. Refer to the table below for the appropriate input type and range.

CAUTION: Electrical noise or a noise event, vibration or excess environmental moisture or temperature may cause Series 965 errors to occur. If the cause of an error is not otherwise apparent, check for these.

Er 4 - Configuration error
The unit's microprocessor is faulty; call the factory.

Er 5 - Non volatile checksum error

The nonvolatile memory checksum discovered a checksum error. Unless a momentary power interruption occurred while the unit was storing data, the nonvolatile memory is bad. Call the factory.

Er 6 - A/D underflow error

The A/D circuit is underrange. An open or reversed polarity sensor is the most likely cause. Check the sensor; if the connection is good and functions properly, call the factory. The A/D underrange voltage is too low to convert an A/D signal. Make sure the In parameter matches your sensor and DIP switches are set accordingly.

Er 7 - A/D overflow error

The A/D circuit is overrange. An open or reversed polarity sensor is the most likely cause. Check the sensor; if the connection is good, and the sensor functions properly, call the factory. The A/D overrange voltage is too high to convert an A/D signal. Make sure the In parameter matches your sensor and DIP switches are set accordingly.
Tuning and Operating, Chapter 5 WATLOW Series 965 User's Manual

25

Error Codes
Error Code Actions

Er 2, Er 6, Er 7 result in these conditions:

If operator access is LOC 0, 1 or 2 ... and the control was in AUTO operation when the error occurred, it goes into manual (% power) operation. If the output power is less than 75% power, and a <5% change in power occurred within the last two minutes, the 965 switches into manual operation at the last automatic power level (bumpless transfer). If the control was in manual operation, it remains there. Press A/M twice to see the error code. The alarm output (if present) is in its alarm state (LED lit). The upper display reads "- - -". The lower display indicates the error code. If the control was operating with stable output values when the error occurred, it continues to operate at those levels on a % power basis. If output values were not stable, the control outputs go to 0% power (OFF). If operator access is LOC 3 or 4 The control remains in auto operation and the outputs go off. The A/M and MODE keys are inactive. The Up-arrow/Down-arrow keys may be used simultaneously to enter the Setup Menu. The alarm output (if present) is in its alarm state (LED lit). The upper display reads "- - - -". The lower display indicates the error code. To clear a corrected error Press M (Mode key).

Er 4 and Er 5 result in these conditons:

The control is in auto operation with both outputs off. The alarm output, if present, are in their alarm state (de-energized with the LED lit). The upper display indicates the process value. The lower display indicates the error code. All keys are inactive. All Setup Menu parameters return to default values. The above conditions occur regardless of the value of LOC, or the presence of the Setup or Calibration Menus. To clear a corrected error Cycle power to the control.

26

WATLOW Series 965 User's Manual

Tuning and Operating, Chapter 5

Noise Guidelines

Appendix 1
Noise and Installation Guidelines
For wiring guidelines, refer to the IEEE Standard No. 518-1982, available from IEEE, Inc. 345 East 47th Street, New York, NY 10017.

Noise Sources
Switches and relay contacts operating inductive loads such as motors, coils, solenoids, and relays, etc. Thyristors or other semiconductor devices which are not zero crossover-fired (randomly-fired or phase angle-fired devices). All welding machinery and heavy current carrying conductors. Fluorescent and neon lights.

Decreasing Noise Sensitivity

Physical separation and wire routing must be given careful consideration in planning the system layout. For example, ac power supply lines should be bundled together and physically kept separate from input signal lines (sensor lines). A 12" (305 mm) minimum separation is usually effective. Keep all switched output signal lines (high power level) separate from input signal lines (sensor lines). Cross other wiring at 90 angles whenever crossing lines is unavoidable. Look at the system layout; identify and locate electrical noise sources such as solenoids, relay contacts, motors, etc. Route the wire bundles and cables as far away as possible from these noise sources. Don't mount relays or switching devices close to a microprocessor control. Don't have phase angle-fired devices in the same electrical enclosure or on the same power line with the control. Shielded cables should be used for all low power signal lines to protect from magnetic and electrostatic coupling of noise. Some simple pointers are: Whenever possible, run low level signal lines unbroken from signal source to the control circuit. Connect the shield to the control circuit common at the control end only. Never leave the shield unconnected at both ends. Never connect both shield ends to a common or ground. Maintain shield continuity at daisy chain connection points by reconnecting the broken shield. Assume no electrostatic shielding when using the shield as a signal return. If you must do this, use triaxial cable (electrostatically shielded coaxial cable).

Appendix

WATLOW Series 965 User's Manual

27

Wiring Guide
Use twisted pair wire any time control circuit signals must travel over two feet, or when you bundle them parallel with other wires. Select the size or gauge of wire by calculating the maximum circuit current and choosing the gauge meeting that requirement. Using greatly larger wire sizes than required generally increases the likelihood of electrostatic (capacitance) coupling of noise. Eliminate ground loops in the entire control system. You can spot the obvious loops by studying the "as-built" wiring diagram. There are also notso-obvious ground loops resulting from connecting internal circuit commons in the manufacturer's equipment. Do not daisy chain ac power (or return) lines, or output signal (or return) lines to multiple control circuits. Use a direct line from the power source to each input requiring ac power. Avoid paralleling L1 (power lead) and L2 (return lead) to load power solenoids, contactors, and control circuits. If an application uses L1 (power lead) to switch a load, L2 (return lead) has the same switched signal and could couple unwanted noise into a control circuit. Tie all ground terminals together with one lead (usually green wire) tied to ground at one point. Don't connect ground to the control case if the control is in a grounded enclosure (preventing ground loops). Do not confuse chassis grounds (safety ground) with control circuit commons or with ac supply L2 (return or neutral line). Each return system wiring must be separate. Absolutely never use chassis ground (safety) as a conductor to return circuit current.

Eliminating Noise
Use "snubbers" (QUENCHARC P/N: 0804-0147-0000) to filter out noise generated by relays, relay contacts, solenoids, motors, etc. A snubber is a simple filter device using a 0.1f, 600 volt, non-polarized capacitor in series with a 100, 1/2 watt resistor. The device can be used on ac or dc circuits to effectively dampen noise at its source. The ultimate protection is an "uninterruptable" power supply. This "senses" the ac power line; when the line fluctuates, a battery powered 60Hz inverted circuit takes over, supplying power within one-half to one cycle of the ac line; very expensive.

28

WATLOW Series 965 User's Manual

Appendix

Appendix 2 Calibration
Before attempting to calibrate, make sure you read through the procedures carefully and have the proper equipment called for in each procedure. Make sure the DIP switches are in the proper position per input type. See Figure 21, Page 14.

Calibration

Entering the Calibration Menu

In the Calibration Menu, various input signals must be supplied for the control to go through its auto calibration. The calibration menu can only be entered from the LOC parameter in the Setup Menu. Press the Up-arrow/Down-arrow keys simultaneously for 3 seconds ( 1 second). The CAL parameter appears in the lower display with "no" in the upper display.

Figure 27 Entering the Calibration Menu.

NOTE: Calibration values will not be retained unless you are in the MANUAL mode. Do not enter the MANUAL mode until you are at the correct input parameters.

Any inadvertent change in the displayed data, when pressing the Up-arrow/ Down-arrow keys, is ignored. Calibration values won't be retained unless you are in the manual mode. Press the Up-arrow/Down-arrow key to change the upper display to YES. Press MODE to enter the calibration sequence. NOTE: Upon entering the calibration menu, the upper display window indicates CAL. It continues to indicate CAL (with the exception of calibration of the 4-20mA output) while the operator walks through the entire calibration parameter list. While calibrating the 4-20mA output, the upper display contains a numeric value to be slewed up or down until the output value is correct. The control uses the lower display to prompt the user as to what the input should be. With the dFL parameter, select either U.S. parameters which include displaying F, rate, reset, and proportional band in degrees or units. Or select SI (System International) and the displayed parameters are C, integral, derivative, and proportional band in % of span. Once the information has been properly established and maintained for at least 5 to 10 seconds, the MODE key may then be used to display the next prompt. After the final input is established, press the MODE key twice to return the unit to the configuration menu at the top of the parameter list.
Appendix WATLOW Series 965 User's Manual

While in the Calibration Menu, the control output(s) go off and the alarm output (if present) is on.

29

Calibration

Restoring Factory Calibration

The rSt parameter restores the factory calibration values to the Series 965. If you calibrate your control incorrectly, you have the option to default to the original values. Once you leave the CAL menu, the values are entered. 1. Press the Up-arrow/Down-arrow keys simultaneously for three seconds. The LOC parameter appears in the lower display. Continue holding the Uparrow/Down-arrow keys until the lower display reads CAL. 2. Press the Up-arrow key until YES appears in the upper display. 3. MODE through the calibration menu until rSt appears in the lower display. 4. Press the Up-arrow key until YES appears in the upper display. 5. Press the MODE key and the 965 advances to test the displays.
This procedure is used only to restore calibration, it is not meant to clear values.

Calibration Menu
CAL No ( )

YES to calibrate, No skips to display test.

Yes

Figure 28 Calibration Parameters

0.00 50.0 tC 440 255 0.00 5.00 4.00 20.0 4A0 2A0 rSt dSP dFL MEM

( ( ( ( ( ( ( ( ( ( ( ( (

) ) ) ) ) ) ) ) ) ) ) ) )

Input 0.00mV for low input. Input 50.00mV for high input. Connect a Type "J" ambient compensator with inputs shorted. Set the low resistance to 44.01. Set the high resistance to 255.42. Set the voltage source to 0.000 volts. Set the voltage source to 5.000 volts. Set the current source to 4.00mA. Set the current source to 20.00mA. Enter 4-20mA output calibration value for 4mA. Enter 4-20mA output calibration value for 20mA. Restores factory calibration values. Factory use only. Select US (rate, reset, proportional band in degrees or units, F) or SI (integral, derivative, proportional band in % of span, C) Factory use only.

Before attempting to calibrate, make sure you have the proper equipment called for in each procedure. The Series 965 is calibrated and tested before leaving the factory. 30
WATLOW Series 965 User's Manual Appendix

Thermocouple Field Calibration Procedure

Equipment Required
Type "J" Reference Compensator with reference junction at 32F/0C, or Type "J" Thermocouple Calibrator set at 32F/0C. Precision millivolt source, 0-50mV min. range, 0.01mV resolution

T/C Calibration

Setup And Calibration

1. Connect the AC line voltage L1 and L2 to the proper terminals. 2. Connect the millivolt source to Terminal 5 Negative and Terminal 3 Positive on the Series 965 terminal strip. Use regular 20 - 24 gauge wire. Make sure the DIP switch is set for thermocouple input, see Chapter 4. 3. Apply power to the unit and allow it to warm up for 15 minutes. After warm-up put the unit in the CAL menu. See Figure 27 on Page 29. Select YEs. 4. Press the A/M key twice to enter the MANUAL mode. The unit is calibrating when MN LED is on. Make sure the unit is in MANUAL mode only when you are in the correct parameters. 5. At the 0.00 prompt, enter 0.00mV from the millivolt source to the control. Allow at least 10 seconds to stabilize. Press the MODE key. 6. At the 50.0 prompt, enter 50.00mV from the millivolt source to the Series 965. Allow at least 10 seconds to stabilize. Press the MODE key. 7. At the tC prompt, disconnect the millivolt source, and connect the reference compensator or T/C calibrator to Terminal 5 Negative, and Terminal 3 Positive on the Series 965 terminal strip. If using a compensator, turn on and short the input wires. If using "J" calibrator, set to simulate 32F/0C. Allow 10 seconds for the control to stabilize. The unit will leave the CAL mode if 1 minute passes between key activations. To conclude the T/C calibration, advance the MODE key to the next prompt or exit the CAL menu. Press the A/M key twice to exit the MANUAL mode.

NOTE: Before calibration on an installed control, make sure all data and parameters are documented. See Setup and Operation Tables, Pages 18 and 20.

RTD Field Calibration Procedure

Equipment Required
1K precision decade resistance box with 0.01 resolution.

Setup And Calibration

1. 2. Connect the ac line voltage L1 and L2 to the proper terminals. Connect the decade resistance box to Terminal 2, 3 and 5 on the terminal strip. Use regular 20 - 24 gauge wire of the same length and type. Make sure the DIP switch is set for RTD input, see Chapter 4. Apply power to the unit and allow it to warm up for 15 minutes. After warm-up put the unit in the CAL menu. See Figure 27 on Page 29. Select YEs. Press the MODE key until the 440 prompt is displayed. Press the A/M key twice to enter the MANUAL mode. The unit is calibrating when the MN LED is on. Make sure the unit is in MANUAL mode only when you are in the correct parameters. At the 440 prompt, set the decade resistance box to 44.01. Allow at least 10 seconds to stabilize. Press the MODE key to enter the calibration data. Press the A/M key twice to exit the MANUAL mode. The unit will leave the CAL mode if 1 minute passes between key activations. To conclude the RTD calibration, advance the MODE key to the next prompt or exit the CAL menu. At the 255 prompt, set the decade resistance box to 255.42. Allow at least 10 seconds to stabilize. Press the MODE key.

NOTE: When the MN LED is on, the unit is automatically calibrating. Your sequence is VERY important. Always move to the next parameter before changing the calibration equipment.

3.

4.

5.

6.

Appendix

WATLOW Series 965 User's Manual

31

Process Input
0-5 Volt Input Field Calibration Procedure
Equipment Required: NOTE:
Before calibration on an installed control, make sure all data and parameters are documented. See Setup and Operation Charts, Pages 18 and 20. Precision DC voltage source 0-5 volt minimum range with 0.001 volt resolution.

Setup and Calibration

1. Connect the AC line voltage L1 and L2 to the proper terminals on the 965. 2. Connect the voltage/current source to Terminal 3 (+) and 5 (-) on the Series 965 terminal strip. Use regular 20 - 24 gauge wire. Make sure the DIP switch is set for process input, see Chapter 4. 3. Apply power to the unit and allow it to warm up for 15 minutes. After warm-up put the unit in the CAL menu. See Figure 27 on Page 29. Select YEs. Press the MODE key until 0.00 is displayed. 4. Press A/M twice to enter the MANUAL mode. The unit is calibrating when the MN LED is on. Make sure the unit is in the MANUAL mode only when you are in the correct parameters. See Figure 28 on Page 30. 5. At the 0.00 parameter, set the voltage source to 0.000 volts. Allow at least 10 seconds to stabilize. Press the MODE key. 6. At the 5.00 parameter, set the voltage source to 5.000V (VDC). Allow at least 10 seconds to stabilize. The unit leaves the CAL mode if 1 minute passes between key activations. Press A/M twice to exit the MANUAL mode. To conclude the 0-5 Volt calibration, advance the MODE key to the next prompt or exit the CAL menu.

NOTE: When the MN LED is on, the unit is automatically calibrating. Your sequence is VERY important. Always move to the next parameter before changing the calibration equipment.

4-20mA Input Field Calibration Procedure

Equipment Required:
Precision current source 0-20mA minimum range with 0.01mA resolution.

Setup and Calibration

1. Connect the AC line voltage L1 and L2 to the proper terminals on the 965. 2. Connect the current source to Terminal 2 (-) and 5 (+) on the Series 965 terminal strip. Use regular 20 - 24 gauge wire. Make sure the DIP switch is set for process input, see Chapter 4. 3. Apply power to the unit and allow it to warm up for 15 minutes. After warm-up put the unit in the CAL menu. See Figure 27 on Page 29. Select YEs. Press the MODE key until 4 is displayed. 4. Press A/M twice to enter the MANUAL mode. The unit is calibrating when the MN LED is on. Make sure the unit is in the MANUAL mode only when you are in the correct parameters. See Figure 28 on Page 30. 5. At the 4.00 parameter, set the current source to 4.00mA. Allow at least 10 seconds to stabilize. Press the MODE key. 6. At the 20.0 parameter, set the current source to 20.00mA. Allow at least 10 seconds to stabilize. The unit leaves the CAL mode if 1 minute passes between key activations. Press A/M twice to exit the MANUAL mode. To conclude, advance the MODE key to the next prompt or exit the CAL menu.

32

WATLOW Series 965 User's Manual

Appendix

4-20mA Output
4-20mA Output Field Calibration Procedure
Equipment Required:
300, 1/2 watt 10% resistor. 4 - 1/2 digit Digital Multimeter.

NOTE:
Before calibration on an installed control, make sure all data and parameters are documented. See Setup and Operation Charts, Pages 18 and 20.

Setup And Calibration

1. 2. Connect the ac line voltage L1 and L2 to the proper terminals of the 965. See Chapter 2. Set the multimeter to measure current. Connect the multimeter in series with the 300 resistor to Terminal 9 Positive and 10 Negative on the Series 965 terminal strip. Use regular 20 - 24 gauge wire. Apply power to the unit and allow it to warm up for 15 minutes. After warm-up put the unit in the CAL menu. Press the MODE key until the 4A0 prompt is displayed. Press the A/M key twice to enter the MANUAL mode. The unit is calibrating when the MANUAL LED is on. At the 4A0 prompt, the multimeter should read approximately 4mA. Allow at least 10 seconds to stabilize. Use the Up-arrow/Down-arrow keys (reverse acting) to adjust the reading on the multimeter for 3.85mA 0.10mA. Press the MODE key. At the 2A0 prompt, the multimeter should read approximately 20mA. Allow at least 10 seconds to stabilize. The unit will leave the CAL mode if 1 minute passes between key activations except for 4-20mA units. Use the UP/DOWN keys (reverse acting) to adjust the reading on the multimeter for 20.15mA 0.10mA. To conclude the 4-20mA output calibration, advance the MODE key to the next prompt or exit the CAL menu.

3. 4. 5. 6. 7.

8. 9.

NOTE: When the MN LED is on, the unit is automatically calibrating. Your sequence is VERY important. Always move to the next parameter before changing the calibration equipment.

Appendix

WATLOW Series 965 User's Manual

33

Glossary, A-P

This glossary includes general thermal system control terms.

Alarm: A condition, generated by a controller, indicating that the process has exceeded or fallen below the set or limit point. Alarm Silence: Disables the alarm relay output. Anti-reset: Control feature that inhibits automatic reset action outside the proportional band. Automatic prompts: Data entry points where a microprocessor-based control "prompts" or asks the operator/programmer for information input. Auto-tune: Automatically tunes the Series 965 PID parameters to fit the characteristics of your particular thermal system. Bumpless transfer: When transferring from auto to manual operation, the control output(s) will not change ("bumpless," smooth transition). Closed loop: Control system that has a sensing device for process variable feedback. Cold junction: Point of connection between thermocouple metals and the electronic instrument. Cold junction compensation: Electronic means to compensate for the effective temperature at the cold junction. Cycle time: The time necessary to complete a full on-through-off period in a time proportioning control system. Derivative: Anticipatory action that senses the rate of change of the process, and compensates to minimize overshoot and undershoot. Also "rate." Deviation alarm: An alarm referenced at a fixed number of degrees, plus or minus, from set point. Default parameters: The parameters, or programmed instructions, permanently stored in microprocessor software to provide a data base. DIN: Deutsche Industrial Norms, a widely-recognized German standard for engineering units. Display capability: In a digital indicating instrument, the entire possible span of a particular parameter or value.

Droop: Difference in temperature between set point and stabilized process temperature. Duty cycle: Percentage of "load on time" relative to total cycle time. Hysteresis: In on/off control, the temperature change necessary to change the output from full on to full off. Hunting: Oscillation or fluctuation of process temperature between set point and process variable. Input: Process variable information being supplied to the instrument. Integral: Control action that automatically eliminates offset, or droop, between set point and actual process temperature. Also "reset." Isolation: Electrical separation of sensor from high voltage circuitry. Allows for application of grounded or ungrounded sensing element. JIS: Joint Industrial Standards. Also Japanese Industrial Standards Committee (JISC). Establishes standards on equipment and components. Offset: Adjustment to actual input temperature and to the temperature values the Series 965 uses for display and control. On/off control: Control of temperature about a set point by turning the output full on below set point and full off above set point in the heat mode. Open loop: Control system with no sensory feedback. Output: Action in response to difference between set point and process variable. Overshoot: Condition where temperature exceeds set point due to initial power up or process changes. P control: Proportioning control. Parameter: A physical property whose value determines the response of an electronic control to given inputs.

34

WATLOW Series 965 User's Manual

Appendix

Glossary, D-P Glossary, P-Z

PD control: Proportioning control with rate action. PI control: Proportioning control with auto-reset. PID control: Proportioning control with auto-reset and rate. Process variable: Thermal system element to be regulated, such as time, temperature, relative humidity, etc. Programmed display data: Displayed information which gives the operator/programmer the "programmed" or intended process information, i.e., intended set point, intended alarm limit, etc. Proportional band: Span of temperature about the set point where time proportional control action takes place. Proportioning control: See Time Proportioning Control. Rate: Anticipatory action that senses the rate of change of temperature and compensates to minimize overshoot. Also "derivative." Rate band: A thermal control band that defines where the rate (derivative) function begins. A Watlow rate band occurs centered on set point at one or more times the width of the proportional band. Reference junction: Synonymous with cold junction. See "Cold junction." Reset: Control action that automatically eliminates offset, or "droop," between set point and actual process temperature. Also "integral." Reset windup inhibit: Synonymous with antireset. See "Anti-reset." RTD: Resistance Temperature Detector. Resistive sensing device displaying resistance versus temperature characteristics. Displays positive temperature coefficient. Set point: Intended value of the process variable. Switching sensitivity: In on/off control, the temperature change necessary to change the output from full on to full off. Thermal system: A regulated environment consisting of a heat source, heat transfer medium, sensing device and a process variable control instrument. Thermocouple: Temperature sensing device that is constructed of two dissimilar metals wherein a measurable, predictable voltage is generated corresponding to temperature. Thermocouple break protection: Fail-safe operation that assures output shutdown upon an open thermocouple condition. Three mode control: Proportioning control with reset and rate. Time proportioning control: Action which varies the amount of on and off time when "close" to the set point, i.e., in the proportional band. This variance is proportional to the difference between the set point and the actual process temperature. In other words, the amount of time the output relay is energized depends on the system temperature. Triac: Solid state switching device. Upper display data: Displayed information which gives the operator/programmer real or "actual" data, i.e., actual process temperature. See "Programmed display data." Warm start: Start-up condition where all program information is remembered by the instrument's memory back-up protection. Zero switching: Action that provides output switching only at the zero-voltage, crossing points of the ac line.

Appendix

WATLOW Series 965 User's Manual

35

Index Index
A Alarms 24 Wiring 11 Appendix 27 A/M key 13 Automatic Operation 13, 23 Auto-tuning 21 B Bumpless transfer 23 C Calibration 29 Calibration Offset 20 D DC Output 1 10 DC Output 2 11 Declaration of Conformity 40 Default Parameters Operation 20 Setup 18 Dimensions Faceplate 5 Panel Cutout 5 Sideview 5 DIP Switches 14 Displays 13, 17 Down-arrow key 13 E Eliminate Noise 28 Entering the Setup Menu 15 Error Codes 25 F, G General Description 4 Glossary 34 H High Voltage Wiring 7 Hysteresis 17 I Input Wiring 8 DIP Switch 14 Ranges 18 Input Installation 5 J, K Keys 13 L L1 & L2 Keys 13 Ladder Wiring Diagram, System 12 Lock Parameter 16 Low Voltage Wiring 7 Lower Display 13 M M/N Key 13 Manual Operation 13, 23 Manual Tuning 22 Mechanical Relay, 5 Amp Output 1 Wiring 10 Output 2 Wiring 11 MODE key 13 Model Number 39 N Noise Eliminating 28 Sources 27 Decreasing Sensitivity 27 O Operation Parameters 19 Output Wiring 5A Mechanical Relay 10, 11 4-20mA 10 DC (Open Collector) 10, 11 Solid State Relay w/o Supp. 10, 11 Overview of the Series 965 4 P Power Limiting 17 Power Wiring 7 Process Input 8, 9 Process Output 10 Q Quick Reference Sheet 41 R Ramping 17 Rate 17 Restoring Calibration 30 Returns 37 RTD Calibration 31 RTD Sensor Wiring 9 S Sensor Wiring 8 Series 965 Input And Output Overview 4 Setup Menu and Parameters 15 Specifications 38 System Wiring Example 12 T Thermocouple Break Protection 7, 8, 16, 23 Thermocouple Calibration 31 Thermocouple Sensor Wiring 8 Tuning 21 U, V, W Up-arrow key 13 Upper Display 13 Warranty 37

36

WATLOW Series 965 User's Manual

Index

Warranty Index
Warranty
The Watlow Series 965 is warranted to be free of defects in material and workmanship for 36 months after delivery to the first purchaser for use, providing that the units have not been misapplied. Since Watlow has no control over their use, and sometimes misuse, we cannot guarantee against failure. Watlow's obligations hereunder, at Watlow's option, are limited to replacement, repair or refund of purchase price, and parts which upon examination prove to be defective within the warranty period specified. This warranty does not apply to damage resulting from transportation, alteration, misuse, or abuse.

Returns
1. Call Watlow Customer Service, (507)454-5300, for a Return Material Authorization (RMA) number before returning any item for repair. We need this information: Ship to address Bill to address Contact name Phone number Ship via Your P.O. number Symptoms and/or special instructions Name and phone number of person returning the material. 2. Prior approval and an RMA number, from the Customer Service Department, is needed when returning any unused product for credit. Make sure the RMA number is on the outside of the carton, and on all paperwork returned. Ship on a Freight Prepaid basis. 3. After we receive your return, we will examine it and determine the cause for your action. 4. In cases of manufacturing defect, we will enter a repair order, replacement order, or issue credit for material. A 20 percent restocking charge is applied for all returned stock controls and accessories. 5. If the unit is unrepairable, it will be returned to you with a letter of explanation. Repair costs will not exceed 50 percent of the original cost.

Watlow Controls
Watlow Controls is a division of Watlow Electric Mfg. Co., St. Louis, MO, a manufacturer of industrial electric heating products, since 1922. Watlow begins with a full set of specifications and completes an industrial product that is manufactured totally in-house, in the U.S.A. Watlow products include electric heaters, sensors, controls and switching devices. The Winona operation has been designing solid state electronic control devices since 1962, and has earned the reputation as an excellent supplier to original equipment manufacturers. These OEMs depend upon Watlow Controls to provide compatibly engineered controls which they can incorporate into their products with confidence. Watlow Controls resides in a 100,000 square foot marketing, engineering and manufacturing facility in Winona, Minnesota.

Index

WATLOW Series 965 User's Manual

37

Specifications
Specifications(1460) Control Mode Microprocessor-based, user selectable control modes Single input, dual output 2.5Hz Input Sampling Rate 1Hz Display Update Rate Ramp to set point: 0 to 9999 degrees or units per hour Heat and cool auto-tune Agency Approvals UL and C-UL recognized, File #E43684, UL873 CE approved 89/336/EEC Electromagnetic Compatibility Directive EN 50081-2: 1994 Emissions EN 50082-2: 1995 Immunity 73/23/EEC Low -Voltage Directive EN 61010-1: 1993 Safety NEMA 4X2, I.P. 65 rating Operator Interface Sealed membrane front panel Dual, four-digit red or green displays MODE, Up-arrow, Down-arrow, and AUTO/ MANUAL keys User selectable screen display Accuracy Calibration accuracy and sensor conformity: 0.1% of span, 1 LSD @ 77F 5F (25C 3C) ambient and rated line voltage Accuracy span: 1000F (540C) minimum Temperature stability: 0.2F/F (0.2C/C) rise in ambient maximum Voltage stability: 0.01% of span per percent of rated line voltage Sensors/Inputs Thermocouple, grounded or ungrounded sensors RTD 2- or 3-wire, platinum, 100 @ 0C calibration to DIN curve (0.00385//C) or JIS curve (0.003916//C); user selectable Process, 4-20mA @ 5, or 0-5V (dc) @ 10k input impedance Sensor break protection de-energizes control output to protect system or selectable bumpless transfer to manual operation F or C or process units display, user selectable Input Range Specified temperature ranges represent the controllers operational span. Thermocouple Type J 32 to 1382F (0 to 750C) Type K -328 to 2282F (-200 to 1250C) Type N 32 to 2282F (0 to 1250C) Type S 32 to 2642F (0 to 1450C) Type T -328 to 662F (-200 to 350C) RTD Resolution (DIN or JIS) 1 -328 to 1292F (-200 to 700C) 0.1 -199.9 to 999.9F (-128.8 to 537.7C) Process 4-20mA @ 5, or -999 to 9999 units 0-5V (dc) @ 10k, or -999 to 9999 units Output 1 (Heating or Cooling) Electromechanical relay 1, Form C, 5A @ 120/240V~ (ac) maximum, without contact suppression, rated resistive load, 5A @ 30V (dc)3 . Switched dc signal provides a non-isolated minimum turn on voltage of 3V (dc) into a minimum 500 load; maximum on voltage not greater than 12V (dc) into an infinite load. 4-20mA reverse or direct acting, non-isolated 0 to 800 load. Solid-state relay3, Form A, 0.5A @ 24V~ (ac) min., 264V~ (ac) max., opto-isolated burst fire switched, without contact suppression. Off-state output impedance is 31M.

Output 2 (Heat, Cool or Alarm) Electromechanical relay1 , Form C, 5A @ 120/240V~ (ac) maximum, without contact suppression, rated resistive load, 5A @ 30V (dc)3. Switched dc signal provides a non-isolated minimum turn on voltage of 3V (dc) into a minimum 500 load; maximum on voltage not greater than 12V (dc) into an infinite load. Solid-state relay3 , Form A, 0.5A @ 24V~ (ac) min., 264V~ (ac) max., opto-isolated burst fire switched, without contact suppression. Off-state output impedance is 31M. Alarm output can be latching or non-latching, and process or deviation with separate high and low values. Alarm silencing (inhibit) on power up. Output Configurations Output 1 User selectable as: on/off: P, PI, PD, PID, heat or cool action Adjustable switching differential: 1 to 99F (1 to 55C) Proportional band: 0 (off) or 1 to 999F (0 to 555C) or 0.0 to 999.9 units Integral: 0 (off) or 0.1 to 99.9 minutes per repeat Reset: 0 (off) or 0.01 to 9.99 repeats per minute Rate/derivative: 0 (off) or 0.01 to 9.99 minutes Cycle time: 0.1 to 999.9 seconds Output 2 User selectable as: Control with action opposite that of Output 1 (heating or cooling) Process or deviation alarm with flashing alarm message Process or deviation alarm without alarm message Alarm with separate high and low set points Hysteresis: 1 to 9999 or units switching differential Line Voltage/Power 100-240V~ (ac), +10%, -15%; (85-264V~ [ac]) 50/60Hz, 5% 12-24V (ac/dc), +10%, -15%; (10-26V [ac/dc]) 50/60Hz, 5% Fused internally (factory replaceable only) Slo-Blo type (time-lag): 1A, 250V for high voltage versions 2A, 250V for low voltage versions Power consumption 5VA maximum Data retention upon power failure via non-volatile memory Operating Environment 32 to 149F (0 to 65C) 0 to 90% RH, non-condensing Storage Temperature -40 to 185F (-40 to 85C) Terminals #6 compression universal head screw terminals, accepts 2014 gauge wire Controller Weight 0.4 lb (0.2 kg) Shipping Weight 0.75 lb (0.34 kg) Dimensions Compact 116 DIN size and NEMA 4X 2, (I.P. 65) front panel make the Series 965 easy to apply and maintain in a wide variety of applications. Unique mounting bezel, gasket and collar make installation a snap. Overall Height: 2.1 inches (55 mm) Width: 2.1 inches (55 mm) Depth: 4.7 inches (120 mm) Bezel Height: 2.1 inches (55 mm) Width: 2.1 inches (55 mm) Depth: 0.6 inches (15 mm) Chassis Height: 1.8 inches (45 mm) Width: 1.8 inches (45 mm) Depth: 4.1 inches (105 mm)
1

Electromechanical relays warranted for 100,000 closures only. Solid-state switching devices recommended for applications requiring fast cycle times or extended service life. To effect NEMA 4X (I.P. 65) rating requires a minimum mounting panel thickness of 0.06inch (1.5 mm) and surface finish not rougher than 0.000032 inch (0.000812 mm). Switching inductive loads (relay coils, etc.) requires using an RC suppressor. Appendix

38

WATLOW Series 965 User's Manual

Model No.
Series 965 Model Number Information
Ordering InformationW965-XMNN Rev A00

965A-3___-00__

Output 1 C = Switched dc output, non-isolated D = Electromechanical relay, Form C, 5A, without contact suppression1 3 F = Process, 4-20mA (dc), non-isolated K = Solid-state relay, Form A, 0.5A, without contact suppression 3 Output 2 A = None C = Switched dc output, non-isolated D = Electromechanical relay, Form C, 5A, without contact suppression1 3 K = Solid-state relay, Form A, 0.5A, without contact suppression 3 Line Voltage/Power 0 = 100-240V~ (ac) nominal (high voltage) 1 = 12-24V~ (ac) nominal or 12-24V (dc) (low voltage) Display Upper Display 00 = Red RG = Red GR = Green GG = Green

Lower Display Red Green Red Green

* Note: If this output will drive a solenoid, MDR, contactor or other inductive device, order a Quencharc (0804-0147-0000) for output protection. See Chapter 2 for wiring.

Spare Parts Mounting collar Case gasket Protective terminal cover Internal bezel gasket Quencharc RC suppressor
Appendix

0822-0395-0000 0830-0402-0002 0822-0426-0001 0830-0402-0001 0804-0147-0000

WATLOW Series 965 User's Manual

39

Conformity Put Declaration of Conformity on this page.

40

WATLOW Series 965 User's Manual

Appendix

Series 965 Quick Reference

Use this page as a quick reference for the Series 965. Tear along the perforation.

Keys & Displays

Upper Display: Red or green, LED display, indicating either process actual temperature, the operating parameter values, or an open sensor. L1: When lit it indicates Output 1 is energized. L2: When lit it indicates when Output 2 is active. This output can be configured as a control or alarm output. MN: Lit when in manual operation. Press A/M twice to enter Automatic. When blinking, press A/M to toggle between Auto and Manual. After 5 seconds without key activations it returns to its previous state.

Lower Display: Red or green, four digit LED display, indicating the set point, output value, parameters for data in the upper display, or error and alarm codes.

MODE Key: Steps the control through the operating menu, also, in the Auto mode, new data is self entering in 5 seconds.

Up-arrow Key: Increases the value of the displayed parameter. New data is self entering in 5 seconds.

Down-arrow Key: Decreases the value of the displayed parameter. New data is self entering in 5 seconds.

Up-arrow/Down-arrow Keys: When pressed simultaneously for 3 seconds, the Setup Menu appears displaying the LOC parameter. Continue to press the UP/DOWN keys, and the Calibration menu appears.

A/M Key: Press once to clear latched alarms and toggles between Auto and Manual. If pressed within 5 seconds it changes from Auto to Manual or vice versa. While in Manual, percent power is in the lower display.

Alarms
Process Alarm sets an absolute temperature. When the process exceeds that absolute temperature limit an alarm occurs. The process alarm set points may be independently set high and low. Under the Setup menu, select the type of alarm output with the Ot2 parameter. PrA = Process alarm Pr = Process alarm with no alarm message displayed the deviation alarm band. Once the process value crosses into the "safe" region, both a latching or a non-latching alarm is ready. Any future deviation outside this safe band triggers an alarm. Both alarms can be latching or non-latching. When the alarm condition is removed a non-latching alarm automatically clears the alarm output. You must manually clear a latching alarm before it will disappear.

Deviation Alarm: Alerts the operator when the process strays too far from set point. The operator can enter Flashing LO or HI in the lower display independent high and low alarm settings. Press once indicates an alarm when Ot2 = PrA or The reference for a deviation alarm is set to clear dEA. The lower display alternately point. Any change in set point causes a a latched shows information from the current corresponding shift in the deviation alarm. parameter and a LO or HI alarm mesand Under the Setup menu, select the type of sage at one second intervals. The alarm output with the Ot2 parameter. corrected alarm output is de-energized, L2 is lit. dEA = Deviation alarm alarm. dE = Deviation alarm with no alarm To clear an alarm... message displayed First correct the alarm condition, then... If the alarm is latching... Alarm Silencing is available with the deviation alarm. When SIL is Clear it manually; press the A/M key once as soon as the selected as "on," the operator must manually disable the alarm by process temperature is inside the HSA parameter alarm limit. pressing the A/M key once on initial power up (in either the latching or If the alarm is non-latching... non-latching mode). Alarm silencing disables the alarm output relay. The alarm clears itself automatically as soon as the process However, the L2 LED (also the lower display when Ot2 = dEA) shows temperature is inside the HSA parameter alarm limit. an alarm condition until the process value is within the "safe" region of

Error Codes
Four dashes, "- - - -" or a negative number, in the upper display indicate a Series 965 error. The error code is visible in the lower display. Er 5 - Non volatile checksum error The nonvolatile memory checksum discovered a checksum error. Unless a momentary power interruption occurred while the unit was storing data, the nonvolatile memory is bad. Call the factory. Er 6 - A/D underflow error The A/D circuit is underrange. An open or reversed polarity sensor is the most likely cause. Check the sensor; if the connection is good and functions properly, call the factory. The A/D underrange voltage is too low to convert an A/D signal. Make sure the In parameter matches your sensor and the DIP switches are set accordingly. Er 7 - A/D overflow error The A/D circuit is overrange. An open or reversed polarity sensor is the most likely cause. Check the sensor; if the connection is good and the sensor functions properly, call the factory. The A/D overrange voltage is too high to convert an A/D signal. Make sure the In parameter matches your sensor and the DIP switches are set accordingly.

Er 2 - Sensor underrange error (For RTD units only) The sensor input generated a value lower than the allowable signal range, or the A/D circuitry malfunctioned. Enter a valid input. Make sure the In parameter matches your sensor and DIP switch setting. Refer to the table below for the appropriate input type and range. Er 4 - Configuration error The unit's microprocessor is faulty; call the factory.

Entering the Setup Menu

The Setup Menu displays the parameters that configure the Series 965's features to your applicaton. Enter the Setup menu by pressing the Up-arrow/Down-arrow keys simultaneously for 3 seconds. The lower display shows the LOC parameter, and the upper display shows its current level. All keys are inactive until you release both keys. You can reach the LOC parameter from anywhere. You will not see all parameters in these menus depending on your unit's configuration and model number.

Setup Menu
( )

Do not enter any values here; make photocopies instead.

Parameters LOC In dEC C_F Value Range 0 through 4 J, K (appears as H), t, n, S, rtd, rt.d, 0-5, 420 0, 0.0, 0.00 C or F Factory Default 0 J 0 C F Input dependent Input dependent ht 3, 0.3, 0.03F Con Appears If:

LOC ( In dEC ( (

) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) )

User lock out Input type Decimal place Celcius__Fahrenheit Range low Range high Output 1 Control hysteresis Output 2 Output 2 hysteresis Latching for alarm Silence alarm RTD calibration curve Ramp func tion Ramp rate Power limiting Display

DIP switch selectable In = 0-5 or 420 dFL = SI or In = T/C or RTD dFL = US or In = T/C or RTD

C_F ( rL rH Ot 1 ( ( (

HSC ( Ot2 (

rL rH Ot1 HSC Ot2

HSA ( LAt SIL rtd rP rt PL dSP 75 ( ( ( ( ( ( (

HSA LAt SIL rtd rP

rt PL dSP

rL to rH rH to rL ht or CL 1 to 99, 0.1 - 9.9, 0.01 - 0.99 Con = Control PrA = Process alarm Pr = Process with no alarm message dEA = Deviation alarm dE = Deviation with no alarm message no = None 1 to 9999, 0.1 - 999.9, 0.01 - 99.99 LAt or nLA On or OFF JIS or din Str = Ramping on power up on = Ramping to set point at all times OFF = None 0 to 9999 0 to 100 nor = Normal SEt = Set Point (lower display only) Pro = Process (upper display only)

3, 0.3, 0.03F nLA OFF din OFF

Ot2 Con or no Ot2 Con or no Ot2 = dEA or dE In = rtd or rt.d

100/hr 100 nor

rP OFF

Operation Menu
( )

Do not enter any values here; make photocopies instead.

Parameters Pb1
75 Pb1 ( ) Control Set Point Proportional band 1 Reset 1/Integral 1
Rate 1/Derivative 1 1 Rate 1/Deviation

Value

Range 0 to 999F/0 to 555C/0 to 999 Units 0 to 99.9F/ 0 to 55.5C/0 TO 99.9 UNITS 0.0 to 999.9% of span 0 = ON/OFF control, HSC = Switching diff. 0.00 to 9.99 repeats/minute / 0.00 = No reset 00.0 to 99.9 minutes/repeat / 0.00 = No integral 0.00 to 9.99 minutes / 0.00 = No rate 0.00 to 9.99 minutes / 0.00 = No derivativew 0.1 to 999.9 seconds 1 to 999F/0 to 555C/0 to 999 Units 1 to 99.9F/ 0 to 55.5C/0 to 99.9 Units 0.1 to 999.9% of span 0.00 to 9.99 repeats/minute / 0.00 = No reset 00.0 to 99.9 minutes/repeat / 0.00 = No integral 0.00 to 9.99 minutes / 0.00 = No rate 0.00 to 9.99 minutes / 0.00 = No derivative 0.1 to 999.9 seconds -999 to 0 rL to AHI 0 to 999 ALO to rH 18F/10C/18 Units 0 = off, 1 = slow, 2 = medium, 3 = fast

Factory Default 25F 2.5F 3% / .3% 0.00 repeats/minute 00.0 minutes/repeat 0.00 minutes 0.00 minutes 5.0 seconds 25F 2.5F 3% / .3% 0.00 repeats/minute 00.0 minutes/repeat 0.00 minutes 0.00 minutes 5.0 seconds -999 rL 999 rH 0 0

Appears If: dFL = US dFL = SI Pb1 0 or dFL = US Pb1 0 or dFL = SI Pb1 0 or dFL = US Pb1 0 or dFL is SI Pb1 0 or Output 1 420 dFL = US dFL = SI, Ot2 = Con, Pb1 0 dFL = US, Ot2 = Con, Pb1 0 dFL = SI, Ot2 = Con, Pb1 0 dFL = US, Ot2 = Con, Pb1 0 dFL = SI, Ot2 = Con, Pb1 0 Ot2 = Con, Pb1 0 Ot2 = dE or dEA Ot2 = Pr or PrA Ot2 = dE or dEA Ot2 = Pr or PrA

rE1/It1 ( ) rA1/dE1 ( ) Ct1 Pb2 ( ) ( )

rE1 It1 rA1 dE1 Ct1 Pb2

Cycle time 1 Proportional band 2 Reset 2/Integral 2

Rate 2/Derivative 2 2 Rate 2/Deviation

rE2/It2 ( ) rA2/dE2 ( ) Ct2 ALO AHI CAL AUt ( ) ( ) ( ) ( ) ( )

Cycle time 2 Alarm low Alarm high Calibration offset Auto-tune

rE2 It2 rA2 dE2 Ct2 ALO AHI CAL AUt

Watlow Series 965 User's Manual

Watlow Controls, 1241 Bundy Blvd., P.O. Box 5580, Winona, MN 55987-5580, Phone: 507/454-5300, Fax: 507/452-4507

WATLOW Series 985 User's Manual

Appendix

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DESCRIPTION MODULE NO O-SUB CONNECTOR PlATE MODULE N1 O-SUB CONNECTOR PlATE MODULE N2 O-SUB CONNECTOR PlATE MODULE N3 O-SUB CONNECTOR PlATE CABLE: CBLPBA2 cABLE: cBL6A CABLE: C;UA CABLE: CBUC CABLE: CBUD CABLE: CBLIE CABLE: CBL2A CABLE: CBL2C CABLE: CBL2D CABLE: CBL2E CABLE: CBL3A CABLE: CBL3C CABLE: CBL3D CABLE: CBL3E "ABLE: cBL3F CABLE: CBLPBB2 CABLE: CBL4A INFEED MULTI-PORT CABLE ASSY. -CBLMPI DISCHARGE MULT1- PORT CABLE ASSY. -CBLMPD MODUlE #O 'SHEET 1 O;: 2 MODULE NO SHEET 2 OF 2 MODULE N1 SHEET 1 OF 2 MODULE N1 SHEET 2 OF 2 MAIN POWER & AC. DRIVE TEMPERATURE CONTROL SYSTEM SHEET 1 OF2 TEMPERATURE CONTROL SYSTEM SHEET 20F 2 CRS: POWER & TB6 MAcHINE CABLE LAYOUl' MODULEN3 DSP l/O BOARD GEN 111 PROCESSOR MODULE N2 SHEET 1 OF 2 MODULEN2 SHEET20F 2 CUB5 RATE / TOTAL COUNTER & TENSION CONTROL W/ SPUCER CABLE CONNECTIONS : CRS

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Allen-Bradley

Bulletin 2706 Dataliner User Manual Message Display DL5 Series

Important User Information

Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards. The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Allen-Bradley does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication. Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application, Installation and Maintenance of Solid-State Control (available from your local Allen-Bradley office), describes some important differences between solid-state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication. Reproduction of the contents of this copyrighted publication, in whole or part, without written permission of Rockwell Automation, is prohibited. Throughout this manual we use notes to make you aware of safety considerations: ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss

Attention statements help you to: identify a hazard avoid a hazard recognize the consequences Important: Identifies information that is critical for successful application and understanding of the product.
Allen-Bradley is a trademark of Rockwell Automation

Table of Contents

Table of Contents
Using this Manual
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2

1 - Introduction to the DL5

Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Memory Storage Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-2 1-3 1-3 1-3

2 - Getting Started
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Initial Desktop Hookup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Initial Desktop Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Initial Power Up of the DL5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Responding to a Yes or No Prompt . . . . . . . . . . . . . . . . . . . . . . . 2-6 Responding to a Numeric Prompt. . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Responding to a Mnemonic Prompt . . . . . . . . . . . . . . . . . . . . . . . 2-8 Using the Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Returning to the Main Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Using the Control Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

toc-iii

Table of Contents

3 - Entering New Messages

Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Edit vs. Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Selecting the Edit Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Edit Mode Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Specifying Message Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Line Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Selecting Line or Scroll Mode . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Selecting Message Wait Time . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Auto Clear Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Auto Repeat Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Flash Message Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Default Values for Message Attributes. . . . . . . . . . . . . . . . . . . . . 3-7 Entering a Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Embedding Numeric Variable Data in A Message. . . . . . . . . 3-9 Entering a Sample Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Programming Multiple DL5s Identically . . . . . . . . . . . . . . . . . . 3-11

4 - Reviewing and Editing Messages

Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reviewing a Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displaying the Amount of Memory Remaining . . . . . . . . . . . . . . Selecting a Message to Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moving the Cursor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deleting a Character . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deleting a Message Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inserting a Message Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deleting an Entire Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Editing Message Attributes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1 4-2 4-3 4-3 4-4 4-4 4-5 4-5 4-6

toc--iv

Table of Contents

5 - Run Mode
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Entering Run Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Run Mode - Parallel Operation . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Run Mode - Serial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Description of Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

6 - Using the Serial Port

Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-232 Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial Port Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Message Trigger [Ctrl][T] . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable Data [CTRL][V]. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1 6-2 6-3 6-3 6-3

7 - Using the Parallel Port

Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Description of the Parallel Port. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Selecting BCD or Binary Data Format . . . . . . . . . . . . . . . . . . . . . 7-3 Using Binary Data Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Using BCD Data Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Logic Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Using the Numeric (Run) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Numeric Mode and Autorun Message . . . . . . . . . . . . . . . . . . . . 7-10 Using DC Outputs to Trigger the DL5 . . . . . . . . . . . . . . . . . . . . 7-11 Determining Current Requirements For DC Outputs . . . . . . 7-12 Parallel Port Power Supply Requirements . . . . . . . . . . . . . . . . . 7-13 Timing Requirements of the Parallel Port . . . . . . . . . . . . . . . . . 7-13

8 - Special Functions
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introducing the Special Functions Menu . . . . . . . . . . . . . . . . . . . Entering the Special Functions Menu . . . . . . . . . . . . . . . . . . . . . . SET PORT Special Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . Run Mode Special Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . Debug Special Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEAR MEMORY Special Function . . . . . . . . . . . . . . . . . . . . . SET AUTORUN Special Function. . . . . . . . . . . . . . . . . . . . . . . . 8-1 8-1 8-3 8-4 8-5 8-6 8-7 8-7

toc-v

Table of Contents

9 - Using the Variable Data Feature

Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable Data Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Creating Messages with Embedded Variable Data. . . . . . . . . . . . Embedding a Decimal Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sending Variable Data Through the Serial Port . . . . . . . . . . . . . . Sending Variable Data Through the Parallel Port . . . . . . . . . . . . Parallel Port Strobe and Data Bits . . . . . . . . . . . . . . . . . . . . . Parallel Port Timing Requirements. . . . . . . . . . . . . . . . . . . . . . . . Suggestions on Using the Variable Data Feature . . . . . . . . . . . . . 9-1 9-1 9-2 9-3 9-3 9-4 9-4 9-5 9-7 10-1 10-1 10-2 10-4 10-5 10-6

10 - Using the DL5 Parallel Port to Replace Pilot Lights

Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of Input Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . Round Robin Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Priority Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the Round Robin Input Mode. . . . . . . . . . . . . . . . . . . . . . Using Priority Input Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 - Using the DL5 to Replace BCD Displays and Lookup Tables

Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 Replacing a BCD Fault Code Display . . . . . . . . . . . . . . . . . . . . 11-1

12 - Installation Instructions
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Wire Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Mounting the DL5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 Power Supply Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 Power/Parallel Port Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

13 - Maintenance and Troubleshooting

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

14 - Specifications
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environmental. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1 14-2 14-3 14-3

toc--vi

Table of Contents

A - ASCII Character Set B - Cabling Diagrams

Abreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Allen-Bradley T3 Terminal Serial Communications Cable (Catalog No. 2706-NC15) . . . . . . B-1 Allen-Bradley 1745-T45 Terminal, VT100 or IBM XT & Compatibles Serial Communications Cable (Cat. No. 2706-NC12) . . . . . . . . . .B-2 Allen-Bradley 6121 or T50 Terminal, IBM AT & Compatibles Serial Communications Cable (Cat.No. 2706-NC13) . . . . . . . . . .B-2 Allen-Bradley 6120 or Industrial PC / XT Serial Communications Cable (Cat. No. 2706-NC14) . . . . . . . . . .B-3

C - Message Display Worksheets D - Application Notes

Unsigned Integer Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . D- 1

toc-vii

Table of Contents

toc--viii

Preface

Using this Manual

Chapter Objectives

Read this chapter to familiarize yourself with the rest of the manual. You will learn about: Contents of this manual Intended audience Conventions used This manual will instruct you on how to install and use your Dataliner DL5. display. The manual is divided into the following chapters:
Chapter Preface 1 2 Title Using this Manual Introduction to the DL5 Getting Started Purpose Provides an overview of the manual. Describes the main features and operating capabilities of the DL5. Provides instructions for the initial desktop setup along with a description of the menus and prompts. Provides step-by-step instructions on how to enter a message along with message attributes. Provides instructions on reviewing and editing previously entered messages. Describes the operation of the DL5 while in the run mode. Describes the operation of the serial port. Describes the connection and operation of the parallel port. Describes the functions available under the Special Functions menu. Provides instructions on how to embed variable data in a message. Provides instructions on how to use the DL5 Pilot Light replacement run modes. Provides instructions on how to replace BCD displays with a DL5. Describes the installation requirements for mounting the display.

Entering New Messages

4 5 6 7 8 9 10 11

Reviewing and Editing Messages The Run Mode Using the Serial Port Using the Parallel Port Special Functions Using the Variable Data Feature Using the DL5 Parallel Port to Replace Pilot Lights Using the DL5 to Replace BCD Displays and Lookup Tables Installation Instructions

12

2706-UM001A-US-P

P-2

Using this Manual

Chapter 13

Title Maintenance and Troubleshooting Specifications Appendices, Glossary, Index

Purpose Provides general maintenance instructions. Also provides instructions on solving some of the most common operating problems. Electrical, mechanical, environmental specifications

14

Intended Audience

No special knowledge is needed to enter or edit messages. However, since the Dataliner message display must be connected to peripheral equipment, you should be familiar with computer communication terminology.

Conventions

The following conventions are used: Messages displayed on the DL5 are shown inside a rectangular box. (',7" A symbol or word in brackets represent a single key that you should press. These include keys such as [A] or [Retrn]. Since the DL5 can be programmed with a variety of terminals, the printing on your terminal keyboard may be different than the symbol or word indicated in brackets. In this manual, we use [Retrn] to specify the carriage return function of the keyboard. On your keyboard this may correspond to the [Enter] or [ ] keys.

Angle brackets, < >, are used when you are to enter variable data. For example, <message number>, means you are to enter a message number at that point. In the following chapters, we refer to the Dataliner DL5 Series Message Display as the DL5.

2706-UM001A-US-P

Chapter

Introduction to the DL5

Chapter Objectives

This chapter briefly describes some of the key features and operating capabilities of the DL5. If you require more detailed information, refer to the section of the manual that describes the use of the feature or operating capability.

Overview

The DL5 stores messages of varying length within its own memory. The stored messages are displayed when the DL5 receives a command from your control system. The messages can be used to show a status condition, help diagnose a problem, or prompt an operator. The Bulletin 2706 DL5 Series Dataliner Message Display (DL5) is available with two display options: One line display (16 characters) Two line display (16 characters per line) Note: The operation of the one and two line displays is similar. The few exceptions are noted in this manual. You can use a variety of devices to program the DL5 The Allen-Bradley line of industrial terminals (T1 through T4). Most DTE type dumb terminals. DEC VT100, VT101 terminals. IBM compatible computers, including Allen-Bradley RAC6000 industrial computers, using the DL5 offline programming software (Catalog No. 2706-NP5). The 16 character display can show a wide variety of characters and symbols, including: Uppercase letters Punctuation

2706-UM001A-US-P

1-2

Introduction to the DL5

Main Features

Serial or Parallel Triggering - Stored messages can be triggered by sending messages to the DL5 serial or parallel ports. Both the serial and parallel ports cannot be used at the same time. The Serial Trigger/ Configure DIP switch (SW1-1) on the back of the DL5 determines which port is used for triggering. DC Input - The parallel port of the DL5 accepts 5-24 volts DC. DL5s are powered by 12-24 volts DC. Round Robin Mode - The round robin mode allows you to replace up to sixteen pilot lights, that are being used as status indicators, with a single DL5 display. Instead of your control system turning on a pilot light, it will trigger a message for display. Priority Mode - The priority mode is similar to the round robin mode. However, the priority mode has an additional feature that allows you to designate certain messages as more important than other messages. If two or more messages are triggered at the same time, only the priority message will be displayed. Numeric Mode - The numeric mode allows you to use the DL5 as a numeric only 3 or 4 digit (BCD) display. Your control system can transmit real time binary coded decimal (BCD) data to the DL5 for immediate display. Use the DL5 to display numbers as large as 999, 999, 999, 999, 999. Binary or BCD Input Mode - Your control system can transmit data and message triggers in either binary or Binary Coded Decimal (BCD) formats. This allows the recall of up to: 94 messages with a one or two line 2K byte DL5 387 messages with a two line 8K byte DL5 Debug Mode - You can verify the operation of the program in a host programmable controller (PLC) using the debug function of the DL5. The debug mode will display the condition (ON or OFF) of the sixteen parallel port data lines. Note: Special application considerations may be necessary for some types of controlling devices. Refer to Chapter 8 for more details.

2706-UM001A-US-P

Introduction to the DL5

1-3

Memory Storage Capacity

The DL5 stores messages in blocks of 16 characters. Message blocks can be strung together to form messages longer than 16 characters. The one and two line 2Kbyte displays can store 94 message blocks (16 characters). The two line 8Kbyte displays can accommodate up to 387 message blocks. Both the one line and two line displays store messages in an EEPROM. No batteries for memory backup are required.

Programming Software

Allen-Bradley offers DL5 offline programming software (Catalog No. 2706-NP5) for IBM PC or compatible computers with a 3 1/2 inch disk drives. This includes Allen-Bradley RAC 6000 industrial computers.

Programming Cables

The following offline programming cables are available.

Serial Cable 2706-NC12 Use with: Personal computers with 25-pin female communication port connector. DEC VT52, VT100, or VT101 terminals. Allen-Bradley RAC 6000 industrial computers. Personal computers with 9-pin female communication port connector (IBM AT and compatible). Allen-Bradley RAC 6000 industrial computers. Allen-Bradley RAC 6000 industrial computers (PC/XT). Allen-Bradley Industrial Terminals T1 through T4 (25-pin male connector).

2706-NC13

2706-NC14 2706-NC15

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Introduction to the DL5

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Chapter

Getting Started

Chapter Objectives

In this chapter, you will learn how to set up the DL5 for desktop use. You will also become familiar with the opening menus and prompts.

Initial Desktop Hookup

To begin desktop programming of the DL5, you must have the following items: 12-24 VDC power supply. An Allen-Bradley Industrial Terminal (Catalog No. 1770-T1 through 1770-T4), a Data Terminal Equipment (DTE) type RS-232 dumb terminal, a DEC VT52, VT100, or VT101 terminal Personal computer with DL5 offline programming software. Programming cable Note: The terminal or host computer must initially operate with the following protocol: 9600 baud rate 8 data bits no parity 1 stop bit This is required for initial communications with the DL5. After initial hook up, change the baud rate using the DL5 menu.

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Getting Started

Initial Desktop Setup

To setup the DL5, perform the following steps:

Step 1
Connect DC power to the DC line terminals (TB2) on the back of the DL5. Note: The input voltage must be between 12 and 24 volts DC.
ATTENTION: To avoid system ground loops, the same power supply must be used for the parallel port and the power input for the DL5.

The terminals are labeled as shown below. For additional power supply requirements refer to the specifications listed in Chapter 14.
DC Line Terminals , Configure/Serial Trigger Switch

Switch 1 (SW-1) Enables Serial Trigger / Configure UP = Serial Trigger DOWN 1 DOWN = Configure

Configure Not Used UP 2 1 2

Serial Trigger Not Used

1 2

12
SW1

TB2 1 COM 2 12-24V DC Input

SW1 1 Serial Trigger/ Configure 2 Not Used

TB2

COMMON 12-24V DC
TB1

RS-232

D3 D2 D1 D0

PD D15 D14 D13 D12 D11 D10 D9 D8 D7 D6 D5 D4

PARALLEL PORT 5-24 VDC INPUT

Step 2
Make sure the Serial Trigger / Configure switch is set to Configure (down).

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2-3

Step 3
Connect the programming device communications cable. Attach one end of the communications cable to an Allen-Bradley Industrial Terminal, a DTE Terminal, or computer. Since there are variations between the connections required, refer to the following guidelines: If you are using an Allen-Bradley Industrial Terminal, connect the D type connector on the communications cable (Catalog No. 2706-NC15) to port B on the terminal. If you are using a DTE type CRT terminal, connect the 2706-NC15 communications cable to the computer communications port on the terminal. The computer communications port is usually labeled Main, EIA, or RS-232. Do not use the terminals labeled Remote, Printer, or Auxiliary. If you are using a DEC VT52, VT100, or VT101, connect a Catalog Number 2706-NC12 cable to the Main or RS-232 port. If you are using a computer and DL5 offline software, connect the appropriate programming cable to the COM1 serial communication port of the computer. Note: For cable requirements, see Chapter 6. Cable diagrams can be found in Appendix B.

Step 4
Plug the other end of the communications cable into the connector labeled RS-232 on the back of the DL5.

Step 5
Set your terminal or computer COM1 port to operate at: 9600 baud rate (default of the DL5) 8 data bits no parity 1 stop bit Important: Some terminals require that power be cycled off and then on before changes to communications protocol take effect. If the DL5 had been previously programmed, the baud rate may have been changed to something other than 9600 baud (e.g., 300 or 1200). The DL5 will display its baud rate on power up.

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Getting Started

Initial Power Up of the DL5

When DC power is applied to the DL5, it will display: '/ 9[[[ / Two separate displays on 1-Line DL5 

All of the light segments are turned on.

7(67,1*

Wait several seconds for the next display: 0(025< [ .

The memory display indicates the device memory capacity: 2Kbyte for Catalog No. 2706-D11J2 and -D21J2 8Kbyte for Catalog No. 2706-D21J8. The SELF TEST OK display indicates that all of the diagnostic tests have been completed. 6(/) 7(67 2.

After the diagnostic tests are completed the DL5 will display: %$8' 5$7( 

Indicating the current baud rate of the RS-232 port. (Default is 9600 baud). Then it will display the serial port address:. $''5(66 

And then depending on the DIP switch setting: 6(5,$/ 352*5$0 6(5,$/ 75,**(5

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2-5

Then the DL5 displays the current run mode: (Numeric, Priority, Round Robin, Binary or BCD) Finally, it will indicate it is entering the run mode and display the AUTORUN message. Note: The DL5 will always come up (after power down) in a run mode. This will be the last run mode that the unit was in before power down. The initial (out-of-the-box) default mode is numeric. Press the [ESC] (Escape) key three times to exit the run mode. You will then be shown the RUN? prompt. 581"

Press [N] and [Retrn] and you will be shown the EDIT? prompt. (',7"

You are now ready to enter messages as described in the next chapter. But first you should become familiar with the DL5s prompts and main menu.

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Getting Started

Responding to a Yes or No Prompt

There are three types of prompts that require a response: Yes or No prompts Numeric prompts Mnemonic prompts The yes or no prompts appear as a word or words followed by a question mark (?). You must respond to a yes or no prompt with either the letter Y (Yes) or the letter N (No). For example, the following prompt appears: (',7"

If you press the [N] key (upper or lowercase), the display will show: (',7"1

You can change your mind by pressing the [Y] key (upper or lowercase). The display now shows: (',7"<

Note: Only the letters Y or N are accepted as responses. You may change your response as many times as you would like prior to pressing the [Retrn] (carriage return) key. If you press the [Retrn] key the selection is entered into the DL5s memory and the next prompt will be displayed. A variation of the yes or no prompt is the default prompt. The default prompt provides an initial response or default for you. For example, assume the following prompt is displayed: )/$6+ 0(6*"1

If you press the [Retrn] key, the response No would be entered into the DL5s memory. If you press the [Y] key, the prompt response will change as in the previous example: )/$6+ 0(6*"<

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2-7

Responding to a Numeric Prompt

The other type of prompt you will encounter is the numeric prompt. You must respond to a numeric prompt with a number. A numeric prompt will appear as a word or words followed by a colon (:). For example, assume the following prompt is displayed: 180%(5 

If you were to press the key [2] the display would appear like this: 180%(5 

Pressing the key [7] will cause the display to change as follows: 180%(5 

Notice that the numbers that are entered scroll in from the right side. If you really wanted to enter the number 5, you could type the new number in over the previous response by first typing in four zeroes (0000) followed by the desired number 5. Pressing the [Retrn] key will now enter your response into the memory of the DL5 and the next prompt will be displayed. Numeric prompts may also have default values. For example, when the following is displayed: :$,7 7,0( 

To record the number 5 as your response, press the [Retrn] key. If you want to enter another value, type over the default. Press the [2] key, the display will show: :$,7 7,0( 

If you press the [Retrn] key, the number 2 would be entered as your response for the wait time.

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Getting Started

Responding to a Mnemonic Prompt

The last type of prompt you must respond to is a Mnemonic Prompt. These only occur when selecting a run mode within the Special Functions menu of the display. These are entered just like numerics. Only alpha characters are accepted. If an invalid mnemonic is entered, the original prompt with the current run mode mnemonic will be displayed. Valid run mode Mnemonics are: NM= PR= RR= BN= BC= NUMERIC PRIORITY ROUND ROBIN BINARY BCD

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Using the Main Menu

There are three selections within the main menu. They are: 1) RUN. While in the run mode, the DL5 accepts message trigger commands or real time variables (data) from the controller and then displays the appropriate message or data. 2) EDIT. Answering Yes to Edit allows you to create new messages or modify old messages. 3) SPECIAL FUNCTIONS. The special functions selection allows you to access special routines such as debug or memory clear functions. It also allows set up of the parallel, and serial ports as well as selection of a run mode. Answering [Y] to one of these main menu prompts will allow access to additional prompts pertaining to that selection. If you press the [N] (No) key and then the [Retrn] key, the prompt for the next main menu selection will be displayed. Refer to the following flow chart of the main menu:
Main Menu Flow Chart Initial Power-Up NUMERIC MODE

Displays current run mode.

0000

Press: [ESC][ESC][ESC] RUN?

Press:[Y]

You are now in RUN Mode. Refer to Chapter 5.

Press:[N] EDIT?

Press:[Y]

You are now in the EDIT mode. Refer to Chapters 3 and 4.

Press:[N] SPECIAL FUNC?

Press:[Y]

You are now in SPECIAL FUNCTIONS mode. Refer to Chapter 8.

Press:[N]

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Getting Started

Returning to the Main Menu

Most functions (except Run) will return you to the main menu when they have been completed. However, you can return to the main menu at any time by simply pressing the [Esc] key three consecutive times. When executed from the Run or Special Functions Modes, this will return you to the RUN? prompt of the main menu. However, when in the Edit Mode pressing the [Esc] key three consecutive times will return you to the Edit? prompt of the Main Menu. You will not lose any data or messages that have been previously entered when you press the [Esc] key.

Using the Control Key

To access certain special functions of the DL5, you may be required to use the [Ctrl] key in conjunction with another key. There are some variations in how you use the control key depending upon the type of terminal or computer you are using to program the DL5. Most terminals or computers will require you to hold down the [Ctrl] key and then press a second key. Note: If you are using an Allen-Bradley Industrial Terminal (Catalog No. 1771-T1, -T2, -T3, or -T4), you must press and release the [Ctrl] key prior to pressing the next key.

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Chapter

Entering New Messages

Chapter Objectives

In this chapter you will learn: How to assign attributes to a message. Message attributes define how a message will be displayed. How to enter messages.

Edit vs. Run Mode

Using the DL5 is a three step process: 1. First, messages are entered into the DL5s memory while in the edit mode. 2. Next, the run mode, autorun message, and operating characteristics of the serial and parallel ports are selected using the special functions menu. 3. Finally, the DL5 is put in the run mode. In the run mode external devices trigger the DL5 to display stored messages or real time variables. The attributes selected for each message, such as flash message, scroll, etc. will control how each message is displayed.

Selecting the Edit Mode

You can either enter a new message or edit an existing message by selecting the edit mode. You select the edit mode by pressing the [Y] key in response to the EDIT? prompt. Note: To get the EDIT? prompt from the RUN mode, press [Esc] three times, answer [N] to RUN?, and press [Retrn]. Once you have entered the edit mode, the DL5 will display a series of prompts. Refer to the next page for a flow chart of the edit mode menu. Important: Menu shown is for a 2 line DL5. One line displays do not have the prompts (USE BOTH?, USE LINE 1?, USE LINE 2?, USE LEAST?).

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Entering New Messages

Edit Mode Menu

EDIT?

Press:[Y]

NUMBER:

NO ROOM!

Enter Number If Message Exists

If Memory Full

SHOWS PORTION OF EXISYING MESSAGE To edit or change the message, use the edit commands described in Chapter 4

If No Message Exists USE BOTH? WAIT TIME:

Press:[Y]

Press:[N] USE LINE 1?

Enter Time AUTO CLEAR? Press:[Y]

Press:[N] USE LINE 2? SCROLL MODE?

Press: [Y] or [N] AUTO REPEAT?

Press:[Y]

Press:[N] USE LEAST?

Press: [Y] or [N] FLASH MESG? Press:[Y]

Press:[N]

Press:[Y] or [N] ENTER MESSAGE

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3-3

Specifying Message Attributes

After you have entered the edit mode and selected a new message number to edit, you must specify the message attributes. The message attributes determine how the message is displayed. The DL5 prompts for each attribute, one at a time. You must respond to all the attribute prompts that are displayed. Note: If any attribute setting is changed and then the [Esc] key is pressed three times, the changed attribute is not saved. It is necessary to carriage return through all attribute settings to change one of them. Some message attributes are mutually exclusive; you can select either one, but not both. Refer to the edit menu diagram (previous page) and the following descriptions when specifying message attributes.

Line Selection
If you are using a single line DL5, there are no line selection prompts and you should refer to the next section. If you are using a two line DL5, the first message attribute that you must specify is the line, or lines, that the message will be displayed on. There are four options: 1) USE BOTH 2) USE LINE 1 3) USE LINE 2 4) USE LEAST As the DL5 (two line only) displays a line selection prompt, you must respond with either a [Y] (Yes) or [N] (No) response. If you respond to a prompt by pressing the [Y] key followed by the [Retrn] key, the message attribute is entered into the memory of the DL5. If you respond by pressing the [N] key followed by the [Retrn] key, the next line selection option will be displayed. The following sections describe what effect each option has on the displayed message.

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Entering New Messages

USE BOTH?

Selecting the USE BOTH option will automatically display the message on both lines of the display as a line mode message. A multi-line message will display with the first line of the message on the first line of the display. The next line of the message is displayed on the second line of the display. If the message is longer than the number of lines of the display, the DL5 will wait for the wait time, and then show the remaining lines of the message.
USE LINE1?

The USE LINE 1 option displays the message only on the first (top) line of the display. Any messages present on the second line (if any) will remain intact.
USE LINE2?

The USE LINE 2 option displays the message only on the second line of the display. Any messages present on the first line of the display (if any) will remain intact.
USE LEAST?

The USE LEAST option displays the message on the least recently used line (oldest line of information). Any messages present on the other line of the display (if any) will remain intact.

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3-5

Selecting Line or Scroll Mode

If you are using a single line DL5, the first prompt you will see displayed is the prompt for the line or scroll mode option. The prompting for line or scroll mode will also be displayed if you are using a two line DL5 and you did not choose the USE BOTH display option. The prompt will appear like this:
SCROLL MODE?

If you do not select the SCROLL MODE option, the line mode will be automatically selected. Scroll Mode A scroll mode message scrolls across the display one character at a time. Characters enter from the right side of the display and exit on the left. Line Mode A line mode message is displayed one message block (16 characters) at a time. Many of the messages that you create may be more than one block long. If a message is made up of more than one message block, the DL5 will display a message block for the specified wait time and then display the next blocks of the message. Remember: If you are using a two line DL5 and selected the BOTH LINES option, the line mode will be selected automatically. You will not be prompted for the SCROLL MODE option.

Selecting Message Wait Time

The next message attribute that you must select is the message wait time. The message wait time controls how long a message or a portion of a message is displayed. The prompt for the message wait time appears like this:
WAIT TIME:

You must enter a wait time value between 0 and 15. The unit of time being selected depends upon whether line or scroll mode was chosen. If the scroll mode has been selected, the wait time is the amount of time that elapses before the next character is scrolled on the display. The unit of time is in tenths of a second. If the line mode has been selected, the wait time is the amount of time that a message block is displayed. The unit of time is in seconds.

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Entering New Messages

Auto Clear Option

The next prompt that you must respond to controls whether or not the display will clear after the message is shown. The prompt appears like this:
AUTO CLEAR?

If you select the AUTO CLEAR option, the DL5 will clear the display after the message has been displayed for the requested wait time. If you do not select the AUTO CLEAR option, the last block of the message will remain on the display until it is replaced with another message.

Auto Repeat Option

The next prompt that you must respond to allows a message to be repeated indefinitely. The prompt for the AUTO REPEAT option appears like this:
AUTO REPEAT?

If you select the AUTO REPEAT option, the message continually re-triggers itself after it completes its display. If you do not select the AUTO REPEAT option, the DL5 will display the message only once for every message trigger that is received. Note: The AUTO REPEAT function will only work with message triggers that are in either binary or Binary Coded Decimal (BCD) format. The function will not work when the DL5 is in the round robin or priority mode of operation.

Flash Message Option

The last prompt determines whether or not the message flashes:
FLASH MESSAGE?

Selecting the FLASH MESSAGE option will cause the message to flash once per second while it is being displayed. After you respond to the FLASH MESSAGE prompt, the DL5 will display a flashing cursor. You can now enter a message.

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3-7

Default Values for Message Attributes

All of the message attributes have default values. The first time you enter a message into a new DL5, or one which has had its memory cleared, the DL5 specifies a default value. From then on, the default values for a new message are the same as the previous message you entered. This feature allows you to quickly enter a number of messages when all of the messages have the same or similar attributes.

Entering a Message

After you have specified all the attributes for a message, you can now enter the actual message. The DL5 stores messages in blocks of 16 characters. A message may be more than one block in length. The number of blocks that comprise a message is limited only by the amount of memory available. After you have specified a messages attributes, the DL5 will inform you that a new message can be entered by flashing an asterisk shaped cursor:
*

Note: You can edit the message being entered, or any previously entered message, by using the edit commands. Chapter 4 describes how to use the edit commands. You can now enter your message. As you type, notice that the cursor moves towards the right side of the display as characters are entered. If the cursor reaches the first character segment on the right, the next character that you enter will position the cursor back at the first character segment on the left. For example, a new message is to be entered on a two line DL5 display (16 characters in a block). The DL5 will position the cursor at the first character position on the left:
*

If the message <Motor Starter #> is entered, the display will appear like this:
MOTOR STARTER #*

If the number <1> is entered at the last character position, the cursor will move to the first character segment on the left. The display will appear like this:
*OTOR STARTER #1

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Entering New Messages

If you would enter any additional characters, the original characters would be overwritten with new characters. If you would type in <AllenBradley> the message would appear like this:
ALLEN-BRADLEY*#1

If you want to enter a message that is comprised of more than 16 characters (one block) in length, you must press the [Ctrl] and [J] keys simultaneously after the first message block is entered. The DL5 will then move the cursor to the beginning of the next block of text. For example, if you wanted to enter the message Feed Conveyor Is On you would need at least two message blocks to enter the message. First you would enter the first part of the message <Feed Conveyor>. The DL5 will display:
FEED CONVEYOR*

You would then select the next message block by pressing the [Ctrl] and [J] keys. The DL5 will display:
*

You can now enter the second block of the message <IS ON>. The DL5 will display:
IS ON*

Note: If you press the [Ctrl] and [J] keys simultaneously at the end of a message, a blank message block at the end of the message will be created. The blank message block will be displayed for the specified wait time. This can cause apparent delays between messages when the display is in the run mode. Do not type [Ctrl] [J] at the end of a message. Now when the message is triggered, a two line DL5 will display the message:
FEED CONVEYOR IS ON

After you have finished entering your message, you can return to the EDIT? prompt in one of two ways: You can press the [Esc] key three times. You can press the [Ctrl] and [Q] keys to select the quit function.
Embedding Numeric Variable Data in a Message

Numeric variable data can be inserted in a message. Refer to Chapter 9 which describes how to use the variable data feature.
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3-9

Entering a Sample Message

The quickest way to learn how to use the DL5 is to enter some messages. This section provides instructions on entering a sample message. Note: Default values will appear on all of the message attribute prompts. If the default value is the desired response, press the [Retrn] key to accept the default value. If necessary, refer back to Chapter 3 descriptions of default values. To enter the sample message, perform the following steps: 1. Make sure that the DL5 is displaying the following prompt:
EDIT?

Note: To get the EDIT? prompt from the RUN mode, press [Esc] three times, answer [N] to RUN?, and press [Retrn]. 2. Press the [Y] and [Retrn] keys to enter the edit mode. The DL5 will display:
NUMBER: 0

3. Enter a message number that does not presently exist and then press the [Retrn] key. The DL5 will display one of two prompts depending upon the type of display (one or two line) that you are using. If you are using the two line version of the DL5, the following will be displayed:
USE BOTH?

Proceed to Step 4

If you are using the one line version of the DL5, the following will be displayed:
SCROLL MODE?

Proceed to Step 6

4. Press the [N] and [Retrn] keys in response to the USE BOTH? prompt. The DL5 will display:
USE LINE1?

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Entering New Messages

5. Press the [Y] and [Retrn] keys in response to the USE LINE 1? option. The DL5 will display:
SCROLL MODE?

6. Press the [N] and [Retrn] keys in response to the SCROLL MODE? prompt. This will select the message to be displayed in the line mode. The DL5 will display:
WAIT TIME:

7. You want each block of the message to be displayed for three seconds. Press the [3] and [Retrn] keys to select a wait time of 3. The DL5 will display:
AUTO CLEAR?

8. You want the message to be cleared from the display after the selected wait time has elapsed so press the [Y] and [Retrn] keys. The DL5 will display:
AUTO REPEAT?

9. The message that is being entered will only be displayed once per trigger, so press the [N] and [Retrn] keys. The DL5 will display:
FLASH MESG?

10. You want the message to flash, so press the [Y] and [Retrn] keys to select the flashing message option. The DL5 will display a flashing cursor which indicates that a new message can be entered. 11. Enter the message <HOLDING TANK #1>. The message will appear on the display:
HOLDING TANK#1*

12. Press the [Ctrl] and [J] keys to move the cursor to the next block of the message. The DL5 will display the cursor at the first character position in the second block of the message.
*

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3-11

13. Enter the second part of the message <IS FULL>. The message will appear on the display:
IS FULL*

14. You have completed entering the message. You can see how the message will appear when triggered by pressing the [Ctrl] and [R] keys simultaneously. The DL5 will flash the first block of the message for approximately three seconds. And then the DL5 will display the second block of the message for three seconds: Note: Chapter 4 describes this and other methods of reviewing a message. 15. Return to the EDIT? prompt by pressing the [Ctrl] and [Q] keys or by pressing the [ESC] (Escape) key 3 times.

Programming Multiple DL5s Identically

A quick method of programming multiple displays with identical messages is to use the DL5 Series Off-line Programming Software (Catalog No. 2706-NP5). Instructions on using the software are provided with the software package. The software can be run on IBM PC or compatible computers with 3 1/2 inch disk drives. This includes Allen-Bradley RAC 6000 industrial computers.

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Entering New Messages

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Chapter

Reviewing and Editing Messages

Chapter Objectives

This chapter describes how to review and edit existing messages using DL5 edit commands. Using a programming terminal, you can display a previously entered message as it would normally be displayed in the run mode. To display a message:

Reviewing a Message

1. Make sure the following prompt is displayed: EDIT?

To get the EDIT? prompt from the Run mode, press [Esc] three times, answer [N] to RUN? and press [Retrn]. 2. Press the [Y] and [Retrn] keys to enter the edit mode. The DL5 will display: NUMBER = 0

3. Enter the message number of the message you want to review and then press the [Retrn] key. The DL5 will display the first block of the message. 4. Press the [Ctrl] and [R] keys simultaneously. The DL5 will then display the message as it would appear with all its selected attributes. 5. After displaying the message, the DL5 will return to showing a portion of the message. The DL5 is still in the edit mode. You can now edit the message using the techniques described in this chapter or you can exit the edit mode by pressing the [Ctrl] and [Q] keys simultaneously. The DL5 returns to the EDIT? prompt.

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Reviewing and Editing Messages

Displaying the Amount of Memory Remaining

You can command the DL5 to display the amount of memory (message blocks) remaining for new messages or additions to existing messages. To display the number of message blocks remaining, press the [Ctrl] and [F] keys simultaneously while the display is in the edit mode showing part of a message. The DL5 will display: FREE SPACE 0020

The number that is displayed is the number of message blocks remaining. Each message block can contain 16 characters. After two seconds, the DL5 will automatically return to the same block of the message that was being displayed prior to the [Ctrl] [F] function. The table below lists the commands available for your use. Use this table as a quick reference for the DL5 commands. DL5 Edit Commands
Keys Pressed [Ctrl] [A] [Ctrl] [C] [Ctrl] [D] [Ctrl] [E] [Ctrl] [F] [Ctrl] [H] [Ctrl] [I] [Ctrl] [J] Command Function Allows access to previously entered message attributes so they can be reviewed or changed. Centers a message on the display. Deletes a single message block. Erases an entire message. Shows the number of free message blocks remaining. Moves the cursor one character position to the left. Inserts a message block between two previously entered message blocks. Creates a new message block after previously entered message blocks or moves the cursor one message block towards the end of the message. Moves the cursor one message block towards the beginning of the message. Moves the cursor one character position to the right. Exits the edit mode with save. Runs a message in the edit mode. Embeds a single digit variable in a message. Displays the data without leading zeros. Imbeds a single digit variable in a message with leading zeros.

[Ctrl] [K] [Ctrl] [L] [Ctrl] [Q] [Ctrl] [R] [Ctrl] [V] [Ctrl] [X]

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4-3

Selecting a Message to Edit

To edit a previously entered message, perform the following steps: 1. Make sure the following prompt is displayed. EDIT?

Note: To get to the EDIT? prompt from the Run Mode, press [Esc] three times, answer [N] to RUN? and press [Retrn]. 2. Press the [Y] and [Retrn] keys to enter the edit mode. The DL5 will display: NUMBER: 0

3. Enter the message number of the message that you want to edit and then press the [Retrn] key. The DL5 will then display a portion of the message you want to edit. You can now edit the message using the edit commands.

Moving the Cursor

All editing activity occurs at the cursor position. To edit a message, you must first position the cursor at the characters that are to be changed. The following commands are used to position the cursor. Forespace [Ctrl] [L] This command moves the cursor one character position to the right. You select the forespace command by pressing the [Ctrl] and [L] keys. If the cursor is already at the last character position, the cursor will move to the first character position on the left side of the display. Note: Many types of terminals have a forward arrow key. This key will often generate the [Ctrl] [L] command. Backspace [Ctrl] [H] This command moves the cursor one character position to the left. You select the backspace command by pressing the [Ctrl] and [H] keys. If the cursor is already at the first character position in the message the cursor will move to the last character position. Note: Many types of terminals have a back arrow or a [BACKSPACE] key. Both of these keys will often generate the [Ctrl] [H] command. Forward One Message Block [Ctrl] [J] This command moves the cursor one message block towards the end of the message. If the cursor is already at the last message block in a message, the command will create a new message block directly after the previous message block. You select the forward one message block command by pressing the [Ctrl] and [J] keys. Note: Do not type [Ctrl] [J] after the final message block has been entered. A blank message block will be created and displayed as part of the message.
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Reviewing and Editing Messages

Back One Message Block [Ctrl] [K] This command moves the cursor one message block towards the beginning of the message. If the cursor is already at the first message block in the message, the DL5 will ignore the command. You select the back one message block command by pressing the [Ctrl] and [K] keys.

Deleting a Character

You can delete a character by typing in a new character directly over the old character. If you want to delete a character and replace it with a blank space, use the [SPACE] key. You can delete an entire message block by pressing the [SPACE] key repeatedly until all of the characters are replaced with blank spaces. However, the message block will not be deleted from memory.

Deleting a Message Block

You can delete an entire block of a message by pressing the [Ctrl] and [D] keys. The delete message block command will delete all 16 characters in a message block. After you delete a message block, the DL5 will then display one of three items: If you deleted the first message block in a multiple block message, the DL5 will display the second block of the message. If you deleted any message block, other than the first message block in a multiple block message, the DL5 will display the previous message block. If you deleted the only message block in a single block message, the entire message is deleted and the DL5 will display the EDIT? prompt. For example, assume that the DL5 contains the following message which is stored in three separate message blocks:
PRESSURE IN RESERVOIR TANK IS NORMAL

Assume the cursor is positioned at the first character in the second message block. The DL5 display will appear like this: *ESERVOIR TANK

If the [Ctrl] and [D] keys are now pressed, the message block RESERVOIR TANK will be deleted. The message now contains just two message blocks:
PRESSURE IN IS NORMAL

The DL5 displays the message block that was preceding the deleted message block: *RESSURE IN

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4-5

Inserting a Message Block

You can insert a message block (if free message blocks are available) between two previously existing message blocks by pressing the [Ctrl] and [I] keys. The new message block is inserted after the message block that was being displayed when the insert message block command was pressed. For example, assume that the DL5 contains the following message which is stored in two separate message blocks:
CONVEYOR BELT HAS STOPPED

Assume that the cursor is positioned at the first character in the first message block. The DL5 display will appear like this: *ONVEYOR BELT

Note: The cursor does not have to be in the first character position. If the [Ctrl] and [I] keys are now pressed, a new message block will be created after the first message block. The DL5 will display: *

If the message <IN SHIPPING> is entered in the new message block, the message would now contain three message blocks:
CONVEYOR BELT IN SHIPPING HAS STOPPED

Deleting an Entire Message

You can quickly delete an entire message from memory by pressing the [Ctrl] and [E] keys. The command will erase all of the message blocks contained in a message. For example, assume that the DL5 contains the following message which is stored in two message blocks:
HOPPER #2 IS EMPTY

Assume that the cursor is positioned at the first character position in the second message block. The DL5 display will appear like this: *S EMPTY

If the [Ctrl] and [E] keys are now pressed, the DL5 will first display: SURE?

Next the [Y] and [Retrn] keys must be pressed to confirm that the message is to be deleted. The DL5 will delete the message and then display: EDIT?

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Reviewing and Editing Messages

Editing Message Attributes

To edit the previously entered attributes of a message, perform the following steps: 1. Make sure the following prompt is displayed: EDIT?

Note: To get to the EDIT? prompt from the Run Mode, press [Esc] three times, answer [N] to RUN?, and press [Retrn]. 2. Press the [Y] and [Retrn] keys to enter the edit mode. The DL5 will display: NUMBER: 0

3. Enter the message number of the message you want to edit and then press the [Retrn] key. The DL5 will display a portion of the message. 4. Press the [Ctrl] and [A] keys. If you are using a one line display, the DL5 will display: SCROLL MODE?

If you are using a two line display, the DL5 will display: USE BOTH?

5. You can now change message attributes by entering new [Y] or [N] responses to the message attribute prompts and then pressing the [Retrn] key. Or you can keep the original attributes by pressing the [Retrn] key. The attribute prompts will appear in the same sequence as when they were first entered.

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Chapter

Run Mode

Chapter Objectives

This chapter describes how to enter and exit run mode. You will also learn how the DL5 operates while in run mode.

Entering Run Mode

Run Mode - Parallel Operation

To enter run mode for parallel operation: 1. Make sure the Serial Trigger / Configure DIP switch (SW1-1) is in the DOWN (Configure) position.
Configure Not Used DOWN 1 2 SW1

2. Check that the following prompt is displayed: RUN?

Note: To get the RUN? prompt from the Special Functions Mode, press [Esc] three times. From the Edit Mode, it is also necessary to answer no to Edit? and Special Functions? 3. Press the [Y] and [Retrn] keys to enter the run mode. The DL5 will display either a blank screen or a selected autorun message. Chapter 8 describes the autorun message and how the autorun message is selected. The DL5 is now in the run mode and will display any messages that are triggered by the control system. To exit the parallel run mode: Press the [Esc] key three times. The DL5 displays the following prompt when run mode is terminated: RUN?

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Run Mode

Run Mode - Serial Operation

To enter the serial triggering run mode: Move the DIP switch (SW1-1) to the UP (serial trigger) position.
Serial Trigger Not Used UP SW1 1 2

This immediately switches the DL5 from the edit to run mode. The operation of the serial port changes from programming to serial message triggering. Note: Any message edits or menu entries are terminated when the DIP switch position is changed. After entering the serial trigger mode, the standard startup screens are displayed followed by the autorun message. The DL5 will then interpret any serial data as a message trigger command. To exit the serial triggering run mode: Move the DIP switch (SW1-1) to the Down (configure) position.
Configure Not Used DOWN 1 2 SW1

This switches the DL5 from the run to edit mode. The operation of the serial port changes from serial message triggering to programming. The following is displayed after exiting the serial triggering mode: RUN?

With the DIP switch in the Configure position, any serial data is interpreted as a menu or edit command.

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5-3

Description of Run Mode

In the run mode, the DL5 waits for the host to send message triggers and/or variable data. The DL5 receives message triggers and variable data through either the parallel or serial port. The serial and parallel ports cannot be active at the same time. The Serial Trigger/Configure DIP switch determines the active port (Serial Trigger position = serial port, Configure position = parallel port). When a message trigger is received, the DL5 searches its memory for the selected message, inserts any imbedded variables, and then displays the message. If another message trigger is sent to the DL5 before the first messages wait time has expired, the DL5 stores the message trigger in a message buffer. The capacity of the message buffer is one message. Refer to the following example which shows how the message buffer operates. 1. The host controller sends a message trigger for message number 27 to the DL5. The DL5 removes the message trigger from the message buffer and displays message number 27.
Control System DL5
Message Trigger #27 Sent Message Buffer 27 Message #27 is displayed

2. While the DL5 is displaying message number 27, the DL5 receives a message trigger for message number 18. The message trigger is stored in the message buffer.
Control System DL5
Message Trigger #18 Sent Message Buffer 18 Message #27 is still displayed; its wait time has not expired.

3. The DL5 receives an additional message trigger for message number 45, while message number 27 is still displayed. Since the message buffer already contains a message trigger, the trigger for message number 45 is ignored.
Control System
Message Trigger #45 Sent

DL5
Message Buffer 18 Message #45 Ignored Buffer is Full Message #27 is displayed

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Run Mode

4. After the DL5 completes the display of message number 27, the DL5 removes the message trigger for message number 18 from the message buffer and then displays message number 18. The message buffer is now ready to accept another message number.
Control System DL5
Message Buffer Message #18 is displayed

Note: While in the priority or round robin modes of operation, the DL5 does not store message triggers in the buffer.

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Chapter

Using the Serial Port

Chapter Objectives

The DL5 has a full duplexed RS-232 serial port which is used for: communication with the offline programmer and for programming input from a dumb ASCII terminal. serial triggering of messages The operation of the serial port is determined by the Serial Trigger/ Configure DIP switch on the back of the DL5 see page 2-2. The RS-232 serial port is a 9-pin male D-shell connector located at the rear of the DL5. A drawing of the DL5s connector is provided below:
DCD

TXD RXD

DTR COM

1
RS-232

2 6
DSR

3 7
RTS

4 8
CTS

5 9
RI

The RS-232 port operates at baud rates of 300, 1200 and 9600 baud. The rate is user selectable through the Special Functions Menu or the Offline Programmer. The default baud rate of the DL5 is 9600 baud.

Programming Cables

Cables are available to connect various programming devices. The following table lists the cable to use with various terminals or computers:
Serial Cable Description Catalog Number 2706-NC12 Personal computers with 25-pin female communication port connector. DEC VT52, VT100, or VT101 terminals. Allen-Bradley RAC 6000 industrial computers. Personal computers with 9-pin female communication port connector (IBM AT and compatible). Allen-Bradley RAC 6000 industrial computers. Allen-Bradley RAC 6000 industrial computers (PC/XT). Allen-Bradley Industrial Terminals T1 through T4 (25-pin male connector).

2706-NC13

2706-NC14 2706-NC15

See Appendix B for cable diagrams and descriptions.

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Using the Serial Port

RS-232 Signals

The DL5s RS-232 port uses Transmit Data signal, Receive Data signal, and Signal Common. The Clear To Send, Data Carrier Detect, and Data Set Ready pins are tied high (+12V) by the DL5, allowing direct connection of the DL5 to terminals or computers requiring a request to send signal. No jumpers at the terminal or computer connector should be required.
Pin Number 1 2 3 4 5 6 7 8 9 Signal Name (Signal Mnemonic) Data Carrier (DCD) Transmit (TXD) Receive Data (RXD) Data Terminal Ready (DTR) Signal Common (COM) Data Set Ready (DSR) Request to Send (RTS) Clear to Send (CTS) Ring Indicator (RI) Signal Type Output Output Input Input -Output Input Output Output

Data Carrier Detect - Pin 1 Indicates that a continuous frequency capable of being modulated or impressed with a signal is being received. The DL5 sets this line high. Transmit Data - Pin 2 Sends out the serialized data from the DL5 (e.g., the serial data is on this pin). Received Data - Pin 3 This signal also carries serial data. However, the serialized data is sent from another device as input to the DL5. Data Terminal Ready - Pin 4 Indicates the transmission device (terminal) is connected, powered up, and ready to send data. The DL5 ignores this line. Signal Common - Pin 5 The ground reference for all other signals. Data Set Ready - Pin 6 Indicates that a communications device is connected, powered up, and ready for data transmission. The DL5 sets this line high. Request to Send - Pin 7 Signal from the terminal device requesting the communication device to send data. This typically turns on the data carrier. The DL5 ignores this line. Clear to Send - Pin 8 This signal indicates to the transmitting device that it can start sending data. The DL5 sets this line high. Ring Indicator - Pin 9 This signal indicates that each device is physically connected to adjacent devices. The DL5 sets this line high.

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6-3

Serial Port Protocol

When the DL5 is set to be triggered through the serial port, use the following protocols to trigger messages and display variable data:

Message Trigger [Ctrl][T]

Use the CTRL-T command to trigger messages while the DL5 is in the binary and BCD modes. The message number and address are decimal values. The command has the following format:
CTRL-T Message Number \ Backslash DL5 Address Carriage Return

where: Message Number is a decimal value in the range 1-999 DL5 Address is a decimal value in the range of 0-127 For example, to trigger Message #123 on a DL5 with an address of 10, the following string would be sent:
ASCII HEX ^T 14 1 31 2 32 3 33 \ 5C 1 31 0 30 ^M 0D

Note: If you need to trigger messages (Round Robin and Numeric modes), with a PLC that does not support unsigned integers, refer to the application note in Appendix D Note: If the DL5 is in serial trigger mode and you attempt to download messages using the offline programming software, data corresponding to a message trigger command will be executed.

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Using the Serial Port

Variable Data [CTRL][V]

Use the CTRL-V command to send data for display in Binary, BCD, Numeric, Priority, and Round Robin modes. All values are decimal values. The command has the following format:
CTRL-V Variable Data \ Backslash Variable Position \ Backslash DL5 Address Carriage Return

where: Variable Data is 1 to 5 ASCII digits (0-65535) Variable Position is single ASCII digit (value is ignored) DL5 Address is 1 to 3 ASCII digits (0-127) For example, to send a value of 500 to a DL5 with an address of 99, the following string would be sent:
ASCII HEX ^V 16 5 35 0 30 0 30 \ 5C 1 31 \ 5C 9 39 9 39 ^M 0D

Note: In Binary mode, variable data can be in the range 0 to 16,383. In BCD mode, variable data must be in the range 0 to 3999. In Round Robin and Numeric modes, variable data can be in the range of 0 to 65535.

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Chapter

Using the Parallel Port

Chapter Objectives

This chapter provides: A description of the parallel port. Data format requirements for parallel input. Descriptions and examples of message triggering. Parallel port interface examples. Note: This chapter describes how you can use the parallel port to trigger messages. If you require information on how to input variable data, refer to Chapter 9.

Description of the Parallel Port

ATTENTION: The DL5 only has single direction communications (receives data, cannot send data). Do not use the DL5 for critical display applications. Single direction communications does not provide verification that messages sent by the control system have been received and displayed by the DL5.

You can use the parallel port of the DL5 to trigger messages and to input variable data. The parallel port is located on the back of the DL5. The parallel port terminals (TB1) are labeled as shown on the next page.

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Using the Parallel Port Parallel Port Connections (TB1)

1 2

12
SW1

TB2 1 COM 2 12-24V DC Input

SW1 1 Serial Trigger / Configure 2 Not Used

TB2 TB1

RS-232

D3 D2 D1 D0

PD D15 D14 D13 D12 D11 D10 D9 D8 D7 D6 D5 D4

PARALLEL PORT 5-24 VDC INPUT

Parallel Port

Terminals D0 through D15 are for message number and data input. Terminal PD is for the enabling or disabling of the parallel port. If PD is tied high, the port is disabled and the DL5 will ignore data on data lines D0-D15. If PD is low, the port is enabled and the DL5 will read and respond to data on data lines D0-D15. As long as PD is controlled separately, using PD will allow multiple DL5s to be connected to one set of outputs (multiplexed). The input voltages for terminals D0 through D15 and PD can vary from 5 to 24 volts DC. The figure below shows a circuit diagram of an input terminal.
Parallel Port Input Circuit

+5 VDC

DATA D0-D15 3.3K COM

100K

LATCH Latch Closes When the PD Terminal On the DL5 Parallel Port Is Open or Low

3.3K

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7-3

Selecting BCD or Binary Data Format

The parallel port will accept data and message triggers in either a binary or Binary Coded Decimal (BCD) format or in non-coded discrete form which allows the DL5 to easily replace pilot lights as described in Chapter 10. Each numbering system, binary or BCD, has its own merits. Your choice will often be based upon the format used by your controller. Both the binary and BCD numbering systems allow you to address all 999 possible message numbers but vastly different maximum variable values. The maximum variable value that can be input in binary or BCD run modes is shown below:
Run Mode BCD Binary Maximum Message # 999 999 Maximum Variable Value 3,999 16,383

You must select which format best suits your needs and then select the run mode as described in Chapter 8.

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Using the Parallel Port

Using Binary Data Input

In the binary (Run) mode, the DL5 interprets data on terminals D0 through D13 as binary data. Terminals D14 and D15 are the strobe lines. Terminal D0 represents the least significant digit and D13 represents the most significant digit. A data line may either be at ground level, which represents a binary value of 0, or a data line may have a voltage present, which represents a binary value of 1. The convention of having a voltage represent a value of 1 and ground representing a value of 0, is known as positive binary logic (high true logic). The opposite convention is known as negative binary logic (low true logic). You can set the DL5 to accept either positive or negative logic (high or low true), refer to Chapter 8. The following table shows the value of each data line. Selecting the binary data run mode is explained in Chapter 8.
Binary Values of the Data Lines

Data Line D0 D1 D2 D3 D4 D5 D6 D7

Value When On (True) 1 2 4 8 16 32 64 128

Data Line D8 D9 D10 D11 D12 D13 D14 D15

Value When On (True) 256 512 1,024 2,048 4,096 8,192 Strobe Line Strobe Line

The table below shows the control functions of the strobe lines:
D14 D15 Function Indicates that binary value on D0 through D13 represents a message number. Indicates that binary value on D0 through D13 represents variable (numeric) data. Binary value on D0 through D13 is ignored.

High or Low High High Low Low Low

Example: Assume that the following logic levels (positive logic) appear on the data lines.
Data Line: Logic Level: Value: D0 1 1 D1 0 0 D2 0 0 D3 0 0 D4 1 16 D5 0 0 D6 0 0 D7 1 128 D8 0 0 D9 0 0 D10 0 0 D11 0 0 D12 1 4,096 D13 0 0 D14 1 0 D15 0 0

Adding the values of the individual data lines provides the value being entered, in this example 4,241. Since strobe line D14 is high (voltage present) and D15 is low (ground level), this value is interpreted as variable data.
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7-5

Using BCD Data Input

The fourteen data lines can also be used to input BCD formatted data. The BCD numbering system uses a group of four data lines to represent a single decimal digit. The table below shows the value of each data line. Selecting the BCD run mode is explained in Chapter 8.
BCD Values of the Data Lines

Data Line D0 D1 D2 D3 D4 D5 D6 D7

Value When On (True) 1 2 4 8 10 20 40 80

Data Line D8 D9 D10 D11 D12 D13 D14 D15

Value When On (True) 100 200 400 800 1,000 2,000 Strobe Line Strobe Line

Control functions of the strobe lines are the same for BCD data input as for binary data input. For example, assume the following logic (positive logic) levels appear on the data lines.
Data Line: Logic Level: Value: D0 1 1 D1 0 0 D2 1 4 D3 0 0 D4 0 0 D5 0 0 D6 1 40 D7 0 0 D8 1 100 D9 0 0 D10 0 0 D11 0 0 D12 1 1,000 D13 0 0 D14 1 0 D15 0 0

Adding the values of the individual data lines provides the value being entered, in this example 1,145. Again, D14 is high (voltage present) and D15 is low (ground level), so this number is interpreted as variable data.

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Using the Parallel Port

Logic Levels

The DL5s parallel port accepts DC inputs of 0-24 volts. These input voltages can be used to trigger messages or transfer variable (numeric) data. The DL5 interprets the voltages that are present on the data lines as either a High or Low condition. There is also a third state which should be avoided, an in between or indeterminate state. The indeterminate state occurs when the input voltage is between the High voltage range and the Low voltage range. The voltage ranges that the DL5 interprets as either High or Low values depends on whether positive or negative binary logic has been selected. The table below lists the voltage ranges and their logic values.
Positive Logic Level High (True) Low (False0 Negative Logic Level Low (True) High (False) Recognized Voltage Range 3.5 to 24V DC 0 to 0.9V DC Indeterminate Voltage Range 0.9 to 3.5V DC 0.9 to 3.5V DC

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7-7

Using the Numeric (Run) Mode

In this mode, the DL5 interprets inputs into the parallel port only as BCD numeric data and immediately displays the BCD number. Only line 1 of the DL5 is used. Inputs to the first twelve terminals (D0 through D11) are always interpreted as three BCD digits. Inputs to the last four terminals (D12 through D15) are interpreted as a fourth BCD digit (if the input is a valid BCD code), or as a special instruction code (if the input is not a valid BCD code). The special instruction code allows you to define a destination on the DL5 display for the three BCD numbers on data lines D0 through D11. This allows a number as large as 15 digits, two 6 digit numbers, or three 3-digit numbers to be displayed on the DL5. The table below defines the special instruction codes of D12 through D15.
Numeric Mode Functions

D15 0 0 0 0

D14 0 0 0 1

D13 0 0 1 0

D12 0 1 0 0

Value 0 1 2 3 4

Function Interprets input as a fourth BCD digit of the value given

0 0 0 1 1 1

1 1 1 0 0 0

0 1 1 0 0 1

1 0 1 0 1 0

5 6 7 8 9 Displays the three BCD digits (from inputs D0-D11) in the first 3 (leftmost) character positions. Displays the three BCD digits (from inputs D0-D11) in the second character position from the left. Displays the three BCD digits (from inputs D0-D11) in the third character position from the left. Displays the three BCD digits (from inputs D0-D11) in the fourth character position from the left. Displays the three BCD digits (from inputs D0-D11) in the fifth character position from the left. Clears the display and sets decimal point.

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Using the Parallel Port

Example:

You want to display the following number and decimal point in the DL5:

2 3

4 5 6

You would send data to the parallel port in the following sequence: 1.
D15 D14 D13 D12 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 1 1 1 1 0 0 0 0 0 0 0 0 0 1 1 0 Clears the display and sets the decimal point. And positions the decimal point 6 places from the right of the display.

2.
D15 D14 D13 D12 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 1 1 0 0 0 0 0 1 0 0 1 0 0 0 1 1 Directs BCD digits to third 3 character position. And sends the BCD number 123

3.
D15 D14 D13 D12 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 1 1 0 1 0 1 0 0 0 1 0 1 0 1 1 0 Directs BCD digits to fourth 3 character position. And sends the BCD number 456

If an invalid BCD digit is received, the corresponding character position on the display will be blank. If the number setting the decimal point is zero, no decimal point is displayed. When the decimal point is used, it takes one character position on the display as shown in the examples. You can update the numbers on the display without clearing the display or resetting all digits. That is, to change three digits of a number, you send only those three digits, along with the appropriate special instruction code; the remaining digits are left unchanged. Note: If you are changing all the numbers on the display, you should clear the entire display.

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Using the Parallel Port

7-9

Example:

You want to change the number in the previous example from 123.456 to 123.789999: 1 2 3 7 8 9 9 9 9

You would send data to the parallel port in the following sequence: 1.
D15 D14 D13 D12 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 1 1 0 1 0 1 1 1 1 0 0 0 1 0 0 1 Directs BCD digits to overwrite the fourth 3 character position. And sends the BCD number 789.

2.
D15 D14 D13 D12 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 1 1 0 0 1 0 0 1 1 0 0 1 1 0 0 1 Directs BCD digits to third 3 character position. And sends the BCD number 999.

Note: No leading zero blanking is performed in the numeric mode. however, individual digits for D0 through D11 can be blanked by setting the input for that digit to a non-BCD value (greater than 9).

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Using the Parallel Port

Numeric Mode and Autorun Message

Using a two line DL5, the numeric mode can display an autorun message on line two in addition to the numeric data on line one. The autorun message is selected as described in Chapter 8. It should be programmed to appear on line two with autoclear set to NO. Each time the display enters the run mode or is powered up, the autorun message will appear on line two. The numeric data being sent will appear on line one. Example: 6 8 9 2 P R 3 1 E S 7 4 5 S P E E D

T E M P

This autorun message serves as a legend or label for the numeric variables. When using the numeric mode, data must be held on the parallel port for 110 milliseconds (see page 7-13).

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7-11

Using DC Outputs to Trigger the There are two types of DC outputs: DL5
Hard contact outputs Hard contact outputs contain mechanically operated contacts. Examples of hard contact outputs include relays, push buttons, limit switches, and contact output modules such as Allen-Bradleys PLC module (Catalog No. 1771-OW) or SLC module (Catalog No. 1746-OW16). Any contact that does not have a leakage current while in the OFF state can be considered a hard contact device. Solid-state DC outputs Solid-state outputs do not have any mechanically operated contacts. All switching functions in a solid-state contact are done electronically. Examples are: PLC Modules Catalog No. 1771-OB or -OBD SLC Modules Catalog No. 1746-OV8, -OV16, -OV32 Catalog No. 1746-OB8, -OB16, -OB32 Catalog No. 1746-OG16 The figure below illustrates how DC outputs can be used to trigger the DL5.
Connecting DC Outputs to the DL5 Data Lines
DL5 Terminals D0 D1 D2 D3 D15

TB2-1 COM
DC Power Supply +

Controlling Device Contacts

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Using the Parallel Port

Determining Current Requirements For DC Outputs

You must check to make sure that the DC outputs supplying the parallel port can supply enough current to handle the requirements of the DL5s parallel port. The table below lists the current requirements for one DL5 parallel port input.
Parallel Port Typical Requirements for DC Outputs

5V DC Input 3.0 mA

12V DC Input 7.3 mA

24V DC Input 14.6 mA

To determine the total current requirements of the parallel port, multiply the number of inputs being used by the value found in the above table. For example: Assume that you are using 24 VDC outputs: Each input will draw a peak current of 14.6 milliamperes. If you are using all sixteen inputs, your output source must be able to provide 234 milliamperes of current (16 x 14.6 mA = 234 mA). The table below lists the voltage and current requirements, per DL5 input, for various Allen-Bradley output devices.
Voltage and Typical Current Requirements Per DL5 Input

Output Type 1771-OB 1771-OBD 1771-OW 1746-OB 1746-OV 1746-OG

Input Voltage 12 or 24V DC 12 or 24V DC 24V DC 12 or 24V DC 12 or 24V DC 5V DC

Input Current 7.3 or 14.6 mA 7.3 or 14.6 mA 14.6 mA 7.3 or 14.6 mA 7.3 or 14.6 mA 3.0 mA

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7-13

Parallel Port Power Supply Requirements

The DL5 parallel ports require an input voltage source between 5-24 VDC with peak-to-peak noise and ripple less than 5% of the input voltage. ATTENTION: To avoid ground loops, the same power supply that powers the display must be used to supply the parallel port.

!
Timing Requirements of the Parallel Port

The DL5 reads (scans) the data lines periodically. You must ensure that the data is present on the data lines long enough to be read. Note: Refer to Chapter 9 for a description of the timing requirements for messages with variable data. In order to ensure that the data is read, the data must remain on the data lines for at least 110 milliseconds. After each scan the DL5 saves a copy of the data that was read. If the next scan reads the same data, the data is ignored. This feature prevents multiple triggering of the same message. The figure below illustrates a typical message trigger sequence. Message #1 is triggered and then message #10 is triggered. In this example, the DL5 is set to accept BCD formatted codes (message or variable).
BCD Message Number Timing Example 110 ms D0 D1 D2 D3 D4 110 ms

D5
D6 D7 D8 D9 D10

D11
D12 D13

D14 D15
t0 t1 t2 t3

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Using the Parallel Port

The following are descriptions of what occurs during each of the four timing intervals (t0, t1, t2, and t3): During t0, the trigger for message No. 1 and strobe line D15 to indicate message number are placed on the data lines. During t1, the message trigger and strobe are kept unchanged at the parallel port for a minimum of 110 milliseconds. During t2, the trigger for message No. 10 and strobe line D15 to indicate message number are placed on the data lines, and the trigger for message number 1 is removed. During t3, the message trigger and strobe are kept unchanged at the parallel port for 110 milliseconds.

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Chapter

Special Functions

Chapter Objectives

In this chapter you will learn how to: set the electrical characteristics and operating mode of the parallel port use debug mode clear memory set the autorun message number

Introducing the Special Functions Menu

The special functions menu is accessed from the main menu. You select the special functions by pressing the [Y] key then the [Retrn] key at the SPECIAL FUNC? prompt. You will then be shown a sequence of prompts for the five special functions. To enter a special function you must press the [Y] key and then the [Retrn] key. If you do not want to enter a particular special function press the [Retrn] key ([N] is the default); the DL5 will then display the next prompt. The five special functions are: SET PORT SET RUN MODE DEBUG CLEAR MEMORY SET AUTORUN

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Special Functions

The figure below shows a flow chart of the Special Functions menu.
N

SPECIAL FUNC?

SET PORT?N
N

HIGH TRUE?Y

Y/N

BAUD: ENTER <3> for 300 <12> for 1200 <96> for 9600 [Retrn]

ADDRESS: xxx

SET RUN
MODE?N N

RUN MODE: ENTER <PR> for Priority <RR> for Round Robin <BN> for Binary <BC> for BCD <NM> for Numeric [Retrn]

DEBUG?N
N

DEBUGGER

[ESC] three times

CLEAR
MEMORY?N N

SURE?N Y POSITIVE?N Y MEMORY LOST

SET
AUTORUN?N N

NUMBER= xxx

ENTER <Message Number> [Return]

RUN?

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8-3

Entering the Special Functions Menu

To enter the special functions menu, follow the steps below. 1. Make sure the RUN? prompt is displayed: RUN?

Note: To get the RUN? prompt from the run mode, press [Esc] three times. From Edit mode it is also necessary to answer [N] to EDIT? and SPECIAL FUNC?. 2. Press the [N] and [Retrn] keys. The DL5 displays: EDIT?

3. Press the [N] and [Retrn] keys. The DL5 displays SPECIAL FUNC?

4. Press the [Y] and [Retrn] keys to enter the Special Functions menu. The DL5 displays: SET PORT?N

The set port prompt is the first special function. To enter the set port function press the [Y] and [Retrn] keys. To enter one of the other four special functions, press the [Retrn] key until the special function that you want is displayed ([N] is the default).

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Special Functions

SET PORT Special Function

The set port function allows you to set the following parallel and serial port parameters. positive or negative logic (high true or low true) of the parallel port baud rate (300, 1200, or 9600) of the RS-232 serial port address of the DL5 (for serial triggering) You enter the set port function by pressing the [Y] and [Retrn] keys in response to the SET PORT? prompt. After selecting the set port function, the first prompt that the DL5 displays: HIGH TRUE?Y

If you answer [Y] (the default) to the high true input option, the DL5 will interpret the voltages on the data lines as positive logic signals. If you answer [N] to the high true option, negative logic is selected. If positive logic is selected: A voltage on a data line is interpreted as an ON (logic 1 / true) condition. The absence of voltage on a data line is interpreted as an OFF (logic 0 / false) condition. If negative logic is selected: A voltage on a data line is interpreted as an OFF (logic 0 / false) condition. The absence of voltage on a data line is interpreted as an ON (logic 1 / true) condition. Note: If possible, we recommend that you configure your system so that in a normal operating condition as few as possible input lines have a voltage applied to them. This will keep the DL5 at a lower operating temperature and extend its life. The next prompt that you must respond to is: Baud (3, 12, 96):96

The present baud rate is the default value. Enter the desired baud rate: 3 for 300, 12 for 1200, and 96 for 9600. The baud rate changes immediately. The DL5 is shipped with a baud rate of 9600 baud. Once the baud rate is changed, the baud rate of your programming device must also be changed to match the DL5 before programming/editing of the DL5 can continue. After specifying a baud rate, the current address is displayed: ADDRESS: xxx

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8-5

After you provide an address, press [Retrn] and the DL5 will display the beginning RUN? prompt.

Run Mode Special Functions

The run mode determines how the DL5 will interpret the data present on the parallel port. The DL5 is shipped in the numeric mode. SET RUN MODE?N

To change or view the run mode selection, respond to the SET RUN MODE? prompt by pressing [Y], then [Retrn].The following appears on the display: RUN MODE=xx
Where xx is the mnemonic for the last entered run mode.

Respond to the RUN MODE = prompt with a two letter mnemonic. The mnemonic that you provide determines which Run Mode is used. The table below lists the run modes of the DL5s parallel port. After you provide a run mode mnemonic the DL5 will return to the RUN? prompt. Once a run mode is selected, the DL5 will enter that run mode on default when power is cycled off, then on. If an invalid mnemonic is entered, the previously selected run mode mnemonic is displayed.
Run Mode Priority Round Robin Binary BCD Numeric Mnemonic PR RR BN BC NM Description Chapter 10 Chapter 10 Chapter 7 Chapter 7 Chapter 7

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Special Functions

Debug Special Function

The Debug special function is very valuable if you are having difficulty triggering messages properly in the run mode. The debug function allows you to visually determine whether or not a voltage is applied to a DL5 data line. If you respond to the DEBUG? prompt by pressing the [Y] and [Retrn] keys, the DL5 displays the status of the data lines: 0000010000010011

The debug mode display consists of sixteen characters (ones and zeros). This display represents the condition of the sixteen data lines. The character on the far left represents data line D15 and the character on the right represents data line D0. If you have set the parallel port for negative logic, a voltage on a data line will be represented by a 0. If positive logic is selected, a voltage on a data line will be represented by a 1. For example, assume that a debug mode display appears like this: 0000100001100100

If positive logic has been selected, the above display would indicate that there is a voltage present on data lines D2, D5, D6, and D11. If negative logic has been selected, the above display would indicate that there is a voltage present on data lines D0, D1, D3, D4, D7, D8, D9,D10, D12, D13, D14, and D15. To exit the debug mode, press the [Esc] key three times.

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8-7

CLEAR MEMORY Special Function

The clear memory special function clears all messages from the DL5 EEPROM memory. To clear the DL5 memory perform the following steps: 1. Press the [Y] and [Retrn] keys in response to the CLEAR MEMORY? prompt. The DL5 displays: SURE?N

2. Press the [Y] and [Retrn] keys in response to the SURE? prompt. The DL5 displays: POSITIVE?N

3. Press the [Y] and [Retrn] keys in response to the POSITIVE? prompt. The DL5 displays: MEMORY LOST

While Memory Lost is displayed, the DL5 is actually clearing the EEPROM. Hitting any key, such as [Escape], will not speed up this function. Depending on the amount of the memory used and the size of the EEPROM (2 or 8 Kbytes), it could take up to 30 seconds before Memory Lost is cleared and the display shows: RUN?

SET AUTORUN Special Function The set autorun function allows you to set the autorun message number. If
the power to the DL5 is interrupted while in the run mode, the DL5 will automatically enter the run mode when the power is reapplied. The autorun message is the first message that the DL5 displays when the DL5 enters the run mode. After the autorun message is displayed the DL5 resumes normal run mode operation. If you press the [Y] and [Retrn] keys in response to the SET AUTORUN? prompt, the DL5 displays: NUMBER: X

Note: X is the value of the last message number edited. You can now enter the message number of the message that you want displayed when the DL5 is powered up in the autorun mode. Enter the autorun message number (0999) and then press the [Retrn] key. If no autorun message is desired, enter a 0 (zero). After entering an autorun message number, the DL5 displays the RUN? prompt.
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Special Functions

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Chapter

Using the Variable Data Feature

Chapter Objectives

In this chapter you will learn how to insert up to five digits of variable data in a message. You will learn: how to program messages with embedded variables. the format of the variable data. timing requirements for the transfer of variable data.

Variable Data Limits

The DL5 can accept message triggers and variable data using either the parallel or serial port. Serial Port - The serial port accepts CTRL-T commands for message triggers and CTRL-V commands for variable data. The range for variable data sent to the serial port is (0-65535). Serial commands always use decimal numeric values (binary and BCD distinctions do not apply). Parallel Port - The parallel port can be set to accept either binary or BCD formatted data for message triggers and variable data input. Whichever format (BCD or binary) you select will be used for both the variable data and message triggers. You cannot input message triggers in one format and variable data in another format. The table below shows the largest variable and message number that can be entered for both binary and BCD formats.
Maximum Ranges for Variable Data sent to Parallel Port

Scan Mode BN BC

Input Format for Message and Variable Data Binary BCD

Maximum Message Number 999 999

Largest Variable Value 16,383 3,999

You cannot enter negative numbers for variable data.

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Using the Variable Data Feature

Creating Messages with Embedded Variable Data

You can program variable data within a message while the message is being created in the edit mode. To embed one digit of a variable, press the [Ctrl] key and [V] keys simultaneously at the location in the message where the variable digit is to appear. The [Ctrl] and [V] command will insert a caret ^ in the message. For example: Assume that the following message is being entered:
7+( &2817 ,6

To embed a single digit of a variable, press the [Ctrl] and [V] keys. The DL5 will display the location of the variable in the message:
7+( &2817 ,6A

Up to five single digit variables (only four variables allowed with BCD format) can be embedded in a message. The embedded variables do not have to be in consecutive positions in a message. For example: The following message has been entered, the DL5 is set to accept BCD formatted data:
AA2)AA%$'

If the number 1050 is transferred to the DL5 and the message is triggered, the DL5 will display:
 2)  %$'

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9-3

Embedding a Decimal Point

You can display numbers which have decimal points. The decimal point is inserted just like any other character and it takes up one full character space. Insert a decimal point before or after the [CTRL] [V] by typing [.]. For example, the following steps would be required to create the message SPEED IS . FPS. 1. Enter the following message:
63((' ,6

2. Enter the first variable digit by pressing the [Ctrl] and [V] keys: 3. Press the [.] key to enter the decimal point. Notice that the decimal point requires a character position. The decimal point becomes a part of the variable. 4. Then enter the second variable digit by pressing [Ctrl] and [V] keys. 5. Finish entering the message by typing [F] [P] [S]. Note: Use [CTRL][X] to imbed variable digits with leading zeros. [CTRL][V] imbeds variable digits without leading zeros.

Sending Variable Data Through Use the CTRL-V command to send data for display in Binary, BCD, Numeric, Priority, and Round Robin modes. All values are decimal values. the Serial Port
The command has the following format:
CTRL-V Variable Data \ Backslash Variable Position \ Backslash DL5 Address Carriage Return

where: Variable Data is 1 to 5 ASCII digits (0-65535) Variable Position is single ASCII digit (value is ignored) DL5 Address is 1 to 3 ASCII digits (0-127) For example, to send a value of 500 to a DL5 with an address of 99, the following string would be sent:
ASCII HEX ^V 10 5 35 0 30 0 30 \ 5C 1 31 \ 5C 9 39 9 39 ^M 0D

Note: In Binary mode, variable data can be in the range 0 to 16,383. In BCD mode, variable data must be in the range 0 to 3999. In Round Robin. Priority and Numeric modes, variable data can be in the range of 0 to 65535. Note: The CTRL-V command in Priority, Round Robin and Numeric modes triggers messages not variables.
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Using the Variable Data Feature

Parallel Port Strobe and Data Bits

The DL5 uses the sixteen data lines (D0 through D15) to input both variable data and message triggers. Data lines D0 through D13 transfer the fourteen data bits and data lines D14 and D15 are the two strobe lines. The strobe lines indicate whether the data on the data lines is a message number or variable data. There are four possible combinations of the two strobe lines. The table below lists the four strobe combinations and the DL5s interpretation of the strobe commands.
Strobe Commands

Strobe Command Ignore Data Lines Variable Data Message Number Message Number

Strobe Line, Data Line D14 OFF ON OFF ON

Strobe Line, Data Line D15 OFF OFF ON ON

Notice that if data line D15 is ON, the DL5 will interpret the data on the data lines as a message number regardless of the condition of data line D14.

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9-5

Parallel Port Timing Requirements

The following is an example of how the strobe commands are used. In this example, message #12 , which contains a two digit variable, is triggered. The message that was entered for message #12 appears like this:
63((' ,6AA)36

First the controller sends the variable value (BCD format) for message #12 to the DL5. Then the controller sends the trigger for message #12. The figure below illustrates the timing of the data transfer and message trigger.
BCD Message Number Timing Example 110 ms D0 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 t0 t1 t2 t3 110 ms

The following describes what occurs during each of the timing intervals. t0- During t0 the variable data 35 and strobe line D14 to indicate variable data is set on the data lines. t1- During t1 the value of 35 and strobe line D14 are maintained for 110 milliseconds. t2- During t2 the message number 12 is placed on the data lines, and D15 is set to indicate a message number. D14 is reset. t3- During t3 the message number 12 and strobe line D15 are maintained for 110 milliseconds. The timing example (previous page) shows the minimum hold time (110 milliseconds) that is required for each step of the variable data transfer and message trigger.

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Using the Variable Data Feature

Note: The PLC program scan time must be added to the hold time. If the scan time is 10 milliseconds, then the minimum data hold time in the PLC program should be 120 milliseconds to make sure data is held at the DL5 for the minimum 110 milliseconds. To summarize the timing requirements: Data and strobes are set all at once. Once data and strobe lines are set, they must remain unchanged for a minimum of 110 milliseconds. The total cycle time for a variable data transfer and message trigger is a minimum of 220 milliseconds. A cycle time of 220 milliseconds allows you to update a variable approximately 4 times per second.

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9-7

Suggestions on Using the Variable Data Feature

Message attribute settings are important to the proper functioning of the variable data feature. Refer to Chapter 3 for review of message attributes. The following message attribute settings are recommended. Line Selection recommendations: Do not use the scroll mode when variables are within a message. The message should appear as one or two lines. Limit each message to one screen (16 characters if a one line message, 32 characters if a two line message). Wait Time recommendation: Set the wait time of a variable message to zero to allow for the fastest update of the variable. Auto Clear recommendation: Set auto clear to NO. Auto Repeat recommendation: Do not use the auto repeat display option for messages that contain variable data. If the auto repeat display option is selected, the DL5 will resample the data lines for variable data each time the specified message wait time has expired. Your controller cannot send variable data for a new message trigger until the auto repeat message is halted. You can halt the display of an auto repeat message by triggering a programmed blank message number. Note: A blank message is one which has been created but has no displayable characters. Its attributes could be Wait Time Zero, Auto Clear No, and Auto Repeat No. For example, the following describes a triggering sequence that occurs using an auto repeat message with four variable digits. The message being triggered is:
AA2)AA%$'

This message has a wait time of zero, and no auto clear. 1. First, the controller sends the variable data 1050. 2. Next, the controller sends the trigger for the message.

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Using the Variable Data Feature

3. The DL5 will then display the message:

 2)  %$'

4. The controller then transmits a new variable 2040. 5. The DL5 will then display the message with the new variable data:
 2)  %$'

6. To enter and display a different message with embedded variable data, the controller must first trigger a programmed blank message to stop display of the variable message. 7. The controller can now send the variable for the new message. 8. The controller can then send the message number for the new message Updating a Variable Frequently If your application requires that the variable data within a message be updated frequently, you should program the message with the following attributes: A wait time of zero. The auto clear function is not selected. These message attribute settings will make it possible to update variable data at the fastest rate (once every 220 milliseconds). This assumes a normal sequence of events to enter variables and message numbers: Send a variable. (110 milliseconds) Send a message number. (110 milliseconds) Send a variable. (110 milliseconds) Send a message number, etc. (110 milliseconds) Note: PLC program scan time must be added to the 110 millisecond data hold time in the PLC program to assure that data is on the DL5 parallel port for 110 milliseconds.

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Chapter

10

Using the DL5 Parallel Port to Replace Pilot Lights

Chapter Objectives

This chapter shows you how to replace up to 16 pilot lights with a single DL5. Descriptions of both the priority and round robin operating modes are provided.

Description of Input Modes

The DL5 has 2 modes of operation which allow you to replace pilot lights: Round Robin input mode - while in the round robin mode of operation, the DL5 will look at the sixteen data lines as individual inputs. Each of the inputs is like the input wire to an individual pilot light. When a data line to the DL5 is triggered, a message corresponding to that data line is displayed. Priority input mode - the priority input mode is similar to the round robin input mode except that each of the data lines is assigned a priority in relation to the other data lines. Note: These pilot light operating modes do not support variable data within a message. Pilot lights are typically used in one of two ways: 1. Pilot lights can be used as status indicators. For example, a pilot light can inform an operator that a motor is on or off. 2. Pilot lights can also be used as diagnostic indicators. For example, a pilot light can inform an operator that an overload relay is tripped.

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Using the DL5 Parallel Port to Replace Pilot Lights

Round Robin Mode

In the Round Robin mode of operation you can specify both an OFF state message and an ON state message for each input. Messages are scanned in sequence beginning with data line D0 and ending with data line D15. If several inputs are ON, the DL5 displays the messages in the sequence that they are scanned. The following table lists the message numbers that are assigned to each of the sixteen inputs.
Data Line No. D0 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 ON Message No. OFF Message No. 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

Notice that each of the sixteen data lines listed in the table has both an ON message number and an OFF message number assigned. You do not have to program both an OFF and an ON message for each input. You can program only an ON or only an OFF state message; or no message at all.

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Using the DL5 Parallel Port to Replace Pilot Lights

10-3

When the DL5 is placed in the round robin mode of operation, the DL5 begins by looking at the first data line D0. One of three events will occur depending upon the condition of the data line and whether or not a message is programmed: If data line D0 is in an ON state, the DL5 will display message #1 (if message #1 is programmed). Message #1 is the ON state message for data line D0. If data line D0 is in the OFF state, the DL5 will display message #17 (if message #17 is programmed). Message #17 is the OFF state message for data line D0. If no message exists, the DL5 will ignore data line D0. The DL5, will then look at the second data line, D1. One of three events will occur depending upon the condition of the data line and whether or not a message is programmed. If data line D1 is in an ON state, the DL5 will display message #2 (if message #2 is programmed). Message #2 is the ON state message for data line D1. If data line D1 is in the OFF state, the DL5 will display message #18 (if message #18 is programmed). Message #18 is the OFF state message for data line D1. If no message exists, the DL5 ignores data line D1. The DL5 then looks at the remainder of the data lines, D2 through D15. After data line D15 is scanned, the DL5 will then start the sequence over again beginning with data line D0. If only one data line is on, the display will not clear before retriggering the message associated with that data line. If no data lines are on, the display is cleared after the message wait time has expired. Note: If a data line is turned ON then OFF before the DL5 scans it, it will not be remembered as being ON by the DL5. The DL5 will not look for additional ON terminals until it is done executing a message it has recognized as ON.

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Using the DL5 Parallel Port to Replace Pilot Lights

Priority Mode

In the priority mode of operation you can only specify an ON state message for each input. If several inputs are ON, only the highest priority message will be displayed. The following table lists the message numbers that are assigned to each of the sixteen inputs.
Data Line No. D0 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 ON Message No. OFF Message No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 (Highest) 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 (Lowest)

If programmed, message #17 is displayed if no data lines are ON. Notice that each of the sixteen data lines listed in the table above only has an ON message number assigned. You do not have to program a message for each of the inputs; if an input does not have a message programmed, the DL5 will ignore the input. Each input has an assigned priority level. Data line D0 has priority over data line D1, data line D1 has priority over data line D2, data line D3 has priority over data line D4, etc. The DL5 displays the message number that corresponds to the highest priority data line. For example: If data lines D1, D4, and D7 are in an ON condition, the DL5 will display message #2 (message #2 is the message assigned to data line D1). Message #2 will continue to be repeated for as long as data line D1 remains in an ON state; unless data line D0 changes to an ON state. If data line D0 changes to an ON state, it overrides data line D1 because data line D0 has a higher priority. The DL5 then displays message #1 (message #1 is the message assigned to data line D0). If only one input is ON and that input goes OFF, the display will automatically clear. In addition to the sixteen messages associated with data lines D0 through D15, there is a message #17. Message #17 is only displayed when none of the data lines is in an ON condition.

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Using the DL5 Parallel Port to Replace Pilot Lights

10-5

Using the Round Robin Input Mode

If you want to operate the DL5 in the Round Robin mode of operation, perform the following steps: 1. You must decide whether the DL5 will be set for positive or negative logic. If positive logic is selected, voltage on a data line will represent an ON condition. If negative logic is selected, the absence of voltage on a data line represents an ON condition. 2. Select the round robin mode of operation as described in Chapter 8 3. Place the DL5 in the edit mode and program messages for the message numbers that are associated with each input. The following message attribute settings are suggested to provide the clearest round robin functionality. Line 1, line 2, or both lines can be selected as desired. Scroll message can be selected as desired. Wait time can be set as desired and will control how long a message is displayed before the DL5 goes on to the next message. Select Auto Clear, to clear the screen after each message. Otherwise you might have a portion of a two line message remaining on the DL5 when a single line message follows. Note: The DL5 will always clear the display when no inputs are on. Auto Repeat has no function in Round Robin mode. Flash Message can be selected as desired. 4. Place the DL5 in run mode.

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Using the DL5 Parallel Port to Replace Pilot Lights

Using Priority Input Mode

In Priority Input mode, only one message (the highest priority) can be on the screen at a time. If you want to operate the DL5 in priority mode, follow these steps: 1. You must decide whether the DL5 will be set for positive or negative logic. If positive logic is selected, voltage on a data line will represent an ON condition. If negative logic is selected, the absence of voltage on a data line represents an ON condition. Chapter 8 describes how you can set the DL5 for either positive or negative logic. 2. Select the round robin mode of operation as described in Chapter 8. 3. Place the DL5 in the edit mode and program messages for the message numbers that are associated with each input. Chapter 3 describes how to enter messages. The following message attribute settings are suggested to provide the clearest round robin functionality. Line 1, line 2, or both lines can be selected as desired. Scroll message can be selected as desired. Wait time can be set as desired and will control how long a message is displayed before the DL5 goes on to the next message. Select Auto Clear, to clear the screen after each message. Otherwise you might have a portion of a two line message remaining on the DL5 when a single line message follows. Note: The DL5 always clears the display when no inputs are on. Auto Repeat has no function in Round Robin mode. Flash Message can be selected as desired. 4. Place the DL5 in run mode.

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Chapter

11

Using the DL5 to Replace BCD Displays and Lookup Tables

Chapter Objectives

This chapter provides instructions on how to replace a 2 or 3-digit BCD numeric display and any associated lookup tables with a single DL5.

Replacing a BCD Fault Code Display

The first step in replacing a BCD display is to determine if your DL5 has enough memory to store all of the BCD codes. Typically a BCD display is used in conjunction with a lookup table. If a code is displayed on the BCD display, an operator will refer to a lookup table to determine the meaning of the code. If you are going to replace a BCD display and lookup table with a DL5 you must make sure that the DL5 can store the meanings of all the codes listed in the BCD lookup table. The DL5 can store 94 or 387 message blocks depending on memory size (2K or 8K). Note: Memory capacity is given in the number of message blocks that are available. Some of the messages that you enter may require more than one message block. A message block is one line of 16 characters. After you have determined that the DL5 has sufficient capacity to store the messages, perform the following steps: 1. You must set the DL5 to accept positive logic. If positive logic is selected, voltage on a data line will represent an ON condition. 2. Set the DL5 to accept BCD input as described in Chapter 8. 3. Place the DL5 in the edit mode and program messages for the message numbers that were previously displayed on the BCD display. 4. Tie strobe line D15 high to indicate message numbers by wiring it to a 5-24 VDC source. 5. Place the DL5 in the run mode.

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Using the DL5 to Replace BCD Displays and Lookup Tables

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Chapter

12

Installation Instructions

Chapter Objectives

In this chapter you will learn how to: Mount the DL5 in a panel or an enclosure. How to wire the DL5 to your control system.

Grounding

Grounding is an important safety measure in installing the DL5. As with all solid-state systems, grounding also helps limit the effect of noise due to electromagnetic interference (EMI). The DL5 mounting studs and nuts (once tightened) connect the DL5 chassis to your equipment ground. Note: The common terminal on the back of the DL5 is not equipment ground. The common terminal must be connected separately to your power supply common.

Wire Routing

Careful wire routing helps reduce electrical noise. Route all DL5 wiring separately and away from all high voltage wiring (115VAC or above). Do not run the DL5 wiring in the same conduit as any AC power wiring (115 VAC and above). When high voltage wiring and the DL5 wiring must cross, their intersection should be perpendicular. In addition, the data line wiring (D0-D15) should be routed away from transformers, solenoids, or other devices that are known to generate electrical noise (EMI). ATTENTION: Fusing the DL5 power wiring is important to protect both the power supply and the DL5 from damage should a short circuit occur. Since the DL5 has no fuses, we recommend you use external fusing.

! !

ATTENTION: You must connect the common lead of the power source to the DL5. Failure to connect the common lead may result in electrical shock. In addition, the common lead protects the DL5 from electrical noise. Do not apply power to the display until all wiring to the DL5 is completed.

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12-2

Installation Instructions

!
Mounting the DL5

ATTENTION: To avoid ground loops and damage to the equipment, the same power supply must be used for the parallel port and the power input to the DL5.

You can mount the DL5 in a custom panel or enclosure. When the DL5 is properly installed, the faceplate of the DL5 provides a NEMA Type 12/13 and 4 enclosure integrity rating. To mount the DL5: 1. Punch and drill the appropriate mounting holes in the enclosure or panel. The following page shows the mounting dimensions of the DL5. ATTENTION: DO NOT install the DL5 until all cutouts and holes are completed. Metal filings may fall into and damage the DL5.

2. Remove the four nuts from the mounting studs on the DL5s face plate. 3. Install the display in the panel cutout and tighten the four nuts on the mounting studs to a torque of 9 lb-in (1.02Nm).

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Installation Instructions

12-3

DL5 Mounting Dimensions in Inches (Millimeters)

FRONT 6.25 (158.8)

DATALINER

TOP 5.25 (133.4) 3.12 (79.3) 4.31(108.0) Max Depending On Panel Thickness PANEL

0.22(5.6) Max

PANEL CUTOUT DIMENSIONS 5.75 (146.1) 5.38 (136.7)

2.25 (57.2)

Cutout 1.31 (33.3) 1.12 (28.6)

2.88 (73.2)

0.171 (4.3 mm) Diameter Hole 4 Places

2706-UM001A-US-P

12-4

Installation Instructions

Power Supply Requirement

ATTENTION: To avoid system ground loops and damage to equipment, the same power supply must be used for the parallel port and the power input to the DL5.

The power supply used to power the DL5 and to supply the parallel port data lines must meet the following specifications: Supply Voltage: Ripple: Noise: Supply Current 12 VDC 24 VDC 250 mA operating (300 mA inrush) 125 mA operating (300 mA inrush) 12-24 VDC 5% of input voltage p-p (max.) 5% of input voltage p-p (max.)

Parallel Port: (17 inputs maximum) 5 VDC 12 VDC 24 VDC Fusing: 3.0 mA per input (typical) 7.3 mA per input (typical) 14.6 mA per input (typical) External fusing should be provided.

After the DL5 has been mounted, the necessary wiring can be connected to the DL5. The following figure illustrates the terminal connections located on the back of the DL5. Perform the following steps to connect wiring to the DL5.

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Installation Instructions

12-5

Wiring the DL5 (Rear View)

Switch 1 (SW-1) Enables Serial Trigger / Configure UP = Serial Trigger DOWN = Configure DOWN Not Used 1 2

Configure Not Used UP 1 2

Serial Trigger Not Used

DC Line Terminals
1 2 12
SW1
TB2 1 COM 2 12-24V DC Input SW1 1 Serial Trigger/Configure 2 Not Used
TB2

TB2 Terminals 1-2 COMMON DL5 Power Terminals 12-24V DC 12-24V DC Required

TB1

RS-232

RS-485 Multidrop Connections

COM

D3 D2 D1 D0

TB1 Terminals Parallel Port Input Data lines Accept 5-24V DC

RS-485 Black Box Converter (Model LD-485A-MP) DL5

RS-232
Pin 2

PD D15 D14 D13 D12 D11 D10 D9 D8 D7 D6 D5 D4

PARALLEL PORT 5-24 VDC INPUT

Terminal PD Disables the Parallel Port Terminal Accepts 5-24V DC

RS-232 Port Allows Connection to Programming Terminal or Computer and serial communications with PLC / SLC

CHA CHB

RxB RxA
Pin 3 Pin 5 Pin 7

TxB
Pin 3

Pin 2

TxA RS-232 IN RS-485

Shield to Ground

RS-485 Black Box Converter Notes: 1. Set RTS/CTS delay time to 5 milliseconds. 2. Set switch S2 to the unterminated position. 3. If the RS-485 Driver Enable is set to Enable When Data is Received on the RS-232 port (Jumper W15 is in the B-C position), set the Disable Timeout Delay (Jumper W17) to 100 msec or greater when communicating at lower Baud rates (300 or 1200 Baud).

2706-UM001A-US-P

12-6

Installation Instructions

Power / Parallel Port Wiring

The parallel port data inputs and power inputs are wired by means of pull-off terminal strips. These strips may be removed and wired separately, and then inserted onto the unit after the unit is mounted in the enclosure. 1. Connect a 12-24 VDC input voltage source to the DL5 power terminals (TB2). The hot lead of the power source is connected to terminal #2 (12-24 VDC). The common lead of the power source is connected to terminal #1. ATTENTION: There are no fuses contained in the DL5. Therefore, we recommend that external fusing be used to avoid any possible damage to the DL5 or power supply.

! !

ATTENTION: You must connect the common lead of the power source to the DL5. Failure to connect the common lead may result in electrical shock. In addition, the common lead protects the DL5 from electrical noise. Do not apply power to the display until all wiring to the DL5 is completed.

2. Connect the communication lines from the host programmable controller, computer, or other controlling devices to the DL5 parallel or serial ports. ATTENTION: The common for the parallel port should be the same common as the power source.

Note: To ensure proper connection through the pull-off terminals, strain relief must be provided for all DL5 wiring.

2706-UM001A-US-P

Chapter

13

Maintenance and Troubleshooting

Troubleshooting Chart

This chapter provides general maintenance and troubleshooting instructions. A troubleshooting chart is provided to aid you in determining the cause of a malfunction. The table below lists the most common operating problems and possible solutions. The DL5 does not contain user serviceable components.
Troubleshooting Chart

Problem DL5 does not power up.

Probable Causes 1. Loose or incorrect wiring to DL5 (TB2) 2. Blown power supply fuse. 3. Bad power supply

Corrective Action(s) 1. Check for proper wiring and that connector TB2 is properly inserted. 2. Check external power supply fuse. 3. Check power supply output. 1. Set Baud rate of terminal to match the DL5. 2. Check that the proper cable is being used.

Reference Chapter 12 N/A 12 2, 8 6, Appendix B

Programming terminal or computer 1. Baud rate of terminal or does not communicate with the DL5. computer does not match the DL5. 2. Incorrect connection cable.

2706-UM001A-US-P

13-2

Maintenance and Troubleshooting

Problem Messages do not trigger properly.

Probable Causes

Corrective Action(s) 1. Check the voltage range of your controller outputs. 2. Check the setting of DIP switch SW1-1 3. Configure your control systems so message numbers are held on the data lines for a minimum of 110 milliseconds. 4. Configure your control system to set the data lines to indicate message number. 5. Set Run mode to match the type of output used by the control system (Binary, BCD, etc.). 6. Program the messages into the DL5. Note: In all cases use the debug mode (Chapter 8) to verify that the inputs to the DL5 parallel port are correct. 1. Configure the control system to set the strobe lines for the type of data (message number or variable data) being sent. 2. Configure the control system to meet timing requirements. 3. Set the Run Mode to match the type of outputs used by the control system. 4. Check for proper insertion of Ctrl-V characters. Edit the message and remove any blank message blocks.

Reference 7, 12 2 7

1. Parallel port voltages are not per DL5 requirements. Messages are not displayed when 2. Serial Trigger / Configure DIP triggered. switch SW1-1 is not in correct position. INVALID MSG# is displayed on DL5 3. Message number is not present on the DL5 data lines for the required hold time. 4. Strobe lines are not being set to indicate message numbers. 5. Incorrect Run mode is selected. 6. Messages being triggered do not exist (INVALID MSG#)

7, 8 8 3

Messages with embedded variables are not displayed properly.

1. Strobe lines are incorrectly set. 2. Data and strobe line timing requirements are not met. 3. Incorrect Run mode is selected 4. Ctrl-V characters incorrectly embedded in message.

9 8 9 3

Delays exist between messages (the screen is blank).

1. Blank message block created at the end of a message due to typing Control J at end of edit.

2706-UM001A-US-P

Chapter

14

Specifications

Electrical

Input Power Requirements

Current: Power: Ripple: Noise:

Voltage

250 mA maximum steady-state @ 12 VDC input. 3 Watts maximum 5% of input voltage p-p maximum 5% of input voltage p-p maximum

12-24 VDC
Operating and Inrush Currents

12 VDC 24 VDC
Parallel Port

250 mA oper. (300 mA inrush) 125 mA oper. (300 mA inrush)

16 data input lines (14 data lines and 2 strobe lines for BCD and Binary modes) and 1 parallel port select input.
Parallel Port Data Input Voltage

5 to 24 volts DC
Voltage Levels for Positive Logic

High: Recognized Indeterminate Low: Recognized Indeterminate 0.0 to 0.9 VDC 0.9 to 3.5 VDC 3.5 to 24.0 VDC 0.9 to 3.5 VDC

Voltage Levels For Negative Logic

Low: Recognized Indeterminate High: Recognized Indeterminate 0.0 to 0.9 VDC 0.9 to 3.5 VDC
2706-UM001A-US-P

3.5 to 24.0 VDC 0.9 to 3.5 VDC

14-2

Specifications

Data Input Current (typical per input)

5 VDC 12 VDC 24 VDC

Serial Programming Port

3.0 mA 7.3 mA 14.6 mA

RS-232
Memory

2K EEPROM - 94 message blocks 8K EEPROM - 387 message blocks

Environmental

Operating Temperature 32F to 122F (0 to 50C)

Storing Temperature

-40 to 185F (-40 to 85C)

Humidity

5% to 95% - No condensation
NEMA

NEMA Type 12, 13 and 4 (indoor use only) panel mount.

Noise Susceptibility

Passes ICS 2230 showering arc noise immunity test.

Approximate Weight

1.5 lbs. (0.68 kg.)

Approximate Shipping Weight

3.0 lbs. (1.35 kg.) U.L. Listing Class 1, Division 2, Groups A, B, C, D Hazardous Location
CSA Certification

Class 1, Division 2, Groups A, B, C, D Hazardous Location

2706-UM001A-US-P

Specifications

14-3

Display Characteristics

Character Height

One line display - .262 in. (6.65 mm.) Two line display - .216 in. (5.5 mm.)
Character Set

Alphanumeric - upper case only

Characters Per Line

16
Character Type

Vacuum fluorescent, 14 segment (plus , and .) characters

Approximate Viewing Distance

10 feet (3 meters)

Programming

Using RS-232 port and an ASCII dumb terminal or IBM compatible computer with off-line program.

2706-UM001A-US-P

14-4

Specifications

2706-UM001A-US-P

Appendix

ASCII Character Set

2706-UM001A-US-P

A-2

ASCII Character Set

2706-UM001A-US-P

Appendix

Cabling Diagrams

Abbreviations

The following table describes the abbreviations used in this appendix.

Abbreviation CTS DCD DSR DTR COM RI RTS RXD TXD Signal Clear to Send Data Carrier Detect Data Set Ready Data Terminal Ready Signal Common Ring Indicator Request to Send Received Data Transmitted Data

Allen-Bradley T3 Terminal Serial Communications Cable (Catalog No. 2706-NC15)

Allen-Bradley T3 Cable DL5 Serial Port Female DB-9* Connector DCD TXD RXD DTR COM DSR RTS CTS 1 2 3 4 5 6 7 8 Allen-Bradley T3 Terminal Male DB-25* Connector 8 3 2 20 7 6 4 5 DCD TXD RXD DTR COM DSR RTS CTS

1 Chassis Ground *=Gender specified is for cable connectors

2706-UM001A-US-P

B-2

Cabling Diagrams

Allen-Bradley 1745-T45 Terminal, VT100 or IBM XT & Compatibles - Serial Communications Cable (Cat. No. 2706-NC12)

Allen-Bradley 1745-T45, VT100, IBM XT Cable DL5 Serial Port Female DB-9* Connector DCD TXD RXD DTR COM DSR RTS 1 2 3 4 5 6 7 Allen-Bradley 1745-T45 Terminal VT100 or IBM XT Serial Port Female DB-25* Connector 8 3 2 20 7 6 4 5 DCD TXD RXD DTR COM DSR RTS CTS

CTS 8 RI 9

22 RI 1 Chassis Ground *=Gender specified is for cable connectors

Allen-Bradley 6121 or T50 Terminal, IBM AT & Compatibles Serial Communications Cable (Cat.No. 2706-NC13)

Allen-Bradley 6121 or T50, IBM AT Cable DL5 Serial Port Female DB-9* Connector DCD 1 TXD 2 RXD 3 DTR 4 COM 5 DSR 6 RTS 7 CTS 8 Allen-Bradley 6121 or T50 Terminal or IBM AT & Compatible Serial Port Female DB-9* Connector 1 DCD 2 RXD 3 TXD 4 DTR 5 COM 6 DSR 7 RTS 8 CTS Chassis Ground *=Gender specified is for cable connectors

2706-UM001A-US-P

Cabling Diagrams

B-3

Allen-Bradley 6120 or Industrial PC / XT Serial Communications Cable (Cat. No. 2706-NC14)

Allen-Bradley 6120 or Industrial PC/XT Cable DL5 Serial Port Female DB-9* Connector DCD TXD RXD DTR COM DSR RTS CTS 1 2 3 4 5 6 7 8 Allen-Bradley Serial Port Female DB-9* Connector 8 3 2 9 7 6 4 5 DCD RXD TXD DTR COM DSR RTS CTS

1 Chassis Ground *=Gender specified is for cable connectors

2706-UM001A-US-P

B-4

Cabling Diagrams

2706-UM001A-US-P

Appendix

Message Display Worksheets

DL5 One Line Worksheet MESSAGE NUMBER Scroll Mode = Wait Time = Auto Clear = Auto Repeat = Flash Message = Scroll Mode = Wait Time = Auto Clear = Auto Repeat = Flash Message = Scroll Mode = Wait Time = Auto Clear = Auto Repeat = Flash Message = Scroll Mode = Wait Time = Auto Clear = Auto Repeat = Flash Message = Scroll Mode = Wait Time = Auto Clear = Auto Repeat = Flash Message = Scroll Mode = Wait Time = Auto Clear = Auto Repeat = Flash Message = Scroll Mode = Wait Time = Auto Clear = Auto Repeat = Flash Message = Scroll Mode = Wait Time = Auto Clear = Auto Repeat = Flash Message = Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N

MESSAGE NUMBER

MESSAGE NUMBER

MESSAGE NUMBER

MESSAGE NUMBER

MESSAGE NUMBER

MESSAGE NUMBER

MESSAGE NUMBER

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C-2

Message Display Worksheets

DL5 Two Line Worksheet MESSAGE NUMBER Use Both = Use Line 1 = Use Line 2 = Use Least = Scroll Mode = Wait Time = Auto Clear = Auto Repeat = Flash Message = Use Both = Use Line 1 = Use Line 2 = Use Least = Scroll Mode = Wait Time = Auto Clear = Auto Repeat = Flash Message = Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N

MESSAGE NUMBER

MESSAGE NUMBER

Use Both = Use Line 1 = Use Line 2 = Use Least = Scroll Mode = Wait Time = Auto Clear = Auto Repeat = Flash Message =

Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N

MESSAGE NUMBER

Use Both = Use Line 1 = Use Line 2 = Use Least = Scroll Mode = Wait Time = Auto Clear = Auto Repeat = Flash Message =

Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N Y or N

2706-UM001A-US-P

Appendix

Application Notes

Unsigned Integer to String Conversion

Serial protocol uses decimal values in the range of 0 to 65535 to send variable data (Ctrl-V command). PLCs that do not support unsigned integers can only generate values in the range of -32768 to 32767. To send decimal values in the range used by the serial protocol, use the following ladder logic. This program converts a 16-bit signed integer to an unsigned ASCII decimal string. The ASCII decimal string can then be used to generate serial commands for the DL5. In this example, the 16-bit integer is in N17:0 (signed value = -12264, unsigned value = 53272). The conversion uses N17:1 and ST18:1-4 as temporary buffers. The ASCII decimal string is returned in ST18:5. The conversion routine ladder logic is as follows:

0000

GEQ Grtr Than or Eql (A>=B) Source A N17:0 -12264< Source B 0 0<

AIC Integer to String N17:0 Source -12264< Dest ST18:5

0001

LES Less Than or Eql (A<B) Source A N17:0 -12264< Source B 0 0<

AIC Integer to String Source Dest

6 6< ST18:1

SUB Subtract Source A Source B Dest

N17:0 -12264< -5536 15536< N17:1 3272<

0002

LES Less Than or Eql (A<B) Source A N17:0 -12264< Source B -5536 -5536<

AIC Integer to String Source Dest

5 5< ST18:1

SUB Subtract Source A Source B Dest

N17:0 -12264< -15536 -15536< N17:1 3272<

2706-UM001A-US-P

D-2

Application Notes

0003

LES Less Than or Eql (A<B) Source A N17:0 -12264< Source B -15536 -15536<

AIC Integer to String Source Dest

4 4< ST18:1

SUB Subtract Source A Source B Dest

N17:0 -12264< -25536 -25536< N17:1 3272<

0004

LES Less Than or Eql (A<B) Source A N17:0 -12264< Source B -25536 -25536<

AIC Integer to String Source Dest

3 3< ST18:1

ADD Add Source A Source B Dest

N17:0 -12264< 3000 3000< N17:1 3272<

0005

LES Less Than (A<B) Source A Source B

N17:1 3272< 1000 1000<

AIC Integer to String 0 Source 0< Dest ST18:2

0006

LES Less Than (A<B) Source A Source B

N17:1 3272< 100 100<

ACN String Concatenate ST18:2 Source A ST18:2 Source B Dest ST18:2

0007

LES Less Than or Eql (A<B) Source A N17:1 3272< Source B 10 10<

AIC Integer to String Source Dest

0 0< ST18:3

ACN String Concatenate ST18:2 Source A Source B ST18:3 Dest ST18:2

2706-UM001A-US-P

Application Notes

D-3

0008

AIC Integer to String N17:1 Source 3272< Dest ST18:4

0009

LES Less Than (A<B) Source A Source B

N17:1 3272< 1000 1000<

ACN String Concatenate ST18:1 Source A ST18:2 Dest ST18:1

0010

LES Less Than (A<B) Source A Source B

N17:0 12264< 0 0<

ACN String Concatenate ST18:1 Source A ST18:4 Source B Dest ST18:5

0011

RET Return

END

2706-UM001A-US-P

D-4

Application Notes

Generate DL5 Variable Data (Ctrl-V) Command

The conversion routine generates a DL5 Ctrl-V command. In this example, the 16-bit signed integer is in N17:0. the ^V is in ST13:9 and \\1\\127^M^M is in ST13:10 The ladder program below converts the integer to an unsigned ASCII string (using the previous conversion program) U:6 and then creates the Ctrl-V serial command string in ST13:20 This command can then be sent out to the DL5.
CTRL-V Variable Data \ Backslash Variable Position \ Backslash DL5 Address Carriage Return

For example: Send 53272 to DL5 with address of 127

ASCII HEX ^V 5 3 2 7 2 \ 1 \ 1 2 7 ^M

16h 35h 33h 32h 37h 32h 5Ch 35h 5Ch 31h 32h 37h 0Dh

0000

To Previous Program JSR Jump to Subroutine Prog File Number U:6

0001

ACN String Concatenate ST18:5 Source A ST18:6 Source B Dest ST18:7

0002

ACN String Concatenate ST13:9 Source A ST18:7 Source B Dest ST13:19

0003

ACN String Concatenate ST13:19 Source A ST18:10 Source B Dest ST13:20

0004

RET Return

0005

END

2706-UM001A-US-P

Index

Index
A
ASCII character set, A-1 Attributes default, 3-7 message, 3-3 Audience Intended, P-2 Auto clear, 3-6 Auto repeat, 3-6 Autorun message, 7-10 Commands edit, 4-2 strobe, 9-4 Communications Protocol, 2-3 Connector serial port, 6-1 Conventions, P-2 Cursor back one block, 4-4 backspace, 4-3 forward one block, 4-3 moving, 4-3

B
Backspace, 4-3 Baud Rate Display, 2-4 BCD timing requirements, 7-13 BCD display replacing, 11-1 BCD input mode, 1-2 Binary data line values, 7-4 Binary mode, 1-2 Buffering messages, 5-3

D
Data line values, 7-4 DC outputs connecting, 7-12 types, 7-11 Debug function, 8-6 Debug mode, 1-2 Decimal point embedding, 9-3 Display options, 1-1 Display specifications, 14-3 Displaying memory, 4-2

C
Cables 2706-NC12, B-2 2706-NC13, B-2 2706-NC14, B-3 2706-NC15, B-1 programming, 2-3, 6-1 signal abbreviations, B-1 Capacity memory, 1-3 Characters, ASCII, A-1 Clear memory function, 8-7

E
Edit commands, 4-2 Edit mode, 2-9, 3-1 Editing messages, 4-2 Embedding decimal point, 9-3 Environmental specifications, 14-2

Index-1

Index

F
Flash message, 3-6 Forespace, 4-3 Functions special, 8-2

G
Grounding, 12-1

H
Hardware Requirements, 2-1

I
Input Voltage, 2-2 Intended Audience, P-1 Intended audience, P-2

L
Line selection, 3-3 Lookup table replacing, 11-1

M
Main Menu, 2-9 Maintenance, 13-1 Manual overview, P-1 Memory clear function, 8-7 Memory capacity, 1-3 Menu mode, 3-2 Message attributes, 3-3 auto clear, 3-6 auto repeat, 3-6 autorun, 7-9 buffering, 5-3

default attributes, 3-7 deleting, 4-5 deleting characters, 4-4 deleting message block, 4-4 editing, 4-2 editing attributes, 4-6 embedding numeric data, 3-8 entering, 3-7 example, 3-9 flash, 3-6 inserting block, 4-5 inserting variable data, 9-1 line mode, 3-3 line selection, 3-5 reviewing, 4-1 scroll mode, 3-5 selecting, 4-3 serial trigger, 6-3 triggering, 5-3 wait time, 3-5 Mnemonic Prompt, 2-8 Mnemonics, 2-8 Mode BCD input, 1-2 binary, 1-2 debug, 1-2 Edit, 2-9 edit, 3-1 menu tree, 3-2 numeric, 1-2, 7-7 priority, 1-2, 10-1, 10-4 round robin, 1-2, 10-1, 10-2, 10-5 Run, 2-9 run, 3-1, 5-1, 8-5 Special Function, 2-9 Modes run, 8-5 Mounting dimensions, 12-3

Index-2

Index

N
Numeric data, 3-8 Numeric mode, 1-2 Numeric mode functions, 7-7

R
Reviewing memory available, 4-2 messages, 4-1 Round robin mode, 1-2, 10-1, 10-2 RS 232 signals, 6-2 Run mode, 2-8, 2-9, 3-1, 8-5

O
Overview Manual, P-1

S
Serial port connector, 6-1 inserting variable message data, 9-3 message trigger, 6-3 pin assignments, 6-2 protocol, 6-3 variable data, 6-4 Set port function, 8-4 Software Programming, 3-11 Special Function Mode, 2-9 Special functions, 8-2 debug mode, 8-6 run mode, 8-5 set autorun, 8-7 set port?, 8-4 Specifications Display, 14-3 display, 14-3 electrical, 14-1 Environmental, 14-2 environmental, 14-2 Strobe commands, 9-4 Strobe lines, 7-4

P
Paralle port input circuit, 7-2 power supply, 7-13 Parallel port connecting DC outputs, 7-12 connections, 7-2 current requirements, 7-12 data line values, 7-4 inserting variable message data, 9-4 strobe lines, 7-4 timing requirements, 7-13 Port parallel, 1-2 serial, 1-2 Power supply, 12-4 Priority mode, 1-2, 10-1, 10-6 Problems troubleshooting, 13-1 Programming Multiple DL5s, 3-11 Software, 3-11 Programming Cables, 2-3 Programming cables, 6-1 Programming terminals, 1-1 Prompt Mnemonic, 2-8 Protocol Communications, 2-3 serial port, 6-3

Index-3

Index

T
Terminal types, 1-1 Timing requirements parallel port, 7-13 Trigger serial port, 6-3 Triggering messages, 5-3 Troubleshooting, 13-1

V
Variable data, 6-4 embedding, 9-2 updating frequently, 9-8 Voltage Input, 2-2

W
Wait time, 3-5 Wire routing, 12-1 Wiring diagram, 12-5 precautions, 12-1 Worksheets, C-1

Index-4

Index

Index-5

DL5 Edit Commands

Keys Pressed [CTRL] [A] [CTRL] [C] [CTRL] [D] [CTRL] [E] [CTRL] [F] [CTRL] [H] [CTRL] [I] [CTRL] [J] Command Function Allows access to previously entered message attributes so they can be reviewed or changed. Centers a message on the display. Deletes a single message block. Erases an entire message. Shows the number of message blocks that are not programmed (free). Moves the cursor one character position to the left. Inserts a message block between two previously entered message blocks. Creates a new message block after previously entered message blocks or moves the cursor one message block towards the end of a message. Moves the cursor one message block towards the beginning of a message. Moves the cursor one position to the right. Exits the edit mode with save. Runs a message in the edit mode. Imbeds a single digit variable in a message. Displays the data without leading zeros. Imbeds a single digit variable in a message with leading zeros.

[CTRL] [K] [CTRL] [L] [CTRL] [Q] [CTRL] [R] [CTRL] [V] [CTRL] [X]

Publication 2706-UM001A-US-P - November 1999

Supersedes Publication 2706-813 - October 1992

PN 40061-180-01(B)
(1999) Rockwell International Corporation. Printed in the U.S.A.

D/DE-Series AC Servodrives
Installation & Operation Manual SAC-D01d

Copyright (c) 1997 Ormec Systems Corp. All rights reserved.

19 Linden Park Rochester, NY 14625 (716) 385-3520 November 8, 1999

Copyright Notice
Copyright 1996 - 1999 by Ormec Systems Corporation. All rights reserved. This manual and any software that it may describe, remain the exclusive property of Ormec Systems Corporation. No part of either may be reproduced in any form without the prior written permission of ORMEC.

Warranty
ORMEC extends no warranty with respect to the merchantability or fitness of this product for any particular purpose. It is the customer's responsibility to determine whether it is suitable for the specific application and whether it meets performance, reliability, and safety requirements when used in that application. ORMEC reserves the right to make improvements to the product as well as this documentation at any time without notice.

Terms and Conditions of Sale

All software sold or otherwise provided by ORMEC is made available subject to ORMEC's published Standard Terms And Conditions Of Sale.

D-Series AC Servodrives Table Of Contents

Table of Contents

1 Welcome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1 2 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3

2.1 Servodrive Capabilities and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3 2.1.1 Servodrive Model Number Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5 2.2 Servomotor Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5 2.2.1 Servomotor Model Number Description . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6

3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 7
3.1 Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7 3.2 Receiving and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7 3.3 Servodrive Panel Mounting and Environment . . . . . . . . . . . . . . . . . . . . . . . . . . page 8 3.4 Terminal Block Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8 3.4.1 Input and Output Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8 3.4.2 External Regenerative Discharge Resistor Connections . . . . . . . . . . page 11 3.5 Input Power Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 13 3.5.1 Servodrive Power Dissipation at Rated Output . . . . . . . . . . . . . . . . . . . page 14 3.5.2 Shielding, Power Line Filtering, and Noise Suppression . . . . . . . . . . page 14 3.5.3 Recommended Motor and Servodrive Wiring Methods . . . . . . . . . . . page 15 3.5.4 Servomotor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15 3.6 Control Circuit Interconnections - Connector CN1 . . . . . . . . . . . . . . . . . . . . . page 16 3.6.1 Interlock and Alarm Reset Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . page 16 3.6.2 Interlock Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 16 3.6.3 Current Command Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 17 3.6.4 Quadrature Position Feedback Signals . . . . . . . . . . . . . . . . . . . . . . . . . . page 17 3.6.5 Velocity Monitor Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18 3.6.6 DC Power Supply Voltages Available on Connector CN1 . . . . . . . . page 18 3.6.7 Absolute Encoder Support Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . page 19 3.7 Optical Position Encoder Connector - Connector CN2 . . . . . . . . . . . . . . . . . page 19 3.8 Display Monitor Module Connector - Connector CN3 . . . . . . . . . . . . . . . . . . page 20 3.9 Analog Monitor Output Connections (SAC-D only) - Connector CN4 . . . page 20 3.10 Motor with Integral Fail-Safe Brake Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . page 20 3.10.1 Brake Coil Circuit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 20 3.11 Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21 3.11.1 Motor Use and Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21 SAC-D01c page i

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3.11.2 Coupling the Servomotor to the Load . . . . . . . . . . . . . . . . . . . . . . . . . . . page 22

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page . . . 23
4.1 Power On and Off Sequencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 23 4.2 Current Command Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 24 4.3 Overload Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 24 4.4 Position Encoder Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 24 4.5 Regenerative Load Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 25 4.5.1 Shunt Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 25 4.5.2 Applications Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 27 4.6 Dynamic Braking Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 27 4.7 Absolute Encoder Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 28 4.7.1 Reading the Absolute Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 29 4.7.2 Absolute Encoder Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 29 4.7.3 Resetting the Absolute Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 30 4.7.4 Absolute Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 31 4.8 Servodrive Display Monitor Module Operation (SAC-OP03A) . . . . . . . . . . page 33 4.8.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 33 4.8.2 Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 33 4.8.2.1 STATUS Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 33 4.8.2.2 ALARM LOG REVIEW Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 34

5 Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page . . . 37

5.1 Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 37 5.1.1 Servomotor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 37 5.1.2 Servodrive Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 37 5.1.3 Preparation for Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 38

6 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page . . . 39
6.1 DE-Series Motors Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 40 6.2 DA-Series Motors Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 40 6.3 DB-Series Motors Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 40 6.4 General Servodrive Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 41 6.4.1 SAC-DE Servodrive Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 41 6.4.2 SAC-D Servodrive Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 42 ii ORM-DOCa

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6.5 MAC-DE Series Incremental Encoder Servomotors Specifications page 43 (115 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 MAC-DE Series Incremental Encoder Servomotors Specifications page 44 (230 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 MAC-DA Incremental Encoder Servomotor Performance page 46 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 MAC-DB Incremental Encoder Servomotor Performance page 48 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 Incremental Encoder Servomotor with Fail-Safe Brake Performance page 51 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10 Absolute Encoder Servomotor Performance Specifications . . . . . . . . . . page 52 6.11 Absolute Encoder Servomotor with Fail-Safe Brake Performance page 53 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12 Fail-Safe Brake Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 54

7 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . page . . . 55

7.1 LED Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 55 7.1.1 SAC-D LED Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 55 7.1.2 SAC-DE LED Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 56 7.2 Status Indicator Code Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 56 7.3 Servodrive Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 58 7.3.1 SAC-D Servodrive Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 58 7.3.2 SAC-DE Servodrive Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 59 7.4 Servodrive Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 60 7.5 IP-67 Motor Shaft Seal Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 70

Appendix A - System Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . A-1

ORION System Wiring Diagram with SAC-D & SAC-S Series Servodrives . . . . A-1 ORION System Wiring Diagram with SAC-DE & SAC-E Series . . . . A-2 Servodrives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B - Component Layout Diagrams . . . . . . . . . . . . . . . . . . . . . B-1

SAC-D04, D08, D12, & D19 Servodrive Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 SAC-D37 Servodrive Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 SAC-D47, D55, & D59 Servodrive Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3 SAC-DE Servodrive Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4 SAC-LF215U Line Filter Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5 SAC-LF230U Line Filter Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5 SAC-D01c page iii

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SAC-LF15U - LF100U Line Filter Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6 SAC-DRR Regen Resistor Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

Appendix C - DSP Axis Module Interface Cables and . . C-1 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CBL-AD D-Series Axis Interface Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 CBL-ADT D-Series to Terminal Block Axis Interface Cable . . . . . . . . . . . . . . . . . . . . C-2 CBL-ADE DE-Series Axis Interface Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3 CBL-ADET DE-Series to Terminal Block Axis Interface Cable . . . . . . . . . . . . . . . . . C-4 CBL-AT3 DSP Axis Module to Terminal Block Cable . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

Appendix D - Motor and Encoder Interface Cables . . . . . . . . . . . . . . D-1

CBL-CBL-DMAC D-Series Encoder Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 CBL-DMAC# D-Series Motor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2 CBL-DMACB# D-Series Motor/Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3 CBL-DMACB D-Series Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4 CBL-DEMAC DE-Series Motor and Servodrive Encoder Cable . . . . . . . . . . . . . . . . D-5 CBL-DEMACD DE-Series Motor to D-Series Servodrive Encoder Cable . . . . . . . D-6 CBL-DEMAC# and CBL-DEMACB# DE-Series Motor and Motor/Brake . . . . D-7 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix E - Motor Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

MAC-DE003A1 & MAC-DE003A2 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 MAC-DE006B1, DE006B2, DE008C1 & DE011C2 Motors . . . . . . . . . . . . . . . . . . . . E-2 MAC-DE021D2 & DE042E2 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3 MAC-DA030F & DA055G Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4 MAC-DA090H, DA110J & DA140K Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5 MAC-DB025L, DB055M & DB080N Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6 MAC-DB100P, DB200Q, DB300R, DB330S & DB465T Motors . . . . . . . . . . . . . . . . E-7 MAC-DB700U Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8

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Welcome

Chapter 1 Welcome
1 Welcome
This manual provides information about ORMEC's D/DE-Series (SAC-D and SAC-DE) AC Brushless Servodrives. It provides both a technical description and information required for their installation, operation, and maintenance. This manual is divided into the following chapters: Chapter 1 Chapter 2 Chapter 3 Welcome introduces you to this manual and how it is organized. General Description gives an overview of the D/DE-Series product family. Installation provides instructions on how to install you servodrive unit. It also provides a complete hardware description of the D/DE-Series servodrives, including detailed interface information. Operation documents the power up and initial configuration approach for the D/DE-Series. Getting Started provides detailed instructions on how to run your D/DE-Series system for the first time. Specifications provides a detailed list of D/DE-Series servodrive and compatible servomotor performance specifications. Maintenance and Troubleshooting documents the various status and alarm indicators. Appendixes contain a detailed drawing set.

Chapter 4 Chapter 5 Chapter 6

Chapter 7 Appendixes

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Welcome

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General Description

Chapter 2 General Description

2 General Description
This manual covers the D/DE-Series AC servodrives, which interface with ORMEC's ORION motion controllers1, and control the D/DE-Series Servomotors. These AC servodrives and their corresponding motors provide the following capabilities: 2.1 Servodrive Capabilities and Features Wide Power Range: Output power ratings from 100 watts to 11 kW. High Peak Current: High peak output current resulting in high peak motor torque, up to three times rated current for a few seconds and twice rated current for up to a minute. All Digital Design: High speed DSP controlled current loops for precise torque mode operation. Torque Mode Operation: When combined with DSP based velocity loops in ORMEC ORION motion controllers, torque mode operation eliminates the need for user adjustable potentiometers and allows extremely high load inertia to motor inertia ratios. Wide Current Loop Bandwidth: For high positioning accuracy and response. Velocity Monitor: A high quality velocity monitor signal, derived from the digital position transducer, provided for testing and analog velocity loop closure. Torque Monitor: A calibrated torque monitor signal simplifies system test.

D-Series (SAC-D) servodrives and cables are compatible with Generation III motion controllers. DE-Series (SAC-DE) servodrives require a modified axis interface cable for use with Generation III motion controllers, contact your ORMEC Sales and Application Engineer for further information.

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D-Series AC Servodrives Modular Servodrive Construction

General Description

Shunt Regulator: All D/DE-Series servodrive models (except the SAC-DE02A1) have a built-in shunt regulator on the bus power supply to handle regenerative load conditions. The SAC-D47, D55, and D59 servodrives require the use of an external resistor (SAC-DRR/0880 and /1760) with the shunt regulator. Safety: The integral control power supply input is distinct from the main power used for electromotive power. This provides superior safety and diagnostic features. Separate control power for fault-detection and diagnostics allows the main power to be disrupted by normally-open relay contacts whenever a fault condition is detected by the built-in microprocessor. Dynamic Braking: Solid-state dynamic braking circuitry is built-in on all D/DE-Series drives to provide an added measure of safety. Panel Mounting: All D/DE-Series servodrives are panel mounted with "footprints" significantly smaller than other servodrives with equivalent output power ratings.

Fault Detection and Diagnostics Fault Detection and Protection: Fault detection and protection features include high bus voltage, low bus voltage, overload, overcurrent, open phase detection, loss of feedback detection, and excessive regeneration detection. Diagnostics: D/DE-Series servodrive diagnostic messages are coded. SAC-D servodrives can display these diagnostic messages using the 5 position seven segment LED Servodrive Display/Monitor Module (SAC-OP03A). SAC-DE servodrives have an integral seven segment LED Alarm indicator for displaying diagnostic messages.

Optically Coupled Safety Interlocks Torque Enable Input: The fail-safe Torque Enable input requires the motion control electronics to actively sink current in order to enable motor output torque. No Alarm Output: The No Alarm output transistor is normally ON (Sinking current) and turns OFF whenever a fault is detected. Fail-safe interlocking is provided when this output is attached to a fail-safe input of the control electronics, as it is with all ORMEC motion controllers. Coded Alarm Outputs: Three alarm outputs are provided to indicate the most recent servodrive fault. Coded alarm outputs provide unique indication for each alarm condition. Remote Alarm Reset: A remote alarm reset allows the ORION motion controller to reset servodrive faults without the need to press a button on the servodrive or cycle control power.

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General Description

2.1.1 Servodrive Model Number Description SAC-D##M1/O1O2 SAC-DE##M1V1/O1 ## M1 Current = continuous current output rating Motor Identifier = A - U (motor matching reference letter) Input Voltage (SAC-DE only) V1 = = 1 (115 VAC input power) 2 (230 VAC input power)

Options (see note): O1 Encoder Type (must be specified) = I (incremental encoder) = A (multi-rev absolute encoder)2 Monitor Module (SAC-D only) = M(monitor module included with servodrive)

O2 NOTE:

The encoder type, option O1, must be specified.

2.2 Servomotor Capabilities Wide Power Range: Output motor power ratings ranges from 0.13 to 15 HP. Wide Torque Range: Continuous stall torques range from 2.8 to 696 in-lb. High Speed: Maximum motor speeds range from 2,000 to 4,500 RPM. High Torque-to-Inertia Ratios: Motors with high Torque-to-Inertia ratios deliver a higher percentage of rated power to the load in applications which require high acceleration and deceleration rates. Durable Construction: Service life is maximized by the brushless motor construction, high thermal efficiency frame and rugged sealed bearings. Industrial Internal Position Transducer: The rugged internal position transducer measures 8,160to 32,640 (incremental encoder motors) precise increments of position, or counts, per revolution. Low Torque Ripple: Sinusoidal construction combined with precise electronic commutation provide low motor output torque ripple.

An ORION DSP Axis Module with absolute encoder support option is required for use with a D-Series or DE-Series absolute encoder motor/servodrive system (ORN-DSP-A_/_A). Refer to the ORION Installation and Operation manual for further information regarding the DSP Axis Module absolute encoder support option.

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D-Series AC Servodrives

General Description Harsh Environment Operation: Standard IP-65 motor sealing with optional IP67 sealing permits motor operation in harsh industrial environments. Fail-Safe Brake: An optional fail-safe brake is available integral to the motor. Multi-Revolution Absolute Encoder: An optional multi-revolution absolute encoder is available, which allows a servomotor to "remember" it's position through power cycles.

2.2.1 Servomotor Model Number Description MAC-D##M1/O1O2O3 MAC-DE###M1V1/O1O2O3 ### M1 Torque = continuous stall torque Motor Identifier = A - U (motor matching reference letter) Input Voltage (MAC-DE only) V1 = = 1 (115 VAC input power) 2 (230 VAC input power)

Option (see note): Encoder Type (must be specified) O1 = = I (incremental encoder) A (multi-rev absolute encoder)3

O2 O3 NOTE:

Sealing = V (IP-67 sealing) Fail-Safe Brake = B (fail-safe brake with 24 VDC coil)

After the encoder type, option O1, only the desired options in the motor model number are specified.

An ORION DSP Axis Module with absolute encoder support option is required for use with a D-Series or DE-Series absolute encoder motor/servodrive system (ORN-DSP-A_/_A). Refer to the ORION Installation and Operation manual for further information regarding the DSP Axis Module absolute encoder support option.

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Installation

Chapter 3 Installation
3 Installation

3.1 Connection Diagram Connection Diagrams for typical D/DE-Series systems are shown in Appendix A. The connections to the servodrive are also described in the next few sections. BEFORE APPLYING POWER, REFER TO THE TEST RUN SECTION OF THE "GETTING STARTED" CHAPTER. NOTE: Install all servodrive and servomotor power wiring (including ground wiring) according to NEC (National Electric Code) or UL (Underwriters Laboratories) specifications and in compliance with local ordinances. D/DE-Series servodrives and Servomotors are high voltage equipment, using 230 VAC input power and a 325 VDC main DC Bus (NOTE: The SAC-DE servodrives also use 115 VAC input power and a 163 VDC main DC Bus).

WARNING:

3.2 Receiving and Inspection ORMEC servodrives, servomotors, and their associated accessories are put through rigorous tests at the factory, prior to shipment. After unpacking, however, check for damage which may have been sustained in transit. The bolts and screws should all be tight, and motor output shafts should rotate freely by hand (except motors with integral fail-safe brakes, MAC-D__/_B). Check the servodrives, and any accessories, for bent or broken components, or any other physical damage before installation.

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3.3 Servodrive Panel Mounting and Environment Panel mounting data is available in the Specifications Section and Appendix B. The servodrive environment should be maintained as follows: Ambient operating temperature should be between 0 and 55C. If the electrical panel is subjected to vibration, mount the units on shock absorbing material. Avoid use in corrosive atmospheres which may cause damage over time. Select a location with minimum exposure to oil, water, hot air, high humidity, excessive dust, or metallic particles. The proper mounting orientation for the servodrives is vertical on a panel using the mounting holes on the base plate. Allow sufficient clearance around servodrives for airflow, and provide proper ventilation. Clearance: 2 inches (50 mm) minimum above and below, and 0.4 inches (10 mm) minimum between servodrives. External regenerative discharge resistors should be mounted in an enclosure separate from the servodrive enclosure, if possible. Regenerative discharge resistors can become extremely hot, and so proper ventilation must be provided.

3.4 Terminal Block Connections

3.4.1 Input and Output Power Connections Terminal blocks on the servodrives are provided for connecting main and control input power, and the servomotor output power. Refer to Table 1 for a description of the SAC-D, and Table 2 for the SAC-DE, input and output power terminal block connections. Refer to Figures 1, 2, and 3 for D-Series (SAC-D) wiring diagrams to various transformer configurations. Refer to Appendix A for typical D/DE-Series system wiring diagrams.

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Terminal RST rt UVW

Function Main Power

1 1

Description Three-Phase 230 VAC, 50/60 Hz. (SAC-D___/) Single-phase 230 VAC, 50/60 Hz. (SAC-D___/) Power to Motor, Connections are: U on drive - A on motor - Red on CBL-DMAC#/NNN V on drive - B on motor - White on CBL-DMAC#/NNN W on drive - C on motor - Black on CBL-DMAC#/NNN Connects to Motor terminal D and motor cable shield drain. Must also be securely attached to earth ground using braided copper wire. Two frame ground terminal connections are provided per servodrive. The P1 terminal is supplied on the SAC-D47 - D59 servodrives only. Connection to the B is not normally required for the SAC-D04 SAC-D37 servodrives. For the SAC-D47 - SAC-D59 the appropriate external regen resistor unit must be connected to these terminals (P1 & B). Refer to the External Regenerative Discharge Resistor Connections section of this chapter for further information. These terminals are connected to the high and low sides of the main DC power supply respectively. The main DC power supply voltage can be measured between these terminals. Connection to these terminals is not normally required.

Control Power Motor Power

Frame Ground

P1 B

External Regen Resistor Connection

PN

Main DC Power Supply Output

Refer to Figures 1-3 for wiring diagrams for various transformer configurations.

Table 1, SAC-D Input & Output Power Terminal Block Connections

Terminal RT rt UVW

Function Main Power Control Power Motor Power

Description Single-phase 115 VAC, 50/60 Hz.(SAC-DE___1/) Single-phase 230 VAC, 50/60 Hz. (SAC-DE___2/) Single-phase 115 VAC, 50/60 Hz.(SAC-DE___1/) Single-phase 230 VAC, 50/60 Hz. (SAC-DE___2/) Power to motor, Connections are: U on drive - A on motor - Red on CBL-DMAC#/NNN V on drive - B on motor - White on CBL-DMAC#/NNN W on drive - C on motor - Black on CBL-DMAC#/NNN Connects to motor terminal D. Must also be securely attached to earth ground using braided copper wire. Two frame ground terminal connections are provided per servodrive. Connection to these terminals is not normally required. Refer to the External Regenerative Discharge Resistor Connections section of this chapter for further information.

Frame Ground

PB

External Regen Resistor Connection

Table 2, SAC-DE Input & Output Power Terminal Block Connections

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Figure 1, SAC-D Input Power Wiring for Wye (Y) Transformer

Figure 2, SAC-D Input Wiring for Delta Transformer with Grounded Phase

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Figure 3, SAC-D Input Wiring for Delta Transformer with Stinger

3.4.2 External Regenerative Discharge Resistor Connections Terminal blocks are provided for connecting an external regenerative resistor. Refer to Table 3 for a description of the external regen resistor connections for each all the D/DE-Series servodrives.

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Terminal

Servodrive SAC-DE01A1 SAC-DE01A2 SAC-DE02B2

Comments Neither an internal regen resistor, or support for an external regen resistor is provided. An internal regen resistor is not provided with these units. An external regen resistor can be added if required by an application. Contact your ORMEC Sales and Application Engineer for further information.

P B

SAC-DE02B1 SAC-DE03C1 SAC-DE03C2 SAC-DE04D2 SAC-D04 SAC-D08 SAC-D12 SAC-D19 SAC-D37 SAC-D47

An internal regen resistor is provided with these units, connection to these terminals is not normally required. If required by an application, support for an external regen resistor can be provided. Contact your ORMEC Sales and Application Engineer for further information.

SAC-DRR/0880 (Connection of an external regen resistor required) SAC-DRR/1760 (Connection of an external regen resistor required) SAC-DRR/1760 (Connection of an external regen resistor required)

P1 B

SAC-D55 SAC-D59

Table 3, External Regen Resistor Terminal Block Connections

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3.5 Input Power Considerations D/DE-Series servodrives can be operated directly on commercial power lines which supply 230 VAC or 115 VAC (DE-Series only). To prevent power line accidents due to grounding error, contact error or to protect the system from a fire, circuit breakers or fuses must be installed according to the number of servodrives used. Slow-blow circuit breakers or fuses should be used, because the internal D. C. power supply capacitors draw substantial inrush current at powerup. To select a transformer and/or fuses for the system, add the required power for the transformer and recommended fuse capacities (Tables 4 & 5) for each servodrive in the system. Servodrive Model SAC-D04 SAC-D08 SAC-D12 SAC-D19 SAC-D37 SAC-D47 SAC-D55 SAC-D59
1 2

Power Required1 (KVA) 1.1 2.0 2.5 4.0 7.5 12.5 15.0 19.0

Recommended Fuse2 (amps) 5 8 10 12 28 32 41 60

Recommended Line Filter SAC-LF15U SAC-LF15U SAC-LF15U SAC-LF30U SAC-LF45U SAC-LF60U SAC-LF60U SAC-LF100

Power listed is the capacity at rate load. Current listed is the recommended slow-blow capacity for each leg of the three-phase power.

Table 4, SAC-D Input Power Requirements

Input Voltage

Servodrive Model

Power Required (KVA) 0.50 0.75 1.40 0.50 0.75 1.20 2.20

Recommended Fuse1 (amps) 5 8 15 5 5 9 16

Recommended Line Filter SAC-LF215U SAC-LF-215U SAC-LF230U SAC-LF215U SAC-LF215U SAC-LF215U SAC-LF230U

SAC-DE02A1 115 VAC SAC-DE03B1 SAC-DE04C1 SAC-DE01A2 230 VAC SAC-DE02B2 SAC-DE03C2 SAC-DE04D2
1

Current listed is recommended slow-blow fuse capacity of the single-phase power.

Table 5, SAC-DE Input Power Requirements

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3.5.1 Servodrive Power Dissipation at Rated Output The D/DE-Series servodrive power dissipation information listed below is provided to assist in the specification of cabinet cooling system requirements. Input Voltage Servodrive Model Control Circuitry (watts) 13 13 13 13 13 13 13 20 20 20 20 24 27 27 30 Main Circuitry (watts) 12.0 16.2 20.1 6.3 14.5 22.2 36.1 27 55 80 120 260 290 330 360 Regeneration Resistor (watts) -----6 6 30 30 30 30 60 180 350 350 Total Dissipation (watts) 25.0 35.2 39.1 19.3 27.5 41.2 55.1 77.0 105 130 170 344 497 707 740

SAC-DE01A1 115 VAC SAC-DE02B1 SAC-DE03C1 SAC-DE01A2 SAC-DE02B2 SAC-DE03C2 SAC-DE04D2 SAC-D04 230 VAC SAC-D08 SAC-D12 SAC-D19 SAC-D37 SAC-D47 SAC-D55 SAC-D59

Table 6, Power Dissipation at Rated Output

3.5.2 Shielding, Power Line Filtering, and Noise Suppression The D/DE-Series servodrives use high voltage switching power transistors in the main circuit. When these transistors are switched, the di/dt or dv/dt switching noise may sometimes prove objectionable, depending on the wiring and/or grounding method. The servodrive also utilizes a microprocessor, which can be susceptible to power line interference caused either by the output switching transistors or other equipment on the power line, such as welders, electrical discharge machines, induction heating equipment, etc. Careful layout of wiring and power line filtering will prevent noise interference. Recommendations with respect to wiring and grounding are described later in this section. It is recommended that line filters be installed to eliminate electro-magnetic interference coming into the system from the power line, as well as blocking switching noise from being transmitted back out to the power line from the servodrives. The recommended noise filters available from ORMEC are shown in Tables 3 and 4.

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For a single servodrive installation, the line filter recommended is listed. In the case of a system using multiple servodrives, only one noise filter is required per cabinet. Select the appropriate line filter by adding the incoming power line power recommendations in Tables 3 and 4. If the noise filter connection or wiring methods are improper, it's effectiveness is significantly reduced. The following is the recommended approach: 1) Separate the input and output leads by a minimum of 10 inches (25.4 cm). Do not bundle them in the same duct or wireway. 2) Do not bundle the ground lead with the filter output line or other signal lines, and do not run them in the same duct. 3) Connect the filter ground lead with a single wire (preferably braid) to the enclosure or the control panel frame grounding terminal. 3.5.3 Recommended Motor and Servodrive Wiring Methods 1) When the motor is mounted to the machine and grounded through the machine frame, dv/dt current flows from the PWM power through the floating capacitance of the motor. To prevent noise effects from this current, and also for safety, the motor housing (terminal D of the motor connector) should be connected to the frame of the servodrive, which should be directly grounded to the control panel frame ground terminal. 2) Wire the frame ground connection (also designated FG) directly to the servodrive case, and connect to the control panel. 3) When motor wiring is contained in metal conduits, the conduits and boxes must be grounded. Use wires of 12 AWG or heavier for grounding to the case (preferably flat woven silver plated copper braid). 4) Route signal and power leads (including motor power) in separate conduits or wireways, separated by a minimum of 10 inches (25 cm). 3.5.4 Servomotor Overload Protection Thermal overload protection for the Servomotor is not provided internal to the Servodrive, and must be provided externally. External overload relays can be used to protect the Servomotor from overheating. Refer to the National Electric Code for information regarding the proper sizing of overload protection. The overload protection should be wired such that it causes the Servodrive main power to be interrupted when an overload occurs, and remain interrupted (latched) until an operator reset occurs. The overload protection must not break the connection between the Servodrive and Servomotor. Refer to the System Wiring Diagram in Appendix A.

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3.6 Control Circuit Interconnections - Connector CN1 Connector CN1 is a 50 pin male connector, 3M part number 10150-3000VE for SAC-D servodrives, and Honda part number MR-50RMA for SAC-DE servodrives. Cable CBL-AD\NN or CBL-ADE\NN is used to connect a SAC-DE or SAC-D respectively to an ORION DSP Axis Module (ORN-DSP). The interface connections for connector CN1 are described below. Refer to Appendix C for further information regarding cables CBL-AD\NN and CBL-ADE\NN. 3.6.1 Interlock and Alarm Reset Input Signals The interlock and alarm reset input signals consist of optically coupled isolators intended for use with +24 VDC. The ORION implementation of these signal uses +/-12 VDC to achieve the 24 VDC requirement. To assert each signal a low resistance connection from the input to - 12 VDC must be provided allowing 5 mA of input current to the optically coupled isolator. Signal T-ENABLE' Pin # Function 40 Torque Enable Description For normal motor operation, this input must be asserted. When not asserted, the servodrive's output transistors are disabled, and a solid state dynamic braking circuit is enabled. If the servodrive has a fault condition, this input can be momentarily asserted to clear it. This input provides power to the servodrive interlock and alarm reset input opto-isolator circuits, which are controlled by the T-ENABLE' and ALM-RESET' inputs respectively. This signal is connected to CN1 pin 23 for a SAC-D, and the ORION DSP Axis Module +12V output for a SAC-DE.

ALM-RESET' D-ENABLE

44 47

Alarm Reset Drive Enable

Table 7, Interlock and Alarm Reset Input Signals

3.6.2 Interlock Output Signals Each of the four interlock output signals is an optically isolated coupled transistor intended for +24 VDC operation, and has the following specifications: Maximum Applied Voltage: 30 VDC Maximum Current Sink Capability: 50 mA

When attaching electromechanical relays to these outputs, a fly-back diode or other transient suppression device is required across the relay coil.

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Signal NO-ALARM'

Pin # Function 31 Servo Alarm

Description This output transistor is normally ON, and turns OFF when a Servo Alarm fault is detected. For details on the alarms, refer to the Maintenance & Troubleshooting section. This output is connected to CN1 pin 2 (servodrive ground). It provides the common for the servodrive no alarm output circuit, which is controlled by the NO-ALARM' output. When the NO-ALARM' transistor is OFF, these output transistors are reporting the existing alarm condition.

NO-ALARM-

32

Servo Alarm Common

AL01' AL02' AL03'

37 38 39

Alarm Code

Table 8, Interlock Output Signals

3.6.3 Current Command Input Signals The current command input signals are analog voltage inputs used in the control of the output current, and therefore torque, of the servodrive-servomotor combination. Signal DRV-CMD Pin # Function 9 Description

Current Command Applying an analog signal from zero to approx. +/-9 volts to this input results in servodrive output current from zero to plus or minus full output, and consequently torque from zero to plus or minus full output torque. (NOTE: +/-3 VDC = +/- rated torque) Current Command This is the current command reference (zero) signal. Common

AGND

10

Table 9, Current Command Signals

3.6.4 Quadrature Position Feedback Signals Quadrature position feedback signals are provided for position control and monitoring electronics. D/DE-Series servodrive quadrature position feedback signals are differential line driver outputs, which are compatible with ORMEC DSP Axis Module differential line receiver inputs.

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Signal ENCA ENCA' ENCB ENCB' ENCZ ENCZ'

Pin # Function 35 36 33 34 19 20

Description

Encoder Feedback Quadrature position encoder outputs after frequency Channel A division; driven with differential line drivers (TI Encoder Feedback 75174), to be received by differential line receivers (TI 75115 or equivalent) Channel B Encoder Reference Once per motor revolution reference signal; driven Channel Z with differential line drivers (TI 75174).

Note: These differential encoder signals are wired with individual twisted pairs within a shielded cable. Table 10, Quadrature Position Feedback Signals

3.6.5 Velocity Monitor Signal An analog output signal is provided for monitoring the speed of the servomotor. This signal is driven by an operational amplifier. Signal TACH Pin # Function 17 Speed Monitor Description This +/-10 volt analog signal is proportional to motor velocity, and is calibrated for +/-1.0 V/1000 RPM, +/- 5% (MAC-DA & MAC-DE) +/- 2.0 V/1000 RPM, +/-5% (MAC-DB)

Table 11, Velocity Monitor Signal

3.6.6 DC Power Supply Voltages Available on Connector CN1 The D/DE-Series servodrive optical isolator inputs require a 24 VDC input signal. The +/-12 VDC supplied by the SAC-D servodrives is used to achieve the required input signal voltage for SAC-D servodrives. For SAC-DE servodrives the +/-12 VDC is supplied by the DSP Axis Module (refer to the SAC-DE Series Servodrive Interface and Servodrive Interface Configuration Jumpers sections of the ORION Installation & Operation Manual for further information), the +/-15 VDC supplied by the servodrive cannot be used for this purpose.

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Signal +12 V

Pin # Function 23 Output Power

Description +/-12 VDC for SAC-D servodrive and +/-15 VDC for SAC-DE servodrives (not used), +/- 5%, 30 mA maximum output current capability. NOTE: This output power is not used on DE-Series servodrives, interlock power for these servodrives is provided by either the ORION DSP Axis Module, or an external power supply. Common for servodrive interface power supply (connected to frame ground).

-12 V DGND

24 1 Digital Ground

Table 12, DC Power Supply on CN1

3.6.7 Absolute Encoder Support Input Signals

Signal ABS

Pin # Function 4 Absolute Encoder Read Command

Description TTL-level signal asserted by the motion controller to cause the absolute encoder position information to be sent; and normal operation initiated for motors with the absolute encoder option only (MAC-D____/A). Absolute encoder backup power input. An optional 3 VDC battery is available for ORION DSP Axis Modules which supplies backup power for the absolute encoder (MAC-D____/A).

BAT+ BAT-

21 22

Absolute Encoder Backup Battery

Table 13, Absolute Encoder Support Signals

3.7 Optical Position Encoder Connector - Connector CN2 Connector CN2 is a 20 pin male connector, Honda part number MR-20RMA for SAC-DE servodrives and 3M part number 10120-3000VE for SAC-D servodrives. It is the interface between the optical position encoder of the servomotor and the servodrive. DE-Series Motor Cable CBL-DEMAC/NNN is used to connect a MAC-DE encoder to a SAC-DE servodrive. Cable CBL-DEMACD/NNN is used to connect a MAC-DE encoder to a SAC-D servodrive.

D-Series Motor A CBL-DMAC/NNN is used to connect a MAC-D encoder to a SAC-D servodrive

Refer to Appendix D for further information regarding cables CBL-DEMAC/NN, CBL-DEMACD/NN, and CBL-DMAC/NN. SAC-D01d page 19

D-Series AC Servodrives

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3.8 Display Monitor Module Connector - Connector CN3 Connector CN3 is a 9 pin D-Sub connector for attachment of the Servodrive Display Monitor Module (SAC-OP03A). Refer to the Servodrive Display Monitor Module Operation (SAC-OP03A) section of the Operation chapter for further information. 3.9 Analog Monitor Output Connections (SAC-D only) - Connector CN4 Connector CN4 on the SAC-D servodrives is a 4 pin header which provides an interface to the analog speed and torque monitors. A CBL-MON/3 can be connected to CN4 to provide convenient access to the analog monitor signals. Refer to Table 14 for a description of the analog monitor output connections. CBL-MON Red Pin # Function 1 Speed Monitor Description Bi-directional speed monitor 1 v/kRPM DE & DA-Series, +/- 5% 2 v/kRPM DB-Series, +/- 5% Signal common

White Black

2 3, 4

Torque Monitor Bi-directional torque monitor (2 v/rated torque, +/- 10%) Signal Ground

Table 14, Analog Monitor Outputs

3.10 Motor with Integral Fail-Safe Brake Wiring For the D/DE-Series motors with integral fail-safe brakes (MAC-D____/__B), the appropriate motor cable with brake support must be used (CBL-DMAC_B/NNN or CBL-DEMAC_B/NNN). In the case of the MAC-DB330, DB465, and DB700, a CBL-DMACB/NNN is also required. Two additional conductors are supplied in each of these cables (In the case of the MAC-DB330, DB465, and DB700, the additional conductors are in the CBL-DMACB/NNN), for supplying brake coil power. Refer to the CBL-DMACX/NNN and CBL-DEMACX/NNN drawings included in Appendix D for further cable information. Refer to the Fail-Safe Brake Specifications section of the Specifications chapter for further information. 3.10.1 Brake Coil Circuit Wiring Figure 4 shows the recommended safety and fault interlock wiring for D/DE-Series motors with integral fail-safe brakes. The primary features of this interlock implementation are: page 20 If the main power is disabled by the main power contactor the brake coil power is disabled and the brake engages. If the servodrive is disabled (i.e. the T-ENABLE' signal is unasserted) the brake coil power is disabled, and the brake is engaged. If both the main power and the servodrive are enabled the brake coil power is enabled, and the brake is disengaged. SAC-D01d

D-Series AC Servodrives

Installation Requires the use of a CBL-ADT/NN or CBL-ADET, for D-Series and DE-Series servodrives respectively, for access to the T-ENABLE' signal from the DSP Axis Module to the servodrive, and an optically isolated solid state relay to control the brake coil power. NOTE: The T-ENABLE' signal is a +24 VDC signal. DO NOT USE THE ORION POWER SUPPLY FOR COIL POWER!!! The ORION power supply should not be used for switching inductive loads, such as a relay coil, a separate 24 VDC power supply must be used.
o r C B L -D E M A C B _ /N N N ( M o to r C a b le ) _

D /D E -S e r ie s S e r v o d r iv e U W V

M a in P o w e r C o n ta c to r A u x ilia r y C o n ta c ts
G R N R E D W H T B L K S H Y E L Y E L + 2 4 V D C C o m m o n

S H IE L D

+ 2 4 V D C P o w e r S u p p ly (P S U -0 2 4 /3 .8 A )

1 C N

C B L -A D T /N N o r C B L -A D E T /N N ( A x is In te r fa c e C a b le )
1
1 3 2 6

O p tic a lly Is o la te d S o lid S ta te R e la y ( s e e ta b le , b e lo w )

3 + 4 T o T B C - D 2 5 ( T - E N A B L E ') P in 8 fo r D - S e r ie s S e r v o d r iv e s ( S A C - D ) P in 8 fo r D E - S e r ie s S e r v o d r iv e s ( S A C - D E ) T o T B C -D 2 5 P in 1 9 ( V + ) fo r D - S e r ie s S e r v o d r iv e s ( S A C - D ) P in 7 ( + 1 2 ) fo r D E - S e r ie s S e r v o d r iv e s ( S A C - D E )

D S P A x is M o d u le (O R N -D S P -A 2 o r O R N -D S P -A Q )

C B L -A T 3 /N N

1 1 4

D - S e r ie s S e r v o d r iv e s (S A C -D ) D E - S e r ie s S e r v o d r iv e s (S A C -D E )

O p tic a O R M G 4 -O G 4 -M

lly E C D C IO

Is o la te d S o lid P /N O p -2 4 G 4 -4 T (ra c k ) G 4

S ta t to -2 O D C P B 4

e R e la y 2 P /N 2 4 R (ra c k )

M IO -D C 6 0 S -3

D C 6 0 S -3

Figure 4, Fail-Safe Brake Interlock Circuit

3.11 Motor Installation

3.11.1 Motor Use and Environment The servomotor is designed for use as described below: Either horizontal or vertical mounting orientation Indoors, clean and dry (for IP-65 motors) Free from corrosive and/or explosive gases or liquids

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Installation If the location is subject to excessive water or oil, protect the motor with a cover. The standard (IP65) motors can withstand a small amount of splashed water or oil. Accessible for inspection and cleaning IP-67 rated motors (MAC-D____/_V_) require shaft seal lubrication. Refer to the IP-67 Shaft Seal Lubrication section of the Maintenance & Troubleshooting section for further information. Environmental conditions: Ambient Temperature: 0 to +40C Storage Temperature: -20 to +80C Humidity: 20% to 80% Relative Humidity (non-condensing)

3.11.2 Coupling the Servomotor to the Load Good alignment of motor and the driven machine is essential to prevent vibration, increase bearing and coupling life, and prevent shaft and bearing failures. For a direct drive application, a high quality zero-backlash taper lock coupling should be used. Timing belts and gear boxes are also commonly used in servo applications. Bearing loading should be kept to a minimum. The allowable radial and axial bearing loading for each motor is listed in the MAC-D_ Motor Performance Specifications section of the Specifications chapter. To insure adequate load stiffness, the driven machine shaft, to which the motor is coupled, should have the same diameter as the motor shaft, or greater. In either case, it is preferable to attach the coupling or pulley to the shaft with a clamping arrangement rather than transmit torque through the keyway, because of the reversing shock torques which the servomotor can generate. A number of mechanical approaches afford this type of attachment including tapered hubs, split hubs, ringfeder devices, etc. The motors are designed for face mounting, and the structural integrity of the mounting can be critical to obtaining the maximum performance from your servomotor application.

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Chapter 4 Operation
4 Operation

4.1 Power On and Off Sequencing For proper operation, input power must be supplied to the control circuit (r, t) first, followed by the main circuit (R, S, T), or simultaneously supplied to both. On power-down (including momentary power failure), the power should be either simultaneously disabled, or the power to the main-circuit removed first, followed by the control power. The main power circuit should be arranged so that it is interlocked with the ORION NO FAULT (NF) relay. Therefore, when a controller or servodrive alarm is detected, the NO FAULT (NF) relay disables the main circuit power. The recommended interlock approaches for both single and multiple axis D/DE-Series systems are detailed in Appendix A. Note the features of the recommended interlock circuit: 1) The E-Stop switch, powered by 115 or 230 VAC, must conduct current for the servomotor to provide output torque. The recommended E-Stop switch is a maintained-contact, red mushroom-head push-button, which must be manually pulled out (reset) after it has been pressed in (asserted). 2) The momentary contact E-Stop Reset push-button switch must be asserted after all power is applied and the E-Stop switch is closed. The E-Stop Reset switch must be closed long enough for the NO FAULT (NF) relay to "pull-in", so that the main power contactor coil circuit is energized. 3) If the E-Stop switch is pressed (asserted) the main circuit power is disconnected. The ORION motion controller then disables the T-ENABLE' signal causing the servomotor to enter dynamic braking.

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4) When power is applied, it will take up to 1 second (normally 200 to 300 msec) to initialize the servodrive, and for the NO-ALARM' signal to be turned on, allowing power to again be applied to the main circuit. 5) Since the servodrive has a large capacity DC. Power Supply for driving the servomotor, high current is present, for approximately one-half second when the main-circuit power is applied . If power is turned on and off frequently, the input current limit resistor may be degraded, causing a malfunction. 6) If any Alarm condition occurs within the servodrive, the main circuit power is disconnected by opening the NO FAULT (NF) relay. The servomotor enters dynamic braking. In this case, the ALARM seven-segment LED display on the front of the servodrive will indicate the type of problem detected. Alarm conditions are cleared by momentarily asserting the ALM-RESET' input. 7) Not only must any alarm condition, including E-Stop, be cleared, but the E-Stop Reset push-button must then be depressed long enough for the relays to pull-up again. 4.2 Current Command Input The servodrive is configured for torque (current) command input. This determines the output current of the servodrive, and therefore the output torque of the motor. The output torque is proportional to the +10 volt analog input signal (DRV-CMD). The peak torque of the servomotor is obtained when DRV-CMD is at approximately 9 volts. 4.3 Overload Characteristics The overload protection circuitry built into the servodrive prevents the motor and servodrive from RMS power overload. Peak currents of 200% to 300% of the RMS rating are typical for this equipment, with a 200% overcurrent typically allowed for more than one minute, and 300% allowed for a few seconds. Should an overload current greater than 100% of rated current be drawn for too long a time, the protective circuitry will turn off the output power. The overcurrent set point is set to protect the servodrive at an ambient temperature of 55C, and cannot be changed. 4.4 Position Encoder Signals Quadrature position signals for "Forward" and "Reverse" travel are illustrated below. Channel A and Channel B are phase quadrature output signals, which allow the servodrive, and associated digital positioning electronics, to determine both travel distance and direction. Programmable motion controllers, such as ORMEC's ORION family, typically decode each transition of both encoder channels, yielding a resolution of four times the linecount specification per revolution e.g. Quadrature signals with 8,160

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pulses/rev, when decoded by a ORION controller yields a positioning resolution of 32,640 cts/rev.

Figure 5, Optical Position Encoder Signals

4.5 Regenerative Load Conditions When conditions exist such that the direction of power flow is from the machine into the motor, the motor acts as a generator. This can occur for a variety of reasons including: 1) Decelerating the machine faster than it would coast. This is especially critical at high speeds and with large inertias; 2) Using the motor to lower a load that is not counterbalanced, and; 3) Using the motor to control an unwind stand for rolls of material, where the tension in the web causes the motor to have to hold back while moving forward. This power flow from the machine into the motor must be dissipated by the servodrive as explained in the Shunt Regulator section of this chapter. 4.5.1 Shunt Regulator The servodrive uses PWM (pulse width modulation) technology to deliver power to the motor. The switching of the PWM amplifier, in conjunction with the inductances and capacitances in the motor and the output circuitry can cause the power supply voltage to increase as energy is generated and returned to the drive from the machine. The power supply has no mechanism for returning energy to the power line in these cases, where the motor acts as a generator, but it does have a shunt regulator for dissipating this excessive voltage build-up. The shunt regulator consists of a voltage comparator, a switching transistor and a regen resistor. When the voltage comparator detects excess power supply voltage (at approximately 220 and 380 VDC for the 115 and 230 VAC versions respectively) it turns on the transistor, dissipating excess energy from the power supply capacitor to the regen resistor. The amount of energy SAC-D01d page 25

D-Series AC Servodrives

Operation

that it can dissipate is dependent on the current capability of the switching transistor and the wattage specification of the regen resistor.

Fuse or Overload Protection +

Bus Power Supply

Capacitor Bus Voltage Comparator

Regen Resistor

Power Transistor

Figure 6, Shunt Regulator Circuitry Internal Shunt Regulator Servodrive Capacitor Resistance (uF) (ohms) 780 1920 1920 180 780 1920 1920 680 680 680 1800 3000 3600 5400 9900 -100 100 --100 100 50 50 25 25 6.25 6.25 3.13 3.13 Power (watts) -30 30 --30 30 140 140 140 140 280 880
* * *

Input Voltage (VAC)

Power Transistor Peak Current (amps) -12 12 --12 12 30 30 50 50 75 75 150 150

Minimum External Shunt Resistor (ohms) -50 50 --50 50 50 50 25 25 6.25 6.25 3.13 3.13

SAC-DE01A1 115 SAC-DE02B1 SAC-DE03C1 SAC-DE01A2 SAC-DE02B2 SAC-DE03C2 SAC-DE04D2 SAC-D04 230 SAC-D08 SAC-D12 SAC-D19 SAC-D37 SAC-D47 SAC-D55 SAC-D59
*

1760

1760

SAC-D47, D55, and D59 servodrives require the use of an external regen resistor.

Table 15, Shunt Regulator Specifications

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D-Series AC Servodrives

Operation

4.5.2 Applications Strategies If regeneration is excessive, a high bus voltage alarm or heat sink overheat alarm may occur. If this happens, the following actions may resolve the problem: Reduce the current limit. Slow down the deceleration curve. Decrease the maximum speed. Change the gearbox.

If you have any questions regarding the amount of regenerative power dissipation capacity required by your application call the ORMEC Service Department. 4.6 Dynamic Braking Circuitry The servodrives all contain integral solid-state dynamic braking circuitry for intrinsic safety, which consists of a triac across the output bridge of the PWM amplifier, which is in series with an internal dynamic braking resistor. Refer to Figure 7 for a diagram of the dynamic braking circuitry.

+ U V W Servomotor U

DC BUS

U -

Braking Resistor

Figure 7, Dynamic Braking Line Diagram

SAC-D01d

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D-Series AC Servodrives

Operation

Input Voltage Servodrive SAC-DE01A1 115 VAC SAC-DE02B1 SAC-DE03C1 SAC-DE01A2 SAC-DE02B2 SAC-DE03C2 SAC-DE04D2 SAC-D04 230 VAC SAC-D08 SAC-D12 SAC-D19 SAC-D37 SAC-D47 SAC-D55 SAC-D59 0 2 2 0 0 2 2 2.5 2.5 1.5 1.5 1.0 1.0 1.0 0.5

DB Resistor (ohms) (watts) -10 10 --10 10 20 20 20 20 30 60 60 80

Max. Current (amps) 3.8 4.6 10.1 1.6 3.5 5 6.9 35 57 58 109 125 147 220

Table 16, Dynamic Braking Circuit Specifications When the servodrive bus power is disabled, the output power transistors switch to a tri-state, which appears as high impedance to the motor. The dynamic braking circuitry (DB) short circuits all three motor phases together. In this way the power generated by the motor rotation is used to bring the motor to a stop. The voltage created by the motor rotation is fed back into the motor and creates a magnetic field opposing that of the motor's permanent magnets. This causes the motor to decelerate until no voltage is generated by the motor rotation. The servodrive dynamic braking circuit is enabled whenever the servodrive is disabled. 4.7 Absolute Encoder Support The D/DE-Series servomotor absolute encoder system consists of three parts: 1) an optical single revolution absolute encoder, 2) a revolution counter, and 3) a micro-controller circuit. The optical single revolution absolute encoder indicates the motor shaft's position within a single revolution. The revolution counter maintains a count of the complete motor revolutions since the absolute encoder was reset (revolution count set to 0). The combination of the absolute position within a revolution, and the cumulative revolution counter determines the servomotor's absolute position. The micro-controller circuitry is the interface between the servomotor and servodrive, it "reads" both the optical absolute encoder and revolution counter data and "sends" the numeric result as serial data to the servodrive via one of the servomotor's encoder quadrature feedback channels. During a loss of control power to the servodrive, the absolute encoder system is able to maintain a cumulative count of servomotor revolutions. The power page 28 SAC-D01d

D-Series AC Servodrives

Operation

supply for the absolute encoder system is provided through an optional battery on the ORION DSP Axis Module (the absolute encoder backup battery), which maintains the charge on the storage capacitor in the servomotor. This capacitor supports the revolution counter and micro-controller circuitry only. The optical absolute encoder is disabled while system control power is off to conserve the absolute encoder backup battery. When the ORION polls the servodrive for the servomotor's absolute position, the servodrive again supplies power to all the absolute encoder system circuits. NOTE: An ORION DSP Axis Module with absolute encoder support option is required for use with a D-Series or DE-Series absolute encoder motor/servodrive system (ORN-DSP-A_/_A). Refer to the DSP Model Number Description section of the ORION Installation and Operation manual for further information. In order for the ORION DSP Axis Module (with absolute encoder support option) to supply backup power to the absolute encoder, the axis interface and encoder cables must be connected. Disabling the servodrive control power and disconnecting either the axis interface or encoder cables for more than 48 hours may result in the loss of the absolute encoder data.

NOTE:

4.7.1 Reading the Absolute Encoder During normal operation the servomotor issues quadrature position data as does a standard incremental encoder, additionally, a circuit in the motor's encoder counts the motor revolutions. When the servodrive and MotionDATA are disabled (MODE@=0 and MD.MODE@=0 respectively), the DSP can poll the servodrive for the absolute position information via axis interface cable (CBL-AD/NN or CBL-ADE/NN) using the MotionBASIC POS.ABS@ variable. The servodrive polls the motor counter circuit for the absolute position data via the motor encoder cable (CBL-DMAC/NN, CBL-DEMAC/NN, or CBL-DEMACD/NN). The servodrive then passes the absolute position information back to the DSP. A poll of the absolute encoder position information should not be attempted until the servodrive has had logic power for 1 second. The entire process required for polling the absolute encoder position data takes approximately 0.5 seconds per motor. The absolute encoder position value returned by the POS.ABS@ variable is in quadrature counts, not User Units. For further information regarding User Units and polling the absolute encoder position refer to the POS.ABS@ variable explanation in the "MotionBASIC Hypertext Manual". 4.7.2 Absolute Encoder Power During loss of ORION and servodrive logic power, the revolution counting circuitry in the motor is powered via the absolute encoder backup battery in the DSP Axis Module. Reading the absolute position data, using the MotionBASIC POS.ABS@ variable, asserts an ABS interface signal which causes the servodrive to supply the encoder with power for the counter circuit. This is done to conserve the absolute encoder backup battery on the SAC-D01d page 29

D-Series AC Servodrives

Operation

DSP Axis Module. For further information on polling the absolute encoder position refer to the POS.ABS@ variable explanation in the "MotionBASIC Hypertext Manual". If the encoder is disconnected from the servodrive, or the ORION and servodrive logic power is off and the servodrive is disconnected from the DSP Axis Module (and therefore disconnected from the absolute encoder backup battery), then a capacitor in the motor itself supplies enough power to allow the revolution counter circuitry to operate. The encoder can be disconnected from the servodrive and/or absolute encoder backup battery for up to 48 hours without loss of the revolution counter information. 4.7.3 Resetting the Absolute Encoder The revolution counter circuit will only need to be reset to zero if the capacitor in the motor is nearly fully discharged, as a result of more than 48 hours without ORION or servodrive logic power or absolute encoder backup battery power. The need to reset the absolute encoder revolution counter is indicated by an ALARM@=10 or 15 on the ORION and/or an "A.00", "A.8_", or "A.C_" on the servodrive monitor module, SAC-OP03A. NOTE: Resetting the absolute encoder resets only the revolution counter to zero. The incremental position value will remain. Therefore, after resetting the absolute encoder, the absolute position value will be somewhere between 0 and the encoder counts/rev. Your application program should be written such that it is not necessary to reset the absolute encoder revolution counter to set the machine home position. The application program should be able to reference a non-zero home position, which is the case even if the revolution counter is reset. Refer to the MotionBASIC Hypertext for further information regarding absolute encoder application programming. You can also call the ORMEC Service Department to obtain a copy of Customer Support Engineering Tech Note 16, Continuous Rotary Motion with Absolute Encoder Support. To reset the absolute encoder revolution counter, the capacitor in the servomotor must be fully discharged. The capacitor can quickly be discharged by following the steps listed later in this section. The following steps outline the procedures for resetting the absolute encoder revolution counter: 1) Connect the encoder cable (CBL-DMAC/NNN, CBL-DEMAC/NNN or CBL-DEMACD/NNN) between the servodrive and motor. 2) Connect the axis interface cable (CBL-AD or CBL-ADE for SAC-D and SAC-DE servodrives respectively) between the servodrive and the DSP Axis Module. 3) Turn on logic power to the ORION and the servodrive, and establish communications with the ORION using MotionPRO. 4) Set the ABS@ variable (ABS@=TRUE) for at least 3 minutes. Ignore any servodrive alarms generated during this time.

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Operation

5) Turn the servodrive power off, and disconnect the encoder cable from the servodrive. 6) Attach the absolute encoder capacitor discharge adapter (MACABSRD with SAC-D, and MACABSRDE with SAC-DE) to the servodrive end of the encoder cable (refer to Figure 8) for at least fifteen minutes. 7) Remove the absolute encoder capacitor discharge adapter, reconnect the encoder cable to the servodrive, apply power, and test the axis. 8) If the axis has an absolute encoder error (ALARM@=10 or 15 on the ORION and/or an "A.00", "A.8_", or "A.C_"" on the servodrive monitor module, SAC-OP03A, and/or a "0", "8" or "C on the SAC-DE 7-Segment display) repeat this procedure.
ABSOLUTE ENCODER CAPACITOR DISCHARGE ADAPTER USE ADAPTER: MACABSRD for MAC-D... with SAC-D... MACABSRDE for MAC-DE... with SAC-DE MACABSRD for MAC-DE... with SAC-D...... ENCODER CABLE CBL-DMAC/X CBL-DEMAC/X CBL-DEMACD/X

MOTOR WINDING CONNECTOR

MAC-D... MAC-DE...

Figure 8, Absolute encoder reset adapter

4.7.4 Absolute Position Polling the absolute position of the motor returns a number between -[50,000*counts/rev]+1(reverse limit) and +[50,000*counts/rev]-1 (forward limit). The absolute position of the motor is relative to the motor position when the encoder was last reset (revolution count set to 0). The absolute position is derived by the following equation: Absolute Pos. = (Number of Revs x Counts/Rev) + Incremental Pos. For Example: POS.ACT@ = POS.ABS@ = (2000 revs * 32,640 cts/rev) + 3956 = 65,283,956

The absolute encoder can count up to 50,000 revolutions in either direction. Resetting the absolute encoder sets the revolution counter value to zero. Moving the motor in the counter-clockwise direction (looking at the motor shaft) causes the absolute position counter to increment, moving in the clockwise direction causes it to decrement. The operation of the absolute encoder, and therefore the polled absolute position information, is not affected by the state of the CW.FWD@ MotionBASIC variable. For further SAC-D01d page 31

D-Series AC Servodrives

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information regarding the CW.FWD@ MotionBASIC variable refer to the "MotionBASIC Hypertext Manual". Moving the motor counter-clockwise (positively) through the forward limit position value causes the absolute position counter to "wrap around" to the reverse limit position value, and continue incrementing. Moving the motor clockwise (negatively) through the reverse position limit value causes the absolute position counter to "wrap around" to the forward limit position value, and continue decrementing. No position counts are lost during "wrap around" at the limit positions. Refer to Figure 9 for a graphical representation of the absolute position "wrap around" feature.
Clockwise Rotation

Counter-Clockwise Rotation -1,631,999,999 cts. -203,999,999 cts (-50,000 revs) D-Series (MAC-DA & MAC-DB) DE-Series (MAC-DE) (0 revs) encoder reset Figure 9, Absolute Encoder Wrap-Around +1,631,999,999 cts +203,999,999 cts (+50,000 revs)

Note: In order for continuous motion applications (where the motor is not rotating through a fixed range of motion) to accurately indicate the absolute motor position after passing through the "wrap around" positions, be sure that the number of revolutions of the motor per load cycle can be evenly divided into 50,000 with no remainder. For example: A load coupled to a motor through a 10:1 gear reduction (50,000 / 10 = 5,000) will properly indicate the absolute motor position, a load coupled through a 7:1 reduction (50,000 / 7 = 7142.8571...) will not.

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Operation

4.8 Servodrive Display Monitor Module Operation (SAC-OP03A) The Servodrive Display Monitor Module (SAC-OP03A) is a five character seven segment LED display with an integral four button keypad intended for use with SAC-D servodrives only4. The SAC-OP03A can be used to monitor current servodrive status or to review a log of the last ten servodrive alarm codes. Three times more alarm code information is available using the SAC-OP03A than with the three standard alarm code outputs, indicated by the MotionBASIC ALARM@ variable. 4.8.1 Installation To install the SAC-OP03A simply plug it into CN3 on a SAC-D servodrive. This may be done with power applied to the unit. Refer to Appendix B for diagrams indicating the location of CN3 on the D-Series servodrives. 4.8.2 Modes of Operation The SAC-OP03A has two functional modes of operation, STATUS and ALARM REVIEW (refer to Figure 10). D-Series servodrives are configured at ORMEC prior to shipment, therefore, SETUP and MONITOR modes and the DATA button (refer to Figure 10) are not required, and have been disabled. The SAC-OP03A mode of operation sequence is STATUS, SETUP (disabled), MONITOR (disabled), and ALARM LOG REVIEW. Pressing the MODE/SET button advances the SAC-OP03A to the next mode of operation. 4.8.2.1 STATUS Mode During STATUS mode operation, the SAC-OP03A displays the current drive status. The SAC-OP03A uses a combination of three horizontal LED segments, two decimal points, and a three character code (alarm codes have an extra decimal point) to indicate the current servodrive status. Refer to the STATUS MODE INDICATOR KEY, in Figure 10, for a definition of the STATUS mode servodrive codes. Refer to the Status Indicator Code Descriptions section of the Maintenance and Troubleshooting chapter for a list of the servodrive alarm codes. While in STATUS mode, you can reset a servodrive alarm by simultaneously pressing the UP and DOWN arrow keys. From STATUS mode (the default mode after powerup), you must advance through SETUP and MONITOR modes, by pressing the MODE/SET button twice, to get to ALARM LOG REVIEW mode.

The SAC-OP03A can be used with a SAC-DE servodrive only through the use of an extension cable, which prevents mounting the display on the servodrive. Therefore, the SAC-OP03A is not recommended for use with SAC-DE servodrives.

SAC-D01d

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Operation

4.8.2.2 ALARM LOG REVIEW Mode During ALARM LOG REVIEW mode operation, the SAC-OP03A can be used to display the contents of the servodrive alarm log. The servodrive ALARM LOG is a history of the 10 most recent alarm/reset codes, and is maintained (not erased) through servodrive logic power cycles. Refer to Figure 10 for a pictorial representation of the servodrive ALARM LOG. Each alarm/reset code in the ALARM LOG has a sequence number. The current alarm/reset code has sequence number 0, the alarm/reset code before the current code has sequence number 1, and so on through sequence number 9. An A.99 (reset code) is added to the log whenever a servodrive alarm is cleared. Servodrive alarms can be cleared by the ORION (refer to the MotionBASIC Hypertext), power cycling the servodrive logic power, or simultaneously pressing the UP and DOWN buttons on the SAC-OP03A while in STATUS mode. NOTE: If the servodrive logic power is cycled, an A.99 will only be added if the servodrive had an alarm when power was turned off.

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Operation

Typical Drive Status

STATUS MODE
SERVOPACK

STATUS MODE
SERVOPACK

STATUS MODE
SERVOPACK

UP

MODE/SET

UP

MODE/SET

UP

MODE/SET

Hold both keys down to reset the alarm.

DN

DATA

DN

DATA

DN

DATA

OP03A

OP03A

OP03A

SETUP MODE (disabled)

SERVOPACK

Alarm State

Enabled

Disabled
UP MODE/SET

DN

DATA

STATUS MODE INDICATOR KEY Current Limit Reached Base Block (torque disabled) Control power ON Torque command more than 10% Main Power Supply ON Data key is not enabled

OP03A

}
Three Character Status Code MONITOR MODE (disabled)
SERVOPACK UP MODE/SET DN DATA

ALARM LOG Oldest Alarm/Reset Occurrence ALARM ACTION Each alarm occurrence is loaded into the log at location zero. All log entries are pushed up and the oldest is dropped off. When an alarm is reset (including power up and remote reset) an alarm code of A-99 (alarm reset status) is loaded into the log at location zero. Newest Alarm/Reset Occurrence Alarm Log Sequence Number ALARM LOG REVIEW MODE
SERVOPACK OP03A

UP

MODE/SET

DN

DATA

OP03A

Figure 10, SAC-OP03A Operation Overview

SAC-D01d

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D-Series AC Servodrives

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D-Series AC Servodrives

Getting Started

Chapter 5 Getting Started

5 Getting Started

5.1 Test Run Before test run, check the following. Correct any problems before proceeding. 5.1.1 Servomotor Check Motor mounting and grounding are correct. Bolts and nuts are tight. For IP-67 rated motors, the shaft seals are not damaged and are properly lubricated. Refer to the IP-67 Shaft Seal Lubrication section of the Maintenance & Troubleshooting section for further information. Motor and Encoder Cables are properly attached.

5.1.2 Servodrive Check

For the SAC-D and 230 VAC version of the SAC-DE servodrives the supply voltage should be 230 VAC, WITH AN ABSOLUTE MINIMUM OF 170 VAC AND ABSOLUTE MAXIMUM OF 253 VAC. CHECK POWER BEFORE APPLYING IT TO THE SERVODRIVE!!!! For the 115 VAC version of the SAC-DE servodrive the supply voltage should be 115 VAC, WITH AN ABSOLUTE MINIMUM OF 85 VAC AND AN ABSOLUTE MAXIMUM OF 126 VAC. CHECK POWER BEFORE APPLYING IT TO THE SERVODRIVE!!!!. Cable connections are firmly seated. Motor cable lug termination's are tight. Motor wiring, fuse connection, and grounding are correct. page 37

SAC-D01d

D-Series AC Servodrives

Getting Started The main power interlock circuit disables main power under servo alarm condition.

5.1.3 Preparation for Test Run During test run, the driven machine should not be attached to the servomotor. If it is necessary to start with the driven machine connected to the motor, proceed with great care. After checking items above, turn on the control power. For SAC-D servodrives check the ALARM LED. If there is a servodrive alarm condition either the MotionBASIC ALARM@ variable or the SAC-OP03A may be used to determine the cause. Refer to the Maintenance & Troubleshooting section for further information. For SAC-DE servodrives check the Alarm Status Indicator. The Alarm Status Indicator, described in the Maintenance & Troubleshooting Section provides several status indications.

When the interlock input signals are appropriately configured (ALARM@=0, MODE@>2), the power circuit in the servodrive will operate and the motor is ready to run.

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Specifications

Chapter 6 Specifications
6 Specifications
Servodrives covered by this manual: SAC-DE01A1/_ SAC-DE02B1/_ SAC-DE03C1/_ SAC-DE01A2/_ SAC-DE02B2/_ SAC-DE03C2/_ SAC-DE04D2/_ SAC-D04_/__ SAC-D08_/__ SAC-D12_/__ SAC-D19_/__ SAC-D37_/__ SAC-D47_/__ SAC-D55_/__ SAC-D59_/__

SAC-D01d

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Specifications

6.1 DE-Series Motors Overview

Maximum Speed: Continuous stall torques: Peak Torques: Peak Acceleration: Rated Power: Position Encoder Resolution:

4,500 RPM 2.8 to 42 lb-in 8.4 to 127 lb-in up to 147,219 rad/sec2 0.13 to 2.0 HP incremental: 8,160 cts/rev (after quadrature decode) absolute: 4,080 cts/rev (after quadrature decode)

6.2 DA-Series Motors Overview

Maximum Speed: Continuous stall torques: Peak Torques: Peak Acceleration: Rated Power: Position Encoder Resolution:

4,500 RPM 28 to 140 lb-in 84 to 422 lb-in up to 59,929 rad/sec2 1.3 to 6.7 HP incremental: 16,320 cts/rev (after quadrature decode) absolute: 32,640 cts/rev (after quadrature decode)

6.3 DB-Series Motors Overview

Maximum Speed: Continuous stall torques: Peak Torques: Peak Acceleration: Rated Power: Position Encoder Resolution:

2,000 to 3,000 RPM 26 to 696 lb-in 79 to 1550 lb-in up to 12,324 rad/sec2 0.6 to 15 HP incremental: 32,640 cts/rev (after quadrature decode) absolute: 32,640 cts/rev (after quadrature decode)

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Specifications

6.4 General Servodrive Specifications

6.4.1 SAC-DE Servodrive Specifications

Environmental Specifications Operating Temperature: Storage Temperature: Operating and Storage Humidity: Mechanical Specifications Mounting Method: Vertically oriented chassis mounting, three or four 10-32 screws. 0 to +55oC -20 to +85oC 0 to 90%, non-condensing

Electrical Specifications Incoming Line Voltage: (Single Phase, 50/60 Hz) Minimum Incoming Line Voltage: Absolute Maximum Incoming Line Voltage: Rated Bus Voltage: Shunt Regulator Activation Bus Voltage: High Bus Voltage Fault: Low Bus Voltage Fault: Encoder Power Voltage: Maximum Encoder Power Current: 115 VAC 85 VAC 126 VAC 163 VDC 220 VDC 240 VDC` 75 VDC 5 VDC, +/-5% 300 mA, incremental encoder 400 mA, absolute encoder1 230 VAC 170 VAC 253 VAC 325 VDC 380 VDC 415 VDC 150 VDC

Input Interlock Circuitry2: Input Voltage Requirements: Input Current (at each input): Output Interlock Circuitry: Maximum Applied Voltage: Maximum Current Sink Capability:
1

+24 VDC @ 15 mA maximum 5 mA typical

+30 VDC -50 mA

The maximum encoder power current for absolute encoders is 400 mA during the encoder's capacitor charging phase. SAC-DE servodrive interlock power is supplied by either the ORION DSP Axis Module or an external power supply.

SAC-D01d

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D-Series AC Servodrives

Specifications

6.4.2 SAC-D Servodrive Specifications Environmental Specifications Operating Temperature: Storage Temperature: Operating and Storage Humidity: Mechanical Specifications Mounting Method: Vertically oriented chassis mounting, four 10-32 screws. 0 to +55oC -20 to +85oC 0 to 90%, non-condensing

Electrical Specifications Incoming Line Voltage: (Three Phase, 50/60 Hz) Minimum Incoming Line Voltage: Absolute Maximum Incoming Line Voltage: Rated Bus Voltage: Shunt Regulator Activation Bus Voltage: High Bus Voltage Fault: Low Bus Voltage Fault: Encoder Power Voltage: Maximum Encoder Power Current: 230 VAC 170 VAC 253 VAC 325 VDC 380 VDC 415 VDC 150 VDC +5 VDC, +/- 5% 300 mA, incremental encoder 400 mA, absolute encoder1

Input Interlock Circuitry2: Input Voltage Requirements: Input Current (at each input): Output Interlock Circuitry: Maximum Applied Voltage: Maximum Current Sink Capability:
1

+24 VDC @ 15 mA maximum 5 mA typical

+30 VDC -50 mA

The maximum encoder power current for absolute encoders is 400 mA during the encoder's capacitor charging phase. The SAC-D servodrive interlock power is supplied by the servodrive.

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Specifications

6.5 MAC-DE Series Incremental Encoder Servomotors Specifications (115 VAC) PERFORMANCE1 Maximum Speed Continuous Stall Torque Rated Torque at 3000 RPM Rated Power Peak Torque
2

Units RPM lb-in

(N-m)

DE003A1/I

DE006B1/I

DE008C1/I

4,500 2.8
(0.32)

4,500 5.6
(0.64)

4,500 8.4
(0.96)

lb-in
(N-m)

2.8
(0.32)

5.6
(0.64)

8.4
(0.96)

HP watts lb-in
(N-m)
2

0.13 100 8.4

(0.96)

0.27 200 17
(1.91)

0.40 300 25
(2.86)

Continuous Stall Torque/Inertia rad/sec MECHANICAL Moment of Inertia2 Friction Torque, static Servomotor Weight2 Mounting Bolt Diameter Pilot Diameter Shaft Diameter Length, mounting face to rear2 Maximum Radial Shaft Load3 Maximum Axial Shaft Load ELECTRICAL Servodrive Model Number2 Torque Sensitivity, Kt Continuous Current Peak Current Servodrive Weight THERMAL Ambient Temperature Thermal Time Constant Insulation Class ENCODER & TACH Quadrature Output Resolution4 Tachometer sensitivity
1 2

49,182 0.057
(0.065)

30,439

27,439

lb-in-sec2x10-3
(kg-m2x10-4)

0.185
(0.209)

0.308
(0.347)

lb-in
(N-m)

0.05
(0.006) (0.7)

0.11
(0.012) (1.4)

0.20
(0.023) (2.1)

lbs

(kg)

1.5

3.1

4.6

inches
(mm) (mm)

2.76
(70) (50)

3.54
(90) (70)

3.54
(90) (70)

inches inches
(mm)

1.97 0.315
(8)

2.76 0.551
(14)

2.76 0.551
(14)

inches
(mm)

2.3
(57)

2.5
(63)

2.5
(63)

lbs
(N)

17
(78) (49)

55
(245) (68)

55
(245) (68)

lbs
(N)

11

15

15

SAClbs-in/amp
(N-m/amp)

DE01A1/I 1.4
(0.16)

DE02B1/I 2.3
(0.26)

DE03C1/I 2.2
(0.25)

amps amps lbs

(kg)

2.2 7.1 4.9

(2.2)

2.7 8.4 7.3

(3.3)

4.3 13.9 7.3

(3.3)

deg. C minutes

40 8 B 8,160 2

40 14 B 8,160 2

40 16 B 8,160 2

counts/rev volts/Krpm

Ratings are obtained with servomotor ambient temperature at 40oC. Specification for incremental encoder motor only. Refer to the Absolute Encoder and Brake Options Servomotor Performance Specifications section for specification of servomotor with absolute encoder and/or brake options. Maximum radial shaft load specification is for a load centered 0.2 inches (5 mm) from the end of the motor shaft. Quadrature output resolution is after four times quadrature decode. Refer to footnote 2 (above).

3 4

SAC-D01d

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6.6 MAC-DE Series Incremental Encoder Servomotors Specifications (230 VAC) PERFORMANCE1 Maximum Speed Continuous Stall Torque Rated Torque at 3000 RPM Rated Power Peak Torque Units RPM lb-in
(N-m)

DE003A2/I DE006B2/I DE011C2/I 4,500 4,500 4,500 2.8 5.6 11

(0.32) (0.32) (0.64) (0.64) (1.27) (1.27)

lb-in
(N-m)

2.8 0.13 100 8.4

(0.96)

5.6 0.27 200 17

(1.91)

11 0.54 400 34
(3.82)

HP watts lb-in
(N-m)

Continuous Stall Torque/Inertia2 rad/sec2 MECHANICAL Moment of Inertia2 Friction Torque, static Servomotor Weight2 Mounting Bolt Diameter Pilot Diameter Shaft Diameter Length, mounting face to rear2 Maximum Radial Shaft Load3 Maximum Axial Shaft Load ELECTRICAL Servodrive Model Number Torque Sensitivity, Kt Continuous Current Peak Current Servodrive Weight THERMAL Ambient Temperature Thermal Time Constant Insulation Class ENCODER & TACH Quadrature Output Resolution4 Tachometer sensitivity
1 2

49,182 0.057
(0.065)

30,439

36,789

lb-in-sec2x10-3
(kg-m2x10-4)

0.185
(0.209)

0.308
(0.347)

lb-in
(N-m)

0.05
(0.006)

0.11
(0.012)

0.20
(0.023)

lbs
(kg)

1.5
(0.7)

3.1
(1.4)

4.6
(2.1)

inches
(mm) (mm) (mm)

2.76
(70) (50) (8)

3.54
(90) (70) (14)

3.54
(90) (70) (14)

inches inches inches

(mm)

1.97 0.315 2.3

(57)

2.76 0.551 2.5

(63)

2.76 0.55 3.3

(84)

lbs
(N)

17
(78)

55
(245)

55
(245)

lbs
(N)

11
(49)

15
(68)

15
(68)

SAClbs-in/amp
(N-m/amp)

DE01A2/I 3.5
(0.39)

DE02B2/I 3.1
(0.35)

DE03C2/I D04C/I 4.7

(0.54)

amps amps lbs

(kg)

0.89 2.8 4.9

(2.2)

2.0 6.0 4.9

(2.2)

2.6 8.0 7.3/8.8

(3.3/4.0)

deg. C minutes

40 8 B 8,160 2

40 14 B 8,160 2

40 16 B 8,160 2

linecount volts/Krpm

Ratings are obtained with servomotor ambient temperature at 40oC. Specification for incremental encoder motor only. Refer to the Absolute Encoder and Brake Options Servomotor Performance Specifications section for specification of servomotor with absolute encoder and/or brake options. Maximum radial shaft load specification is for a load centered 0.2 inches (5 mm) from the end of the motor shaft. Quadrature output resolution is after four times quadrature decode. Refer to footnote 2 (above).

3 4

page 44

SAC-D01d

D-Series AC Servodrives PERFORMANCE1 Maximum Speed Continuous Stall Torque Rated Torque at 3000 RPM Rated Power Peak Torque Units RPM lb-in
(N-m)

Specifications

DE021D2/I DE042E2/I 4,500 21

(2.39)

4,500 42
(4.77)

lb-in
(N-m)

21
(2.39)

42
(4.77)

HP watts lb-in
(N-m)

(7.10)

1.0 750 63

2.0 1500 127

(14.3)

Continuous Stall Torque/Inertia2 rad/sec2 MECHANICAL Moment of Inertia2 Friction Torque, static Servomotor Weight2 Mounting Bolt Diameter Pilot Diameter Shaft Diameter Length, mounting face to rear2 Maximum Radial Shaft Load Maximum Axial Shaft Load ELECTRICAL Servodrive Model Number2 Torque Sensitivity, Kt Continuous Current Peak Current Servodrive Weight THERMAL Ambient Temperature Thermal Time Constant Insulation Class ENCODER & TACH Quadrature Output Resolution4 Tachometer sensitivity
1 2

11,304 1.87
(2.11) (0.036) (4.6)

11,839 3.57
(4.03) (0.060) (6.6)

lb-in-sec2x10-3
(kg-m2x10-4) (N-m)

lb-in

0.32 10.1 5.71

(145)

0.53 14.6 5.71

(145)

lbs
(kg)

inches
(mm)

inches
(mm)

4.33
(110)

4.33
(110)

inches
(mm)

0.63
(16) (81.5) (392) (147)

0.75
(19) (109.5) (490) (147)

inches
(mm)

3.21 88 33

4.31 110 33

lbs
(N) (N)

lbs

SAClbs-in/amp
(N-m/amp)

DE04D2/I D08D/I 5.7

(0.64)

D12E/I
(0.69)

6.1

amps amps lbs

(kg)

4.1 13 7.3/8.8
(3.3/4.0)

7.5 28 8.8
(4.0)

deg. C minutes

40 18 B 8,160 2

40 18 B 8,160 2

linecount volts/Krpm

Ratings are obtained with servomotor ambient temperature at 40oC. Specification for incremental encoder motor only. Refer to the Absolute Encoder and Brake Options Servomotor Performance Specifications section for specification of servomotor with absolute encoder and/or brake options. Maximum radial shaft load specification is for a load centered 0.2 inches (5 mm) from the end of the motor shaft. Quadrature output resolution is after four times quadrature decode. Refer to footnote 2 (above).

3 4

SAC-D01d

page 45

D-Series AC Servodrives

Specifications

6.7 MAC-DA Incremental Encoder Servomotor Performance Specifications PERFORMANCE1 Maximum Speed Continuous Stall Torque Rated Torque at 3000 RPM Rated Power Peak Torque
2

Units RPM lb-in

(N-m)

DA030F/I 4500 28
(3.18) (3.18)

DA055G/I

DA090H/I

4,500
(6.36) (6.36)

4,500
(9.8) (9.8)

56 56

87 87

lb-in
(N-m)

28 1.3 1000 84
(9.54)
2

HP watts lb-in
(N-m)

2.7 2000 169

(19.1)

4 3000 260
(29.4)

Continuous Stall Torque/Inertia rad/sec MECHANICAL Moment of Inertia2 Friction Torque, static Servomotor Weight2 Mounting Bolt Diameter Pilot Diameter Shaft Diameter Length, mounting face to rear2 Maximum Radial Shaft Load3 Maximum Axial Shaft Load ELECTRICAL Servodrive Model Number2 Torque Sensitivity, Kt Continuous Current Peak Current Servodrive Weight THERMAL Ambient Temperature Thermal Time Constant Insulation Class ENCODER & TACH Quadrature Output Resolution4 Tachometer sensitivity
1 2

18,312 1.54
(1.74)

20,000

14,032

lb-in-sec2x10-3
(kg-m2x10-4)

2.82
(3.19)

6.20
(7.00)

lb-in
(N-m)

0.43
(0.049)

0.62
(0.070)

0.74
(0.084)

lbs
(kg)

10.1
(4.6)

15.4
(7.0)

24.2
(11.0)

inches
(mm) (mm) (mm)

4.53
(115)

4.53
(115)

5.71
(145) (110)

inches inches inches

(mm)

3.740
(95) (24)

3.740
(95) (24)

4.331 1.102
(28)

0.945 5.9
(150)

0.945 7.8
(200)

7.9
(200)

lbs
(N)

154
(686)

154
(686)

221
(980)

lbs
(N)

44
(196)

44
(196)

88
(392)

SAClbs-in/amp
(N-m/amp)

D08F/I 5.7
(0.64)

D19G/I 5.0
(0.56)

D37H/I 5.1
(0.57)

amps amps lbs

(kg)

(4.0)

5.7 17 8.8 40 12 F

12.4 42 11.0
(5.0)

18.8 56 17.6
(8.0)

deg. C minutes

40 23 F 16,320 2

40 33 F 16,320 2

linecount volts/Krpm

16,320 2

Ratings are obtained with servomotor ambient temperature at 40oC. Specification for incremental encoder motor only. Refer to the Absolute Encoder and Brake Options Servomotor Performance Specifications section for specification of servomotor with absolute encoder and/or brake options. Maximum radial shaft load specification is for a load centered 0.2 inches (5 mm) from the end of the motor shaft. Quadrature output resolution is after four times quadrature decode. Refer to footnote 2 (above).

3 4

page 46

SAC-D01d

D-Series AC Servodrives PERFORMANCE1 Maximum Speed Continuous Stall Torque Rated Torque at 3000 RPM Rated Power Peak Torque Units RPM lb-in
(N-m)

Specifications

DA110J/I

DA140K/I

4,500 112
(12.6)

4,500 140
(15.8)

lb-in
(N-m)

112
(12.6)

140
(15.8)

HP watts lb-in
(N-m)

5.4 4000 336

(37.8)

6.7 5000 422

(47.6)

Continuous Stall Torque/Inertia2 rad/sec2 MECHANICAL Moment of Inertia2 Friction Torque, static Servomotor Weight2 Mounting Bolt Diameter Pilot Diameter Shaft Diameter Length, mounting face to rear2 Maximum Radial Shaft Load Maximum Axial Shaft Load ELECTRICAL Servodrive Model Number2 Torque Sensitivity, Kt Continuous Current Peak Current Servodrive Weight THERMAL Ambient Temperature Thermal Time Constant Insulation Class ENCODER & TACH Quadrature Output Resolution4 Tachometer sensitivity
1 2

13,176 8.50
(9.60) (0.11)

12,844 10.9
(12.3) (0.12)

lb-in-sec2x10-3
(kg-m2x10-4) (N-m)

lb-in

0.95 30.9

1.1

lbs
(kg)

37.5
(17.0)

(14.0)

inches
(mm)

5.71
(145)

5.71
(145)

inches
(mm)

4.331
(110)

4.331
(110)

inches
(mm)

1.102
(28) (236)

1.102
(28)

inches
(mm)

9.3

10.9
(277) (1176) (392)

lbs
(N) (N)

(1176) (392)

265 88

265 88

lbs

SAClbs-in/amp
(N-m/amp)

D37J/I 4.9
(0.55)

D37K/I 5.4
(0.61)

amps amps lbs

(kg)

24.1 77 17.6
(8.0)

28.2 84 17.6
(8.0)

deg. C minutes

40 36 F 16,320 2

40 40 F 16,320 2

linecount volts/Krpm

Ratings are obtained with servomotor ambient temperature at 40oC. Specification for incremental encoder motor only. Refer to the Absolute Encoder and Brake Options Servomotor Performance Specifications section for specification of servomotor with absolute encoder and/or brake options. Maximum radial shaft load specification is for a load centered 0.2 inches (5 mm) from the end of the motor shaft. Quadrature output resolution is after four times quadrature decode. Refer to footnote 2 (above).

3 4

SAC-D01d

page 47

D-Series AC Servodrives

Specifications

6.8 MAC-DB Incremental Encoder Servomotor Performance Specifications PERFORMANCE1 Maximum Speed Continuous Stall Torque Rated Torque at 1500RPM Rated Power Peak Torque Units RPM lb-in
(N-m)

DB025L/I

DB055M/I

DB080N/I

3,000 26
(2.96) (2.84)

3,000 54
(6.07) (5.39)

3,000 79
(8.90) (8.34)

lb-in
(N-m)

25 0.6 450 79
(8.92)

48 1.1 850 122

(13.8)

74 1.7 1300 207

(23.3)

HP watts lb-in
(N-m)

Continuous Stall Torque/Inertia2 rad/sec2 MECHANICAL Moment of Inertia2 Friction Torque, static Servomotor Weight2 Mounting Bolt Diameter Pilot Diameter Shaft Diameter Length, mounting face to rear2 Maximum Radial Shaft Load3 Maximum Axial Shaft Load ELECTRICAL Servodrive Model Number2 Torque Sensitivity, Kt Continuous Current Peak Current Servodrive Weight THERMAL Ambient Temperature Thermal Time Constant Insulation Class ENCODER & TACH Quadrature Output Resolution4 Tachometer sensitivity
1 2

4,082 6.41
(7.24)

4,369

4,328

lb-in-sec2x10-3
(kg-m2x10-4)

12.3
(13.9)

18.2
(20.5)

lb-in
(N-m)

0.43
(0.049)

0.65
(0.073)

0.87
(0.10)

lbs
(kg)

12.1
(5.5)

16.8
(7.6)

21.2
(9.6)

inches
(mm) (mm) (mm)

5.71
(145) (110)

5.71
(145) (110)

5.71
(145) (110)

inches inches inches

(mm)

4.331 0.748
(19)

4.331 0.748
(19)

4.331 0.866
(22)

5.4
(137)

6.3
(160)

7.3
(185)

lbs
(N)

110
(490)

110
(490)

154
(686)

lbs
(N)

22
(98)

22
(98)

77
(343)

SAClbs-in/amp
(N-m/amp)

D08L/I 7.3
(0.82)

D08M/I 7.3
(0.83)

D12N/I 7.4
(0.84)

amps amps lbs

(kg)

(4.0)

3.8 11 8.8 40 12 F

(4.0)

7.1 17 8.8 40 17 F

10.7 28 8.8
(4.0)

deg. C minutes

40 25 F 32,640 2

linecount volts/Krpm

32,640 2

32,640 2

Ratings are obtained with servomotor ambient temperature at 40oC. Specification for incremental encoder motor only. Refer to the Absolute Encoder and Brake Options Servomotor Performance Specifications section for specification of servomotor with absolute encoder and/or brake options. Maximum radial shaft load specification is for a load centered 0.2 inches (5 mm) from the end of the motor shaft. Quadrature output resolution is after four times quadrature decode. Refer to footnote 2 (above).

3 4

page 48

SAC-D01d

D-Series AC Servodrives PERFORMANCE1 Maximum Speed Continuous Stall Torque Rated Torque at 1500RPM Rated Power Peak Torque Units RPM lb-in
(N-m)

Specifications
DB300R/I

DB100P/I

DB200Q/I

3,000 102
(11.5)

3,000 199
(22.5)

3,000 303
(34.3)

lb-in
(N-m)

102
(11.5)

165
(18.6)

252
(28.4)

HP watts lb-in
(N-m)

2.4 1800 254

(28.7)

3.9 2900 404

(45.6)

5.9 4400 630

(71.1)

Continuous Stall Torque/Inertia2 rad/sec2 MECHANICAL Moment of Inertia2 Friction Torque, static Servomotor Weight2 Mounting Bolt Diameter Pilot Diameter Shaft Diameter Length, mounting face to rear Maximum Radial Shaft Load3 Maximum Axial Shaft Load ELECTRICAL Servodrive Model Number2 Torque Sensitivity, Kt Continuous Current Peak Current Servodrive Weight THERMAL Ambient Temperature Thermal Time Constant Insulation Class ENCODER & TACH Quadrature Output Resolution4 Tachometer sensitivity
1 2

3,630 28.1
(31.7) (0.11)

4,893 40.7
(46.0) (0.16)

5,074 59.8
(67.5) (0.26)

2 lb-in-sec-4 x10-3 2

(kg-m x10 ) (N-m)

lb-in

1.0

1.4

2.3

lbs
(kg)

30.9
(14.0)

39.7
(18.0)

50.7
(23.0)

inches
(mm)

7.87
(200)

7.87
(200)

7.87
(200)

inches
(mm)

4.500
(114.3)

4.500
(114.3)

4.500
(114.3)

inches
(mm)
2

1.379
(35) (165)

1.379
(35) (190)

1.379
(35) (226)

inches
(mm)

6.5

7.5

8.9

lbs
(N) (N)

(1176) (490)

265 110

(1470) (490)

331 110

(1470) (490)

330 110

lbs

SAClbs-in/amp
(N-m/amp)

D19P/I
(0.73)

D37Q/I
(0.83)

D37R/I
(0.91)

6.5

7.3

8.1

amps amps lbs

(kg)

16.7 42 11.0
(5.0)

23.8 56 17.6
(8.0)

34.7 84 17.6
(8.0)

deg. C minutes

40 34 F 32,640 2

40 35 F 32,640 2

40 36 F 32,640 2

linecount volts/Krpm

Ratings are obtained with servomotor ambient temperature at 40oC. Specification for incremental encoder motor only. Refer to the Absolute Encoder and Brake Options Servomotor Performance Specifications section for specification of servomotor with absolute encoder and/or brake options. Maximum radial shaft load specification is for a load centered 0.2 inches (5 mm) from the end of the motor shaft. Quadrature output resolution is after four times quadrature decode. Refer to footnote 2 (above).

3 4

SAC-D01d

page 49

D-Series AC Servodrives PERFORMANCE1 Maximum Speed Continuous Stall Torque Rated Torque at 1500RPM Rated Power Peak Torque Units RPM lb-in
(N-m)

Specifications
DB330S/I DB465T/I DB700U/I

3,000 333
(37.6)

3,000 466
(52.6)

2,000 696
(78.6)

lb-in
(N-m)

310
(35.0)

425
(48.0)

620
(70.0)

HP watts lb-in
(N-m)

7.4 5500 776

(87.6)

10 7500 1050
(119)

15 11000 1550
(175)

Continuous Stall Torque/Inertia2 rad/sec2 MECHANICAL Moment of Inertia2 Friction Torque, static Servomotor Weight2 Mounting Bolt Diameter Pilot Diameter Shaft Diameter Length, mounting face to rear Maximum Radial Shaft Load3 Maximum Axial Shaft Load ELECTRICAL Servodrive Model Number2 Torque Sensitivity, Kt Continuous Current Peak Current Servodrive Weight THERMAL Ambient Temperature Thermal Time Constant Insulation Class ENCODER & TACH Quadrature Output Resolution4 Tachometer sensitivity
1 2

4,220 78.8
(89.0) (0.34)

4,197 111
(125) (0.45)

2,795 249
(281) (0.81)

2 lb-in-sec-4 x10-3 2

(kg-m x10 ) (N-m)

lb-in

3.0

4.0

7.2

lbs
(kg)

66.1
(30.0)

88.2
(40.0)

127
(57.5)

inches
(mm)

7.87
(200)

7.87
(200)

9.25
(235)

inches
(mm)

4.500
(114.3)

4.500
(114.3)

7.874
(200)

inches
(mm)
2

1.634
(42)

1.634
(42)

1.634
(42)

inches
(mm)

10.2
(259) (1764) (588)

13.2
(335) (1764) (588)

13.3
(337) (1764) (588)

lbs
(N) (N)

397 132

396 132

397 132

lbs

SAClbs-in/amp
(N-m/amp)

D47S/I
(0.88)

D55T/I
(0.93)

D57U/I
(1.25)

7.8

8.2

11.1 58.6 140 50.7

amps amps lbs

(kg)

42.1 110 33.1

(15.0)

54.7 130 33.1

(15.0)

(23.0)

deg. C minutes

40 44 F 32,640 2

40 46 F 32,640 2

40 68 F 32,640 2

linecount volts/Krpm

Ratings are obtained with servomotor ambient temperature at 40oC. Specification for incremental encoder motor only. Refer to the Absolute Encoder and Brake Options Servomotor Performance Specifications section for specification of servomotor with absolute encoder and/or brake options. Maximum radial shaft load specification is for a load centered 0.2 inches (5 mm) from the end of the motor shaft. Quadrature output resolution is after four times quadrature decode. Refer to footnote 2 (above).

3 4

page 50

SAC-D01d

D-Series AC Servodrives

Specifications

6.9 Incremental Encoder Servomotor with Fail-Safe Brake Performance Specifications The fail-safe brake holding torque is equivalent to the motor's rated torque. Refer to the Motor with Integral Fail-Safe Brake wiring section of the Installation chapter further fail-safe brake information.
Servomotor Servodrive Continuous Stall Torque/Inertia Moment of Inertia Servomotor Servomotor Quadrature Length Weight Output Res.

MACSACDE003A1/I_B DE02A1/I DE006B1/I_B DE03B1/I DE008C1/I_B DE04C1/I DE003A2/I_B DE01A2/I DE006B2/I_B DE02B2/I DE011C2/I_B DE03C2/I D04C/I DE021D2/I_B DE04D2/I D08D/I DE042E2/I_B D12E/I DA030F/I_B DA055G/I_B D08F/I D19G/I

rad/sec2 30,890 20,713 21,395 30,890 20,713 28,685 9,468 9,971 16,301 18,543 11,097 11,045 9,831 3,106 3,670 3,730 2,918 4,121 4,500 4,028 3,818 2,551

lb-in-sec2x10-3 2 -4
(kg-m x10 )

inches
(mm)

lbs
(kg)

0.091
(0.103)

3.4
(86)

2.0
(0.9)

counts/rev 8,160 8,160 8,160 8,160 8,160 8,160 8,160 8,160 16,320 16,320 16,320 16,320 16,320 32,640 32,640 32,640 32,640 32,640 32,640 32,640 32,640 32,640

0.272
(0.307)

3.7
(94)

4.2
(1.9)

0.394
(0.445) (0.103)

4.5
(114) (86)

5.7
(2.6) (0.9)

0.091 0.272

3.4 3.7

2.0 4.2

(0.307)

(94)

(1.9)

0.394
(0.445)

4.5
(114)

5.7
(2.6)

2.23
(2.52)

4.7
(118)

13.5
(6.1)

4.24
(4.78) (1.96) (3.41)

5.8
(146) (193) (242)

17.9
(8.1)

1.73

7.6 9.6 9.4

13.2
(6.0) (8.5)

3.01 7.84

18.7 30.9
(14.0)

DA090H/I_B D37H/I DA110J/I_B DA140K/I_B DB025L/I_B D37J/I D37K/I D08L/I

(8.85)

(237)

10.14
(11.45)

10.8
(274)

37.5
(17.0)

12.5
(14.2)

12.4
(314)

44.1
(20.0)

8.05
(9.09) (15.8) (22.4)

7.0
(176) (199) (223)

16.5
(7.5)

DB055M/I_B D08M/I DB080N/I_B DB100P/I_B DB200Q/I_B DB300R/I_B DB330S/I_B DB465T/I_B DB700U/I_B D12N/I D19P/I D37Q/I D37R/I D47S/I D55T/I D59U/I

13.9 19.8 35.0

7.9 8.8 8.6

21.2
(9.6) (12.0)

26.5 41.9

(39.5)

(217)

(19.0)

47.6
(53.8)

9.6
(243)

51.8
(23.5)

66.7
(75.3)

11.0
(277)

62.8
(28.5)

85.7
(96.8) (133)

12.3
(311)

77.1
(35.0)

118 261

15.2
(385) (383)

100.3
(45.5) (65.0)

15.1

143.3

(294)

SAC-D01d

page 51

D-Series AC Servodrives

Specifications

6.10 Absolute Encoder Servomotor Performance Specifications

Servomotor Servodrive Continuous Stall Torque/Inertia Moment of Inertia Servomotor Servomotor Quadrature Length Weight Output Res.

MACDE003A1/A DE006B1/A DE008C1/A DE003A2/A DE006B2/A DE011C2/A DE021D2/A DE042E2/A DA030F/A DA055G/A DA090H/A DA110J/A DA140K/A DB025L/A DB055M/A DB080N/A DB100P/A DB200Q/A DB300R/A DB330S/A DB465T/A DB700U/A

SACDE02A1/A DE03B1/A DE04C1/A DE01A2/A DE02B2/A DE03C2/A D04C/A DE04D2/A D08D/A D12E/A D08F/A D19G/A D37H/A D37J/A D37K/A D08L/A D08M/A D12N/A D19P/A D37Q/A D37R/A D47S/A D55T/A D59U/A

rad/sec2 35,512 27,221 25,617 35,512 27,221 25,617 11,155 11,757 17,060 19,093 13,781 13,004 12,712 4,028 4,338 4,308 3,619 4,882 5,067 4,216 4,193 2,795

lb-in-sec2x10-3 2 -4
(kg-m x10 ) (0.090) (0.234)

inches
(mm) (102) (87)

lbs
(kg) (0.9) (1.6)

0.079

4.1 3.5 4.2

2.0 3.5 5.1

counts/rev 4,080 4,080 4,080 4,080 4,080 4,080 4,080 4,080 32,640 32,640 32,640 32,640 32,640 32,640 32,640 32,640 32,640 32,640 32,640 32,640 32,640 32,640

0.207 0.329

(0.372)

(107)

(2.3)

0.079
(0.090)

4.1
(102)

2.0
(0.9)

0.207
(0.234)

3.5
(87)

3.5
(1.6)

0.329
(0.372) (2.14)

4.2
(107) (106)

5.1
(2.3)

1.89

4.2 5.3

10.6
(4.8) (7.1)

3.59
(4.06)

14.7 11.0
(5.0)

(134)

1.65
(1.87)

6.4
(163)

2.93
(3.32)

8.4
(212)

16.3
(7.4)

6.31
(7.13) (9.73) (12.4)

8.4
(213) (250)

25.4
(11.5) (14.5) (17.5)

8.61

9.9

32.0 38.6 13.0

(5.9)

11.0 6.5

11.5
(290)

6.0
(152)

(7.34)

12.4
(14.0)

6.9
(175)

17.6
(8.0)

18.3
(20.6)

7.9
(199)

22.0
(10.0)

28.2
(31.8) (46.1) (67.9)

7.1
(180) (206) (240)

30.9
(14.0) (18.5) (24.0)

40.8 59.9 78.9

8.2 9.5

40.8 52.9 66.1

10.8
(274)

(89.1)

(30.0)

111
(125)

12.8
(327)

88.2
(40.0)

249
(281)

13.9
(352)

127
(57.5)

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Specifications

6.11 Absolute Encoder Servomotor with Fail-Safe Brake Performance Specifications The fail-safe brake holding torque is equivalent to the motor's rated torque. Refer to the Motor with Integral Fail-Safe Brake wiring section of the Installation chapter for further fail-safe brake information.

Servomotor

Servodrive

Cont. Stall Torque/Inertia

Moment of Inertia

Servomotor Servomotor Quadrature Length Weight Output Res.

MACSACDE003A1/A_B DE02A1/A DE006B1/A_B DE03B1/A DE008C1/A_B DE04C1/A DE003A2/A_B DE01A2/A DE006B2/A_B DE02B2/A DE011C2/A_B DE03C2/A D04C/A DE021D2/A_B DE04D2/A D08D/A DE042E2/A_B D12E/A DA030F/A_B DA055G/A_B DA090H/A_B DA110J/A_B DA140K/A_B DB025L/A_B D08F/A D19G/A D37H/A D37J/A D37K/A D08L/A

rad/sec2 24,917 19,170 20,270 24,917 19,170 27,177 9,363 9,912 15,301 17,874 10,939 10,924 9,754 3,072 3,648 3,714 2,910 4,114 4,495 4,023 3,815 2,550

lb-in-sec2x10-3 2 -4
(kg-m x10 )

inches
(mm)

(kg)

lbs

0.113
(0.128)

5.2
(131)

2.7
(1.2)

counts/rev 4,080 4,080 4,080 4,080 4,080 4,080 4,080 4,080 32,640 32,640 32,640 32,640 32,640 32,640 32,640 32,640 32,640 32,640 32,640 32,640 32,640 32,640

0.294
(0.332)

4.7
(118)

4.6
(2.1)

0.416
(0.470) (0.128) (0.332)

5.5
(138) (131) (118)

6.2
(2.8) (1.2) (2.1)

0.113 0.294 0.416

5.2 4.7 5.5

2.7 4.6 6.2

(0.470)

(138)

(2.8)

2.26
(2.55)

5.6
(142)

13.7
(6.2)

4.26
(4.81)

6.7
(170)

19.0
(8.6)

1.84
(2.08) (3.53) (8.98)

8.2
(207)

14.3
(6.5)

3.12 7.95

10.1
(256) (251)

19.8
(9.0) (14.5)

9.9

32.0 38.6

10.25
(11.58)

11.4
(288)

(17.5)

12.7
(14.3)

13.0
(328)

45.2
(20.5)

8.14
(9.19)

7.5
(190)

17.4
(7.9)

DB055M/A_B D08M/A DB080N/A_B DB100P/A_B DB200Q/A_B DB300R/A_B DB330S/A_B DB465T/A_B DB700U/A_B D12N/A D19P/A D37Q/A D37R/A D47S/A D55T/A D59U/A

14.0
(15.8) (22.4) (39.5)

8.4
(213) (237) (231)

22.0
(10.0) (12.0) (19.5)

19.9 35.0 47.6

9.4 9.1

26.5 43.0 51.8

10.2
(257)

(53.8)

(23.5)

66.7
(75.3)

11.5
(291)

63.9
(29.0)

85.7
(96.8)

12.8
(325)

79.3
(36.0)

118
(133) (294)

15.8
(399)

110.2
(50.0)

261

15.7
(397)

144.4
(65.5)

SAC-D01d

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D-Series AC Servodrives

Specifications

6.12 Fail-Safe Brake Specifications The time delay between application of brake coil power and the releasing of the brake is 180 msec (maximum). The time delay between disabling the coil power and the brake engaging is 100 msec (maximum).
Servomotor Holding Torque Coil Resistance

MACDE003A1/__B DE006B1/__B DE008C1/__B DE003A2/__B DE006B2/__B DE011C2/__B DE021D2/__B DE042E2/__B DA030F/__B DA055G/__B DA090H/__B DA110J/__B DA140K/__B DB025L/__B DB055M/__B DB080N/__B DB100P/__B DB200Q/__B DB300R/__B DB330S/__B DB465T/__B DB700U/__B

lb-in
(N-m)

4.3
(0.49) (0.98) (1.96)

ohms (at 20C) 114 116 89 114 116 89 77 58 82 82 70 70 70 70 70 70 31 31 31 25 18 18

Coil Voltage Coil Current VDC amps (at 20C) 24 0.23 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 0.21 0.29 0.23 0.21 0.29 0.31 0.42 0.29 0.29 0.34 0.34 0.34 0.34 0.34 0.34 0.77 0.77 0.77 0.98 1.3 1.3

8.6 17

4.3
(0.49)

8.6
(0.98)

17
(1.96)

32
(3.63) (7.16)

63 28

(3.1)

56
(6.3)

87
(9.8)

112
(12.6)

140
(15.8)

25
(2.8)

48
(5.3)

74
(8.3)

102
(11.5)

165
(18.6)

252
(28.4)

310
(35.0)

425
(48.0)

620
(70.0)

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SAC-D01d

D-Series AC Servodrives

Maintenance and Troubleshooting

Chapter 7 Maintenance and Troubleshooting

7 Maintenance and Troubleshooting

7.1 LED Status Indicators

7.1.1 SAC-D LED Status Indicators

LED POWER ALARM CHARGE or BUS POWER

Description Illuminated when the servodrive logic power is on (r, t). Illuminated when there is a servodrive alarm condition. Illumination indicates bus capacitor is charged. This LED is recessed in the servodrive chassis, be sure you can see this LED before deciding it is not illuminated. WARNING: DO NOT SERVICE THE SERVODRIVE WHEN THIS LED IS EVEN DIMLY ILLUMINATED. WAIT FOR IT TO BE COMPLETELY UNILLUMINATED (SERVODRIVE BUS TO FULLY DISCHARGED) BEFORE SERVICING THE SERVODRIVE, THIS CAN TAKE SEVERAL MINUTES.

SAC-D01d

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D-Series AC Servodrives

Maintenance and Troubleshooting

7.1.2 SAC-DE LED Status Indicators LED 7-Segment Display Description Single character display which indicates the servodrive status. Refer to the Status Indicator Code Descriptions section of this chapter for a description of the 7-Segment Display codes. Illumination indicates bus capacitor is charged. WARNING: DO NOT SERVICE THE SERVODRIVE WHEN THIS LED IS EVEN DIMLY ILLUMINATED. WAIT FOR IT TO BE COMPLETELY UNILLUMINATED (SERVODRIVE BUS TO FULLY DISCHARGED) BEFORE SERVICING THE SERVODRIVE, THIS CAN TAKE SEVERAL MINUTES.

BUS POWER

7.2 Status Indicator Code Descriptions SAC-DE 7-Seg. LED SAC-OP03A ALARM@ Status Description Servodrive output current is disabled in the output circuitry (not an error). Servodrive output current is enabled and the unit is operating normally (not an error). Absolute encoder data not received or not valid. Servodrive configuration data checksum error. Servodrive configuration data out of range. Servodrive commanding excessive current output. Input power fuse blown (SAC-DE only). Regenerative discharge circuit not operating properly, or excessive regen. current.

n.a. n.a.

Servodrive disabled Servodrive enabled Absolute encoder data error Configuration Parameter Fault Configuration Parameter Error Overcurrent Input power fuse blown Regenerative discharge fault

10 10 10 11 12 13

13 14 15

Servodrive Config. Servodrive configuration incorrect. Error High Bus Voltage Fault Overspeed Servodrive bus voltage too high. Servomotor speed is at least 10% higher than the maximum motor speed.

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SAC-D01d

D-Series AC Servodrives

Maintenance and Troubleshooting

SAC-DE 7-Seg. LED SAC-OP03A ALARM@ Status

Description Servomotor torque greater than approx. twice rated torque for at least 3 secs. Servomotor torque greater than rated torque, but less than twice rated, for at least 100 secs. Absolute encoder data incorrect or absent. (MAC-DE only) Absolute encoder backup power failure caused loss of rev. counter data. (MAC-DE only) Absolute encoder data checksum is not correct. (MAC-DE only) Absolute encoder backup battery voltage is below 2.8 VDC. (MAC-DE only) Absolute encoder data invalid. (MAC-DE only) Absolute encoder polled while motor is rotating over 400 RPM. (MAC-DE only) Indicates the servodrive has been reset, this is not an error condition. Displayed in the ALARM LOG only.

17 17

Overload (twice rated) Overload (rated torque) Absolute encoder error Absolute encoder backup error Absolute encoder checksum error Absolute encoder battery error Absolute encoder data error Absolute encoder overspeed Servodrive reset

10 10 10 10

10 10 n.a.

17 10 15 15 15 15 12

Heat sink high Servodrive heat sink temperature too temperature error high. Invalid torque command input Encoder error (overrun) Encoder channel error Servodrive torque command input either absent or invalid. Encoder speed higher than the maximum motor speed. Encoder feedback data absent or invalid.

Encoder channel A Encoder channel A or B wiring not or B open wire connected to encoder. Encoder reference Encoder reference channel wiring not channel open wire connected to encoder. Input power phase One phase of the main servodrive error power (R, S, T) absent or the wrong voltage. Input power loss Servodrive main power (R, S, T) voltage or frequency incorrect.

12

Table 17, Status indicator code descriptions

SAC-D01d

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D-Series AC Servodrives

Maintenance and Troubleshooting

7.3 Servodrive Test Points

7.3.1 SAC-D Servodrive Test Points The SAC-D servodrive test points are accessible through a 4 pin header (TEST POINTS) on the top of the servodrive. Refer to Table 18 for a description of the test points. The CBL-DMON/3 column indicates the color wire, in a CBL-DMON/3, on which the corresponding signal is available. The CBL-DMON/3 is recommended for easier access to the SAC-D servodrive test points.

Torque Velocity

POWER ALARM
Common

TEST POINTS SW1

Figure 11, SAC-D Test Point Layout

CBL-DMON Description Red Speed monitor: +/-2 VDC/1000 RPM (MAC-DB), or +/-1 VDC/1000 RPM (MAC-DA and MAC-DE) Torque monitor: +/-2 VDC/100% rated torque Monitor common

White Black Black

Table 18, SAC-D Servodrive Test Points

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SAC-D01d

D-Series AC Servodrives

Maintenance and Troubleshooting

7.3.2 SAC-DE Servodrive Test Points The SAC-DE servodrive test points are accessible through the 3 terminals (TORQ, TACH, and GND) on the front of the unit. Refer to Table 18 for a description of the test points. The Locator column indicates the PC board locator for each test point.

Test Points
CH1

TORQ TACH GND

CN3

Figure 12, SAC-DE Test Point Layout

Terminal Locator Description TORQ TACH GND CH1 CH2 CH3 Torque monitor: +/-2 VDC/100% rated torque Speed monitor: +/-1 VDC/1000 RPM Monitor common

Table 19, SAC-DE Servodrive Test Points

SAC-D01d

CH3

CH2

page 59

D-Series AC Servodrives

Maintenance and Troubleshooting

7.4 Servodrive Troubleshooting Guide

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description Absolute encoder data not received or not valid. Corrective Action

10
Detection Condition When power is applied to the control circuit or the ABS input is asserted (ABS@=ON or POS.ACT@=POS.ABS@)

Absolute encoder data error Probable Cause

Servodrive not supplying power Check the encoder cable model to the absolute encoder number and connection. Incorrect absolute encoder signal channel wiring Absolute encoder malfunction Perform absolute encoder reset procedure, refer to the Resetting the Absolute Encoder section of the Operation chapter. Verify that the servodrive is configured for absolute encoder operation (/A option). Replace servomotor. Replace servodrive Description Servodrive configuration data checksum error. Corrective Action Replace servodrive

Incorrect servodrive encoder configuration Defective absolute encoder Defective servodrive

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

10
Detection Condition When power is applied to the control circuit

Configuration parameter fault Probable Cause Defective servodrive

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description Servodrive configuration data out of range. Corrective Action Replace servodrive

10
Detection Condition When power is applied to the control circuit

Configuration parameter fault Probable Cause Defective servodrive

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SAC-D01d

D-Series AC Servodrives

Maintenance and Troubleshooting

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description Servodrive commanding excessive output current. Corrective Action Check motor wiring.

11
Detection Condition During servomotor operation

Overcurrent Probable Cause

Wiring grounded between servodrive and motor

Motor phase (U, V, W) grounded Replace motor. at motor When power is applied to the Defective servodrive main circuit, or the servodrive is enabled (MODE@>2)
SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Replace servodrive.

Description Input power fuse blown (SAC-DE only). Corrective Action Replace servodrive. Replace servodrive Description Regenerative discharge circuit not operating properly, or excessive regen. current. Corrective Action Replace servodrive. For servodrives with an external regen. resistor (SAC-D47S - 59U), check the regen resistor unit wiring. For all other servodrives, replace servodrive. Replace servodrive.

12
Detection Condition When power is applied to the main circuit.

Input power fuse blown Probable Cause

Blown input power fuse blown Defective servodrive

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

13

Regenerative discharge fault Probable Cause

Detection Condition

During servomotor operation or Defective regenerative approximately 1 second after discharge transistor power applied to main circuit Disconnection of the regen. resistor

When power is applied to the control circuit

Defective servodrive

SAC-D01d

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D-Series AC Servodrives

Maintenance and Troubleshooting

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description

13
Detection Condition During servomotor operation When power is applied to the main circuit

Servodrive Servodrive configuration incorrect. configuration error Probable Cause Defective servodrive Defective servodrive Corrective Action Replace servodrive. Replace servodrive.

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description Servodrive bus voltage too high. Corrective Action Replace servodrive Reduce the load inertia.

14
Detection Condition When power is applied to the control or main circuits

High bus voltage fault Probable Cause Defective servodrive

Load exceeds regenerative discharge capacity of the servodrive

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description Servomotor speed at least 10% higher than the maximum motor speed. Corrective Action Check the motor cable connection, and the encoder cable model number and connection. Check the encoder cable connection. If cables were not supplied by ORMEC, verify proper shielding as shown in the CBL-DMAC and CBL-DEMAC in Appendix D. Check the servodrive model number to verify that it is the appropriate servodrive for use with this motor. Replace servodrive Replace servodrive

15
Detection Condition

Overspeed Probable Cause

When the servodrive is enabled Incorrect motor and/or encoder (MODE@>2) or during wiring servomotor operation Electrical noise in encoder wiring

Wrong servodrive model

Defective servodrive When power is applied to the control or main circuits. Defective servodrive

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SAC-D01d

D-Series AC Servodrives

Maintenance and Troubleshooting

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description Servomotor torque greater than approx. twice rated torque for at least 3 secs. Servomotor torque greater than rated torque, but less than twice rated, for at least 100 secs. Corrective Action Check the motor cable connection. Check the encoder cable model number and connection. Reduce the load inertia, or switch to a higher torque motor and servodrive. Replace servodrive.

17 17

Overload (twice rated) Overload (rated torque) Probable Cause

Detection Condition

When the servodrive is enabled Incorrect motor wiring (MODE@>2) or during servomotor operation Incorrect encoder wiring Load exceeds the motor torque rating When power is applied to the control or main power circuit. Defective servodrive

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description Absolute encoder data is incorrect or absent. Corrective Action Replace servodrive. Check the encoder cable model number and connection. Reset servodrive alarm, and poll absolute encoder (POS.ACT@=POS.ABS@).

18
Detection Condition When power is applied to the control power circuit. During servomotor operation.

Absolute encoder error Probable Cause Defective servodrive Incorrect encoder wiring.

Absolute encoder malfunction.

Electrical noise in encoder data. Check the encoder cable connection, and separate encoder and power wiring. If cables were not supplied by ORMEC, verify proper shielding as shown in the CBL-DMAC and CBL-DEMAC drawings in Appendix D.

SAC-D01d

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D-Series AC Servodrives

Maintenance and Troubleshooting

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description Absolute encoder backup power failure caused loss of the revolution counter data (MAC-DE only). Corrective Action Replace servodrive. Follow the procedure in the Resetting the Absolute Encoder section of the Operation chapter.

18

Absolute encoder backup error Probable Cause Defective servodrive

Detection Condition When power is applied to the control power circuit. When the absolute encoder position is polled (POS.ACT@=POS.ABS@).

48 hours, or more, without ORION or servodrive logic power, or absolute encoder backup battery power, and the axis interface (CBL-AD or CBL-ADE) and encoder cables (CBL-DMAC, CBL-DEMAC, or CBL-DEMACD) connected. Defective absolute encoder

Replace servomotor.

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description Absolute encoder data checksum is not correct (MAC-DE only). Corrective Action

18
Detection Condition When the absolute encoder position is polled (POS.ACT@=POS.ABS@) or during motor operation.

Absolute encoder checksum error Probable Cause

Absolute encoder memory error. Follow the procedure in the Resetting the Absolute Encoder section of the Operation chapter. If error occurs frequently, replace servomotor.

When power is applied to the control power circuit.

Defective servodrive

Replace servodrive.

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SAC-D01d

D-Series AC Servodrives

Maintenance and Troubleshooting

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description Absolute encoder backup battery voltage is below 2.8 VDC (MAC-DE only). Corrective Action Check the encoder (CBL-DEMAC) and axis interface (CBL-ADE) cable model numbers and connection Check the absolute encoder backup battery (DSP Axis Module) voltage. Refer to the Measuring Battery Voltage section of the Maintenance & Troubleshooting chapter of the ORION Installation & Operation Manual for further information. Replace Servodrive.

18

Absolute encoder battery error Probable Cause Incorrect encoder or axis interface wiring

Detection Condition When the absolute encoder position is polled (POS.ACT@=POS.ABS@) or during motor operation.

Absolute encoder backup battery voltage below 2.8 VDC.

When power is applied to the control power circuit.

Defective servodrive

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description Absolute encoder data invalid (MAC-DE only). Corrective Action Replace servodrive.

18
Detection Condition

Absolute encoder data error Probable Cause

When power is applied to the Defective servodrive control power circuit, when the absolute encoder position is polled (POS.ACT@=POS.ABS@), or during motor operation.

SAC-D01d

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D-Series AC Servodrives

Maintenance and Troubleshooting

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description Absolute encoder polled while the motor was rotating over 400 RPM (MAC-DE only). Corrective Action Reduce motor speed below 400 RPM, reset the servodrive alarm, and poll the absolute encoder again. Replace servodrive.

18

Absolute encoder overspeed Probable Cause

Detection Condition

When absolute encoder position Motor rotating at 400 RPM or is polled greater. (POS.ACT@=POS.ABS@). When power is applied to the control circuit Defective servodrive

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description Servodrive heat sink temperature too high. Corrective Action

17

Heat sink temperature too high Probable Cause

Detection Condition During servomotor operation

The ambient temperature of the Lower the ambient temperature servodrive exceeds 55C below 55C. Air flow around the servodrive is restricted Provide sufficient space around the servodrive as indicated in the Servodrive Panel Mounting and Environment section of the Installation chapter. Replace servodrive Reduce the motor load inertia, or command slower motor motion. Replace servodrive.

Defective servodrive fan Motor load excessive

When power is applied to the control circuit

Defective servodrive

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description Servodrive torque command input either absent or invalid. Corrective Action Check axis interface cabling. Replace servodrive.

10
Detection Condition During servomotor operation

Invalid torque command input Probable Cause

Loss of torque command input

During servomotor operation or Defective servodrive when enabling the servodrive (MODE@>2)

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SAC-D01d

D-Series AC Servodrives

Maintenance and Troubleshooting

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description Encoder speed higher than the maximum motor speed. Corrective Action Check the motor cable connection. Check the encoder cable model number and connection. Replace motor. Replace servodrive. Replace servodrive.

15
Detection Condition During servomotor operation

Encoder error (overrun) Probable Cause

Incorrect servomotor wiring Incorrect encoder wiring Defective encoder Defective servodrive

When power is applied to the control circuit

Defective servodrive

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description Encoder feedback data absent or invalid. Corrective Action Separate encoder cabling from motor cabling and other high voltage wiring. If cables were not supplied by ORMEC, verify proper shielding as shown in the CBL-DMAC and CBL-DEMAC in Appendix D. Check the encoder cable model number and connection. Replace motor. Replace servodrive. Replace servodrive.

15
Detection Condition Within 1 to 3 seconds after power is applied to the control circuit, or during normal servomotor operation

Encoder channel error Probable Cause

Electrical noise on encoder channels

Incorrect encoder wiring Defective encoder Defective servodrive When power is applied to the control circuit Defective servodrive

SAC-D01d

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D-Series AC Servodrives

Maintenance and Troubleshooting

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description

15
Detection Condition

Encoder channel A Encoder channel A or B wiring not or B open wire connected to encoder. Probable Cause Corrective Action Separate encoder cabling from motor cabling and other high voltage wiring. If cables were not supplied by ORMEC, verify proper shielding as shown in the CBL-DMAC and CBL-DEMAC in Appendix D. Check the encoder cable model number and connection. Replace motor. Replace servodrive. Replace servodrive.

Within 1 to 3 seconds after Electrical noise on encoder power is applied to the control channels circuit, when the servodrive is enabled (MODE@>2), or during normal servomotor operation

Incorrect encoder wiring Defective encoder Defective servodrive When power is applied to the control circuit Defective servodrive

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description Encoder reference channel wiring not connected to encoder. Corrective Action Separate encoder cabling from motor cabling and other high voltage wiring. If cables were not supplied by ORMEC, verify proper shielding as shown in the CBL-DMAC and CBL-DEMAC in Appendix D. Check the encoder cable model number and connection. Replace motor. Replace servodrive. Replace motor.

15
Detection Condition

Encoder reference channel open wire Probable Cause

Within 1 to 3 seconds after Electrical noise on encoder power is applied to the control channels circuit, when the servodrive is enabled (MODE@>2), or during normal servomotor operation

Incorrect encoder wiring Defective encoder Defective servodrive When power is applied to the control circuit Defective encoder

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D-Series AC Servodrives

Maintenance and Troubleshooting

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description One phase of the main servodrive power (R, S, T) absent or the wrong voltage. Corrective Action Check the incoming power line voltage and wiring. Check noise filter, contactor, etc. and associated wiring. Check the incoming power line voltage. Replace servodrive.

12
Detection Condition When power is applied to the main circuit

Input power phase error Probable Cause

One phase of the main circuit power (R, S, T) is disconnected

One phase of the main circuit power has a low line voltage When power is applied to the control circuit Defective servodrive

SAC-OP03A ALARM@ Status SAC-DE 7 Seg. LED

Description Servodrive main power (R, S, T) voltage or frequency incorrect. Corrective Action

12
Detection Condition When power is applied to the main circuit During normal servomotor operation

Input power loss Probable Cause

Time between main power (R, S, Disable the main power and T) cycles less than 0.5 seconds wait at least 0.5 seconds before reapplying main power. Main power (R, S, T) input voltage drop Main power (R, S, T) input voltage interrupted for at least 1/2 cycle Check the main power input line voltage. Check the main power input frequency/integrity.

SAC-D01d

page 69

D-Series AC Servodrives

Maintenance and Troubleshooting

7.5 IP-67 Motor Shaft Seal Lubrication Motors with the IP-67 sealing option (MAC-D_____/_V_) have a shaft seal (Figure 13), which requires lubrication. You should check the shaft seal frequently, depending on your application, and verify that it is lubricated. An insufficiently lubricated shaft seal will deteriorate with use (motor rotation), and decrease in effectiveness. A gear oil (SAE70 to 90) should be applied directly to the shaft seal as lubrication.

Shaft Seal

Shaft Opening

Figure 13, Motor Shaft/Oil Seal Cross Section

page 70

SAC-D01d

D-Series AC Servodrives System Wiring Diagrams ORION System Wiring Diagram with SAC-D & SAC-S Series Servodrives MAIN POWER MAIN CONTACTOR (230 VAC) COIL POWER (THREE PHASE) (115 or 230 VAC) W A R N IN G : L3
D S e is o f S e r rv o c r it th e O p e ra in fo r m ie s (S A C d r iv e in p ic a l. R e f D /D E -S e tio n m a n a tio n . -D 0 1 u t p e r to r ie s u a l o w s In fo ) e r e c t s ta r fu p h io n lla rth a s in g 3 .4 tio n & e r

Appendix A

CONTROL POWER (230 VAC)

L1 L2

Safety Ground

TB1

L1

GND

L2

FUSES (or CIRCUIT BREAKER)

10,15,20 AMP Circuit Breaker

LINE FILTER

MAIN CONTACTOR (MOTOR POWER)

NF E-STOP

Filter & Power Supplies

MP
MP-AUX

NF
NF

NO-FAULT RELAY

TB8

RESET (RED) ORION CPU CPU RESET SPECIAL FUNCTION PB1 (BLK)

24
E-STOP RESET

NO DIAGNOSTIC FAULT

E STOP-OK LED LIMIT OVERRIDE

AND

FWD

REV

ES
See Note 2

NO DRIVE FAULTS NO OPEN ENCODER WIRES ON ENABLED MOTORS

NO FAULT LED

OPTIONAL OVERTRAVEL LIMIT SWITCHES

C4 T

ORION
Model 70 Model 50 Model 30

SAC-D, SAC-S SERIES SERVO DRIVE(S)

See Note 3

U R

V W

W B

GND

CN2

CN1

G Encoder Cable CBL-DMAC/NN CBL-SMAC/NN (1-150 ft. max)

Axis Interface Cable (1 - 50 ft.) CBL-AD/NN CBL-AS/NN

Connects to DSP AXIS MODULE(S)

Motor Cable CBL-DMACX/NN CBL-SMACx/NN (1-150 ft. max)

SHIELD
See Note 1

MOTOR

Notes: 1) Motor thermal overload protection is not provided internal to the amplifier and must be provided externally. Thermal overload relay contacts should disable incoming drive main (bus) power, and must not break the drive-motor connection (U, V, W). Refer to National Electric Code for proper sizing of overload protection, and the Installation section of this manual forfurther information. 2) The configuration shown is an alternative approach, the Hardware Overtravel Limit Switches should be wired to the DSP I/O Terminal Block. 3) The SAC-D47S, D55T, D59U, and S45H require an external regen resistor not shown in this diagram. Refer to the D-Series and S-Series AC Servodrives Installation and Operation manuals for further information.

SAC-D01d

A-1

D-Series AC Servodrives

Appendix A

ORION System Wiring Diagram with SAC-DE & SAC-E Series Servodrives MAIN POWER MAIN CONTACTOR CONTROL POWER (115 or 230 VAC) COIL POWER (115 or 230 VAC) (SINGLE PHASE) (115 or 230 VAC) See Note 4
L1 L2 L1 L2 L1 Safety Ground L2

TB1

L1

GND

L2

FUSES (or CIRCUIT BREAKER)

10,15,20 AMP Circuit Breaker

LINE FILTER

MAIN CONTACTOR (MOTOR POWER)

NF E-STOP

Filter & Power Supplies

MP
MP-AUX

NF
NF

NO-FAULT RELAY

TB8

RESET (RED) ORION CPU CPU RESET SPECIAL FUNCTION PB1 (BLK)

24
E-STOP RESET

NO DIAGNOSTIC FAULT

E STOP-OK LED LIMIT OVERRIDE

AND

FWD

REV

ES
See Note 2

NO DRIVE FAULTS NO OPEN ENCODER WIRES ON ENABLED MOTORS

NO FAULT LED

OPTIONAL OVERTRAVEL LIMIT SWITCHES

C4 T

ORION
Model 70 Model 50 Model 30

SAC-DE, SAC-E Series SERVO DRIVE(S)

U R V W W B
GND

CN2

CN1

G Encoder Cable CBL-DEMAC/NN CBL-SMACE/NN (1-150 ft. max)

Axis Interface Cable (1 - 50 ft.) CBL-ADE/NN See Note 3 CBL-AE/NN

Connects to DSP AXIS MODULE(S)

Motor Cable CBL-DEMACX/NN CBL-SMACX/NN (1-150 ft. max)

SHIELD
See Note 1

MOTOR

Notes: 1) Motor thermal overload protection is not provided internal to the amplifier and must be provided externally. Thermal overload relay contacts should disable incoming drive main (bus) power, and must not break the drive-motor connection (U, V, W). Refer to National Electric Code for proper sizing of overload protection, and the Installation section of this manual forfurther information. 2) The configuration shown is an alternative approach, the Hardware Overtravel Limit Switches should be wired to the DSP I/O Terminal Block. 3) SAC-DE and SAC-E Servodrives require different DSP Axis Module jumper configurations!!! Refer to the Servodrive Interface Configuration Jumpers section of the ORION Installation and Operation manual for further details. 4) SAC-DE servodrives can operate with either 115 VAC or 230 VAC input power, depending on the model. The control (r, t) and main (R, S, T) power for SAC-DE servodrives must be the same voltage, either 115 VAC or 230 VAC.

A-2

SAC-D01d

D-Series AC Servodrives Component Layout Diagrams SAC-D04 , D08, D12, & D19 Servodrive Layout

Appendix B

2 0.22 [5.5] MTG HOLES W W1

CN3

OPTIONAL STATUS MONITOR MODULE 0.59 [15]

9.25 [235] 9.84 [250]

POWER ALARM TEST POINTS SW1

D-Series Servodrive
CN1 CN2

0.22 [5.5]
MINIMUM VENTILATION CLEARANCE: 2" [50 MM] ABOVE AND BELOW, AND 0.4" [10 MM] BETWEEN SERVODRIVES.

8.86 [225]
ALTERNATE MOUNTING SURFACE REFERENCED FOR DUCT VENTILATED OPERATION

2.56 [65]

Servodrive SAC-D04 SAC-D08 SAC-D12 SAC-D19

W inches [mm] 4.33 [110] 4.33 [110] 4.33 [110] 5.31 [135]

W1 inches [mm] 3.62 [92] 3.62 [92] 3.62 [92] 4.61 [117]

SAC-D01d

B-1

D-Series AC Servodrives SAC-D37 Servodrive Layout

Appendix B

INTERNAL REGEN RESISTOR 2 0.24 [6] MTG HOLES OPTIONAL STATUS HEAT SINK MONITOR MODULE

CN3

9.25 [235]
POWER ALARM

CN4 SW1

9.84 [250]
BUS POWER

D-Series Servodrive
CN1 CN2

0.24 [6] 5.91 [150]

8.27 [210]
MINIMUM VENTILATION CLEARANCE: 2" [50 MM] ABOVE AND BELOW, AND 0.4" [10 MM] BETWEEN SERVODRIVES.

1.18 [30]

FAN 8.86 [225]

ALTERNATE MOUNTING SURFACE REFERENCED FOR DUCT VENTILATED OPERATION.

2.72 [69]

B-2

SAC-D01d

D-Series AC Servodrives SAC-D47, D55, & D59 Servodrive Layout

Appendix B

2 0.28 [7] MTG HOLES

CN3

H1
BUS POWER

H
POWER ALARM CN4 SW1

D-Series Servodrive
CN1 CN2

P1

.28 [7] W1 W
MINIMUM VENTILATION CLEARANCE: 2" [50 MM] ABOVE AND BELOW, AND 0.4" [10 MM] BETWEEN SERVODRIVES. SHIELD GROUND SCREW

D1 D
ALTERNATE MOUNTING SURFACE REFERENCED FOR DUCT VENTILATED OPERATION.

Servodrive SAC-D47 SAC-D55 SAC-D59

W W1 H H1 D D1 inches [mm] inches [mm] inches [mm] inches [mm] inches [mm] inches [mm] 9.06 [230] 9.06 [230] 10.24 [160] 7.09 [180] 7.09 [180] 7.87 [200] 13.78 [350] 13.78 [350] 17.72 [450] 13.19 [335] 13.19 [335] 17.13 [435] 9.25 [235] 9.25 [235] 11.2 [285] 3.54 [90] 3.54 [90] 4.92 [125]

SAC-D01d

B-3

D-Series AC Servodrives SAC-DE Servodrive Layout

.59 [14.9] W1 3.25 [82]
TORQ TACH

Appendix B

MINIMUM SPACE REQUIRED FOR CABLE CLEARANCE

.70 [17.8]
CN3

.30 [7.6]

GND

BUS POWER

10.06 [256]
R T r t P B U V W CN2 CN1

8.66 [220]

DE-Series Servodrive

.21 [5] W
MINIMUM VENTILATION CLEARANCE: 2" [50 MM] ABOVE AND BELOW, AND 0.6" [15 MM] BETWEEN SERVODRIVES.

Servodrive SAC-DE02A1 SAC-DE03B1 SAC-DE04C1 SAC-DE01A2 SAC-DE02B2 SAC-DE03C2 SAC-DE04D2

W W1 D inches [mm] inches [mm] inches [mm] 2.36 [60] 2.95 [75] 2.95 [75] 2.36 [60] 2.36 [60] 2.95 [75] 2.95 [75] 1.19 [30] 1.77 [45] 1.77 [45] 1.19 [30] 1.19 [30] 1.77 [45] 1.77 [45] 8.46 [215] 10.39 [264] 10.39 [264] 8.46 [215] 8.46 [215] 10.39 [264] 10.39 [264]

B-4

SAC-D01d

D-Series AC Servodrives SAC-LF215U Line Filter Layout

Appendix B

4.00 1.06 2.12 SAC-LF215U

0.187 (6 places)

2.00

2.91

3.62
SAC-LF230U Line Filter Layout

1/4" TAB

5.50
0.187 (4 places)

2.75

2.50

SAC-LF230U

3.00

4.87

#8-32 x 0.62

SAC-D01d

B-5

D-Series AC Servodrives SAC-LF15U, 30U, 45U, 60U, & 100U Line Filter Layout

Appendix B

W1

SAC-LFXXU

S
(4 PLACES)
LINE A

L1

SAC-LF15U & LF45U

SAC-LF30U, LF60U & LF100U

LOAD A

PART NUMBER STUD SIZE SAC-LF15U #10-32 x 0.93 SAC-LF30U #10-32 x 0.93 SAC-LF45U #10-32 x 0.93 SAC-LF60U 1/4-20 x 1.12 SAC-LF100U 5/16-18 x 1.12
LINE A LOAD A

N
See Note

N
See Note

C GND

GND

GND

GND

SAC-LF15U & SAC-LF45U

NOTE: 1) The line filter neutral phase (N) should only be connected to the neutral of a wye configured transformer. 2) For a delta configured transformer, leave the neutral phase disconnected. 3) DO NOT CONNECT THE NEUTRAL PHASE (N) to CHASSIS GROUND (GND) 4) Refer to section 3.4.1 (Input and Output Power Connections) for further information regarding input power transformer configurations.

SAC-LF30U, SAC-LF60U & SAC-LF100U

Line Filter SAC-LF15U SAC-LF30U SAC-LF45U SAC-LF60U

W W1 L L1 D S inches [mm] inches [mm] inches [mm] inches [mm] inches [mm] inches [mm] 4.0 [102] 5.0 [127] 5.0 [127] 6.5 [165] 3.3 [83] 4.0 [102] 4.0 [102] 4.3 [108] 4.3 [108] 8.6 [219] 10.0 [254] 13.0 [330] 14.0 [356] 14.0 [356] 7.8 [198] 9.0 [229] 12.0 [305] 13.0 [330] 13.0 [330] 4.0 [102] 4.8 [121] 4.8 [121] 4.8 [121] 4.8 [121] 0.2x0.4 [5x9] 0.3x0.5 [7x13] 0.3x0.5 [7x13] 0.3x0.6 [8x16] 0.3x0.6 [8x16]

SAC-LF100U 6.5 [165]

B-6

SAC-D01d

D-Series AC Servodrives SAC-DRR Regen Resistor Layout

Appendix B

L1 L

R1

R2

D W1 W
Regen Resistor SAC-DRR/0880 8.7 [220] SAC-DRR/1760 11.8 [300] 7.1 [180] 9.9 [250] 13.8 [350] 13.8 [350]

Mounting Hole - 4 Places O - 0.24 inches [6 mm]

W W1 L L1 D inches [mm] inches [mm] inches [mm] inches [mm] inches [mm] 13.2 [335] 13.2 [335] 3.7 [92] 3.8 [95]

SAC-D01d

B-7

D-Series AC Servodrives

Appendix C

C-1

SAC-D01d

D-Series AC Servodrives

Appendix C

SAC-D01d

C-2

D-Series AC Servodrives

Appendix C

C-3

SAC-D01d

D-Series AC Servodrives

Appendix C

SAC-D01d

C-4

D-Series AC Servodrives

Appendix C

C-5

SAC-D01d

D-Series AC Servodrives

Appendix D

SAC-D01d

D-1

D-Series AC Servodrives

Appendix D

D-2

SAC-D01d

D-Series AC Servodrives

Appendix D

SAC-D01d

D-3

D-Series AC Servodrives

Appendix D

D-4

SAC-D01d

D-Series AC Servodrives

Appendix D

SAC-D01d

D-5

D-Series AC Servodrives

Appendix D

D-6

SAC-D01d

D-Series AC Servodrives

Appendix D

SAC-D01d

D-7

D-Series AC Servodrives

Appendix D

D-8

SAC-D01d

D-Series AC Servodrives Motor Outline Drawings MAC-DE003A1 & DE003A2

OPTICAL ENCODER CONNECTOR MOTOR CONNECTOR

Appendix E

L LE LM
0.24 [6] 1.9 [48]

0.0016 A [0.04]
2.36 [60]

0.0016 A [0.04]

0.12 [3]

0.98 [25]
0.12 [3] 0.12 [3] 0.07 [1.8]

2.76 [70]
+0.000 -0.025

0.55 [14]
2.36 [60]

A 1.97 -0.001 [50] +0.000

1.970 [50] REF

0.315 + 0.0000 -0.0003 0.0008 A [0.02] 8

0.22 [5.5] (4) HOLES THRU
+ 0.000 -0.009

L Motor Model Number MAC-DE003A1 MAC-DE003A2 Incremental 2.3 [57] 2.3 [57] Absolute 4.1 [102] 4.1 [102] Incremental 1.9 [48] 1.9 [48]

LE Absolute 3.7 [94] 3.7 [94] LM 1.3 [32] 1.3 [32]

NOTE: Minimum cable clearance from motor centerline for Encoder Cable is 2.8 inches [71 mm]; for Motor Cable is 3.8 inches [97 mm]. Cable lengths to connector approximately 11 inches [280 mm].

SAC-D01d

E-2

D-Series AC Servodrives MAC-DE006B1, DE006B2, DE008C1 & DE011C2

Appendix E

OPTICAL ENCODER CONNECTOR

MOTOR CONNECTOR 0.0016 A [0.04] L

LE LM

3.15 [80]
0.0016 A [0.04] 1.18 [30] 0.120 [3]

0.31 [8] 2.3 [58]

2.756 +.0000 -.0012 A [70] +.0000 -.030

3.54 [90]

0.63 [16]
2.756 [70] REF

0.12 [3]

0.20 [5] 0.20 [5]

3.15 [80]

0.551+.0000 -.00043 0.0008 A [0.02] 14 +0.000 -0.011

0.28 [7] [4] HOLES THRU

LE

L Motor Model Number MAC-DE006B1 MAC-DE006B2 MAC-DE008C1 MAC-DE011C2 Incremental 2.5 [63] 2.5 [63] 3.3 [84] 3.3 [84] Absolute 3.5 [87] 3.5 [87] 4.2 [107] 4.2 [107] Incremental 2.1 [53] 2.1 [53] 2.9 [73] 2.9 [73]

Absolute 2.9 [75] 2.9 [75] 3.7 [95] 3.7 [95]

LM 1.6 [40] 1.6 [40] 2.4 [60] 2.4 [60]

NOTE: Minimum cable clearance from motor centerline for Encoder Cable is 3.2 inches [81 mm]; for Motor Cable is 4.2 inches [107 mm]. Cable lengths to connector approximately 11 inches [280 mm].

E-3

SAC-D01d

D-Series AC Servodrives MAC-DE021D2 & DE042E2

OPTICAL ENCODER CONNECTOR MOTOR CONNECTOR

Appendix E

MAC-DE021D2

0.0016 A [0.04] L LE LM

0.0016 A [0.04]

4.72 [120]

0.12 [3]

0.20 [5] 0.20 [5]

1.57 [40]
0.39 [10]
3.5 [138] 5.71 [145]

0.14 [3.5] 0.87 [22] 4.331 4.72 [110] [120] REF

0.630 +.0000 -.00043 16 +0.000 -0.011
MAC-DE042E2 0.24 0.14 [6] [3.5] 0.24 [6]

4.331 -.0014 +.0000 [110] -.035

+.0000

0.0008 A [0.02]

0.39 [10] (4) HOLES THRU

0.750 +.0000 -.00043 19 +0.000 -0.011

L Motor Model Number MAC-DE021D2 MAC-DE042E2 Incremental 3.2 [82] 4.3 [110] Absolute 4.2 [106] 5.3 [134] Incremental 2.8 [72] 3.9 [100]

LE Absolute 3.5 [89] 4.7 [120] LM 2.2 [56] 3.3 [84]

NOTE: Minimum cable clearance from motor centerline for Encoder Cable is 4.0 inches [102 mm]; for Motor Cable is 5.0 inches [127 mm]. Cable lengths to connector approximately 11 inches [280 mm].

SAC-D01d

E-4

D-Series AC Servodrives MAC-DA030F & DA055G

MOTOR CONNECTOR 0.0016 A [0.04] L

Appendix E

OPTICAL ENCODER CONNECTOR

LE LM
0.39 [10]

0.0016 A [0.04]

3.94 [100]

0.12 [3]

1.77 [45]

3.94 [100] 3.43 [87]

A

4.53 [115]
3.740 [95]
+.0000 -.0014 +.000 -.035

3.740 [95] REF 3.94 [100]

1.26 [32]

0.15 [4]

0.31 [8] 0.28 [7]

5.12 [130] 0.0008 A [0.02]

0.078 [2]

0.59 [15]

0.945

+.0000 -.0005

0.28 [7] (4) HOLES THRU

24 +0.000 -0.013

L Motor Model Number MAC-DA030F MAC-DA055G Incremental 5.9 [150] 7.8 [200] Absolute 6.4 [163] 8.4 [212] Incremental 5.1 [130] 7.0 [178]

LE Absolute 5.6 [142] 7.5 [191] LM 3.0 [76] 4.9 [125]

NOTE: Minimum cable clearance from motor centerline for Encoder Cable is 6.2 inches [157 mm]; for Motor Cable is 6.6 inches [168 mm].

E-5

SAC-D01d

D-Series AC Servodrives MAC-DA090H, DA110J & DA140K

MOTOR CONNECTOR 0.0016 A [0.04] L

Appendix E

OPTICAL ENCODER CONNECTOR

0.0016 A
LE LM
0.47 [12] [0.04]

5.12 [130]

0.236 [6]

2.48 [63]

4.69 [119] 3.43 [87]

A

5.71 [145]
4.331+.0000 -.0014 [110] +.000 -.035

1.97 [50] 4.331 [110] REF 0.157 [4]

0.315 [8]

0.275 [7]

5.12 [130]
6.50 [165]

0.078 [2] 0.59 [15]

0.0008 A [0.02]

1.102

+.0000 -.0005

28 -0.013

+0.000

0.35 [9] (4) HOLES THRU

L Motor Model Number MAC-DA090H MAC-DA110J MAC-DA140K Incremental 7.9 [200] 9.3 [236] 10.9 [277] Absolute 8.4 [213] 9.9 [250] 11.5 [290] Incremental 7.0 [177] 8.4 [213] 10.0 [254]

LE Absolute 7.6 [192] 9.0 [229] 10.6 [269] LM 4.8 [122] 6.2 [157] 7.8 [198]

NOTE: Minimum cable clearance from motor centerline for Encoder Cable is 6.2 inches [157 mm]; for Motor Cable is 7.5 inches [191 mm].

SAC-D01d

E-6

D-Series AC Servodrives MAC-DB025L, DB055M & DB080N

MOTOR CONNECTOR L OPTICAL ENCODER CONNECTOR LE LM 0.47 [12] 5.71 [145] 6.50 [165] 0.0008 A [0.02] 0.35 [9] (4) HOLES THRU 0.0016 A [0.04] 5.12 [130] 0.24 [6]

Appendix E

0.0016 A [0.04] 2.28 [58]

MAC-D025L & MAC-055M

0.118 [3] 0.197 [5] 0.197 [5]

0.748 +.0000 -.0005 0.98 [25] 5.12 4.331 [130] [110] REF 19 +0.000 -0.013

4.72 [120] 3.46 [88]

4.331-.0014 [110] +.000 -.035

+.0000

MAC-D080N
0.47 [12]
0.138 0.59 [3.5] [15] 0.236 [6] 0.236 [6]

0.866

+.0000 -.0005

22 +0.000 -0.013

L Motor Model Number MAC-DB025L MAC-DB055M MAC-DB080N Incremental 5.4 [137] 6.3 [160] 7.3 [185] Absolute 6.0 [152] 6.9 [175] 7.9 [199] Incremental 4.6 [117] 5.5 [140] 6.4 [162]

LE Absolute 5.1 [131] 6.0 [154] 7.0 [178] LM 2.5 [64] 3.4 [86] 4.4 [112]

NOTE: Minimum cable clearance from motor centerline for Encoder Cable is 6.3 inches [160 mm]; for Motor Cable is 7.0 inches [178 mm].

E-7

SAC-D01d

D-Series AC Servodrives MAC-DB100P, DB200Q, DB300R, DB330S & DB465T

MOTOR CONNECTOR L OPTICAL ENCODER CONNECTOR LE LM 0.0016 [0.04] 0.71 [18] K 3.46 [88]
A

Appendix E

0.0016 [0.04]

7.09 [180]

MAC-DB100P, MAC-DB200Q & MAC-DB300R 0.13 2.98 [3.2] [75.8] 0.394 [10] 0.197 2.36 [5] 0.315 [60] [8] 4.500 [114.3] REF
+.0004

3.11 [79]
7.87 [200] 7.09 [180] 0.13 [3.2]

1.379 -.0000 35 -0.000

+0.01

4.500 +.0000 -.001 [114.3] +.0000 -.025

9.06 [230] 0.0008 [0.02] A 0.531 [13.5] (4) HOLES THRU

MAC-DB330S & MAC-DB465T 4.32 [109.8] 0.197 3.54 [5] [90]

4.500 [114.3] REF

0.472 [12] 0.315 [8]

4.45 [113]

1.654

+.0000 -.0006

42 -0.006

+0.000

L Motor Model Number MAC-DB100P MAC-DB200Q MAC-DB300R MAC-DB330S MAC-DB465T Incremental 6.5 [165] 7.5 [190] 8.9 [226] 10.2 [259] 13.2 [335] Absolute 7.1 [180] 8.2 [206] 9.5 [240] 10.8 [274] 13.7 [348] Incremental 5.7 [145] 6.7 [170] 8.1 [205] 9.4 [239] 12.3 [312]

LE Absolute 6.2 [159] 7.2 [185] 8.6 [219] 9.9 [253] 12.8 [327] LM 3.5 [89] 4.5 [114] 5.8 [147] 6.8 [173] 9.7 [246] K 5.8 [147] 5.8 [147] 5.8 [147] 5.9 [150] 5.9 [150]

NOTE: Minimum cable clearance from motor centerline for Encoder Cable is 6.3 inches [160 mm]; for Motor Cable is 9.5 inches [241 mm].

SAC-D01d

E-8

D-Series AC Servodrives MAC-DB700U

MOTOR CONNECTOR 13.27 [337] 0.0016 [0.04] 12.48 [317] 9.88 [251] 0.71 [18] 6.61 [168] 3.46 [88]
A

Appendix E

OPTICAL ENCODER CONNECTOR

0.0016 [0.04]

8.66 [220]

0.157 [4]

4.41 [112] 3.54 [90] 0.197 [5]

7.874+.0000 -.0018 [200] +.0000 -.046

9.25 [235] 10.63 [270] 8.66 [220]

7.874 [200] REF 0.078 [2] 4.57 [116] 0.885 [22.5]

0.472 [12] 0.315 [8]

0.0008 [0.02]

0.531 [13.5] (4) HOLES THRU

1.654

+.0000 -.0006

42 -0.016

+0.000

L Motor Model Number MAC-DB700U Incremental 13.3 [337] Absolute 13.9 [352] Incremental 12.5 [314]

LE Absolute 13.0 [331] LM 9.8 [249]

NOTE: Minimum cable clearance from motor centerline for Encoder Cable is 6.3 inches [160 mm]; for Motor Cable is 9.5 inches [241 mm].

E-9

SAC-D01d

MITSUBISHI ELECTRIC
Programmable Logic Controllers

130

MELSEC AnS, QnAS

130

54,5

6,5

93,6

130

54,5

6,5

93,6

130

130

A 1S62P
POWER RUN ERROR

A 1SCPU
LCLR RESET

A 1SX80
RUN RESET 0 1 2 3 4 5 6 7

A 1SY80
8 9 A B C D E F 0 1 2 3 4 5 6 7

STOP

ERR 8 9 A B C D E F

A 1SY80
0 1 2 3 4 5 6 7

ERR 8 9 A B C D E F

A 1SX81
A 0 1 2 3 4 5 6 7

A 1SY81
0 1 2 3 4 5 6 7 8 B 9 A B C D E A 0 1 2 3 4 5 6 7

8 9 A B C D E F

8 9 A B C D E F

0 1 2 3 4 5 6 7

ERR 8 B 9 A B C D E

MITSUBISHI

MITSUBISHI

0 OUTPUT INPUT 3A AC 100/110/120V DC5V AC 200/220/240V 1 2 3 4 5 6 7 8 9 A B C D E F PULL

0 1 2 3 4 5 6 7 8 9 A B C D E F

0 1 2 3 4 5 6 7 8 9 A B C D E
2/24V 3/7mA NC NC A1SX81 DC12/24V 0.1A 0 1 2 3 4 5 6 7 8 9 A B C D E F 0 1 2 3 4 5 6 7 8 9 A B C D E F
COM

69,5

34,5

6,5

0 1 L 2 3 4 5 6 7 8 9 A B C D E F 0 1 2 3 4 5 6 7 8 9 A B C D E _ F
COM

93,6

DC

A1SY81

Technical Catalogue

2000
Return

MELSEC AnS/QnAS
New Items in this Catalogue

cts New Produ 03/00

Basic Components The SLOT PLC A80BDE-A2USH-S1 adds a MELSEC CPU in the form of a plug-in board for a personal computer to the CPUs of the AnS/QnAS series. Communications and Special Functions Modules The line of MELSECNET/10 modules is extended by the floating master module AJ71QLR21 for coaxial connections. The former MELSECNET/10 interface boards A7BDE-J71LP21 and A7BDE-J71BR11 were replaced by the 4 newly developed boards A70BDE-J71QLP23, A70BDE-J71QLP23GE, A70BDE-J71QLR23, and A70BDE-J71QBR13. For the AS interface the master module A1SJ71AS92 is provided for the connection between the AnS/QnAS and the AS-I network. Software The graphical programming software IDR-BLOK for closed-loop control systems is supplemented by the co-processor module A1SD51S-IDR and the function modules IDR10F-STD and IDR10F-ADV

Further Publications within the PLC Range

L ME SE C

AnU, QnA Series Technical Catalogue

Product catalogue for programmable logic controllers and accessories for the MELSEC A and Q series (art no. 61747)

Technical Catalogues

nN AA A An Q n U An

EC LS ME

FX Series Technical Catalogue

Product catalogue for programmable logic controllers and accessories for the MELSEC FX family (art. no. 68544)

0S FX N 0 FX N 2 FX

L ME

SE

HMI Technical Catalogue

Product catalogue for operator terminals, visualisation software and accessories (art. no. 68542)

C MA DU T GO

DIN ISO 9001 / EN 29001

Zertifikat: 09 100 4371

About this product catalogue This catalogue is periodically updated due to product range enlargement, technical changes or new or changed features. For actual information about updates, changes, news or even support matters please contact the MITSUBISHI MEL-FAX faxback system (fax: +49 2102 486-485 or -790 ) or have a look at the MITSUBISHI ELECTRIC web pages under www.mitsubishi-automation.com. Both media are nearly daily updated and available in two languages. Texts, figures and diagrams shown in this product catalogue are intended exclusively for explanation and assistance in planning and ordering the programmable logic controllers of the MELSEC series and the associated accessories. Only the manuals supplied with the units are relevant for installation, commissioning and handling of the units and the accessories. The information given in this documentation must be read before installation and commissioning of the units or software. Should questions arise with regard to the planning of devices described in this product catalogue, do not hesitate to contact MITSUBISHI ELECTRIC EUROPE B.V. in Ratingen (Germany) or one of its distributors (see cover page). No parts of this product catalogue may be duplicated, stored in an information system or transmitted without prior express written permission from MITSUBISHI ELECTRIC EUROPE B.V. MITSUBISHI ELECTRIC EUROPE B.V. 03/2000 (7th edition)

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
CONTENTS

MELSEC AnS/QnAS
SYSTEM DESCRIPTION Introduction of the MELSEC AnS series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Introduction of the MELSEC QnAS series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Structure and handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 BASIC COMPONENTS Base units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Power supply modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 CPU modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 DIGITAL MODULES Input modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Output modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 SPECIAL FUNCTION MODULES Analog modules, temperature control modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Counter, timer and positioning modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Interface modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Communications modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Communications modules for ETHERNET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Communications modules for MELSECNET/10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Communications modules for MELSECNET (II). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Communications modules for MELSECNET/B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Communications modules for CC-Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Communications modules for MELSEC I/O-Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Communications modules for PROFIBUS/DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Communications modules for DeviceNet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Communications modules for AS Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Pulse catch and interrupt modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 ACCESSORIES Dummy modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Cables, converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Memory cassettes, adapter units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Battery, fuses, network accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 TERMINALS AND DIMENSIONS Terminal assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

A Q
BASICS

PROGRAMMING SYSTEMS
PROGRAMMING Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Programming unit, EPROM writer, Cable for programming units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Teaching Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

APPENDIX
Order form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
SYSTEM DESCRIPTION The MELSEC AnS Series Series AnS

A Q
BASICS

Description
With the MELSEC AnS system, MITSUBISHI ELECTRIC presents its most compact modular PLC, permitting access to the world of network technology. The small size and the communications capability are two important characteristics of the MELSEC AnS. Its compactness ensures that it occupies less space in the switchgear cabinet and its diverse communication facilities guarantee flexibility and openness. Expandable from 32 to 1024 inputs/outputs, this controller is particularly suitable for performing small to medium automation tasks, very fast automation also being possible with the A2ASCPU. The individual systems can be installed in a local network (MELSECNET), enabling them to communicate with one another. The number of I/O points can thus be increased several times over. All CPU types can be combined freely with one another. The MELSEC AnS is a member of the MELSEC PLC family, which offers compatibility across the range.

Special features
expandable from 32 to 1024 inputs/ output points interchangeable intelligence diverse communications facilities

easy installation individual adaptation to existing systems innovative technology for future applications

MELSEC A/QnA MELSEC FX2N

1S62PN

MELSEC FX0N MELSEC FX0S MELSEC AnS/QnAS

Expandability and performance

In the AnS series, simply changing the CPU ensures that the performance of the PLC grows with the application. Thus, up to 1024 input/output addresses and up to 60 k program memories can be accessed. The AnS CPUs all have a permanently installed RAM of up to 256 kbyte in which, among other things, the PLC program can be saved. However, EPROM and EEPROM memory cassettes are also available for permanent storage. In all CPU modules, the memory content is protected by an integrated backup battery. The MELSEC AnS offers tailor-made performance through seven different CPUs: A1SHCPU, the standard CPU with 256 I/O points and a PLC program memory of 8 k steps A2SHCPU, the more powerful alternative with 512 I/O points and a PLC program memory of 14 k steps A2SHCPU-S1, the extended version of the A2SHCPU with 1024 I/O points and a PLC program memory of 30 k steps A2ASCPU, the most powerful CPU for realizing extremely fast automation tasks with 512 I/O points and a PLC program memory of 14 k steps

A2ASCPU-S1, A2ASCPU-S30/-S60 the extended alternative to the A2ASCPU for up to 1024 I/O points and a PLC program memory of 14 k steps for the A2ASCPU-S1 and 30 k or 60 k steps for the A2ASCPU-S30 and A2ASCPU-S60.

With up to 0.15 s per logical instruction, time-critical automation tasks can also be performed. The A2ASCPU-S30 and A2ASCPU-S60 is thus intended for very complex applications.

60

30

Overview of the AnS series CPUs

14 12 10 8 6 4 2 0
A1SH A2SH A2SH-S1 A2AS A2AS-S1

A2AS-S30 A2AS-S60

Number of I/Os (x 100)

Program memory size (k steps)

Cycle time

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Layout and Configuration Equipment Features
Owing to the modular concept, the AnS series has a broad range of use with many possible applications. The following modules are available for assembling the system: To maximize the operational safety, all modules are isolated from the environment by means of optocouplers. All I/O modules with screw contacts have their own removable terminal blocks which ensures easy handling during installation.

SYSTEM DESCRIPTION

A Q
BASICS

Digital input/output modules for various signal levels with triac, relay or transistor switches Pulse catch and interrupt modules Digital input modules for pulse storage and for processing subroutines

DIGITAL INPUTS/ OUTPUTS PULSE CATCH/ INTERRUPT MODULES DIGITAL INPUTS/ OUTPUTS

CPU

Analog input/output modules for current/voltage signals and for temperature measurement as well as temperature controlling with facility for direct connection of Pt100 resistance thermometers or thermocouplers

Communications modules Interface modules with RS232/RS422/ RS485 interface for connection of peripherals or for PLC-PLC coupling. Network modules for Ethernet and Profibus and for setting up MITSUBISHI networks. Master modules for use of local analog or digital I/O modules

COMMUNICATIONS MODULES

POSITIONING MODULES
Positioning modules High-speed counter modules with possibility for connection of incremental shaft encoder or multiaxial positioning modules for servo and step drive

Use of digital and special function modules

The use of digital and analog modules and most special function modules is dependent only on the maximum addressable number of addresses and thus on the CPU used in each case. With some special function modules, the use within a system is limited. These restrictions also apply to the use of modules of the MELSEC AnU series in the AnS system. All affected modules are listed in the adjacent table.
Module types AnS/QnAS series AnU/QnA series AD51(-S3), AD51H(-S3), AD57G(-S3), AJ71C22, AJ71C24(-S3/-S6/-S8), AJ71UC24, AJ71E71(-S3) AI61(-S1) AJ71AT21B, AJ71AR21, AJ71AP21 AJ71BR11, AJ71LP21GE, AJ71LP21 AJ71QBR11, AJ71QLP21, AJ71QLP21G AJ71QE71 AJ71QC24 Limitation A1SHCPU, A2SHCPU(-S1) A2ASCPU(-S1), A2ASCPU-S30/-S60 Q2ASCPU(-S1), Q2ASHCPU(-S1)

A1SJ71UC24-R2 (PRF/R4), A1SJ71E71-B2(-S3), A1SD51S

up to 2 modules per system

up to 6 modules per system

up to 6 modules per system

A1SI61 A1SJ71AT21B, A1SJ71AR21 A1SJ71BR11, A1SJ71LP21GE, A1SJ71LP21 A1SJ71QBR11, A1SJ71QLP21 A1SJ71QE71-B2/-B5 A1SJ71QC24(-R2)

only 1 module per system only 1 module per system only 1 module per system not possible not possible not possible

only 1 module per system up to 2 modules per system * up to 4 modules per system * not possible not possible not possible

only 1 module per system up to 2 modules per system * not possible up to 4 modules per system * no limit

* In this case the total number of modules is limited to 4 (e.g. 2 x AJ71AT21B + 2 x A1SJ71BR11)

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
SYSTEM DESCRIPTION The MELSEC QnAS Series Series QnAS

A Q
BASICS

Description The MELSEC QnAS(H) series is an extremely compact and very powerful new generation of controllers from MITSUBISHI ELECTRIC. Outstanding features include very fast program cycles, ample memory for large amounts of data (approx. 1 mega words) and significantly increased network access speed. These controllers are ideal for medium-scale applications requiring up to 1024 centralised I/Os in the switchgear cabinet or up to 8192 remote I/Os. The QnAS series is also hardware-compatible to the AnS series this means you can continue to use your modules from this series.

A1SJ71QBR11, A1SJ71QE71-B2/B5 QnAS(H)CPU

Ideal for time-critical applications with execution speeds as fast as 0.075 s per logical instruction. Integrated memory for up to 60 k program steps. Many additional functions are also possible without additional instruction QnAS series networks support high-speed access to CPU data during the END instruction, bringing a speed increase of up to a factor of 8 compared to conventional systems.

A1S38HB
High-speed base unit that significantly increases the overall performance of the entire system. If high-speed access to the QnAS series CPU via the network is not necessary, a standard base unit can be used.

PCMCIA RAM/EEPROM
One slot for PCMCIA RAM/ EEPROM cards

Expansion capability and performance As with other Mitsubishi controllers the power of the QnAS series grows with your application you simply replace the CPU. The system can be upgraded to a maximum capacity of 1024 centralised I/Os or 8192 remote I/Os. The integrated memory of 240 KB RAM can easily be expanded by up to 2 MB at any time just by slotting in a PCMCIA RAM card. PCMCIA EEPROM cards are also available for permanent storage of your controller programs. An integrated battery protects the data in the CPUs internal RAM against power failures. The QnAS(H) series includes four different CPU models for tailor-made configurations: Q2ASCPU 28 k steps program memory, program cycle period 0.15 s/logical instruction, 512 I/O points on the system rack. Q2ASCPU-S1 60 k steps program memory, program cycle period 0.15 s/logical instruction, 1024 I/O points on the base unit. Q2ASHCPU 28 k steps program memory, program cycle period 0.075 s/logical instruction, 512 I/O points on the base unit. Q2ASHCPU-S1 60 k steps program memory, program cycle period 0.075 s/logical instruction, 1024 I/O points on the base unit.

60

28
Overview of the QnAS series CPUs

14 12 10 8 6 4 2 0
Q2AS Q2AS-S1 Q2ASH Q2ASH-S1

Number of I/Os (x 100) Program memory size (k steps)

Cycle time/log. instruction (s)

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Layout and Configuration Equipment Features
QnAS highlights
High program execution speed and extremely fast network access were top priorities in the development of this new generation of controllers. At the same time, our engineers also took utmost care to maintain full compatibility to the existing A1S hardware to protect our users investment in their existing systems. The QnAS CPUs high-speed network access features require the A1S38HB high-speed base unit in combination with the appropriate network card. All conventional I/O modules (both analog and digital) and positioning modules can be used on the high-speed base unit.

SYSTEM DESCRIPTION

A Q
DIGITAL INPUTS/ OUTPUTS PULSE CATCH/ INTERRUPT MODULES
ITS E UN ks) BAS ting rac
un (mo
BASICS

MELSEC QnAS

QnAS CPU

ANALOG INPUTS/ OUTPUTS

COMMUNICATIONS MODULES
High-speed components for high-speed processing

POSITIONING MODULES

Integrated real-time clock with year, month, day, hour, minute and second, accuracy 2.5 seconds per year

The system can address up to 8192 digital I/O points, 1024 of which can be installed directly on the mounting rack.

Integrated RAM for up to 60 k program steps

Up to 4096 program subroutines possible (program pointers)

User-programmable timers, in units of 1 ms

Integrated backup battery

MITSUBISHI

INSERT

User-programmable software interrupt time base, in units of 5 ms

SRAM

CARD

Floating-point maths, string handling

LOCK

761 instructions, e.g. PID, MIN, MAX, SIN, COS, TAN

PCMCIA slot for RAM/EEPROM expansion cards with up to 2 MB additional memory, e.g. for file registers (up to 1018 k file registers possible)

IEC 1131.3 standard programming supported with MELSEC MEDOC plus from

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
SYSTEM DESCRIPTION Configuration Structure and Handling

A Q
BASICS

System structure
The CPU and modules are held in a base unit which has an internal bus connection for communication between the individual modules and the CPU. The power supply module which supplies the voltage for the entire system is also installed on this base unit. The main base units are available in 4 different versions with 2 to 8 module slots. Each base unit can be supplemented by means of an extension base unit, providing additional slots. If you wish to keep open the option of subsequent extension of your PLC or if you have free slots on your main base unit, you can insert dummy modules here. They serve to protect the free slots from soiling or from mechanical effects but can also be used for reserving I/O points. For cabling larger systems and machines e.g. in a modular design - the use of remote I/O modules offers additional communications facilities. These modules are connected by means of a shielded two-wire cable.
CPU module Digital I/O module Special function module

Power supply module

Protective cover for removable terminal block

Key switch

Interface for extension base unit

Interface for extension base unit Backup battery

Base unit

Memory cassette

Programming interface

Extension
The main base unit and extension base units are simply connected to one another by extension cables. These connecting cables also supply the extension base units with the operating voltage of 5 V DC. Up to three extension base units can be connected to a main base unit. The extension may be in the horizontal or vertical direction. When choosing the power supply module, the total power consumption of the I/O modules, of the special function modules and of the peripherals must be taken into account. If necessary, an extension base unit with a further power supply module should be used. Base units of the MELSEC AnA/AnU series can also be combined with the AnS series using a special cable.
Main base unit

Extension 1

Extension 2

Extension 3

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Structure and Handling Handling
Mounting the modules
The modules are easily mounted on the main base unit with the aid of a guide lug and a fixing screw. Installation can thus be carried out quickly and without problems. If it becomes necessary to change an I/O module, the screw terminal block can be removed beforehand. Thus, it is not necessary to disconnect the entire cabling but only 2 screws.

SYSTEM DESCRIPTION

A Q
BASICS

Mounting the base unit

The base unit can be mounted on a DIN rail or by conventional screw attachments. The individual base units can be mounted either side by side or up to 6 m apart.

General specifications
General Specifications Ambient temperature Storage temperature Ambient relative humidity Protection Noise durability Insulation withstand voltage Shock resistance Vibration resistance Insulation resistance Ground Environment Certifications Data 0 +55 C -20 +75 C max. 90 % (non-condensing) IP 20 1500 Vpp with noise generator; 1 s at 25 60 Hz AC 1500 V, 1 min. 10 G (3 times each in 3 directions) 2 G: resistant to vibrations from 10 55 Hz for 2 hours along all 3 axes; 0,5 G for DIN rail mounting >5 M (500 V DC) Class 3 Avoid environments containing corrosive gases, install in a dust-free location. UL / CSA / CE / DNV / RINA / LR

Approvals for MELSEC AnS series and CE certifications for MELSEC QnAS series as described on the following pages.

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
SYSTEM DESCRIPTION MELSEC Networks Networks

A Q
BASICS

TCP/IP ETHERNET
Ready for immediate operation with the worldwide standard TCP/IP protocol. A PC connected to the Ethernet has full access to all PLCs in the MELSECNET, all the way down to the I/Os on the production level.

MELSECNET/B
A cost-effective alternative within the production level. Enables implementation of easily-manageable configurations for complex applications by means of distributed intelligence.

MELSEC I/O-LINK
Remote module distribution to the machine. Devices of third party manufacturers can be integrated. Cabling with twisted pair cable in a tree structure.

MELSECNET/10 und -NET(II)

Low-cost cabling, brilliantly simple set-up and maximum availability thanks to redundancy and Floating Master. The maximum coverage is up to 30 km.

CC-Link
The network for the control and I/O level comprises capabilities like real-time processing and distributed intelligence. Modules of third party manufacturers can be integrated.

MELSEC FX Peer-to-Peer
The PPN construction enables a network for up to 8 FX2N and FX0N controllers as clients. The max. coverage is up to 500 m. A standard twisted-pair cable can be used as the communications media.

COMMAND LEVEL TCP/IP ETHERNET

TCP/IP ETHERNET

CONTROL LEVEL MELSECNET/10 MELSECNET(II) MELSECNET/B

AnS/QnAS

QnA/ AnU

MELSECNET/10 MELSECNET/B
AnS/ QnAS QnA/ AnU
QnA/ AnU

MELSECNET/10 MELSECNET(II)
AnS/ QnAS

AnS/ QnAS

PRODUCTION LEVEL CC-Link MELSEC I/O-LINK MELSEC FX-PPN

FX0N/FX2N

Remote I/Os

Ans/ QnAS

CC Link
GRAPHIC OPERATION TERMINAL

MELSEC FX-PPN

MELSEC I/O-LINK

Remote I/Os

MITSUBISHI

GOT series

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MELSEC AnS/QnAS
Networks Open Networks
MAP 3.0 ETHERNET Interdepartmental data exchange between the command and production levels using a non-proprietary protocol with short throughput times.

SYSTEM DESCRIPTION

Profibus FMS
Communication between equipment from different manufacturers within a single plant. Automatic data exchange with MELSEC networks.

DeviceNet
Cost-effective CAN-based network communications. Fault-resistant network structure where components of different manufacturers can be integrated quickly and easily.

A Q
BASICS

Profibus DP
Enables quick and simple connection of sensors and actuators from different manufacturers to MELSEC PLCs, with data transfer rates of up to 12 Mbaud.

AS Interface
International standard for the lowest field bus level. Connection of conventionel sensors and actuators with twisted pair cable.

COMMAND LEVEL MAP 3.0 ETHERNET

MAP 3.0 ETHERNET

P R O F
PROCESS FIELD BUS

CONTROL LEVEL Profibus FMS

QnA/ AnU

B U S

AnS

MAC E series I/O modules Inverter

Hz RUN A MON PU EXT

DeviceNet

PRODUCTION LEVEL Profibus DP DeviceNet AS Interface

RUN

STOP RESET

PROFIBUS DP

FX2N
M

MT series

AS Interface

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MELSEC AnS/QnAS
BASIC COMPONENTS MELSEC AnS/QnAS Main Base Units Base Units

A Q
BASICS
5V SG 5V SG FG

The main base unit is used for holding and coupling CPU, power supply unit, input modules, output modules and special function modules.

Special features:
CPU POWER MITSUBISHI I/O 0 I/O 1 I/O 2 I/O 3 I/O 4
AIS35B

The modules are automatically addressed. In general, it is assumed that base units with 8 slots will be used. Dummy slots or missing slots (in the case of base units with less than 8 slots) are assigned to 16 addresses. The automatic addressing can be changed by means of the function I/O assignment. The units are mounted by means of screws or on a profiled rail with an integrated adapter.

Specifications I/O modules Installation Weight Dimensions (W x H x D) Order information

A1S32B-E A1S33B-E A1S35B-E 2 3 5 All base units possess an installation hole 6 mm and M5 screws. * 0.65 0.75 kg 0.52 255 x 130 x 28 325 x 130 x 28 mm 220 x 130 x 28 Art. no. 48370 48371 48372

A1S38B-E 8 0.97 430 x 130 x 28 48373

A1S38HB-EU 8 1.0 430 x 130 x 28 69663

* An adapter is integrated for mounting on a DIN rail.

MELSEC AnS/QnAS Extension Base Units

The extension base units are connected to the main base unit by means of assembled bus cables. Thus, an AnS/QnAS system can be expanded to 32 I/O modules. Extension base units with or without their own power supply module are available.
I/O 0 POWER I/O 1 I/O 2 I/O 3 I/O 4 I/O 5 I/O 6 I/O 7
AIS68B

5V SG

5V SG FG

MITSUBISHI

Special features:
A total of three extension base units can be connected to a main base unit. The maximum distance from the first to the last base unit is 6 m. An extension base unit with a power supply module must be used in the following cases: If the power consumption of the inserted modules exceeds the capacity of the power supply module on the main base unit. If the voltage drops below 4.75 V between the main base unit and the extension base unit.

Specifications Power supply modules I/O modules Installation Weight Dimensions (W x H x D) Order information Accessories

A1S52B-S1 A1S55B-S1 A1S58B-S1 2 5 8 All base units possess an installation hole 6 mm and M5 screws. * 0.61 0.87 kg 0.38 260 x 130 x 28 365 x 130 x 28 mm 155 x 130 x 28 Art. no. 39667 38073 38072

A1S65B-S1 1 5 0.71 315 x 130 x 28 38071

A1S68B-S1 1 8 0.95 420 x 130 x 28 38070

Connection cables (refer to page 79)

* An adapter is integrated for mounting on a DIN rail.

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Power Supply Modules MELSEC AnS/QnAS Power Supply Modules
Power supply modules
They supply the individual modules with the voltages required for operation. The choice is dependent on the power consumption of the individual modules.
MITSUBISHI

BASIC COMPONENTS

A Q
BASICS

MELSEC A 1S61PN
POWER

MELSEC A 1S61PN
POWER

MITSUBISHI

Special features:
The readiness for operation is indicated by a red LED. For example, controllers can be supplied by means of additional 24 V DC output (A1S62PN). The power supply modules A1S61PN and A1S62PN can be used world wide because they support the wide input range from 100 to 240 V AC at 50/60 Hz.

INPUT 100-240VAC 105VA 50/60Hz

OUTPUT 5VDC 5A

INPUT 100-240VAC 105VA 50/60Hz

OUTPUT 5VDC 5A

NC NC

(FG)

(LG)

INPUT 100-240VA C A1S61PN

Specifications Input voltage (+10%, -15%) (+30%, -35%)

Input frequency Inrush current Max. input apparent power 5 V DC Rated output current 24 V DC 10 % 5 V DC Overcurrent protection 24 V DC 5 V DC Overvoltage protection 24 V DC Efficiency between primary Insulation with- and 5 V DC stand voltage between primary and 24 V DC Max. compensation time at power failure Power indicator Terminal screw size Applicable wire size Weight Dimensions (W x H x D) Order information

A1S61PN V AC 100 240 V DC Hz 50 / 60 (5 %) 20 A within 8 ms 105 VA A 5 A A 5.5 A V 5.5 6.5 V 65 % 2830 V AC, 1 min. ms 20 All modules possess a power LED display. All modules possess terminal screw size M 3.5 x 7. AWG 18 14 kg 0.8 mm 54.5 x 130 x 93.6 Art.no. 65051

A1S62PN 100 240 50 / 60 (5 %) 20 A within 8 ms 105 VA 3 0.6 3.3 0.66 5.5 6.5 65 % 2830 V AC, 1 min. 2830 V AC, 1 min. 20

A1S63P 24 81 A within 8 ms 41 W 5 5.5 5.5 6.5 65 % 500 V AC, 1 min. 1

AWG 18 14 0.8 54.5 x 130 x 93.6 65052

AWG 16 22 0.5 54.5 x 130 x 93.6 29536

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MELSEC AnS/QnAS
BASIC COMPONENTS MELSEC AnS CPU Modules CPU Modules

A Q
BASICS
A1SHCPU A1SHCPU

A1SHCPU, A2SHCPU(-S1)
7 different CPUs with graded performance are available for the MELSEC AnS. All versions are upwardly compatible. Thus, the MELSEC AnS can grow with the application if the CPU is changed.

Special features:
Integrated RAM as standard feature for storing the PLC program and data Integrated backup battery for backing up the RAM and definable PLC operands Nonvolatile EPROM and EEPROM memories can be inserted as options Integrated programming interface in the form of a differential interface (RS422) Processing of the inputs and outputs in direct mode or as refresh mode

Specifications I/O points (internal) Total I/O points (with remote I/O units) CPU self-diagnostic functions Battery buffer Memory type overall max. for PLC program max. for internal microcomputer program

A1SHCPU A2SHCPU 256 512 2048 2048 CPU error detection, Watch Dog, battery error detection, memory error detection, program check, power supply error detection, fuse error detection All modules are fitted with a lithium-battery with a life expectancy of 5 years. RAM, EPROM, EEPROM RAM, EPROM, EEPROM 64 64 kByte 8 k steps kByte 14 0.333 s/log. instruction 256 256 2048 / 256 1024 / 256 Max. 8192 32 256 256 2 2 1024 / 1024 Max. 4032 261 mA 300 ms 20 kg 0.33 mm 54.5 x 130 x 93.6 Art.no. 66612 Memory cassettes (refer to page 78) 14 k steps 14 0.25 s/log. instruction 256 256 2048 / 256 1024 / 256 Max. 8192 32 256 256 2 2 1024 / 1024 Max. 4032 261 400 20 0.33 54.5 x 130 x 93.6 66613

A2SHCPU-S1 1024 2048

RAM, EPROM, EEPROM 192 30 k steps 30 0.25 s/log. instruction 256 256 2048 / 256 1024 / 256 Max. 8192 32 256 256 2 2 1024 / 1024 Max. 4032 261 400 20 0.33 54.5 x 130 x 93.6 66611

Program capacity

Cycle time Timer (T) Counter (C) Internal / special relay (M) Data register / special register (D) File register (R) Interrupt pointer (I) Pointer (P) Annunciator (F) Accumulator (A) Index register (V, Z) Link relay (B) / link register (W) Comments Instructions Internal power consumption (5 V DC) Max. compensation time at power failure Weight Dimensions (W x H x D) Order information Accessories

Dependent on one another Number dependent on the memory configuration

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CPU Modules MELSEC AnS CPU Modules
A2ASCPU(-S1), A2ASCPU-S30/-S60
In performance, the CPU types A2AS(-S1) correspond to the A1S/A2S(-S1) types. The A2ASCPU-S30/-S60 diposeofmoreprogramcapacityandshortercycletime. The AnAS types are also particularly suitable for applications where short PLC cycle times are required.

BASIC COMPONENTS

A Q
BASICS

Special features:
Processing the inputs and outputs with refresh mode Floating point arithmetic according to IEEE 754 Special statements for processing PID control loops Mathematical functions, such as angle/exponential functions and logarithm

A1SMCA -14KE

Specifications I/O points CPU self-diagnostic functions Battery buffer Memory type overall Program max. for capacity PLC program Cycle time Timer (T) Counter (C) Internal / special relay (M) Data register / special register (D) File register (R) Interrupt pointer (I) Pointer (P) Annunciator (F) Accumulator (A) Index register (V, Z) Link relay (B) / link register (W) Comments /expanded comments Instructions Internal power consumption (5 V DC) Max. compensation time at power failure Weight Dimensions (W x H x D) Order information Accessories

A2ASCPU A2ASCPU-S1 A2ASCPU-S30 A2ASCPU-S60 512 1024 1024 1024 CPU error detection, Watch Dog, battery error detection, memory error detection, program check, power supply error detection, fuse error detection All modules are fitted with a lithium-battery with a life expectancy of 5 years. RAM, EPROM, EEPROM RAM, EPROM, EEPROM RAM, EPROM, EEPROM RAM, EPROM, EEPROM 256 256 256 kByte 64 14 k steps 0.2 s/log. instruction 2048 1024 8192 / 256 6144 / 256 Max. 8192 32 256 2 048 2 14 4096 / 4096 Max. 4032 / max. 3968 463 mA 320 ms 20 kg 0.41 mm 54.5 x 130 x 93.6 Art.no. 38067 Memory cassettes (refer to page 80) 14 k steps 0.2 s/log. instruction 2048 1024 8192 / 256 6144 / 256 Max. 8192 32 256 2 048 2 14 4096 / 4096 Max. 4032 / max. 3968 463 320 20 0.41 54.5 x 130 x 93.6 42615 30 k steps 0.15 s/log. instruction 2048 1024 8192 / 256 6144 / 256 Max. 8192 32 256 2 048 2 14 4096 / 4096 Max. 4032 / max. 3968 463 320 20 0.41 54.5 x 130 x 93.6 56084 60 k steps 0.15 s/log. instruction 2048 1024 8192 / 256 6144 / 256 Max. 8192 32 256 2 048 2 14 4096 / 4096 Max. 4032 / max. 3968 463 320 20 0.41 54.5 x 130 x 93.6 63884

Independent Number depends on memory configuration

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MELSEC AnS/QnAS
BASIC COMPONENTS MELSEC QnAS CPU Modules CPU Modules

A Q
BASICS

Q2ASCPU(-S1), Q2ASHCPU(-S1)
These controllers make it possible to use small modular systems in complex production systems calling for short cycle times. These CPUs can also handle really large recipes, making them ideal for use in networks.

Special features:
Processing of inputs and outputs as process I/O image (direct processing instructions are available) IEEE 754 floating point maths Dedicated instructions for PID controller circuits Mathematical functions including trig, exponents and logarithms The CPU can store an entire controller cycle program including the graphical information. This means that the entire program information is available when you download the program from the CPU to the PC.
PULL

Specifications Q2ASCPU Q2ASCPU-S1 Q2ASHCPU Q2ASHCPU-S1 Max. I/O points overall 8192 8192 8192 8192 Max. I/O points on mounting rack 512 1024 512 1024 CPU self-diagnostic functions Program plausibility, watchdog (time), battery check, memory test, CPU test, line voltage monitor, fuse test Battery buffer All modules are fitted with a lithium-battery with a life expectancy of 5 years. Memory type RAM, EEPROM RAM, EEPROM RAM, EEPROM RAM, EEPROM overall 240 112 240 kByte 112 Program capacity max. for PLC program 28 k steps 60 k steps 28 k steps 60 k steps Cycle period LD: 0.20 / MOV: 0.60 LD: 0.075 / MOV: 0.225 LD: 0.075 / MOV: 0.225 s LD: 0.20 / MOV: 0.60 Timers (T) 2048 2048 2048 2048 Counters (C) 1024 1024 1024 1024 Relays / special relays (M) 8192 / 2048 8192 / 2048 8192 / 2048 8192 / 2048 Data registers / special registers (D) 12288 / 2048 12288 / 2048 12288 / 2048 12288 / 2048 File registers (R) 1018 k words x 1 (PCMCIA memory card required. Number of file registers depends on capacity of PCMCIA memory card.) Interrupt pointer (I) 48 48 48 48 Pointer (P) 4096 4096 4096 4096 Annunciator (F) 2048 2048 2048 2048 Index register (Z) 16 16 16 16 Link relay (B) / link register (W) 8192 / 8192 8192 / 8192 8192 / 8192 8192 / 8192 Comments Approx. 64 k (PCMCIA memory card required. Number of comments depends on capacity of PCMCIA memory card.) Instructions Sequential: 39, others: 722 Sequential: 39, others: 722 Sequential: 39, others: 722 Sequential: 39, others: 722 Internal power consumption (5 V DC) 300 700 700 mA 300 Max. compensation time ms Depends on power supply unit used, see page 13. at power failure Weight 0.5 0.5 0.5 kg 0.5 Dimensions (W x H x D) 54.5 x 130 x 110 54.5 x 130 x 110 54.5 x 130 x 110 mm 54.5 x 130 x 110 Order information Accessories Interdependent Number depends on memory configuration Art. no. 61039 Memory cards (refer to page 80) 61031 61044 61045

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MELSEC AnS/QnAS
CPU Modules MELSEC Slot PLC
PLC based controller
The slot PLC A80BDE-A2USH-S1 is a MELSEC CPU in the form of a PC slot-in board and is designed for the installation in a PC with the operating system MS Window NT (from version 4.0)

BASIC COMPONENTS

A Q
BASICS

Special features:
A8 DA0BD TE -A 2 99USH 08 -S AC 1

RUN ERR. RESET

A-BUS

BD808C101G51

32 bit PCI board with 33 MHz bus clock rate Extension units with modules of the AnU/AnS series can be connected Installation software included when shipped Programmabel by MELSEC MEDOC plus and GPP/Win Access to devices of the CPU with the help of the programming languages Visual C++ or Visual Basic (from version 5) Extensive software package (see accessories in the table below)

BD808C086G51

Specifications A80BDE-A2USH-S1 Max. I/O points 8192 total / 1024 on base unit (192 I/O points 00-BF used by the system) CPU self-diagnostic functions Program plausibility, Watch Dog (time), battery check, memory error detection, CPU error detection, power supply error detection, fuse test Backup battery The board is equipped with a lithium-battery with a durability of 5 years. Memory type RAM, EPROM overall kBytes 448 Program capacity max. for PLC program 30 k steps Cycle time 0.09 s/log. instruction Timer (T) 2048 Counter (C) 1024 Internal relay / special relay (M) 8192 / 256 Data register / special register (D) 8192 / 256 File register (R) Max. 8192 Interrupt pointer (I) 32 Pointer (P) 256 Annunciator (F) 2048 Accumulator (A) 2 Index register (V, Z) 14 Link relay (B) / link register (W) 8192 / 8192 Comments Max. 4032 Instructions 462 Internal current consumption A Max. 2 External voltage supply +5 V DC (+-5%) Weight kg 0.5 Dimension Standard PCI board Order information Accessories Art. no. 129404 Base driver software for CPUPC communications: SW3D5F-CSKP-E, software tool for simple data exchange between CPU and MS-EXCEL: SW3D5F-OLEX-E, user programmable visualization package: SW3D5F-XMOP-E, memory cassette art. no.: 24706, 24746, 4103

Dependent on one another Number dependent on the memory configuration

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MELSEC AnS/QnAS
DIGITAL MODULES MELSEC AnS/QnAS Digital Input Modules Input / Output Modules

A Q
BASICS

Detection of process signals

A1SX80
0 1 2 3 4 5 6 7

8 9 A B C D E F

A1SX80
0 1 2 3 4 5 6 7

8 9 A B C D E F

Various input modules are available for converting the digital process signals with different voltage levels into the levels required by the PLC.

Special features:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

0 1 2
0 1 2 3 4 5 6 7 8 9 A B C D E F

3 4 5 6 7
COM

8 9 A B C D E DC NC NC
COM

The input points can be operated alternatively as positive or negative switching. Potential isolation between process and control by means of an optocoupler is a standard feature Indication of input status via LEDs Modules with 16 connection points have removable terminal blocks with screws. Modules with 32 connection points have a 37-pin D-sub plug (supplied with the module) Assembled cables are available for modules with D-sub plugs (A32CBL: 3 m).

DC12V 3mA DC24V 7mA A1SX80

Specifications Input points Isolation method Rated input voltage Operating voltage range Max. simultaneously ON Inrush current Rated input current voltage ON current voltage OFF current Load resistance OFF ON Response time ON OFF Common terminal arrangement Power indicator Connection terminal No. of occupied I/O points Applicable wire size Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information Accessories Spare parts mm2 mA kg mm mA V mA V mA k ms ms

A1SX10EU A1SX20EU A1SX80 16 16 16 Photocoupler isolation between input terminals and PC power for all modules. 110 120 V AC (50 / 60 Hz) 200 240 V AC (50 / 60 Hz) 12 / 24 V DC AC 85 132 V AC 170 264 V AC 100 % 60 % (at 220 V AC) 100 % (at 26.4 V DC) 200 mA for 1 ms 500 mA for 1 ms (at 132 V AC) (at AC 264 V) 7 mA (at 120 V AC, 60 Hz) ca. 11 (at 240 V AC, 60 Hz) ca. 3 / ca. 7 AC 80 AC 80 DC 8 AC 5 AC 4 DC 2 AC 30 AC 30 DC 4 AC 1 AC 1 DC 1 ca. 21 (50 Hz) / ca. 18 (60 Hz) ca. 27 (50 Hz) / ca. 22 (60 Hz) ca. 3.3 20 (100 V AC, 60 Hz) 30 (200 V AC, 60 Hz) 10 (24 V DC) 35 (100 V AC, 60 Hz) 55 (200 V AC, 60 Hz) 10 (24 V DC) 16 16 16 All modules possess a status LED per input/output. 20-point removable 20-point removable 20-point removable terminal block terminal block terminal block 16 16 16 0.75 1.5 0.75 1.5 0.75 1.5 50 (all input points ON) 50 (all input points ON) 50 (all input points ON) 0.21 0.23 0.2 34.5 x 130 x 93.6 34.5 x 130 x 93.6 34.5 x 130 x 93.6 53665 24973

A1SX80-S1 16 24 V DC 100 % (at 26.4 V DC) ca. 7 DC 17 DC 5 DC 5 DC 1.7 ca. 3.3 0,4 (24 V DC) 0,5 (24 V DC) 16 20-point removable terminal block 16 0.75 1.5 50 (all input points ON) 0.2 34.5 x 130 x 93.6 31536

A1SX81 32 12 / 24 V DC 60 % (at 26.4 V DC) ca. 3 / ca. 7 DC 8 DC 2 DC 4 DC 1 ca. 3.3 10 (12 / 24 V DC) 10 (12 / 24 V DC) 32 Compact plug type 37 D-Sub 32 0.3 80 (all input points ON) 0.24 34.5 x 130 x 93.6 24974 Adapter cable (see page 77)

Art. no. 54914

20-point removable terminal block and cover: A1STEC-S, art. no. 31248

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MELSEC AnS/QnAS
Input / Output Modules MELSEC AnS/QnAS Digital Output Modules
Adapted output technology
A1SY80
0 1 2 3 4 5 6 7 ERR 8 9 A B C D E F

DIGITAL MODULES

A1SY80
0 1 2 3 4 5 6 7

ERR 8 9 A B C D E F

The MELSEC AnS output modules have different switching elements for adaptation to many control tasks.

A Q
BASICS

Special features:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

L
0 1 2 3 4 5 6 7 8 9 A B C D E F
+ _ + _

0 1 2 3 4 5 6 7
COM1

8 L 9 A B C D E F
COM2

AC100/240V 0.6A A1SY80

Output modules with relay, transistor or triac switches Potential isolation between process and control by means of an optocoupler is a standard feature Modules with potential isolation between the channels Modules with 16 protection points have removable terminal blocks with screws Modules with 32 connection points have a 37-pin D-sub plug (supplied with the module) Assembled cables are available for the modules with D-sub plugs (A32CBL: 3 m)

Specifications Outputs Output type Common terminal arrangement Isolation method Rated output voltage Operating voltage range Min. switching load Max. switching voltage Max. output current Output current per group TYP. Inrush current Leakage current at OFF OFF ON ON OFF mechanical Life electrical Max. switching frequency Noise suppression Fuse Power indicator Fuse blown indicator Connection terminal No. of occupied I/O points Applicable wire size voltage Ext. power supply req. current Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Response time Order information Accessories Does not comply to CE standard

points

A A

mA ms ms

mm2 mA mA kg mm

A1SY10EU A1SY14EU A1SY18AEU A1SY22 A1SY28EU 16 12 8 16 8 Relay Relay Relay Triac Triac 8 4 1 8 4 Photocoupler isolation between output terminals and PC power for all modules. 24 V DC / 120 V AC 24 V DC / 240 V AC 24 V DC / 240 V AC 100 240 V AC 100 240 V AC 24VAC(100 mA) 24VAC(15mA) 5 V DC (1 mA) 5 V DC (1 mA) 5 V DC (1 mA) 100VAC(10mA) 100VAC(15mA) 240VAC(20mA) 240VAC(15mA) 125VDC/132VAC 125VDC/264VAC 125VDC/264VAC 264 V AC 264 V AC 2 2 2 0.6 0.6 8 8 2 2.4 1.9 20 A for 10 ms, 30 A for 10 ms, 8 A for 100 ms 15 A for 100 ms 1.5 mA (120 V AC), 1.5 mA 3 mA (240 V AC) (240VAC/60Hz) 10 10 10 1 1 12 12 12 0.5 period +1 ms 0.5 period +1 ms Switching 20 million times Switching 100000 times or more Switching 3600 times/h CR (0.01F,47) CR (0.01F,47) 5 All modules possess a status LED per output. LED 20-point removable terminal block 16 16 16 16 16 0.75 1.5 0.75 1.5 0.75 1.5 0.751.5 0.751.5 90 100 75 2 24 V DC, 10 % 24 V DC, 10 % 24 V DC, 10 % 100 240 V AC 240 V AC 120 120 240 270 270 0.25 0.25 0.25 0.24 0.24 34.5 x 130 x 93.6 34.5 x 130 x 93.6 34.5 x 130 x 93.6 34.5 x 130 x 93.6 34.5 x 130 x 93.6 54349 53667 24976 54348

A1SY68A 8 Transistor 1

A1SY80 16 Transistor 8

A1SY81 32 Transistor 32 12 / 24 V DC 10.2 30 V DC 0.1 2 0.4 A for 10 ms 0.1 2 2 Zener diode 3,2 LED D-Sub plug 32 0.3 8 12/24 V DC 500 0.23 34.5 x 130 x 93.6 24978 Adapter cable

5/12/24/48VDC 12 / 24 V DC 4.5 52.8 V DC 10.2 30 V DC 2 2 8 A for 10 ms 0.1 3 10 Zener diode 16 0.75 1.5 110 0.2 34.5 x 130 x 93.6 33199 0.8 3.2 8 A for 10 ms 0.1 2 2 Zener diode 5 LED 16 0.75 1.5 20 12/24 V DC 120 0.2 34.5 x 130 x 93.6 24977

Art. no. 53666

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MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES MELSEC AnS/QnAS Analog Input Modules Analog Modules

A Q
BASICS

Detection of analog process signals

A1S68AD
RUN

A1S68AD
RUN

The analog input modules convert analog process signals, for example pressure, flow or fill level, linearly into digital values, which are further processed by the AnS/QnAS CPU.

+ + C H _ C 1 H_ 2 AG
AG
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Special features:
Up to 8 channels per module (A1S68AD) and up to 256 channels per system (A2SCPU-S1/ A2ASCPU-S1/-S30/-S60) Resolution of 0.83 mV and 3.33 A (A1S64AD) Conversion time of 0.5 msec./channel (A1S68AD) Calculation of average value over the time or measurement cycles can be configured Potential isolation between process and control by means of an optocoupler is a standard feature. The module is provided with a removable terminal block fastened with screws.

0 1 2 3 4 5 6 7
8

+
C H_ 4

+ C H

3 _

+ + C H _ C 5 H_ 6 AG
AG

9 A B C D E F

+
C 7 _ H_ 8
A/D 0~HV 0~20mA

+ C H

A1S68AD

Specifications Input points Analog input Resolution Load resistance Max. input voltage current voltage current M V mA

I/O characteristics

A1S64AD 4 -10 V / +10 V (-20 mA / +20 mA) 16 bits binary (incl. sign) 1 250 15 30 Analog input Voltage Current +10 V +5 V +20 mA 0V 0 mA -5 V - 20 mA -10 V

Digital output 1/4000 4000 2000 0 -2000 -4000 1/4 000 2.5 mV 10 A

1/8000 8000 4000 0 -4000 -8000 1/8000 1.25 mV 5 A

1/12000 12000 6000 0 -6000 -12000 1/12000 0.83 mV 3.33 A

A1S68AD 8 -10 V / +10 V (0 mA / +20 mA) 16 bits binary (incl. sign) 1 250 35 30 Analog input Voltage Current 0 +10 V -10 +10 V 0 +5 V 1 +5 V 0 20 mA 4 20 mA

Digital output 0 +4000 -2000 +2000 0 +4000 0 +4000

resolution Max. resolution voltage input current input Overall accuracy

1.0 % (for the whole measurement range)

0 +10 V 2.5 mV -10 +10 V 5 mV 0 +5 V 1.25 mV 1 +5 V 1 mV 0 20 mA 5 A 4 20 mA 4 A 1.0 % (for the whole measurement range) 0.5 32

ms/ 20 Max. conversion time channel Isolation method Photocoupler isolation between output terminals and PC power for all modules. I/O points 32 Connection terminal All modules are fitted with a terminal block with 20 screw terminals. External power consumption Not neccessary for both modules Applicable wire size mm2 0.75 1.5 Internal power consumption (5 V DC) mA 400 Weight kg 0.25 Dimensions (W x H x D) mm 34.5 x 130 x 93.6 Order information Art. no. 25707

0.75 1.5 400 0.27 34.5 x 130 x 93.6 46478

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MELSEC AnS/QnAS
Analog Modules MELSEC AnS/QnAS Analog Output Modules
Output of analog control signals
A1S68DAV
RUN

SPECIAL FUNCTION MODULES

A1S68DAV
RUN

The analog output modules convert digital values predetermined by the CPU into an analog current or voltage signal. For example, frequency inverters, valves or slide valves are controlled by means of these signals.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

A Q
BASICS

HLD/CLD
0 1 2 3 4 5 6 7 8 9 A B C D E F
D/A 0~HV

C H 1 C H 2 C H 3 C H 4 C H 5 C H 6 C H 7 C H 8

V+ VV+ VV+ VV+ VV+ VV+ VV+ VV+ VFG

Special features:
Up to 8 channels per module (A1S68DAV/DAI) and up to 256 channels per system (A2SCPU-S1/ A2ASCPU-S1/-S30/-S60) Resolution of 0.83 mV and 1.7 A (A1S62DA) Conversion time of 4 msec. / 8 channels (A1S68DAV/DAI) Potential isolation between process and control by means of an optocoupler is a standard feature. The module is provided with a removable terminal block fastened with screws.

A1S68DAV

Specifications Output points Digital input Analog output Load resistance Voltage output voltage current

A1S62DA 2 -4000 +4000 -8000 +8000 -12000 +12000 -10 V DC +10 V DC (0 mA +20 mA DC) 2 k 1 M 0 600 1/4000 1/8000 8000 4000 0 -4000 -8000 1.25 mV 1/8000 1/12000 12000 6000 0 -6000 -12000 0.83 mV 1/12000 Voltage output +10 V +5 V 0V -5 V -10 V (10 V) Current output 20 mA 12 mA 4 mA (20 mA)

A1S68DAV 8 -2048 +2047 -10 V DC +10 V DC 2 k 1 M Voltage output +10 V +5 V 0V -5 V -10 V

A1S68DAI 8 0 +4096 4 mA +20 mA DC 0 600

I/O characteristics Max. resolution Current output

digital input

4000 2000 0 -2000 -4000 2.5 mV 1/4000

2000 1000 0 -1000 -2000 5 mV

Currrent output 20 mA 12 mA 4 mA

I/O digital characteinput ristics Max. resolution Overall accuracy Max. conversion time Isolation method I/O points Connection terminal Applicable wire size Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information

4000 8000 12000 2000 4000 6000 0 0 0 5 A 2.5 A 1.7 A 1.0 % (for the whole measurement range) 25 ms / 2 channels (or 1 channel) 32

1.0 % (for the whole measurement range) 4 ms / 8 channels 32 0.75 1.5 650 0.28 34.5 x 130 x 93.6 46475

4000 2000 0 4 A 1.0 % (for the whole measurement range) 4 ms / 8 channels 32 0.75 1.5 850 0.28 34.5 x 130 x 93.6 46477

Photocoupler isolation between output terminals and PC power for all modules. All modules are fitted with a terminal block with 20 screw terminals. mm2 0.75 1.5 mA 800 kg 0.32 mm 34.5 x 130 x 93.6 Art. no. 25709

MITSUBISHI ELECTRIC

21

MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES MELSEC AnS/QnAS Analog Input/Output Modules Analog Modules

A Q
BASICS

Analog modules with inputs and outputs

A1S63ADA
RUN
CH
9
87
6

OFFSET

A1S63ADA
RUN
CH
9
87
6

OFFSET

SET GAIN UP DOWN

SET GAIN UP DOWN

These modules have both analog inputs and one or two analog outputs. Individual channels operate autonomously but can also be coupled to one another.

Special features:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

TEST

0 1 2 3 4 5 6 7 8 9 A B C D E F

H L D /C L R

C H 1 I N C H 2 I N C H 3 O U T

V+ I+ COM SLD V+ I+ COM SLD V+ VI+ IAG FG

A/D 0~HV 0~PmA D/A 0~HV 4~20mA

A1S63ADA

Specifications A/D conversion Analog input Resolution

A1S63ADA -10 V DC +10 V DC (-20 mA +20 mA DC) -4096+4095(1/4000),-8192+8191(1/8000), -12288+12287(1/12000) Analog input Digital output -10 +10 V voltage input current input -20 20 mA -4000 4000 -8000 8000 -12000 12000 -2000 2000 -4000 4000 -6000 6000

I/O characteristics Max. resolution

Overall accuracy Max. conversion time Absolute max. input Analog input points D/A conversion Digital input Analog output I/O characteristics Max. resolution voltage input current input

0.83 mV (at resolution 1/12000) 3.3 A (at resolution 1/12000) 1.0 % 1 ms/channel (at 1/4000); 2 ms/channel (at 1/8000); 3 ms/channel (at 1/12000) Voltage: 15 V, current: 30 mA 2

-4000 +4000 (1/4000), -8000 +8000 (1/8000), -12000 +12000 (1/12000) 04000 (12bitbinary) 0 +4000 (1/4000), 0 +8000 (1/8000), 0 +12000 (1/12000)) -10 V +10 V (0 +20 mA DC) -10 0 10 V DC (0 20 mA DC) Digital input Analog output Digital input -4000 4000 -8000 8000 -12000 12000 -2000 2000 -4000 4000 -6000 6000 -10 +10 V 4 20 mA

Overall accuracy Max. conversion time Absolute max. output Analog output points Isolation method I/O points Connection terminal Applicable wire size Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information

0.83 mV (at resolution 1/12.000) 1.7 A (at resolution 1/12.000) 1.0 % (to the maximum value) 1 ms (1/4000), 2 ms (1/8000), 3 ms (1/12000) Voltage: 12 V, current: 28 mA 1 Photocoupler isolation between output terminals and PC power. 32 The module is fitted with a terminal block with 20 screw terminals. mm2 0.75 1.5 mA 800 kg 0.3 mm 34.5 x 130 x 93.6 Art. no. 36251

22

54

2 or 4 analog input points and 1 or 2 analog output points Resolution of 0.83 mV and 3.3 A (input)/ 1.7 A (output) Extremely short processing time due to high-speed conversion with the A1S66ADA Linkage of input/output via formulae or X/Y graph Potential isolation between process and control by means of an optocoupler is a standard feature. The modules are provided with a removable terminal block fastened with screws.

A1S66ADA -10 0 +10 V DC (0 20 mA DC) 0 4095 (12 bit binary) Analog input Digital output 0 10 V 05V 0 20 mA 0 4095 15V 4 20 mA -10 10 V 1 mV (for analog input range from 1 to 5 V) 4 A (for analog input range from 4 to 20 mA) 1.0 % 400 s (for 4 channels); scan time 80 s (for 1 channel) Voltage: 15 V, current: 30 mA 4

Analog output 0 10 V 05V 0 20 mA 0 4000 15V 4 20 mA -10 10 V 1 mV (for analog input range from 1 to 5 V) 4 A (for analog input range from 4 to 20 mA) 1.0 % (to the maximum value) 240 s (for 2 channels); scan time 80 s (for 1 channel) Voltage: 12 V, current: 28 mA 2 Photocoupler isolation between output terminals and PC power. 64 The module is fitted with a terminal block with 20 screw terminals. 0.75 1.5 210 0.33 34.5 x 130 x 93.6 70543

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Analog Modules MELSEC AnS/QnAS Analog Modules for Pt100-Elements
Temperature measurement by resistance thermometer
A1S62RD4
RUN
CH1 CH2 OFFSET SET GAIN UP DOWN

SPECIAL FUNCTION MODULES

A1S62RD4
RUN
CH1 CH2

OFFSET SET GAIN UP DOWN

These analog modules are used for direct connection of Pt100 resistance thermometers. The measurement is based on the three-conductor or four-conductor method.
1 2 3 4 5

A Q
BASICS

TEST
0 1 2 3 4 5 6 7 8 9 A B C D E F
INPUT PT 100

Special features:
Linearized measuring range from -180 C to 600 C Pt100 elements according to DIN and JIS are supported. A cable break is indicated to the CPU by the module. Calculation of average value over the time or measurement cycles can be configured. Potential isolation between process and control by means of an optocoupler is a standard feature. The module is provided with a removable terminal block fastened with screws.

C H 1

a1 A1 B1 b1 SLD a2 A2 B2 b2 SLD AG FG

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

C H 2

A1S62RD4

Specifications Method of measurement Pt100-input points Connectable temperature measuring resistants Temperature input range Detected temperature value Max. resolution Overall accuracy Max. conversion time Isolation method I/O points Connection terminal Applicable wire size Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information

A1S62RD3 3-wire type 2

A1S62RD4 4-wire type 2

type Pt100 (conforms to JIS C 1604-1989 and DIN IEC 751), JPt100 (conforms to JIS C 1604-1981) C Pt 100: -180 600 (27.08 313.59 ), JPt 100: -180 600 (25.8 317.28 ) 16 bits signed binary: -1800 +6000 16 bit signed binary: -1800 +6000 32 bits signed binary: -180000 +600000 32 bit signed binary: -180000 +600000 0.025 C 0.025 1 % (to the maximum value) 1 % (to the maximum value) 40 ms per channel ON 40 ms per channel ON No isolation between channels. Photocoupler isolation between input terminal and PC CPU power. 32 32 All modules are fitted with a terminal block with 20 screw terminals. 0.75 2 mm2 0.75 2 440 mA 540 0.28 kg 0.29 34.5 x 130 x 93.6 mm 34.5 x 130 x 93.6 Art. no. 25710 25712

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23

MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES MELSEC AnS/QnAS Analog Module for Temperature Measurement Analog Modules

A Q
BASICS

Temperature measurement by thermocouple

A1S68TD
RUN

A1S68TD
RUN

This module is used for temperature measurement by means of a thermocouple. The reference temperature is determined by means of a Pt100 resistance thermometer.

CH1+
B T D

1 2 3 4 5 6 7 8 9 10
11

Special features:
The module has 8 thermocouple inputs and a Pt100 input for the reference temperature. Linearized measuring range up to 1700 C (thermocouple-dependent) The thermocouple types B, R, S, K, E, J and T with the thermoelectric voltage curves according to DIN IEC 584-1 are supported. Potential isolation between process and control by means of an optocoupler is a standard feature. The module is provided with a removable terminal block fastened with screws.

0 1 2 3 4 5 6 7
8

+ H C 4 _ H_ 5 + + C H _ C 6 H_ 7 +
C
H

12 13 14 15 16 17 18 19 20

+ C H

9 A B C D E F

6 _

5 _

+
FG C H _ 8 FG
A/D 0~HV 0~20mA

A1S68TD

Specifications Input points Temperature input range Detected temperature value Scaling value

Thermocouple

A1S68TD 8 C 0 1 700 16 bits signed binary: 0 17000 (value to the first decimal place x 10) C 16 bits signed: 0 +2000 Temperature Conversion accuracy Type measurement range (at operating ambient temperature is Ta = 25 5C) B 800 1700 C 2.5 C R 300 1600 C 2 C S 300 1600 C 2 C K 0 1200 C E 0 800 C 0.5 C or 0.25 % of the measured temperature which ever is larger J 0 750 C

Temperature characteristic (whenoperatingambienttemperaturevariesbyT=1C) 0.4 C 0.3 C 0.3 C 0.07 C or 0.02 % of the measured temperature which ever is larger

Cold junction compensation accuracy Overall accuracy Max. resolution Max. conversion time Absolute max. input voltage Isolation method I/O points Connection terminal Applicable wire size Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information V

mm2 mA kg mm

T 0 350 C 1 C (Conversion accuracy Ta) + (temperature characteristic) x (operating ambient temperature variation) 1 C * B, R, S: 0.3 C K, E, J, T: 0.1 C 400 ms / 8 channels, without respect to the number of used channels 5 Transformer 32 The module is fitted with a terminal block with 20 screw terminals. 0.75 1.5 320 0.28 34.5 x 130 x 93.6

Art. no. 46476

* Example: Overall accuracy = (conversion accuracy at Ta = 25 C 5 C) + (temperature characteristic by T = 1 C) x (operating ambient temperature variation) + ( 1 C) Example for thermocouple type 3 when the operating ambient temperature is 35 C = (2.5 C) + (0.4 C) x (5 C) + (1 C) = 5.5 C Ta = operating ambient temperature T = operating ambient temperature variation

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MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Temperature Control Modules MELSEC AnS/QnAS Temperature Control Modules
Temperature control modules with PID algorithm
A1SJ64TCTT
CH1 CH2 OUT ALM BR.W OUT ALM BR.W RUN OUT ALM BR.W OUT ALM BR.W CH3 CH4

SPECIAL FUNCTION MODULES

A1SJ64TCTT
CH1 CH2 OUT ALM BR.W OUT ALM BR.W

RUN OUT ALM BR.W OUT ALM BR.W CH3 CH4

These modules enable PID algorithm temperature control without placing any load on the PLC CPU for the temperature control tasks.

A Q
BASICS

Special features:
L1 L2 L3 L4 NC NC

C H 2

C H 1

C J
NC

Four temperature input channels Auto-tuning function for the 4 PID control circuits Temperature control can continue even when the PLC program is stopped Transistor output with pulse train to drive the actuator in the control circuit The module is provided with a removable terminal block fastened with screws

C H 4

C H 3

A1S64TCTT

Specifications Control output Inputs Supported thermocouples Sampling cycle Control output cycle Input filter Temperature control method PID constant setting proportional band P PID constant range integral constant I differential constant D Target value setting range Dead band setting range output signal rated load voltage Transistor output max. load current max. rush current max. voltage drop when ON response time Isolation method I/O points Connection terminals Applicable wire size Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information

A1S64TCRT-S1 type Transistor 4 channels per module Pt100 (-200 +600 C), JPt100 (-200 +500 C) 0.5 s / 4 channels s 1 100 1 100 s (0 s: input filter OFF) PID ON/OFF impulse or 2-position control Setting with automatic tuning possible 0.0 100.0 % (0 %: 2-position control) 1 3600 s 1 3600 s (0 setting for PID control) Within the temperature range of the Pt100 sensor used 0.1 10.0 % ON/OFF pulse 10.2 30 V DC 0.1 mA/1 point, 0.4 mA/common 400 mA for 10 ms 0.1 V DC (TYP) 0.1 A 2.5 V DC (MAX) 0.1 A OFF ON: < 2 ms ON OFF: < 2 ms Transformer 32 The module is fitted with a terminal block with 20 screw terminals. mm2 0.75 1.5 mA 330 kg 0.27 mm 34.5 x 130 x 93.6 Art. no. 126507

A1S64TCTT-S1 Transistor 4 channels per module R, K, J, T, S, B, E, N, U, L, P L II, W5Re/W26Re 0.5 s / 4 channels 1 100 1 100 s (0 s: input filter OFF) PID ON/OFF impulse or 2-position control Setting with automatic tuning possible 0.0 1000.0 % (0 %: 2-position control) 1 3600 s 1 3600 s (0 setting for PID control) Within the temperature range of the thermocouple used 0.1 10.0 % ON/OFF pulse 10.2 30 V DC 0.1 mA/1 point, 0.4 mA/common 400 mA for 10 ms 0.1 V DC (TYP) 0.1 A 2.5 V DC (MAX) 0.1 A OFF ON: < 2 ms ON OFF: < 2 ms Transformer 32 The module is fitted with a terminal block with 20 screw terminals. 0.75 1.5 420 0.3 34.5 x 130 x 93.6 66227

MITSUBISHI ELECTRIC

25

MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES MELSEC AnS/QnAS High-Speed Counter Modules Counter Module

A Q
BASICS

High-speed counter with automatic detection of rotation direction

A1SD61
RUN A B PRESET FUNCTION 1 2 3 4 5 6 7 8

OUT

A1SD61
RUN A B PRESET FUNCTION

1 2 3 4 5 6 7 8

OUT

These counter modules detect signals with a frequency which cannot be detected by normal input modules. For example, simple positioning tasks or frequency measurements can be realized.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

A
0 1 2 3 4 5 6 7 8 9 A B C D E F
DC12/24V 0.1A A1SD61

Special features:
Input for incremental shaft encoder with automatic forward and reverse detection Preset count via external signals or the PLC program with the aid of the PRESET function Ring counter function for counting up to a predefined value with automatic resetting to the starting value Functions such as speed measurement, definition of switching points or periodic counting are available. The module is provided with a removable terminal block fastened with screws.

B
PRESET F.START

1 L 2 3 4 5 6 7 8
+ _

COM

Specifications Counter inputs Signal levels Max. counting frequency kHz 1-phasekHz Max. counting input speed 2-phasekHz input Counting range Counter type Comparison range External digital input points Rated voltage/current for external input External digital output points (Coincidence signal) I/O points Connection terminal Applicable wire size mm2 Internal power consumption (5 V DC) mA Weight kg Dimensions (W x H x D) mm Order information

A1SD61 1 for incremental rotary transducer 5 / 12 / 24 V DC (2 5 mA) 50 50 or 10 50 or 7

A1SD62E 2 5 / 12 / 24 V DC ( 2 5 mA) 100 100 or 10 100 or 7

31 bits + sign (binary), -2147483648 +2147483647 23 bits + sign (binary), 0 16777215 Both modules are equipped with UP/DOWN preset counter and ring counter function. 31 bits + sign (binary) 24 bits + sign (binary) Preset, function start Preset, function start 5 / 12 / 24 V DC (3 6 mA) 5 / 12 / 24 V DC (2 5 mA) 8 transistor outputs (open collector) 12 / 24 V DC, 4 transistor outputs (2/point) (source type) 12 / 24 V DC, 0.1 A/point, 0.8 A/common 0.1 A/point, 0.4 A/common 32 32 All modules are fitted with a detachable terminal block with 20 screw terminals. 0.75 1.5 0.75 1.5 350 100 0.27 0.25 34.5 x 130 x 93.6 34.5 x 130 x 93.6 54951

Art. no. 25713

26

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Timer Modules MELSEC AnS/QnAS Timer Module
Set timers directly without any programming
The A1ST60 provides 8 timers that can be set directly with a screwdriver to values between 0.1 and 600 seconds.

SPECIAL FUNCTION MODULES

A Q
BASICS

A 1ST60
Y0 Y1 Y2 Y3 Y4 Y5 Y6 Y7

X0 X1 X2 X3 X4 X5 X6 X7

Special features:
Eight additional hardware timers to supplement the PLC CPUs own internal timers Timer setting ranges: 0.1 to 1.0 s 1 to 10 s 10 to 60 s 60 to 600 s Timer status indicated by LEDs Integrated pause function for stopping the time of active timers

78

901

SET UP T0 T1 T2 T3 T4 T5 T6 T7
105 1E 105 1E 105 1E 105 1E 105 1E 105 1E 105 1E 105 1E

A1ST60

Specifications Input points Timer setting range Overall accuracy Setting possibilities I/O points Applicable wire size Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information

A1ST60 8 potentiometers for timer setting 0.1 1.0 s, 1 10 s, 10 60 s, 60 600 s 2.0 % Separate setting with potentiometers and DIP switches 16 mm2 0.75 1.5 mA 55 kg 0.13 mm 34.5 x 130 x 93.6 Art. no. 33196

MITSUBISHI ELECTRIC

23

TIM. SET

456

ON OFF

27

MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES MELSEC AnS/QnAS Axes Positioning Modules Positioning Modules

A Q
BASICS

Positioning with an open control loop

A1SD75P1
RUN RDY BSY

The modules generate the travel command via a pulse chain. The speed is proportional to the pulse frequency and the distance travelled is proportional to the pulse length.

AX1 MODE

Special features:
RS-422

A1SD75P1

Control of up to three axes with linear interpolation (A1SD71-S2, A1SD75P2/P3) or circular interpolation (A1SD75P2/P3) Storage of up to 400 positional data in the A1SD71-S2 (battery-supported) or 600 positional data in the A1SD75P1/P2/P3 (flash ROM) Units of travel can be defined in pulses, mm, inch or degrees. In the A1SD71-S2, configuration and presetting of positional data is performed via the PLC program or with the aid of the teaching unit AD71TU. In the A1SD75P1/P2/P3, configuration and presetting of positional data is carried out by means of the PLC program (all 400 positional data) or with the aid of the MS-DOS software SW1IVD-AD75PE
A1SD75P3-S3 3 Linear and circular interpolation Peripheral: 600, PC: 100 Pulse generator phase 1 400 000

Specifications Control axes Interpolation Points per axis Output signal Output frequency method

A1SD71-S2 A1SD75P1-S3 A1SD75P2-S3 2 1 2 Linear interpolation Linear and circular interpolation 400 Peripheral: 600, PC: 100 Peripheral: 600, PC: 100 Pulse generator phase Pulse generator phase Pulse generator phase 1 400000 1 400000 kHz 10 200000 Pulse control: absolute data and/or incremental; speed/position swiching control: incremental; locus control: absolute data and/or incremental Absolute data method: -2147483648 2147483647 pulse -214748364.8 214748364.7 m -21474.83648 21474.83647 inch 0 359.99999 degree -2147483,648 -214 748 364.8 -21474.83648 -21474.83648 2147483 647 pulse 214 748 364.7 m 21474.83647 degree 21474.83647 nch pulse m degree inch

1 16252928 pulse, max. 162 m (command unit: 0.1 10 mm/pulse), positioning units max. 16200 degree or max. 16200 inch (command unit: 1 x 105 0.001 degree/pulse 1 x 105 0.001 inch/pulse)

Incremental method: Speed/position switching control:

Positioning

positioning speed

acceleration/deceleration processing acceleration and 64 50000 ms deceleration time rapid stop decceleration time I/O points 48 (2 slots) Internal power consumption (5 V DC) mA 800 External power consumption mA 50 (4.75 26.4 V DC) Weight kg 0.38 Dimensions (W x H x D) mm 69.5 x 130 x 93.6 Order information Accessories Art.no. 33200

10 200000 pulse/s, 10 120000 mm/min, 1 12000 degree/min 1 12000 inch/min Automatic trapezoidal acceleration and deceleration

1 0.01 0.001 0.001

1000000 6000000.00 600000.000 600000.000

0 2147483647 0 214748364.7 0 21474.83647 0 21474.83647 pulse/min mm/min degree/min inch/min

Automatic trapezoidal or S-pattern acceleration and deceleration 1 65535 [8388608]* ms (4 patterns each can be set) 1 65535 [8388608]* ms 32 700 0.35 34.5 x 130 x 93.6 65028

32 700 0.35 34.5 x 130 x 93.6 65029

32 700 0.35 34.5 x 130 x 93.6 65030

Software for all A1SD75: SW1 VD-AD75PE, art. no.: 65619; adapter cable: A1SD75-C01H, art. no.: 54943; spare part plug for axis control, 36 pins, art. no.: 62890

* Values in brackets indicate stepping motor mode

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MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Positioning Modules MELSEC AnS/QnAS Single Axis Positioning Module
Positioning with position control loop
The module is used for positioning by means of servo drives. Here, the output delivers an analog voltage. To monitor the position, the displacement transducer is fed back to the module.

SPECIAL FUNCTION MODULES

A Q
BASICS

A1SD70
IN-POS. POLE 0 1 N 2 2 3 4 5

6 7 8 9 2N 10 11 12 13

PC RDY SV RDY ZERO BUSY ERR.1 ERR.2 EEX V-MODE

DOG STOP FLS RLS A

B

Z WDT ERR.

OUT

Special features:
The positional data is preset by means of the PLC program. Integrated digital/analog converter for converting the digital adjustment into an analog signal Online speed and address change possible Online monitoring of setpoint value (command pulses), actual value (feedback pulses) and adjustment (difference between command and feedback) An electronic gear function permits adjustment of the distance travelled per pulse

GND
CONT.

GAIN ZERO

+15V 0V -15V FG SERVO

A1SD70

Specifications Axes Signal input level Max. counting frequency Counting resolution Acceleration/deceleration time Positioning speed External digital inputs Input rating External digital outputs Output rating In position control range Acceleration and deceleration Analog output for speed control I/O points Internal power consumption (5 V DC) External power consumption Weight Dimensions (W x H x D) Order information

kHz ms

mA kg mm

A1SD70 1 (with position control) 5 V DC (TTL, RS422), 12 V DC (open collector) 100 31 bits + sign (binary), -2 147 483 648 +2 147 483 647 2 9999 1 400000 pulses/s Zero, stop, upper/lower range limit, servo ready, control mode 5 24 V DC (6 mA) Servo error / module error 5 24 V DC Adjustable between 1 2047 pulses (hard / smooth) Automatic, trapeziodal acceleration and deceleration 10 V DC (adjustable between 5 V and 10 V) 48 (2 slots) 300 200 mA (+15 V DC), 20 mA (-15 V DC) 0.4 69.5 x 130 x 93.6

Art.no. 29539

MITSUBISHI ELECTRIC

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MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES MELSEC AnS/QnAS Interface Modules Interface Modules

A Q
BASICS

Data exchange with peripheral devices

A1SJ71C24-PRF
RUN SD RD CPU PRT NEU ACK NAK C/N P/S PRO SIO

This module enables communication with peripheral devices via a standard RS-232C interface. The peripherals are connected point-to-point on a 1:1 basis.

Special features:
Enables PCs connected to the system to access the full data set of the MELSEC AnS CPU using graphic process supervision or monitoring software Support for plain ASCII data exchange with connected devices such as barcode readers, scales and identification systems Options for connection of a printer Integrated 32KB EEPROM memory for logging quality, productivity or alarm data that can be printed out when required Module and communications status shown by LEDs The A1SJ71UC24-R4 has the same features as the A1SJ71UC24-R2. The only difference is that a PC can access up to 32 controllers via RS422/485 version.
A1SJ71UC24-R4 RS422 / 485 Full duplex / half duplex Asynchronous communications 300 19200 (computer link) 19200 38400 (multidrop) 500 32 1 start bit, 7 or 8 data bits, 1 or 0 parity bits, 1 or 2 stop bits Parity check, checksum YES / NO selectable YES / NO selectable 32 100 0.55 34.5 x 130 x 93.6 64562 A1SJ71C24-PRF RS232C Full duplex / half duplex Asynchronous communications 300 19200 15 1 start bit, 7 or 8 data bits, 1 or 0 parity bits, 1 or 2 stop bits Parity check, checksum YES / NO selectable YES / NO selectable 32 kbyte (400 x 80 characters) 32 100 0.22 34.5 x 130 x 93.6 29537

E
F0 1 2

SW
3466

03 04 05 06 07 08 09 10 11 12

MODE 1:FORM1 2:FORM2 3:FORM3 4:FORM4 5:NOFORM

RS-232-C

A1SJ71C24-PRF

Specifications Interface Communications mode Synchronisation Data transfer rate

A1SJ71UC24-R2 type RS232C Full duplex / half duplex Asynchronous communications bit/s 300 19200

distance m 15 Max. no of stations in a multidrop network 1 start bit, 7 or 8 data bits, 1 or 0 parity bits, Data format 1 or 2 stop bits Error correction Parity check, checksum DTR/DSR control YES / NO selectable X ON / X OFF (DC1 / DC3) YES / NO selectable EEPROM memory I/O points 32 Internal power consumption (5 V DC) mA 100 Weight kg 0.49 Dimensions (W x H x D) mm 34.5 x 130 x 93.6 Order information Art. no. 64561

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MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Interface Modules MELSEC AnS/QnAS MODBUS Slave Interface Modules
Modbus protocol via RS232 / RS422 / RS485
The A1SJ71UC24-R4-S2 and A1SJ71UC24-R2-S2 enable third-party devices to access MELSEC AnS and QnAS controllers using the MODBUS protocol.

SPECIAL FUNCTION MODULES

A Q
BASICS

A1SJ71UC24-S2

Special features:
Support for both ASCII and RTU procedures Slave functionality up to 31 MELSEC controllers can be allocated to a third-party device. Support for functions 1, 3, 58, 11, 12, 1517, 20 and 21 Enables access to the entire data of AnAS respec. QnAS CPUs.

A1SJ71UC24-R4-S2

Specifications Module type Interface Communications mode Synchronisation rate Data distance transfer mode Data format Error correction Isolation method I/O points Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information Accessories

type

bit/s m bit

mA kg mm

A1SJ71UC24-R2-S2 Slave RS232 Half duplex Asynchronous communications 300 19200 15 ASCII and RTU 1 start bit, 7 or 8 data bits, 1 or 0 parity bits, 1 or 2 stop bits Parity check (ASCII mode: LRC, RTU mode: CRC-16) Photocoupler 32 100 0.49 34.5 x 130 x 93.6

A1SJ71UC24-R4-S2 Slave RS422 / 485 Half duplex Asynchronous communications 300 19200 500 ASCII and RTU 1 start bit, 7 or 8 data bits, 1 or 0 parity bits, 1 or 2 stop bits Parity check (ASCII mode: LRC, RTU mode: CRC-16) Photocoupler 32 100 0.55 34.5 x 130 x 93.6 54354

Art. no. 54355 Interface converter CR01-R2/R4 SET, art. no. 56172 (refer to page 79)

MITSUBISHI ELECTRIC

31

MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES MELSEC QnAS Interface Modules Interface Modules

A Q
BASICS

High-speed data communications

The QnAS interface modules provide extremely high data throughput rates, which can be invaluable for process supervision software and similar applications. Up to 480 data words can be exchanged between the PLC CPU and the PC per END instruction.

A1SJ71QC24
RUN ERR. C.R/W NEU C/N ACK P/S NAK PRO SIO SD.W. SD RD
CH1
ERROR

SW.E. NEU ACK NAK SD.W. SD RD

ERR. C/N P/S PRO SIO

CH2

DISPLAY
STS

CC
X10
2 3 7 8

Special features:
Enables PCs connected to the system to access the full data set of the MELSEC QnAS CPU with process supervision or monitoring software Support for plain ASCII data exchange with connected devices such as barcode readers, scales and identification systems Compatible to A1SJ71UC24R2/R4 with protocol formats 1 4 When the special dedicated Q instructions are used (protocol format 5) PC process supervision software can access data at least 5 times faster than it is now possible using the conventional protocol formats 1 4. The integrated EEPROM can store up to 200 pre-programmed protocols for accessing third-party devices.
A1SJ71QC24 1 x RS232, 1 x RS422 / 485 Full duplex / half duplex USART 300 19200 1200 32 1 start bit, 7 or 8 data bits, 1 or 0 parity bits, 1 or 2 stop bits Parity check, checksum RS232 RS422/485 YES / NO selectable 32 240 0.294 34.5 x 130 x 93.6 66543

ERR
2 3

X1
4 5 6

4 5 6 9 0 1

7 8

CH1
3456 3456
7 89A

SW

CH1/2 1 9 2 10 3 11 4 12 5 6 7 8 ON

CH2 RS-422/485

SDA

SDB

RDA

RDB

CH1 RS-

Specifications Interface Communications mode Synchronisation rate Data transfer distance Max. stations in a multidrop network Data format Error correction DTR / DSR RS / CS Flow control CD DC X ON / X OFF (DC1 / DC3) I/O points Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information Accessories

A1SJ71QC24-R2 Typ 2 x RS232C Full duplex / half duplex USART bit/s 300 19200 m 15 bits 1 start bit, 7 or 8 data bits, 1 or 0 parity bits, 1 or 2 stop bits Parity check, checksum RS232 YES / NO selectable 32 mA 160 kg 0.249 mm 34.5 x 130 x 93.6 Art. no. 66542 Interface converter CR01-R2/R4 SET, art. no. 56172 (refer to page 79)

32

F 012

F 012

MODE

9 0 1

STATION NO.

CH2
7 89A

B CDE

B CDE

SG

FG

NC

C24

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Communications Modules MELSEC AnS/QnAS High-Speed Communications Module
Programmable interface module
A1SD51S
RUN S.ERR. PROG. MTSE P1.RUN P1.ERR P2.RUN P2.ERR
6
789 A
B C DE

SPECIAL FUNCTION MODULES

CH1 SD CH1 RD CH2 SD CH2 RD CH3 SD CH3 RD M.PRO.

This module works through its own program independently of the PLC CPU. Thus, peripherals can be operated or mathematical operations performed without imposing an additional load on the PLC CPU. Programming is in AD51H BASIC.

A Q
BASICS

RUN STOP RES.

SW 1 2 3 4 5 6 7 8 9 10 11 12

Special features:
Two RS232C interfaces and one RS422/485 interface Two BASIC programs can be operated in parallel (multitasking). The tasks can be stored in the module as interpreter programs or in compiled form. The integrated EEPROM is used for storage. Online and offline program creation is possible. The module and communication status is indicated by means of LEDs.

CH1(RS-232-C)

CH2(RS-232-C)

ON

FRONT SIDE CH3

T E R M IN A T O R R O R S P S ' E ' 4 N 4 8 2 5 2

A1SD51S

Specifications Interfaces type Microprocessor type Number of parallel tasks Start conditions for tasks rate bit/s Data transfer distance m Program language program kbyte memory common memory kbyte for tasks Internal memory data buffer to PLC kbyte extension relays extension data registers Memory backup capability Memory for programs I/O points Internal power consumption (5 V DC) mA Weight kg Dimensions (W x H x D) mm Order information Accessories

A1SD51S 1 x RS422/485, 2 x RS232 80C186 (15 MHz) Max. 2 Started by power on, started by the start command from another task, start by an interruption from the PC CPU. 300 19200 500 (RS422/485), 15 (RS232C) AD51H-BASIC 64 x 1 task or 32 x 2 tasks 8 6 1024 1024 (2 kbyte) Provided for common memory, extension relay and extension register. EEPROM memory: 64 kbyte 32 (1 slot) 400 0.3 34.5 x 130 x 93.6

Art. no. 46276 Programming software for PC/AT (MS-DOS): SW1IX-AD51HPE, art. no.: 33102

MITSUBISHI ELECTRIC

33

MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES MELSEC AnS/QnAS High-Speed Communications Module Communications Modules

A Q
BASICS

Communications module with 3964R procedure

A1SD51S-BAL

The A1SD51S-BAL has 3 standard interfaces for communications with intelligent peripheral devices that support the 3964R (RK512 active) communications protocol. This makes it possible to connect products from other manufacturers without any additional programming.

Special features:
All three interfaces can be used simultaneously. You can store up to 30 commissions by setting the appropriate parameters. Up to 10 commissions can be executed simultaneously. Optoelectronic couplers for isolation of process and control systems are fitted as standard equipment The module can request data from e.g. a S5-CP525 or CP524 via the 3964(R)RK512 procedure. However, it can not respond to the requests of other devices.

A1SD51S-BAL

Specifications Interface Transmission system Synchronisation rate Data transfer distance Data format Error correction method Supported 3964R (RK512) functions Supported data blocks Supported A series devices Processing time for FETCH or SEND of 32 data words X ON / X OFF (DC1 / DC3) I/O points Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information Accessories

A1SD51S-BAL type 2 x RS232, 1 x RS422 Half duplex / full duplex Asynchronous communications bit/s 300 9600 15 m at RS232, 500 m at RS422 1 start bit, 7 or 8 data bits, 1 or 0 parity bit, 1 or 2 stop bit Parity check, checksum FETCH and SEND data block (active). The module can not respond to requests from other stations. DB0 and DB255 D, W, R ms Approx. 300 YES / NO selectable 32 mA 400 kg 0.3 mm 34.5 x 130 x 93.6 Art. no. 65065

34

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Communications Modules ETHERNET
Data communications
ETHERNET is now one of the most widely-used networks. It provides the link between the office world and control systems. ETHERNET is a platform for a very wide range of data communications protocols. The combination of ETHERNET and the extremely widespread TCP/IP protocol enables high-speed data communications between process supervision systems and the MELSEC AnSH, QnAS, AnU and QnA series.
PC

SPECIAL FUNCTION MODULES

A Q
BASICS

ETHERNET
AnSH

Terminator Tranceiver Repeater

Notebook

Structure
Up to 5 ETHERNET segments can be linked to one another per repeater. There are two standard cable types: Yellow cable using the 10BASE5 interface and Cheapernet cable (Thin Ethernet) using the 10BASE2 interface. Bus segments using Yellow cable can be up to 500m long. Cheapernet configurations support bus segment cable lengths of up to 185m.
AnSH/QnAS

QnAS

Data exchange
TCP/IP provides logical point-to-point links between two ETHERNET stations. Using the TCP/IP protocol a process supervision system can request 256 data words per query, or a full 480 words if a QnAS compatible ETHERNET card is used. The speed of the response to the query varies depending on the type of CPU used (AnAS or QnAS) and the ETHERNET module. The response time of a pure QnAS system (QnAS + A1SJ71QE71-B2/B5) is around eight times faster than that of an equivalent AnAS system.
QnAS AnSH QnAS AnU/QnA

Administration MELSEC MEDOC plus function blocks are available for all the PLC CPUs, making the configuration of one or more TCP/IP links a quick and easy process. Cable and logic diagnostics are also simple because all MELSEC ETHERNET cards support the PING instruction.

FTP server functionality

The QnAS compatible ETHERNET modules also provide FTP server functionality, in addition to the normal TCP/IP communications services. This means that a personal computer running standard communications software can read from and write to the QnAS CPU sequence program via the Internet.
Specifications Cable type Max. distance between 2 stations Min. distance between 2 stations Max. segment length Max. permitted no. of repeaters Max. stations per segment Yellow Cable 10BASE5 2500 m 2.5 m 500 m 4 100 Thin Ethernet, Cheapernet 10BASE2 925 m 0.5 m 185 m 4 30

MITSUBISHI ELECTRIC

35

MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES MELSEC AnS ETHERNET Module Communications Modules

A Q
BASICS

The high-speed connection to the PLC

A1SJ71E71-B2
RUN RDY BSY B1 B2 B3 B4 B5 B6 B7 B8 ON OFF SW1 SW2 SW3 SW4
7

RAM CHK RAM ERR. ROM CHK ROM ERR. S.C. S.C.ERR. COM.ERR. FROM/TO

This module connects the MELSEC AnS system to the open, non-proprietary ETHERNET. This enables process supersion packages and other programs from a wide variety of vendors to access all devices of the controller at a rate of 10 Mbits per second.

10BASE2
A1SJ71E71-B2

Specifications Module type Communications method Interface transfer rate transfer type max. network length Communica- max. segment tions data length nodes min. distance between 2 nodes fixed buffer Data buffer RAM buffer Simultaneous connections Transport protocol I/O points Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information Accessories

A1SJ71E71-B2-S3 Client / server ETHERNET: CSMA/CD type 10BASE2 Mbit/s 10 Base band m 925 m 185 Max. 30/segment m 0.5 2 kbyte x 8 6 kbyte x 2 Max. 8 TCP/IP with ARP, UDP/IP 32 mA 520 kg 0.27 mm 34.5 x 130 x 93.6 Art. no. 62663

36

23

456

Special features:
Both cable types are supported: 10BASE2 (Cheapernet using RG58 coax cable) 10BASE5 (ETHERNET using Yellow cable) Communications protocol TCP/IP with ARP Module and communication status indicated by LEDs Full support for the MELSEC MEDOC plus programming software package (read and write programs, monitoring, remote PLC operating mode change (RUN/STOP)) Ready-to-use MELSEC MEDOC plus function block available Integrated bus cable diagnostics PING diagnostics function support Automatically detects whether the communication partner is ready to communicate.

1 2 3 4

MODE

0 :O N L IN E 1 :O F F L IN E 2 :T E S T 1 3 :T E S T 2 4 :T E S T 3

901

A1SJ71E71-B5-S3 Client / server ETHERNET: CSMA/CD 10BASE5 10 Base band 2500 500 Max. 100/segment 2.5 2 kbyte x 8 6 kbyte x 2 Max. 8 TCP/IP with ARP, UDP/IP 32 350 0.27 34.5 x 130 x 93.6 62662

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Communications Modules MELSEC QnAS ETHERNET Module
The high-speed connection for the QnAS series
A1SJ71QE71-B5
RUN RDY BSY B1 B2 B3 B4 B5 B6 B7 B8 CPU R/W TRAN. S TRAN. R FTP SW ERR. COM.ERR. TEST TEST ERR.

SPECIAL FUNCTION MODULES

This module connects the MELSEC QnAS system to the open, non-proprietary ETHERNET. This enables process supervision packages and other programs from a wide variety of vendors to access all devices of the QnAS controller at a rate of 10 Mbits per second. Special features: Both cable types are supported: 10BASE2 (Cheapernet using RG58 coax cable) 10BASE5 (ETHERNET using Yellow cable ) Communications protocol TCP/IP with ARP PING diagnostics function support FTP server function enabling program uploads and downloads via the Internet with standard communications software Rapid response times because the system can exchange 480 data words per protocol Integrated easy bus cable diagnostics A function block library for MELSEC MEDOC plus makes the configuration of TCP/IP links quick and easy.
A1SJ71QE71-B5 Client / server ETHERNET: CSMA/CD 10BASE5 10 Base band 2500 500 100 2.5 1 k words x 8 6 k words 8 + 1 FTP connection TCP/IP with ARP, UDP/IP 32 600 0.27 34.5 x 130 x 93.6 66546

A Q
BASICS

OFF ON
2 3

SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8

7 8

901

456

MODE 0:ONLINE 1:ONLINE 2:TEST1 3:TEST2 4:TEST3 5:TEST4

10BASE

INPUT 12VDC

(FG)
A1SJ71QE71-B5

Specifications Module type Communications method Interface type transfer rate Mbit/s transfer type max. network length m Communica- max. segment m tions data length nodes min. distance m between 2 nodes fixed send/receive buffer Data buffer variable buffer Simultaneous connections Transport protocol I/O points Internal power consumption (5 V DC) mA Weight kg Dimensions (W x H x D) mm Order information Accessories

A1SJ71QE71-B2 Client / server ETHERNET: CSMA/CD 10BASE2 10 Base band 925 185 30 0.5 1 k words x 8 6 k words 8 + 1 FTP connection TCP/IP with ARP, UDP/IP 32 800 0.28 34.5 x 130 x 93.6

Art. no. 66550

MITSUBISHI ELECTRIC

37

MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES MELSECNET/10 Network Communications Modules

A Q
BASICS

Data communications
MELSECNET/10 enables extremely fast cyclic data exchange between the MELSEC PLCs of the AnSH, QnS, AnA/U and QnA series. It can also be used to connect remote I/O modules to these controllers. You can connect up to 255 individual MELSECNET/10 networks to one another. An integrated routing function makes it very easy to pass data from one network to another.
Standard PC

QnAS

QnAS

AnSH

Structure
The ring structure of MELSECNET/10 enables very large network coverage of up to 30 km.

MELSECNET/10
Cable types
MELSECNET/10 gives you a wide choice of cable types and topologies: Coaxial bus (max. 500 m) Coaxial duplex loop (max. 30 km) Fibre-optics duplex loop (max. 30 km)
Standard PC

Data exchange
Efficient cyclic data exchange is ensured with an exceptionally large data volume of 8192 words and 8192 relays.

AnA/AnU

AnSH

AnSH

Administration
MELSECNET/10 enables you to program and monitor every PLC in the system from any station. The Floating Master architecture ensures reliable network operation even if the network manager fails.

Specifications Cable type rate Data transfer distance between 2 stations total coverage impedance(100kHz) Media transmission losses transmission bandwidth Connectors Connection system Order information

Electrical Coaxial bus Mbit/s 10 m m 500 (2500) 75 RG59 Art. no. Coaxial duplex loop 10 (20) 500 30000 75 RG59

Optical Glass fibre Glass fibre SI185/230 m GI50/125 m 10 (20) 1 000 30000 5.5 dB / km 10 (20) 2 000 30000 3 dB / km Glass fibre GI62.5/125 m 10 (20) 2 000 30000 3 dB / km

Special features
In parallel to the cyclic data exchange it is also possible for any station to send data to and read data from any other station, even across several networks. The system also supports multicast and broadcast functions. In MELSECNET/10 systems you only have to set parameters for the network manager, making installation very quick and simple.

20 MHz / km 300 MHz / km 300 MHz / km CA7003 69365 CA9003S 29603 CA9003S 29603

Cable type

Layout Connection plugs at both ends; 2-conductor type for interior installation; simple cable protection Connection plugs at both ends; 2-conductor type for interior installation; simple cable protection Adapter cable from Hitachi CA9103S plug ST plug

Max. length Fixed length 2 m Fixed length 5 m

Order information AS-2P-2M-A AS-2P-5M-A

Art. no. 126228 62430 52353 62457 104330 38784 58630 58632 58631

SI cable GI cable GI62,5/125 m GI cable GI50/125 m GI cable GI50/125 m GI cable GI62,5/125 m

Fixed length 30 m AS-2P-30M-A Fixed length 50 m AS-2P-50M-A Fixed length 5 m Fixed length 5 m Fixed length 4 m Fixed length 3 m Fixed length 4 m AGS-2P-05 M-625A AG-2P-5M-A AGS-CS-4M-50A AGS-CS-3M-625A AGS-CS-4M-625A

38

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Communications Modules MELSEC AnS MELSECNET/10 Modules
Reliable and flexible communications
MELSECNET/10 is the most powerful MELSEC network, supporting both high-speed cyclic communications and powerful acyclic communications functions.

SPECIAL FUNCTION MODULES

A Q
BASICS

A1SJ71BR11
RUN MNG S .M N G PW PC REM. S W .E . D .L IN K M /S .E . T .P A S . P R M E . C P U R /W

E R R O R UNDER SD RD

CRC OVER AB.IF TIME DATA

Special features:
High data transfer rate (10 Mbits/s) with coaxial bus systems and optional 10/20 Mbits/s with optical loop systems The A1SJ71 BR11 and A1SJ71LP21(GE) modules can be used for: PLC PLC, PC data communications PLC remote I/O control Floating Master technology guarantees trouble-free operation no matter which station in the system is powered down. Up to four MELSECNET/10 modules can be installed in a single PLC, handling routing functions across up to as many as 255 networks. The network system supports data communications between any two stations no matter how many networks lie between them. Large data volumes via link devices for cyclic data communications.
A1SJ71LP21 Floating Master Token ring Redundant optical loop system Frame synchronisation method Redundant loop 8192 (0 1FFF) 2000 bytes NRZI Conform to HDLC Max. 255 64 (1 manager, 63 local stations) Max. 9 10 (20) SI 200/220: 500 m, QSI 185/230: 1000 m CA7003 20 32 650 0.33 34.5 x 130 x 93.6 47868 A1SJ71LP21GE Floating Master Token ring Redundant optical loop system Frame synchronisation method Redundant loop 8192 (0 1FFF) 2000 bytes NRZI Conforms to HDLC Max. 255 64 (1 manager, 63 local stations) Max. 9 10 (20) GI 62.5/125: 2000 m CA7003S 20 32 650 0.33 34.5 x 130 x 93.6 53457

D BC E

MODE 0:ONLINE(A.R) 2:OFFLINE

A1SJ71BR11

Specifications A1SJ71BR11 Module type Manager / local stations Communications method Token bus Topology Coaxial bus system Synchronisation Frame synchronisation method Transmission channel Single bus Link registers 8192 (0 1FFF) Max. cyclic data for link in one station 2000 bytes Modulation method Manchester Transmission format Conforms to HDLC Terminating resistor 75 No. of networks in one system Max. 255 Stations per network 32 (1 manager, 31 local stations) Groups (multicast) Max. 9 rate Mbit/s 10 distance 300 m / 500 m (depends on cable used) Transmission cable RG59 BU / RG6 AU connectors BNC-P-3-Ni / BNC-P-5 Max. compensation time ms 20 during power failure I/O points 32 Internal power consumption (5 V DC) mA 800 Weight kg 0.33 Dimensions (W x H x D) mm 34.5 x 130 x 93.6 Order information Art. no. 47869

Accessories

Terminating resistor: BNC-75 OHM, art. no.: 53871

MITSUBISHI ELECTRIC

3 46 6

MODE

23

X1

456

23

ST.NO. X10

456

23

GR.NO.

456

78

78

78

23

X1

456

23

X10

456

23

X100

456

NETW ORK NO. 78

DISPLAY R L

78

78

901
F0 1 2

901

SW 1 2 3 4 5 6 7 8

OFF ON PC REM: N.ST MNG PRM D.PRM ST. SIZE 8, 16, 32, 64 LB/LW SIZE 2, 4, 6, 8k

901

901 901 901

OFF ON

SW 1 2 3 4 5 6 7 8

Optical duplex plug for SI cable: CA7003, art. no. 9546 Optical duplex plug for GI cable: CA9003S, art. no. 29603 Optical SI cable: 2 m: AS-2P-2M-A, art. no. 126228, 5 m: AS-2P-5M-A, art. no. 62430, 30 m: AS-2P-30M-A, art. no. 52353, 50 m: AS-2P-50M-A, art. no. 62457; up to 1000 m on request Optical GI cable: fibre optics GI62,5/125 mm; AGS-GS-3M-625A, art. no. 58632 fibre optics GI62,5/125 mm; AGS-GS-4M-625A, art. no. 58631

39

MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES MELSEC QnAS MELSECNET/10 Modules Communications Modules

A Q
BASICS

Reliable and flexible communications

A1SJ71QLP21
RUN PW PC MNG S.MNG REM. SW.E. D.LINK M/S.E. T.PAS. PRM E. XX XX CPU R/W

CRC OVER AB.IF TIME DATA UNDER SD RD

E R R O R

MELSECNET/10 is the most powerful MELSEC network, supporting both high-speed cyclic communications and powerful acyclic communications functions. The extremely high-speed data access performance of the QnAS CPUs guarantees very short response times in communications between two controllers. Special features: High data transfer rate (10Mbits/s) with coaxial bus systems and optional 10/20Mbits/s with optical loop systems The modules can be used for: PLC PLC, PC data communications PLC remote I/O control Otherwise these modules have the same features as the modules on the previous page, plus they can also be used for the configuration of a redundant master system for remote I/Os in MELSECNET/10.

NETWORK NO. X100

456

78 23 78 23

DISPLAY R L

901 901

(F.L.)

(R.L.)

X10

456

78 23 78 23

X1

GR.NO. ST.NO. X10

78

78

ON SW OFF REM PC 1 MNG 2 N.ST XXX XXX 3 XXX D.PRM ST. SIZE 4 5 X, X, X, X 6 LB/LW SIZE 2, 4, 6, X 7 8

901 901 901 901

456 456

456

456

BCDE

MODE 0:ONLINE(A.R) 2:OFFLINE

FRONT SIDE

IN

OUT

A1SJ71QLP21

Specifications A1SJ71QBR11 Module type Floating master Communications method Token bus Topology Coaxial bus system Synchronisation Frame synchronisation method Transmission channel Single bus Link register 8192 (0 1FFF) Max. cyclic data for link in one station 2000 bytes Modulation method Manchester Transmission format Conforms to HDLC Terminating resistor 75 No. of networks in one system 255 Stations per network 32 (1 manager, 31 local stations) Groups (multicast) Max. 9 rate Mbit/s 10 distance m 300 m / 500 m (depends on cable used) Transmission cable RG59 BU / RG6 AU plug BNC-P-3-Ni / BNC-P-5 Max. compensation time ms 20 during power failure I/O points 32 Internal power consumption (5 V DC) mA 800 Weight kg 0.3 Dimensions (W x H x D) mm 34.5 x 130 x 93.6 Order information Art. no. 66540

Accessories

Terminating resistor: BNC-75 OHM, art. no.: 53871

40

3 4 66

MODE

23

X1

23

OFF ON SW 1 2 3 4 5 6 7 8

F0 1 2

A1SJ71QLR21 Floating master Token ring Coaxial bus system Frame synchronisation method Redundant loop 8192 (0 1FFF) 2000 bytes Manchester Conforms to HDLC 75 255 64 (1 manager, 63 local stations) Max. 9 10 (acc. to 20 multiplex) 300 m / 500 m (depends on cable used) RG59 BU / RG6 AU BNC-P-3-Ni / BNC-P-5 20 32 650 0.3 34.5 x 130 x 93.6 128797

A1SJ71QLP21 Floating master Token ring Optical loop system Frame synchronisation method Redundant loop 8192 (0 1FFF) 2000 bytes NRZI Conforms to HDLC 255 64 (1 manager, 63 local stations) Max. 9 10 (acc. to 20 multiplex) SI 200/220: 500 m, QSI 185/230: 1000 m CA7003 20 32 650 0.3 34.5 x 130 x 93.6 66541 Optical duplex plug for SI cable: CA7003, art. no. 69365 Optical SI cable: 2 m: AS-2P-2M-A, art. no. 126228, 5 m: AS-2P-5M-A, art. no. 62430, 30 m: AS-2P-30M-A, art. no. 52353 50 m: AS-2P-50M-A, art. no. 62457; up to 1000 m on request

Terminating resistor: BNC-75 OHM, art. no.: 53871

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Communications Modules MELSEC QnAS MELSECNET/10 Module
Complex remote Inputs/Outputs
Enables fast and cost-effective connection of extremely complex remote I/Os to a host PLC CPU in MELSECNET/10 networks. Special features: Enables configuration of very complex remote inputs and outputs with: Digital I/Os Analog I/Os Positioning modules Communications modules (ETHERNET/ Computer Link) Etc. Supports definition of a Standby Master for remote I/Os in MELSECNET/10 networks (only with AnS and QnAS series CPUs). The Master CPU can be programmed and monitored from the remote module. Installation on the main base unit in the place of the PLC CPU.

SPECIAL FUNCTION MODULES

A Q
BASICS

A1SJ72QBR15

RUN

PW

HOLD RMT.E. D.LINK SW.E. T.PASS ST.E. WAIT PRM.

CRC OVER AB.IF TIME DATA UNDER SD RD

E R R O R

AB
RESET STATION NO. 7 8 X10
456

DISPLAY R L
SW Setting OFF ON 1 QnA A 2 3 OFF 4 5

7 8 2 3

X1 MODE

456

SW 1 2 3 4 5

901 901
F 01 2

MODE 0:ONLINE(A.R.) 2:OFFLINE

Specifications Module type Communications method Topology Synchronisation Transmission channel No. of I/Os in a network No. of data per slave Modulation method Transmission format Terminating resistor No. of networks in one system Stations per network rate distance Transmission cable plug Max. compensation time during power failure I/O points Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information

A1SJ72QBR15 Slave Token bus Coaxial bus system Frame synchronisation method Single bus Max. 8192 Max. 1600 bytes Manchester Conforms to HDLC 75 255 33 (1 manager, 32 local stations) Mbit/s 10 m 300 m / 500 m (depends on cable used) RG59 BU / RG6 AU BNC-P-3-Ni / BNC-P-5 ms 20 mA 700 kg 0.43 mm 54.5 x 130 x 93.6 Art. no. 68450

Accessories

Terminating resistor: BNC-75 OHM, art. no.: 53871

MITSUBISHI ELECTRIC

3 4 56

789 A

BCDE

2 3

OFF ON

A1SJ72QLP25 Slave Token ring Optical loop system Frame synchronisation method Redundant loop Max. 8192 Max. 1600 bytes NRZI Conforms to HDLC 255 64 (1 manager, 63 local stations) 10 (20) SI 200/220: 500 m, QSI 185/230: 1000 m CA7003 20 520 0.41 54.5 x 130 x 93.6 68449 Optical duplex plug for SI cable: CA7003, art. no. 69365 Optical SI cable: 2 m: AS-2P-2M-A, art. no. 126228, 5 m: AS-2P-5M-A, art. no. 62430, 30 m: AS-2P-30M-A, art. no. 52353 50 m: AS-2P-50M-A, art. no. 62457; up to 1000 m on request

41

MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES Interface Boards for MELSECNET/10 Communications Modules

A Q
BASICS

Interface boards for MELSECNET/10

These interface boards enable you to integrate personal computers into a MELSECNET/10-Netzwerk.

Special features:
Fast data rates between the personal computer and the programmable logic controller (faster than ETHERNET) The PC can access all other CPUs, even across multiple networks (integrated routing function) Perfect for PLC programming at MELSECNET/10 Ideal for data and program archiving Up to 4 interface boards can be installed in each personal computer.

R-SD F-SD

R-SD

IN F-RD

F-SD

OUT R-RD

BD080C114G51

Specifications Module type Transmission method Transmission path Synchronisation method Modulation Link points per connection Link devices Transmission format Max. link points in one system Stations per network Max. number of local station groups type/medium rate Transmission distance between 2 stations cable connectors Error detection Boards per PC Internal current consumption (5 V DC) Weight Dimensions Order information

A70BDE-J71QLP23 Local station Duplex loop Token ring Frame synchronisation method NRZI (Non Return to Zero Inverted) 2 x W + (B+Y)/8 2000 bytes 8192 link relays / registers Conforms to HDLC Max. 239 Max. 64 9 Optical (SI 200/220, QSI 185/230) Mbit/s 10 / acc. to 20 multiplex m SI 200/220: 500 m,m QSI 185/230: 1000 Fibre optics CA7003 for SI cable, CA7003 for QSI cable CRC based and overflow Max. 4 A 1.3 kg 0.5 mm ISA bus board Art. no. 126888 Optical fibre cable, SI type

A70BDE-J71QLP23GE Local station Duplex loop Token ring Frame synchronisation method NRZI (Non Return to Zero Inverted) 2 x W + (B+Y)/8 2000 bytes 8192 link relays / registers Conforms to HDLC Max. 239 Max. 64 9 Optical (GI 62.5/125) 10 / acc. to 20 multiplex GI 62,5/125: 1000 m Fibre optics CA9103S for GI cable CRC based and overflow Max. 4 1.3 0.5 ISA bus board 126887 5 m: AS-2P-5M-A, art. no. 62430; 30 m: AS-2P-30M-A, art. no. 52353; 50 m: AS-2P-50M-A, art. no. 62457; up to 1000 m on request

A70BDE-J71QLR23 Local station Duplex loop Token ring Frame synchronisation method Manchester 2 x W + (B+Y)/8 2000 bytes 8192 link relays / registers Conforms to HDLC Max. 239 Max. 64 9 Electrical 10 / acc. to 20 multiplex 3C-2V: 300 m, 5C-2V: 500 m, 2500 with Repeater Coaxial cable BNC-P-5 / BNC-P-3-NI or equivalent CRC based and overflow Max. 4 1.3 0.5 ISA bus board 128856

A70BDE-J71QBR13 Local station Single bus Token bus Frame synchronisation method Manchester 2 x W + (B+Y)/8 2000 bytes 8192 link relays / registers Conforms to HDLC Max. 239 Max. 32 9 Electrical 100 3C-2V: 300 m, 5C-2V: 500 m, 2500 with Repeater Coaxial cable BNC-P-5 / BNC-P-3-NI or equivalent CRC based and overflow Max. 4 1.3 0.5 ISA bus board 126889

Accessories

Terminating resistor: BNC-75 OHM, art. no.: 53871

42

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Communications Modules The MELSECNET(II) Network
Data communications
MELSECNET(II) enables cyclic data exchange between personal computers and MELSEC programmable logic controllers of the AnSH, QnAS, AnA/U and QnA series. The network also supports the integration of remote I/O modules. A subordinate MELSECNET(II) or MELSECNET/B network can be connected to a MELSECNET(II) configuration.

SPECIAL FUNCTION MODULES

A Q
BASICS

AnU/QnA

MELSECNET(II)
Structure
The loop architecture of MELSECNET(II) enables the configuration of large networks with a coverage of up to 10 km.
AnSH/ QnAS AnSH/QnAS Standard PC

Cable type
The network supports two different cable types: Coaxial duplex loop (max. 10 km) Fibre-optics duplex loop (max. 10 km)

Forward direction Reverse direction

Data exchange
The network supports a large cyclic data exchange volume of 1024 (4096) words and 1024 (4096) relays.
Data Cable type rate Transmission distance between 2 stations total coverage impedance (100 kHz) Media Connectors Connection system Order information RG59 Art. no. CA7003 69365 CA9003S 29603 CA9003S 29603 transmission losses transmission band width Electrical Coaxial duplex loop Mbit/s 1.25 m 500 m 10000 75 Optical Glass fibre SI200/250 m 1.25 1000 10000 5.5 dB / km 20 MHz / km Glass fibre GI50/120 m 1.25 2000 10000 3 dB / km 300 MHz / km Glass fibre GI62,5/125 m 1.25 2000 10000 3 dB / km 300 MHz / km

Administration
In parallel to the cyclic data exchange you can also program and monitor every slave PLC in the system from the master PLC. The Master/Slave procedure ensures extremely efficient network management. Cable breaks are registered automatically and continued operation is ensured by the redundant data cable.

Special features
MELSECNET(II) is very simple to install. The only parameters that need to be entered are in a table for the master station specifying the data available for the cyclic data exchange process.

Cable type

Layout Connection plugs at both ends; 2-conductor type for interior installation; simple cable protection Connection plugs at both ends; 2-conductor type for interior installation; simple cable protection Adapter cable from Hitachi CA9103S plug ST plug

Max. length Fixed length 2 m Fixed length 5 m

Order information AS-2P-2M-A AS-2P-5M-A

Art. no. 126228 62430 52353 62457 104330 38784 58630 58632 58631

SI cable GI cable GI62,5/125 m GI cable GI50/125 m GI cable GI50/125 m GI cable GI62,5/125 m

Fixed length 30 m AS-2P-30M-A Fixed length 50 m AS-2P-50M-A Fixed length 5 m Fixed length 5 m Fixed length 4 m Fixed length 3 m Fixed length 4 m AGS-2P-05 M-625A AG-2P-5M-A AGS-CS-4M-50A AGS-CS-3M-625A AGS-CS-4M-625A

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MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES MELSECNET(II) Modules Communications Modules

A Q
BASICS

Communication with redundant coaxial cable

A1SJ71AR21
RUN SD RD F.LOOP CPU CRC OVER AB.IF TIME DATA UNDER F.LOOP R.LOOP E R R O R

MELSECNET(II) permits a dual communication line. One is in the standby mode and maintains the communication in the event of an error on the active line (cable break).

Special features:
456
78

X10 X1

BC E

0:ONLINE(A.R.) 1:ONLINE(U.R.) 2:OFFLINE 3:TEST 1(F.L.) 4:TEST 2(R.L.) 5:TEST 3(B.M.) 6:TEST 4(B.S.) 7:TEST 5(S.R.)

FRONT SIDE R-SD IN F-RD F-SD OUT

A1SJ71AR21

Specifications A1SJ71AR21 Module type Master / slave Communications method Half duplex Synchronisation Frame synchronisation method Transmission channel Duplex loop Link register 4096 (0 FFF) Max. cyclic data for link in one station 2 048 Stations per network 65 (1 master/64 slaves) Modulation method CMI Transmission format Conforms to HDLC Remote I/O points 512 rate Mbit/s 1.25 Transmission distance m 500, max. total length 10000 Cable type RG59B/U Max. compensation time ms 10 during power failure I/O points 32 Internal power consumption (5 V DC) mA 630 Weight kg 0.33 Dimensions (W x H x D) mm 34.5 x 130 x 93.6 Order information Accessories Art. no. 42069 Optical fibre cable with attached connectors; SI type:

44

3466

MODE

23

456

STATION NO.

78

Ring topology with coaxial or optical cable as transmission line Very simple start-up of cyclic and acyclic communication Loopback function in the event of failure of a local station Central programming and program monitoring of all stations in the network Extensive diagnostics facilities via peripherals or internal register

901

23

901

F 0 12

R-RD

A1SJ71AP21 Master / slave Half duplex Frame synchronisation method Duplex loop 4096 (0 FFF) 2048 65 (1 master/64 slaves) CMI Conforms to HDLC 512 1.25 1000, max. total length 10000 SI200/250m 10 32 330 0.3 34.5 x 130 x 93.6 42323 2 m: AS-2P-2M-A, art. no. 126228, 5 m: AS-2P-5M-A, art. no. 62430; 30 m: AS-2P-30M-A, art. no. 52353; 50 m: AS-2P-50M-A, art. no. 62457; up to 1000 m on request

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Communications Modules Interface Boards for MELSECNET (II)
Interface boards for MELSECNET (II)
These interface boards enable you to integrate personal computers into a MELSECNET (II) network.

SPECIAL FUNCTION MODULES

A Q
BASICS

Special features:
Very high-speed data rates between personal computers and controller, faster than ETHERNET Access to all data in the entire network The PC can access all other CPUs Available for both coaxial and fibre-optics cables
IN

OUT

RN SD RD 1 2

P21

Specifications Module type Transmission method Max. link points in one system Transmission format Demodulation method Number of linkable networks Stations per network rate Transmission distance between 2 stations cable type connector Boards per PC Internal current consumption (5 V DC) Weight Dimensions (W x H x D) Order information Accessories

A7BDE-J71AP21 Master / slave Half duplex, bit serial 4.096 link relay / register Conforms to HDLC CMI Max. 65 1 Master, up to 64 slaves Mbit/s 1.25 m Max. 1000; overall max. 10000 Fibre-optics cable SI200 / SI250 m CA9003 1 A 0.9 kg 0.4 mm 362 x 143 x 30 (long AT-bus slot) Art. no. 29622 Device driver and test software: Optical fibre cable with attached connectors; SI type:

A7BDE-J71AR21 Master / slave Half duplex, bit serial 4.096 link relay / register Conforms to HDLC CMI Max. 65 1 Master, up to 64 slaves 1.25 Max. 500; overall max. 10000 Coaxial cable RG59 BU / RG6 AU BNC-P-5 / BNC-P-3-NI 1 1.3 0.4 362 x 143 x 30 (long AT-bus slot) 29621 SW1-IM-M NET, art. no. 32191 2 m: AS-2P-2M-A, art. no. 126228, 5 m: AS-2P-5M-A, art. no. 62430; 30 m: AS-2P-30M-A, art. no. 52353; 50 m: AS-2P-50M-A, art. no. 62457; up to 1000 m on request

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MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES The MELSECNET/B Network Communications Modules

A Q
BASICS

Data communications
MELSECNET/B is an extremely costeffective network, providing cyclic data communication for MELSEC AnSH, QnAS, AnU and QnA controllers. You can also integrate remote I/O modules in the network. A lower-level MELSECNET(II) or MELSECNET/10 network can be connected to a MELSECNET/B configuration.

MELSECNET/B

AnSH RS485 data line

AnU/QnA

Structure
The bus cable can be up to 1200 m long, depending on the data transfer rate. Up to 32 stations can be connected to one network.

Cable type
This network type uses shielded twistedpair cabling as the data transfer medium (2 pairs).

AnS remote I/O module

QnA

QnAS

Total coverage max. 1200 m (125 kbit/s) for max. 32 stations

Data exchange
MELSECNET/Bs cyclic data exchange provides an excellent data volume of 1024 (4096) words and 1024 (4096) relays, depending on the master PLC used: 1024 relays and words with the CPU types A1S, A1S-S1, A2S, and 4096 relays and words with all other CPU types.
Interface Cable type No. of pairs DC resistance Insulation resistance (20C) Electrostatic capacity (1kHz) Impedance (100 kHz) RS485 Shielded twisted-pair 2 39.4 / km 10 M / km 70 nF / m or less 110 10

Administration
In parallel to the cyclic data exchange you can also program and monitor every slave PLC in the system from the master PLC. The Master/Slave procedure ensures extremely efficient network management.

Cable recommendation: Lappkabel Unitronic-Li2YCYv(TP)/AWG20 2x2x0,50

Special features
MELSECNET/B is very simple to install. The only parameters that need to be entered are in a table for the master station specifying the data available for the cyclic data exchange process.

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MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Communications Modules MELSECNET/B Module
Communication with economical two-wire line
A1SJ71AT21B
E CRC OVER R A B .IF R T IM E O DATA R UND
4 9 01

SPECIAL FUNCTION MODULES

SD RD
125K 250K 500K 1M

B R A T E

MELSECNET/B makes it possible to establish an integrated system of up to 32 MELSEC PLC systems via an RS485 interface.

A Q
BASICS

F 0 12

901

SDA/RDA SDB/RDB SG(L) FG

A1SJ71AT21B

Specifications Module type Communications method Topology Synchronisation Link register / bus Max. cyclic data for link in one station Stations per network Modulation method Transmission format Remote I/O points rate Transmission distance cable Max. compensation time during power failure I/O points Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information

A1SJ71AT21B Master / slave Half duplex Bus Frame synchronisation method 4096 (0 FFF) 2048 32 NRZI Conforms to HDLC 512 kbit/s 125 / 250 / 500 / 1000 m 1200 / 600 / 400 / 200 (depends on the transmission rate) Shielded twisted-pair ms 20 32 mA 660 kg 0.22 mm 34.5 x 130 x 93.6 Art. no. 25723

MITSUBISHI ELECTRIC

B C DE

78

X1

901

78

78 23 23

X10

Special features:
Bus topology with shielded two-wire line as transmission medium Very simple start-up of cyclic and acyclic communication Automatic data exchange with MELSECNET(II) and MELSECNET/10 possible Central programming and program monitoring of all stations in the network Extensive diagnostics facilities via peripherals or internal register Remote I/Os can be connected to the network by installing the module A1SJ72T25B as a slave in the PLC CPU location of the main base unit.

3466

STATION NO.

MODE

4 6

BAUD RATE

A1SJ72T25B Slave (remote I/O link module) Half duplex Bus Frame synchronisation method 4096 (0 FFF) 2048 32 NRZI Conforms to HDLC 512 125 / 250 / 500 / 1000 1200 / 600 / 400 / 200 (depends on the transmission rate) Shielded twisted-pair 20 660 0.4 54.5 x 130 x 93.6 47871

47

MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES The CC-Link Network Communications Modules

A Q
BASICS

Data communications
The MELSEC CC-Link network provides fast data communications with different devices. The following components among others can be integrated: Remote digital inputs/outputs Remote analogue inputs/outputs High-speed counters Positioning modules Modules for temperature measurement Distributed intelligence (e.g. FX2N) Frequency inverters (e.g. FR-A 540) Operator terminals (e.g.. GOT) Third party devices like gateways, solenoid valves, barcode readers, etc.

AnSH/QnAS

AnU/QnA

QnAS

CC LINK

Structure
The maximum bus segment extension is 1,200 m (at 156 kbit/s max.). With a reduced extension, transfer rates of up to 10 Mbit/s can be achieved.

Cable types
The data communications requires standardized shielded twisted-pair cable.

Data exchange
Various data like digital and analogue data can be exchanged easily. In addition to the cyclic transmission of word data, CC-Link systems handle transient transmission (message transmission) as well. This enables data communication with intelligent devices such as display devices, bar code readers, measuring devices, and personal computers. Various special features provide a particular economic network administration: Automatic online return function after the removal of a unit from the network. Stand-by master function for redundancy across the system. Automatic link cutoff function of a faulty slave station without interrupting network communications. Link status confirmation. Extensive test and diagnostics functions.

Administration
The programming software packages MELSEC MEDOC plus and MELSEC MEDOC GPP/WIN ensure an easy setup and commissioning.

Cabel Diameter Cable resistance (20 C) Electrostatic capacity (1kHz) Impedance (1 MHz) Insulation resistance Voltage withstand Maximal distance

Shielded twisted-pair 0,5 mm2 (1 pair) 37,8 / km 60 nF / km 100 15 % 10.000 M / km 500 V DC for 1 minute 1.200 m

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MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Communications Modules CC-Link Master Module
Connection of remote inputs/outputs
A1SJ61QBT11
RUN ERR. MST S MST LOCAL CPU R/W L RUN L ERR. SW M/S PRM TIME LINE SD RD

SPECIAL FUNCTION MODULES

E R R O R

The CC-Link enables the control and monitoring of I/O modules on a remote machine. The data is transferred to the central controllers via the master module.

A Q
BASICS

Special features:
The parameters of all modules across the network are set directly via the master module. The communication between the remote modules and the master module is performed automatically (refresh rate of up to 3.9 ms for 2048 I/O points). With one master module a system can be extended by up to 2048 remote I/O points. An additional stand-by master establishes a duplex system. Automatic link cutoff function of a faulty slave station without interrupting network communications. Automatic online return of a station after error corrective action without network reset. Data transfer via shielded twisted pair cable.

STATION NO. X 10 X 1

MODE

OFF M/L

ON S MST

CLEAR 1

HOLD 4

B RATE 156K 0 625K 1 2.5M 2 5M 3 10M 4

NC DA NC DB NC DG NC SLD NC (FG)

Specifications Module type CPU series Link points per station I/O points register

A1SJ61BT11 Master / Local Station MELSEC AnS series 32 8 2048

A1SJ61QBT11 Master / Local Station MELSEC QnAS series

Decentral I/O points Number of connectable modules I/O refresh time speed Transmission type distance total distance Synchronizations method Modulation Tramsmission route type Transmission format type no. of cores cable resistance (20 c) Transmission cable insulation resistance (1 kHz) characteristic impedance (100 kHz) cable resistance (20 C) diameter I/O points Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information Accessories

Max. 64 (Remote I/O modules: max. 64; Remote special function modules: max. 42; local stations: max. 24) ms 3.9 6.7 Mbit/s 10; 5; 2.5; 0.62; 0.15 Bus m 100 m at 10 Mbit/s; 150 m at 5 Mbit/s; 200 m at 2.5 mbit/s; 600 m at 0,62 Mbit/s; 1200 m at 0.15 Mbit/s m Max. 1200m Frame synchronisation NRZI Bus (RS485) HDLC Shielded twisted-pair 2 Max. 37.8 /km Max. 60 nF/km 100 15 10000 M/km 0.5 mm2 32 mA 400 kg 0.25 mm 37.5 x 130 x 93.6 Art. no. 75497 126738

Programming software: MELSEC MEDOC plus or MELSEC MEDOC GPP/WIN (see page 92)

MITSUBISHI ELECTRIC

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MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES CC-Link Remote Digital Input and Combination Modules Communications Modules

A Q
BASICS
B RATE

Remote inputs
The remote input modules acquire the signals within short distance from the machine. The advantage is a reduced cabling requirement and the capability of aquiring data and operation results of individual machine modules autonomously, electrically, and mechanically. Besides three different input modules with up to 32 inputs, a combined module with 8 inputs and 8 outputs is available.

MITSUBISHI
PW L RUN SD

AJ65BTB1-16D
RD L ERR.

01 2 3 4

STATION NO.
X10

X1

9 A B C D E F 0 1 2 3 4 5 6 7 8
13 12 14 15 16 17 18 19 20 21 22 23

01 901 2 2 8 3 3 7 6 54 6 54

25 24 26

27

1 DA 2

3 DG 4 DB

5 +24V 6

7 24G 8

9 10

11

B116D

SLD

(FG)

Special features:
1 DA 2 DB 3 DG 4 SLD 5 +24V 6 (FG) 7 24G 8 X0 9 X1 10 X2 11 X3 12 X4 13 X5 14 X6 15 X7 16 COM 17 NC 18 X8 19 X9 20 XA 21 XB 22 XC 23 XD 24 XE 25 XF 26 27 NC

B1COM 16D

9 A B C D E F 0 1 2 3 4 5 6 7 8

3 3 7 6 54 6 54

Up to 64 I/O modules with a maximum of 32 inputs each can be connected. All modules are very compact. Tough, highly shock-resistant pattern. Status indicator LEDs for the inputs. Standard electrical isolation between process and control via optocouplers. Mounting with DIN rail adapters or screws. Modules can be mounted in horizontal arrangement or in one of 4 orientations on a flat surface.

Specifications Module type Inputs Outputs Input type No. of points per module Output type No. of points per module Insulation type Input voltage Input current Max. output current Damping voltage Response time per output per group ON voltage OFF voltage OFF ON ON OFF

AJ65BTB1-16D Input modules 16 DC input (sink / source type) 16 24 V DC mA 7 V 14 V 6 ms 2 ms 2 LED 16 Terminal block mm2 0.75 2.0 mA 60 kg 0.32 mm 151.9 x 65 x 46 Art. no. 75447

AJ65BTB2-16D 16 DC input with 8 potential terminals (sink / source type) 16 24 V DC 7 14 6 2 2 LED 16 Terminal block 0.75 2.0 60 0.4 197.4 x 65 x 46 75450

AJ65BTC1-32D 32 DC input (sink / source type) 32 24 V DC 7 14 6 2 2 LED 32 Connector 0.75 2.0 70 0.27 165 x 65 x 46 75455

AJ65BTB1-16DT Combination module 8 8 DC input (sink type) 8 Transistor 8 24 V DC 7 0,5 4 14 6 10 12 LED 16 Terminal block 0.75 2.0 70 0.33 151.9 x 65 x 46 75448

All modules feature photocoupler insulation.

Status display of inputs Error (RUN) display of stations I/O points Connection terminals Applicable wire size Internal power consumption Weight (without terminal block) Dimensions (W x H x D) Order information

All modules provide LEDs for each input.

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MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Communications Modules CC-Link Remote Digital Output Modules
Remote outputs
The remote output modules output the signals within short distance to the machine. The advantage is a reduced cabling requirement and the capability of controlling and monitoring data and operation results of individual machine modules autonomously, electrically, and mechanically.

SPECIAL FUNCTION MODULES

A Q
BASICS

B RATE

MITSUBISHI
PW L RUN SD

AJ65BTB1-16T
RD L ERR.

01 2 3 4

STATION NO.
X10

X1

9 A B C D E F 0 1 2 3 4 5 6 7 8
13 12 14 15 16 17 18 19 20 21 22 23

01 901 2 2 8 3 3 7 6 54 6 54

25 24 26

27

1 DA 2

3 DG 4 DB

5 +24V 6

7 24G 8

9 10

11

B116T

Special features:
Up to 64 I/O modules with a maximum of 32 outputs each can be connected. All modules are very compact. Tough, highly shock-resistant pattern. Status indicator LEDs for the outputs. Standard electrical isolation between process and control via optocouplers. Mounting with DIN rail adapters or screws. Modules can be mounted in horizontal arrangement or in one of 4 orientations on a flat surface.

SLD

(FG)

1 DA 2 DB

3 DG 4 SLD

5 +24V 6 (FG)

7 24G 8 Y0

9 Y1 10 Y2

11 Y3 12 Y4

13

Y5 14

27 25 23 21 19 17 YF CLT2+ YD YB Y7 CLT1+ Y9 26 24 B122 20 18 16 YE COM2- 16T YC YA Y6 COM1- Y8 15

3 3 7 6 54 6 54

9 A B C D E F 0 1 2 3 4 5 6 7 8

Specifications Module type Outputs Output type No. of points per module Insulation type Output rated voltage Max. output current per output per group OFF ON ON OFF

AJ65BTB1-16T Output modules 16 Transistor 8 All modules feature photocoupler insulation. 12/24 V DC A 0.5 A 4 ms 2 ms 2 Zener diode All modules provide LEDs for each output. LED 16 Terminal block mm2 0.75 2.0 mA 80 kg 0.34 mm 151.9 x 65 x 46 Art. no. 75449

AJ65BTC1-32T 32 Transistor 32 12 /24 V DC 0.1 2 2 2 Clamp diode LED 32 Connector 0.75 2.0 115 0.28 165 x 65 x 46 75456

AJ65BTB2-16R 16 Relay 8 24 V DC 240 V AC 2 8 10 12 LED 16 Terminal block 0.75 2.0 85 0.47 197.4 x 65 x 46 75453

Leak current output OFF Response time

Overvoltage protection Status display of outputs Error (RUN) display of stations I/O points Connection terminals Applicable wire size Internal power consumption Weight (without terminal block) Dimensions (W x H x D) Order information

MITSUBISHI ELECTRIC

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MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES CC-Link Remote Analog Input Modules Communications Modules

A Q
BASICS
B RATE STATION NO. X1 X10 01 901 01 2 28 2 3 3 7 3 4 6 54 6 54

Analog linking to the CPU

The analog input module AJ65BT-64AD converts analog process signals into digital values that can be processed by the CPU.

MITSUBISHI

-64AD AJ65BT-64DAI

PW RUN L RUN SD RD L ERR.

RESET UP CH. OFFSET GAIN SET 01 2 3 4 GAIN DOWN

Special features:
4 analog input channels per module. Selectable current or voltage input. Resolution 5 mV and 20 mA. Converting time 1 ms per channel. Converts analogue values in the range of -10 to 10 V or -20 to +20 mA into digital values from -2000 to +2000. Status indicator LEDs. Standard electrical isolation between process and control via optocouplers. Input characteristics can be user-modified via offset/gain settings. Ready for use with all CC-Link master modules.

1 DA 2

3 DG 4 DB

5 +24V 6

7 24G 8

9 10

11 12

13 14

15 16

17 18

19 20

21 22

23 24

25 26

27

BT64DAI 64AD

SLD

(FG)

1 DA 2 DB

3 DG 4 SLD

5 +24V 6

7 24G 8

9 10

11
CH1 V+

13 COM 14
SLD

15
CH2 V+

17 COM 18
CH3 V+

19
CH3 I+

21
SLD

23
CH4 I+

25
SLD

27
FG1

12

16

20 COM
3 4

22
CH4 V+

24 COM

26
AG

(FG) TEST TEST

CH1 I+

CH2 I+

BT64AD

L ERR.

Specifications Analog inputs Resolution

AJ65BT-64AD 4 16 bit, -2048 / +2047 Analog input Voltage Current -20 20 mA 0 20 mA 0 20 mA 4 20 mA -20 20 mA 0 20 mA 0 20 mA 4 20 mA Digital output Voltage 0 4000 0 4000 0 4000 0 4000 5 mV 2.5 mV 1.25 mV 1 mV Current -2000 2000 -2000 2000 -2000 2000 -2000 2000 20 A 10 A 5 A 4 A

I/O characteristics

-10 V 10 V 0 10 V 05V 15V -10 V 10 V 0 10 V 05V 15V 1 ms/channel 15 V 30 mA

Max. resolution Overall accuracy Max. conversion time Max. input Isolation I/O points External power consumption Applicable wire size Internal power consumption (24 V DC) Weight Dimensions (W x H x D) Order information voltage current

1.0 % (for the whole measurement range)

Photocoupler isolation between output terminals and PC power for all modules. 2 stations (each 32 devices) 24 V DC mm2 0.75 2.00 mA 120 kg 0.35 mm 152 x 65 x 63 Art. no. 75444

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MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Communications Modules CC-Link Remote Analog Output Modules
Digital to analog converter modules
These modules serve as remote 4-channels digital to analog converter modules with 12-bit or 13-bit binary resolution and output an analog current or voltage signal. With this signal for example, frequency inverters, valves or sliders can be controlled.

SPECIAL FUNCTION MODULES

A Q
BASICS

MITSUBISHI

AJ65BT-64DAI

PW RUN L RUN SD RD L ERR.

X1 X10 01 901 01 2 28 2 3 3 7 3 4 6 54 6 54 RESET CH. OFFSET UP SET 01 2 3 4 GAIN DOWN

1 DA 2

3 DG 4 DB

5 +24V 6

7 24G 8

9 10

11 12

13 14

15 16

17 18

19 20

21 22

23 24

25 26

27

Special features:
BT64DAI

SLD

(FG)

1 DA 2 DB

3 DG 4 SLD

5 +24V 6

7 24G 8

9
HDL/ CLR

11
HDL/ CLR

13 14 COM

15
CH1 I+

17 18 COM
L ERR.

19
CH2 I+

21 22 COM
3 4

23
CH3 I+

25 26

27
CH4 I+

10

12

16

20

24

BTCOM 64DAI

(FG) TEST TEST

GAIN DOWN

Up to 4 channels per module. Resolution of the digital input signals selectable in 3 steps: 1/4000, 1/8000, 1/12000. Gain and offset setting provided for each channel. Converting time of 1 ms per channel and 4 ms for 4 channels. Status indicator LEDs. Standard electrical isolation between process and control via optocouplers. Ready for use with all CC-Link master modules.

Specifications Analog outputs Resolution Analog output

AJ65BT-64DAV 4 12 bit, -2048 to +2.047 -10 V 0 V +10 V DC (external input resistance 2 k 1 M) Digital input Resolution Analog output Voltage +10 V +5 V 0V -5 V -10 V

AJ65BT-64DAI 4 12 bit, 0 4095 4 20 mA DC (external input resistance 0 600 ) Digital input Resolution 4000 2000 0 Yes (users or factory setting) 1.0 % (for the whole measurement range) Max. 1 ms/1 channel, 4 ms/4 channels 2 stations (32 devices) 0.75 2.0 270 0.4 152 x 65 x 63 75445 Analog output Current +20 mA +12 mA +4 mA

I/O characteristics

2000 1000 0 -1000 -2000 Yes (users or factory setting)

Offset/Gain setting Overall accuracy Max. conversion time Isolation method I/O points Applicable wire size Internal power consumption (24 V DC) Weight Dimensions (W x H x D) Order information

1.0 % (for the whole measurement range) Max. 1 ms/1 channel, 4 ms/4 channels 2 stations (32 devices) mm2 0.75 2.0 mA 180 kg 0.4 mm 152 x 65 x 63 Art. no. 75446

All modules fitted with photocoupler isolation between input terminals and internal circuit.

MITSUBISHI ELECTRIC

53

MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES CC-Link Remote Analog Input Modules for Pt100-Elements Communications Modules

A Q
BASICS
B RATE

Connection of Pt100-elements
STATION NO. X1 X10 01 901 01 2 28 2 3 3 7 3 4 6 54 6 54

MITSUBISHI

-64RD AJ65BT-64DAI4

The analog modules AJ65BT-64RD3 and AJ65BT-64RD4 provide analog inputs for measuring values of Pt100 elements.

SW 0 1~4 9

MODE NORMAL TEST CH. TEST

PW RUN L RUN SD RD L ERR.

RESET CH. OFFSET UP SET 01 2 3 4 GAIN DOWN

Special features:
Linear measuring range without adjustment of the measuring values. Direct output of the measuring values in C. Temperature measuring range of -180C to +600C in combination with a Pt100-element according to DIN IEC 751. Platinum sensors can be connected directly. A line break is indicated to the PLC by the module. The conversion can be enabled or disabled for each channel individually. Averaging on time or measuring cycles can be parametrized. Status indicator LEDs. Standard electrical isolation between process and control via optocouplers. Ready for use with all CC-Link master modules.

1 DA 2

3 DG 4 DB

5 +24V 6

7 24G 8

9 10

11 12

13 14

15 16

17 18

19 20

21 22

23 24

25 26

27

BT64RD4 64DAI

SLD

(FG)

1 DA 2 DB

3 DG 4 SLD

5 +24V 6 (FG)

7 24G 8 a1

9 A1 10 B1

11

13

15 A2 16 B2

17 b2 18 a3

19 A3 20 B3
3 4

21 b3 22 SLD

23 SLD 24 a4

25 A4 26 B4

27 b4 BT64RD4

b1 SLD 14 12 a2 SLD
9 TEST

L ERR.

GAIN DOWN

Specifications Pt100-input points Method of measurement Connectable temperature measuring resistants Temperature Overall accuracy Resolution Max. conversion time Isolation Modules per network I/O points Applicable wire size External voltage sopply Internal power consumption (24 V DC) Weight Dimensions (W x H x D) Order information Measurement range Detected value at 25 C (5%) at <20 C or > 30 C

AJ65BT-64RD3 4 3-wire type

AJ65BT-64RD4 4 4-wire type

Pt100 (conforms to JIS C 1604-1989 and DIN IEC 751), JPt100 (conforms to JIS C 1604-1981) C -180 +600 16 bits signed binary: -1800 +6000 32 bits signed binary: -180000 +600000 0.1 % (for the whole measurement range) 0.25 % (for the whole measurement range) C 0.025 40 ms / Pt100 input Photocoupler isolation between output terminals and PC power for all modules. Max. 16 Pt100 analog input modules in one network 4 stations (128 devices) mm2 0.75 2.0 24 V DC mA 170 kg 0.38 mm 152 x 65 x 63 Art. no. 88026 Max. 16 Pt100 analog input modules in one network 4 stations (128 devices) 0.75 2.0 24 V DC 170 0.38 152 x 65 x 63 88027 -180 +600 16 bits signed binary: -1800 +6000 32 bits signed binary: -180000 +600000 0.1 % (for the whole measurement range) 0.25 % (for the whole measurement range) 0.025 40 ms / Pt100 input

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MELSEC AnS/QnAS
Communications Modules CC-Link Remote High-Speed Counter Modules
Automatic hardware counter
STATION NO. X1 X10 01 901 01 2 28 2 3 3 7 3 4 6 54 6 54 PLS CH. 1 2 ON LOW HIGH RESET

SPECIAL FUNCTION MODULES

B RATE

MITSUBISHI
CH. 1 A B DEC PRE F ST. EQU1 EQU2

-D62D AJ65BT-64DAI
CH. 2 A B DEC PRE F ST. EQU1 EQU2

PW RUN L RUN SD RD L ERR.

The high-speed counter modules acquire signals at a frequency which conventional input modules can not acquire. Positioning tasks or frequency measurements for example can be performed.

A Q
BASICS

RING CH. 1 2

Special features:
27 BTD62D 64DAI

1 DA 2

3 DG 4 DB

5 +24V 6

7 24G 8

9 10

11 12

13 14

15 16

17 18

19 20

21 22

23 24

25 26

SLD

(FG)

27 25 23 21 19 EQR 17 CH2 15 CH1 13 CH2 11 CH2 9 CH2 7 CH2 5 CH1 3 CH1 EQR1 EQR2 COM CH1 B(B) PRST F. ST CH. 1 B(B) COM A(A) 26 24 BT22 DG +24V 24G A(A) 20 DA 18 16 CH2 +12 14 CH1 12 CH2 10 CH2 8 CH2 24V D62D 6 CH2 4 EQR1 CH1 2 CH1 CH1 B(B) COM EQR1 PRST F. ST A(A) SLD (FG) A(A) B(B) DB L ERR. HIGH EQU1 EQU1 EQU2 EQU2

Input for incremental shaft encoder with automatic forward and reverse detection. Count preset via external signals or via the PLC program by the PRESET function. Ring counter for counting up to a predefined valuewith automatic reset to the initial value. Functions such as velocity measurement, determining switching points or periodical counting are provided. Automatic multiplication of the counted values. Status indicator LEDs. Ready for use with all CC-Link master modules.

Specifications Counter inputs Signal levels Max. counting frequency Counting range Comparison range Counter type External digital input points Min. input pulse width inputs External response time outputs response time OFF ON

AJ65BT-D62 2 (1 or 2 phases) 5 / 12 / 24 V DC (2 5 mA) pulse/s 200000 23 bits + sign (binary), 0 16777215 24 bits + sign (binary) Preset, count disable function 1 / 2 phase: 5 s 1 phase: 100 s; 2 phase: 142 s 5 / 12 / 24 V DC (2 5 mA) ON < 0.5 ms OFF < 3 ms 2A < 0.1 ms 4 stations (128 devices) mm2 0.75 2.0 mA 70 kg 0.41 mm 152 x 65 x 63 Art. no. 88028

AJ65BT-62D / 62D-S1 2 (1 or 2 phases) EIA Standard, RS-422-A difference driver 400000 23 bits + sign (binary), 0 16777215 24 bits + sign (binary) Preset, count disable function 1 phase: 2.5 s; 2 phase: 3.3 s; 1 phase: 100 s; 2 phase: 142 s 5 / 12 / 24 V DC (2 5 mA) < 0.5 ms < 3 ms 2A < 0.1 ms 4 stations (128 devices) 0.75 2.0 D62D: 100; D62D-S1: 120 0.42 152 x 65 x 63 88029 / 88030

Both modules are equipped with UP/DOWN preset counter and ring counter function.

External I/O points

Applicable wire size Internal power consumption (24 V DC) Weight Dimensions (W x H x D) Order information

MITSUBISHI ELECTRIC

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MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES CC-Link Remote Input Modul for Temperature Measurement Communications Modules

A Q
BASICS
B RATE STATION NO. X1 X10 01 901 01 2 28 2 3 3 7 3 4 6 54 6 54

Temperature measuring via thermoelement

This module supports temperature measurements via thermocouples.
MITSUBISHI
-68TD AJ65BT-64DAI
PW RUN L RUN SD RD L ERR.

SW 0 1~8 9

MODE NORMAL TEST CH. TEST

RESET CH. OFFSET UP SET 01 2 3 4 GAIN DOWN

Special features:
The module provides 8 thermoelement inputs that can be addressed independently. Linearized measuring range up to 1700 C (depending on thermoelement). Support for thermoelement types B, R, S, K, E, J, T with characteristics of thermoelectric voltages according to DIN IEC 584-1. Line break detection for each input channel. Cold junction compensation is possible. Standard electrical isolation between process and control via optocoupler.

1 DA 2

3 DG 4 DB

5 +24V 6

7 24G 8

9 10

11 12

13 14

15 16

17 18

19 20

21 22

23 24

25 26

27

BT64DAI 68TD

SLD

(FG)

1 DA 2 DB

3 DG 4 SLD

+24V 6

27 25 23 21 19 17 15 13 11 9 CH8+ RTD RTD CH4+ CH5+ CH6+ CH7+ CH1+ CH2+ CH3+ 26 24 BT22 20 18 16 14 12 10 NC 68TD CH8- NC CH4- CH5- CH6- CH7(FG) CH1- CH2- CH33 L ERR. 4 9 TEST GAIN DOWN 7 24G 8

Specifications Input points Temperature input range Detected temperature value Scaling value

Thermocouple

AJ65BT-68TD 8 C 0 1700 16 bits signed binary: 0 17000 (value to the first decimal place x 10) C 16 bits signed: 0 +2000 Temperature Conversion accuracy Type measurement range (at operating ambient temperature is Ta = 25 5C) B 600 1700 C 2.5 C R 200 1600 C 2 C S 200 1600 C 2 C K 0 1200 C E 0 800 C 0.5 C or 0.25 % of the measured temperature which ever is larger J 0 750 C

Temperature characteristic (whenoperatingambienttemperaturevariesbyT=1C) 0.4 C 0.3 C 0.3 C 0.07 C or 0.02 % of the measured temperature which ever is larger

Cold junction compensation accuracy Overall accuracy Max. conversion time Absolute max. input voltage Isolation method I/O points Applicable wire size Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information

mm2 mA kg mm

T 0 350 C 1 C (Conversion accuracy Ta) + (temperature characteristic) x (operating ambient temperature variation) 1 C 45 ms / channel, without respect to the number of used channels 5 Transformer 4 stations (128 devices) 0.75 2.0 81 0.40 152 x 65 x 63

Art. no. 88025

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MELSEC AnS/QnAS
Communications Modules CC-Link Remote Positioning Module
Positioning with an open control loop
B RATE STATION NO. X1 X10 01 901 01 2 28 2 3 3 7 3 4 4 6 54 6 5

SPECIAL FUNCTION MODULES

MITSUBISHI

AJ65BT-D75P2-S3
PW RUN L RUN SD RD L ERR.

The module generates the go command via a pulse chain. The velocity is proportional to the pulse frequency. The travel is proportional to the pulse length.

A Q
BASICS

MODE RESET

AX1 AX2

Special features:
Control of up to two axes, linear interpolation or circular interpolation. Storage of up to 600 items of positioning data. Travel unit can be specified pulse, mm, inch or degree. In connection with the MELSERVO MR-J2 servo amplifier an absolute position detection system can be configured. 7 types of home position return functions are available. Parameterization and specification of positioning data can be be done entirely by the PLC program or by the MS-DOS Software SW1IVD-AD75PE.

1 DA 2

3 DG 4 DB

5 +24V 6

7 24G

SLD

(FG)

B RATE

MITSUBISHI

AJ65BT-D75P2-S3
PW RUN L RUN SD RD L ERR.

STATION NO. X1 X10 01 901 01 2 28 2 3 3 7 3 4 4 6 54 6 5

MODE RESET

AX1 AX2

1 DA 2 DB

5 3 +24V DG 6 4 (FG) SLD

7 24G AJ65

Specifications Control axes Interpolation Points per axis method

AJ65BT-D75P2-S3 2 Linear interpolation (2 axes), circular interpolation(2 axes) 600 Pulse control "Point to Point" (absolute data and/or incremental); speed/position swiching control: (incremental); locus control (absolute data and/or incremental) absolute data: -2147483648 -214748364.8 -21474.83648 0 -2147483648 -214748364.8 -21474.83648 -21474.83648 0 0 0 0 2147483647 214748364.7 21474.83647 359.99999 2147483647 214748364.7 21474.83647 21474.83647 pulse m degree inch pulse m inch degree pulse m degree inch

positioning units Positioning

incremental:

Speed/position switching control:

2147483647 214748364.7 21474.83647 21474.83647

positioning speed acceleration/ deceleration processing acceleration and deceleration time Offset I/O points Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information Accessories

1 0.01 0.001 0.001

1000000 6000000.00 600000.000 600000.000

pulse/min mm/min degree/min inch/min

Automatic trapezoidal or S-pattern acceleration and deceleration 1 65535 ms (4 patterns each can be set) Electronic gear and backlash compensation 4 stations with each 128 devices mA 300 kg 0.5 mm 170 x 63.5 x 80

Art. no. 88002 Software for all MELSEC positioning modules: SW1IVD-AD75PE, art. no.: 65619; adapter cabel: A1SD75-C01H, art. no.: 54943

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MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES CC-Link Remote RS232C Interface Module Communications Modules

A Q
BASICS
B RATE

Data exchange with peripherals

STATION NO. X1 X10 01 901 01 2 28 2 3 3 7 3 6 54 6 54 4 RESET ON

MITSUBISHI

AJ65BT-R2

RS-232-C

1 DA 2

3 DG 4 DB

5 +24V 6

7 24G 2 4 6 R2 AJ65

SLD

(FG)

MITSUBISHI

AJ65BT-R2

1 DA 2 DB

5 3 +24V DG 6 4 (FG) SLD

7 24G AJ65

RS-232-C

Specifications Interface Communications mode Synchronisation Data transfer Data format Error correction DTR/DSR control X ON / X OFF (DC1 / DC3) Universal I/Os I/O points External power supply Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information input data output data speed channel distance m

AJ65BT-R2 Typ RS232C (D-Sub, 9 pole) Full duplex (without protocol) Start/stop synchronisation bit/s 300, 600, 1200, 2400, 4800, 9600, 19200 (selectable) Bus (RS485) 15 1 start bit, 7 or 8 data bits, 1 or 0 parity bits, 1 or 2 stop bits Parity check, checksum YES / NO selectable YES / NO selectable 2 inputs 24 V DC (sink / source type) 2 Transistor outputs 12/24 V DC 1 station (32 adresses) V DC 24 mA 110 kg 0.4 mm 170 x 80 x 63,5 Art. no. 88003

58

BCDE

BCDE

PW RUN L RUN SD RD L ERR.

RS-232-C SD RD ERR.

XC XD YC YD

This module serves for the communication with peripheral devices through a standard RS232C interface. The peripherals are connected point to point (1:1).

MODE SW
6
78 9 A

I/O

Special features:
7

B RATE RS-232-C SD RD ERR.

PW RUN L RUN SD RD L ERR.

XC XD YC YD

STATION NO. X1 X10 01 901 01 2 28 2 3 3 7 3 4 4 6 54 6 5 MODE SW

6
78 9 A

RESET ON

1 XC 2 COM1

3 XD 4 NC

5 YC 6 COM1

7 YD R2

Access capabilities of host PCs with visualization or monitor software to the complete data set of the MELSEC AnAS CPU. Supported ASCII data exchange with connected devices such as bar code readers, weighing or identification systems. Two universal digital inputs and outputs each. Printer control options. LED indicators for the module and communications status.

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Communications Modules Interface Boards for CC-Link
Interface board for CC-Link
The interface board serves for the integration of a personal computer as local station into the CC-Link network.

SPECIAL FUNCTION MODULES

A Q
BASICS

Special features:
PCI board for plug-and-play without DIP switch configuration. Monitor and test function of data available within the network supported. Prepared for user-defined programming.

RUN ERR

SD

RD

DB DG SDL BD NO.

A80BD-J61BT13 BD808C083G51

Specifications Module type Transmission speed Max. transmission distance Link devices per system per station

A80BD(E)-J61BT13 Slave Mbit/s 0.156; 0.625; 2.5; 5; 10 (selectable) Dependend on the transmission speed (see master module) 2048 link relays , 256 registers 30 link relays , 256 registers Polling Frame synchronisation method NRZI Bus (RS485) HDLC Max. 4 Windows NT Workstation 4.0 or higher, with Pentium prozessor 133 MHz, 1 free PCI slot, min. 32 MB RAM, min. 20 MB ROM (harddisk) mA 400 kg 0.16 mm 192 x 107 x 8.8 Art. no. 102866

Communications method Synchronisation method Modulation Transmission method Transmission format Boards per network System requirements (PC) Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information

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MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES MELSEC I/O Link Network Communications Modules

A Q
BASICS

Communications Modules
MELSEC I/O Link enables you to operate up to 64 remote inputs and 64 remote outputs. All I/Os in the network are automatically and cyclically updated at 5.4 s intervals. Up to 16 I/O modules can be connected to a master unit.

AnS / QnAS

AnU / QnA

Structure
The data lines tree topology enables you to install T-junctions at any point, similar to a normal house service installation. You only need to ensure that the total coverage of the network does not exceed 200 m.

MELSEC I/O Link

Cable type
The network uses ordinary shielded twisted-pair cabling as the communications medium.

Administration
For the control program there is no difference at all between the remote I/Os and the local I/Os on the PLCs base units. The station numbers of the remote I/O modules are set with simple rotary switches, making installation very easy. You also need to set the master station DIP switches for the assigned station numbers to ON.

I/O-Link modules AJ55TB

Interface Cross-section Loop resistance Electrostatic capacity Impedance (100 kHz) Insulation resistance Maximum distance

Shielded twisted-pair cabling 0.75 mm2 (1 pair) 29 / km 75 nF / km 110 10 % 500 M / km 200 m

Important: Do not exceed the specified electrostatic capacity!

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MELSEC AnS/QnAS
Communications Modules MELSEC I/O Link Master Module
Local I/Os with flexible installation
The MELSEC I/O Link is very simple to handle. To put it into operation, all that is necessary is to set DIP switches to indicate which stations are present. Otherwise, the local I/Os behave in the same way as locally installed ones and are programmed in the same way via the PLC program.

SPECIAL FUNCTION MODULES

A Q
BASICS

24V RUN SD RD E S H OR T R OP E N ITY R PAR

A1SJ51T64
0 1 2 3 4 5 6 7

8 9 A B C D E F

ES RT RA OT RI O N

Special features:
DATA DG FG +24 24G RUN A RUN B

Online diagnostics by means of LEDs Cabling in tree structure (T connections possible) Up to 128 inputs/outputs per module Refresh time of 5.4 ms for 64 I/Os The number of master modules is limited only by the address range of the CPU. Transmission distance up to 200 m (cable length) Indication of faulty stations by means of LEDs

A1SJ51T64

Specifications Controllable I/O points I/O refresh time rate method synchronization method error control Commusystem nication transmission path transmission total distance I/O stations type Communo. of cores nication cable diameter Error (RUN) display of stations No. of occupied I/O points Applicable wire size voltage supply External current supply (24 V DC) Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information Accessories

A1SJ51T64 128 (using mixed modules with 4 inputs / 4 outputs) ms ca. 5.4 bit/s 38400 Register insertion method Combination of frame-synchronization and bit-synchronization Parity check Bus / tree system m 200 16 (modules with 4 I/Os) Shielded twisted pair cable 2 0.5 mm2 LED 64 (definable by I/O assignment) 0.75 21.6 27.6 V DC

mm2

mA 90 mA 115 kg 0.3 mm 34.5 x 130 x 93.6 Art.no. 47192 I/O link modules AJ55TB (refer to the following page)

MITSUBISHI ELECTRIC

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MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES MELSEC I/O Link Modules for A1SJ51T64 Communications Modules

A Q
BASICS

Local I/Os in compact design

The local I/Os have little granularity. For example, mixed modules with 2 input points and 2 output points are available. This system is perfect for updating existing machinery.

Special features:
Very compact design Three-conductor connection technology for input points Installation by screws or integrated DIN rail adapter Modules with 4, 8 and 16 input/output points Galvanic isolation between process and controller by photocoupler is a standard feature. Indication of the status of the input/output points by LEDs Adjustment of station numbers via rotaryswitch

Specifications Controllable I/O points Operating voltage range Rated input voltage Rated output voltage Switch ON Switch OFF voltage current voltage current

AJ55TB3-4D 4 V DC 19.2 26.4 24 V DC (7 mA)

AJ55TB3-8D 8 19.2 26.4 24 V DC (7 mA)

AJ55TB3-16D 16 19.2 26.4 24 V DC (7 mA)

Load resistance Min. switching load Max. switching voltage OFF ON Response time ON OFF mechanical Life electrical Max. switching frequency Max. inputs ON simultaneously Input/output indicator Isolation method Communication cable I/O unit power voltage supply current External voltage supply External power consumption (24 V DC) Weight Dimensions (W x H x D) Ordering information Accessories

14 14 V 14 3.5 3.5 mA 3.5 6 6 V 6 1.7 1.7 mA 1.7 3.3 3.3 k 3.3 V 10 10 ms 10 10 10 ms 10 100 % 100 % 100 % All modules provide a red LED for each input/output. All modules fitted with photocoupler isolation between input terminals and internal circuit. Shielded twisted pair 0.75 mm2 x 1P / lead cable 0.75 mm2 x 2C (for further information contact the Mitsubishi Electric service) 15.6 27.6 15.6 27.6 15.6 27.6 15.6 27.6 V DC 15.6 27.6 45 60 40 50 mA 35 24 V DC / 240 V AC 24 V DC / 240 V AC 12 23 mA 0.3 0.4 0.2 0.3 kg 0.2 114 x 45 x 66 177 x 45 x 66 82 x 45 x 66 114 x 45 x 66 mm 82 x 45 x 66 Art. no. 47191 47190 58548 47186 47185

AJ55TB32-4DR 2+2 21.6 26.4 24 V DC (7 mA) 24 V DC (2 A/point) 240VAC(4A/common) 14 3.5 6 1.7 3.3 5 V DC (1 mA) 250 V AC / 110 V DC In: 10 / Out: 10 In: 10 / Out: 12 20 Mio. cycles 100000 cycles 3600 cycles/h 100 %

AJ55TB32-8DR 4+4 21.6 26.4 24 V DC (7 mA) 24 V DC (2 A/point) 240VAC(4A/common) 14 3.5 6 1.7 3.3 5 V DC (1 mA) 250 V AC / 110 V DC In: 10 / Out: 10 In: 10 / Out: 12 20 Mio. cycles 100000 cycles 3600 cycles/h 100 %

AJ55TB32-16DR 8+8 21.6 26.4 24 V DC (7 mA) 24 V DC (2 A/point) 14 3.5 6 1.7 3.3 5 V DC (1 mA) 49.9 V AC In: 10 / Out: 10 In: 10 / Out: 12 20 Mio. cycles 100000 cycles 3600 cycles/h 100 %

15.6 27.6 70 24 V DC 45 0.4 177 x 45 x 66 58546

In case of 240 V AC the unit does not comply to CE-standard.

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MELSEC AnS/QnAS
Communications Modules MELSEC I/O Link Modules for A1SJ51T64 SPECIAL FUNCTION MODULES

A Q
BASICS

Specifications Controllable I/O points Operating voltage range Rated input voltage Rated output voltage Switch ON Switch OFF voltage current voltage current

V DC

Load resistance Min. switching load Max. switching voltage OFF ON Response time ON OFF mechanical Life electrical Max. switching frequency Max. inputs ON simultaneously Input/output indicator Isolation method Communication cable I/O unit power voltage supply current External voltage supply External power consumption (24 V DC) Weight Dimensions (W x H x D) Ordering information

V mA V mA k

ms ms

mA mA kg mm

AJ55TB2-4R AJ55TB2-8R 4 8 24 V DC (2 A/point) 24 V DC (2 A/point) 240 V AC (8 A/common) 240 V AC (8 A/common) 5 V DC (1 mA) 5 V DC (1 mA) 250 V AC / 110 V DC 250 V AC / 110 V DC 10 10 12 12 20 Mio. cycles 20 Mio. cycles 100000 cycles 100000 cycles 3600 cycles/h 3600 cycles/h All modules provide a red LED for each input/output. All modules fitted with photocoupler isolation between input terminals and internal circuit. Shielded twisted pair 0.75 mm2 x 1P / lead cable 0.75 mm2 x 2C (for further information contact the Mitsubishi Electric service) 15.6 27.6 V DC 15.6 27.6 V DC 50 65 24 V DC / 240 V AC 24 V DC / 240 V AC 23 45 0.2 0.3 82 x 45 x 66 114 x 45 x 66 47187

AJ55TB2-16R 16 24 V DC (2 A/point, 8 A/common) 5 V DC (1 mA) 49.9 V AC 10 12 20 Mio. cycles 100000 cycles 3600 cycles/h

15.6 27.6 V DC 85 24 V DC 90 0.4 177 x 45 x 66 58549

Art. no. 47189

Accessories In case of 240 V AC the unit does not comply to CE-standard.

MITSUBISHI ELECTRIC

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MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES The PROFIBUS/DP Network Communications Modules

A Q
BASICS

Data Communications
The open PROFIBUS/DP network enables extremely fast data exchange with a very wide variety of slave devices, including: Remote digital I/Os Remote analog I/Os Remote intelligence PLC (FX0N, FX2N) Frequency inverters (FR-A 240, FR-A 540 (L), FR-E 500) Operator terminals (MAC E series) A range of other devices from third-party manufacturers

Master PLC

AnSH / QnAS

AnU / QnA

Slave units
FX0N / FX2N

max. 1200 m at 93.75 kbit/s without repeater 16 outputs

Structure
The maximum coverage of a bus segment is 1200 m (at a maximum of 93.75 kbit/s). Up to 3 repeaters are allowed. Thus the maximum distance between 2 stations is calculated with 4800 m.

several MAC E series

P R O F
PROCESS FIELD BUS

I
MT series

B U S

Cable types
To help reduce costs PROFIBUS/DP uses RS 485 technology with simple twistedpair cabling. Suitable cables include the UNITRONIC BUSLD from Lappkabel and the DUE 4451 from Alcatel.

FR-E 520/540 FR-A 540(L)EC

MC series

Specifications Communications protocol Cabling

Master AJ71PB92 EN 50170 / DIN 19245-T3

Master A1SJ71PB92D

Data exchange
The PROFIBUS AJ71PB92D and A1SJ71PB92D master modules support slave device data exchange with up to 244 send bytes and 244 receive bytes. This means you can exchange a total of up to 128 bytes with a slave unit per network cycle.

Shielded twisted-pair with 24 AWG = 0.22 mm2, impedance: 100 130 ; Shielded twisted-pair with 22 AWG = 0.34 mm2, impedance: 135 165 ; RS485 distance 1 200 m 1 000 m 400 m 200 m kbit/s 9.6 / 19.2 / 93.75 kbit/s 187.5 kbit/s 500 kbit/s 1 500 m 4800 (3 repeaters) 60 32 3 ProfiConT: PROFIBUS 9-pin D-SUB plug connector for up to 12 Mbaud, art. no. 87035 (refer to page 82) 12000 / 6000 / 3000 (100 m) 1500 (200 m)

Interface

Data transfer rate

Administration
In combination with the MELSEC ProfiMap configuration software the AJ71PB92D PROFIBUS/DP master unit gives you user-friendly plug-and-play technology. The configuration software is self-explanatory, using a graphical model for setting up the network. You simply select the slave unit (e.g. FX2N), assign the station numbers and specify where the information is stored in the master CPU. Of course, PROFIBUS/DP slaves from MITSUBISHI ELECTRIC can also be connected to master devices from other manufacturers.

Max total distance Slave units per master Stations per segment Repeaters per network Accessories

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MELSEC AnS/QnAS
Communications Modules PROFIBUS DP/FMS Module
The open standard for MELSEC PLCs
The A1SJ71PB96F PROFIBUS/FMS module and the A1SJ71PB92D PROFIBUS/DP module enable MELSEC programmable logic controllers to communicate with other PROFIBUS devices.

SPECIAL FUNCTION MODULES

A Q
BASICS

Special features:
The A1SJ71PB92D PROFIBUS/DP master can communicate with up to 60 slave units. Up to 32 input bytes and 32 output bytes can be processed at a time per slave station. Supported functions include Sync, Freeze and specialised diagnostics messages for the specific slave types used. The A1SJ71PB96F PROFIBUS/FMS master supports up to 32 links and supports simple variables, records and arrays.

Specifications Module type Protocol Interface Communications mode Topology Modulation Cabling 9.6 kbps 19.2 kbps 93.75 kbps 187 kbps Communica500 kbps tions distance 1500 kbps 3 Mbps 6 Mbps 12 Mbps Max. nodes Repeaters per network I/O points Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information Accessories

A1SJ71PB96F Master EN50170, DIN19245T1+2 type RS485 Logical token ring with subordinate Master/Slave procedure Bus NRZ Shielded twisted-pair m 1200 m 600 m 200 m 100 m 32, 62 (1 repeater), 92 (2 repeaters), 122 (3 repeaters) Max. 3 32 mA 560 kg 0.27 mm 34.5 x 130 x 93.6 Art. no. 46421

A1SJ71PB92D Master EN50170, DIN19245T3 RS485 Logical token ring with subordinate Master/Slave procedure Bus NRZ Shielded twisted-pair 1200, 4800 (3 repeaters) 1000, 4000 (3 repeaters) 400, 1600 (3 repeaters) 200, 800 (3 repeaters) 100, 400 (3 repeaters) 32, 62 (1 repeater), 92 (2 repeaters), 126 (3 repeaters) Max. 3 32 560 0.27 34.5 x 130 x 93.6 63393

Configuration software incl. configuration cable for A1SJ71PB92D, A1SJ71PB96F: MELSEC ProfiMap, art. no.: 102996 PROFIBUS plug connector for up to 12 Mbaud: ProfiConT, art. no 87035 (refer to page 82)

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MELSEC AnS/QnAS
SPECIAL FUNCTION MODULES PROFIBUS/DP Compact I/O Modules Communications Modules

A Q
BASICS

Compact I/O modules for PROFIBUS/DP

These PROFIBUS/DP I/O modules enable signal registration at the machine with relatively short cables. The reduced cabling requirements and the ability to activate individual machine components automatically are among the great advantages of these modules.

Special features:
I/Os and PROFIBUS/DP cable electrically isolated from the internal circuitry Outputs protected with melt fuse Support for data transfer rates from 9 600 baud to 12 Mbaud 3-pole sensor connection technology Removable terminal block with screw terminals Integrated switchable terminating resistors Rotary switch station number allocation Both DIN rail and screw mounting supported

Specifications Controllable I/O points I/Os in groups with Occupied stations Input data Operating voltage range Rated input voltage voltage Switch ON current voltage Switch OFF current Input resistance Input type Output data Output voltage Max. output load OFF ON ON OFF External voltage supply External power consumption (24 V DC) Withstand strength Isolation resistance Response time Common data Isolation voltage current Applicable wire size Weight Dimensions (W x H x D) Power consumption Order information Accessories V DC mA mm2 kg mm

AJ95TB3-16D 16 Input points 16 1 V DC 19.2 26.4 24 V DC (7 mA) V 14 mA 3.5 V 6 mA 1.7 k 3.3 Sink/souce ms 10 (input) ms 10 (input) mA V AC 500 10 M

AJ95TB2-16T 16 Transistor outputs 8 1 Source output 12/24 V DC (0.8 A/channel) (3.2 A/total) 0.8 A / output 2 (output) 2 (output) 10.8 26.4 V DC 35, all I/Os ON, no load 500 10 M

AJ95TB32-16DT 8 Input points / 8 transistor outputs 8 1 19.6 26.4 24 V DC (7 mA) 14 3.5 6 1.7 3.3 Sink/source input, source output 0.8 A / output 10 (input), 2 (output) 10 (input), 2 (output) 10.8 26.4 V DC 18, all I/Os ON, no load 500 10 M

All modules fitted with photocoupler isolation between I/Os. 15.6 31.2 15.6 31.2 174 (24 V DC) 188 (24 V DC) 0.18 2 0.18 2 0.45 0.45 197.4 x 80 x 46.5 197.4 x 80 x 46.5 63080

15.6 31.2 183 (24 V DC) 0.18 2 0.45 197.4 x 80 x 46.5 63081

Art. no. 63079

PROFIBUS plug connector for up to 12 Mbaud: ProfiConT; art. no 87035 (refer to page 82)

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Communications Modules PROFIBUS/DP MT Modules
Basic module (head station) of the MT series
MITSUBISHI ELECTRIC
23

SPECIAL FUNCTION MODULES

X10

PB-DP

STN-NO

LOC

Specifications Module type Communications protocol medium

Interface Operation modes Communications rate Max. total distance No. of connectable extension modules Adressable digital I/Os I/O points Integrated inputs Digital inputs Isolation Rated input current OFF ON Response time ON OFF Short circuit protection Status display for inputs Common data Applicable wire size Power supply Internal power consumption (24 V DC) Weight Dimensions (W x H X D) Order information

MT-DP12 Basic module of the MT series, PROFIBUS/DP slave DIN 19245-T3 Shielded twisted-pair with 24AWG = 0.22 mm2, impedance: 100 130 ; Shielded twisted-pair with 22AWG = 0.34 mm2, impedance: 135 165 RS485 Sync mode and freeze mode are supported 9.6; 19.2; 93.75; 187.5; 500 kBit/S, 1.5; 3; 6; 12 Mbit/s m 4800 (3 repeater) Max. 16 extension modules (digital and analog I/O modules) 256 ms ms mm2 V DC A kg mm 0.75 2.5 24 Max. 0.5 (with maximum configuration) 0.28 96 x 114 x 60

Art.-Nr. 68887 Local system adapter MT-LE with extension cable MT-LE-CBL50 (length 0,5 m) = MT-LE-SET, art. no. 69759 Screw type terminal block MT-DP12-TBS, art. no. 68888 Cache clamp terminal block MT-DP12-TBC, art. no. 68889 PROFIBUS connector for up to 12 Mbaud: ProfiConT, art. no. 87035 (see page 82)

Accessories

MITSUBISHI ELECTRIC

78

901

23

MT-DP12

The basic module connects the extension modules of the MT series (MT = Modular Type) to the PROFIBUS/DP. The MT devices are mounted to a DIN rail. Due to the additional second interface on the basic module the extension modules can be installed in two rows. The modules on the separate DIN rail are supplied with data and the system voltage via an extension cable and the local system extension module.

A Q
BASICS

456

78

901

X1

456

Special features:
Up to 16 digital and 8 analog extension modules can be connected. Automatic detection of the data transfer rate Optocouplers between interface and system Two selectable types of connecting terminals: screw type and cache clamp terminals Supported installation in two rows through the local extension MT-LE-SET to be connected to the basic module. Up to 256 digital inputs/outputs per basic module

UB UB

UB UB

0V 0V

0V 0V

PE PE

PE PE

MT-DP12E Basic module of the MT series, PROFIBUS/DP slave EN50170, DIN 19245-T3 Shielded twisted-pair with 24AWG = 0.22 mm2, impedance: 100 130 ; Shielded twisted-pair with 22AWG = 0.34 mm2, impedance: 135 165 RS485 Sync mode and freeze mode are supported 9.6; 19.2; 93.75; 187.5; 500 kBit/S, 1.5; 3; 6; 12 Mbit/s 4800 (3 repeater) Max. 4 extension modules (digital and analog I/O modules) 72 8 Optocoupler isolation between input terminals and internal power. 24 V DC (18 30 V) 1 1 Electronic The module posseses of status LEDs for all inputs. 0.75 2.5 24 Max. 0.5 (with maximum configuration) 0.35 96 x 114 x 60 124622 Screw type terminal block MT-DP12E-TBS, art. no.: 124624 Cache clamp terminal block MT-DP12E-TBC, art. no.: 124623 ROFIBUS connector for up to 12 Mbaud: ProfiConT, art. no. 87035 (see page 82)

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SPECIAL FUNCTION MODULES PROFIBUS/DP MT Modules Communications Modules

A Q
BASICS
X0 X1 X2

Digital input/mixed modules

MT-X16
INPUT DC24V X3 X4 X5 X6 X7 +24V

RUN US

X8

X9

XA

XB

XC

XD

XE

XF

UI

The digital input modules of the MT series facilitate the evaluation of process data (contacts, limit switches, etc.) via a PROFIBUS/DP master. Modules with 4, 8 and 16 inputs are supplied. Beside the 4 inputs the mixed module MT-X4Y4T consists of 4 transistor outputs.

MT-X16

Special features:
For the 16-type modules potential terminal blocks in three-wire technique are available. The driving power supplying the sensors and actors (except relay output) is directly fed into the module. Connection of the sensory circuits in three-wire technique Standard potential isolation between process and module Two selectable types of connecting terminals: screw type and cache clamp terminals

06 07 UI UI 00 01 02 03 04 05

06 07 UI UI 00 01 02 03 04 05

14 15 0V 0V 08 09 10 11 12 13

14 15 0V 0V 08 09 10 11 12 13

22 23 PE PE 16 17 18 19 20 21

22 23 PE PE 16 17 18 19 20 21

Specifications Inputs Simultaneously ON inputs Outputs Output type Common terminal arrangement Isolation Input voltage (sensor supply) Output voltage range Output voltage (actor supply) Max. switching voltage Rated input current per output Max. current per group Inrush current Leakage current at OFF OFF ON Response time ON OFF Short circuit protection Status display for inputs Error indicator I/O points Connection terminal Applicable wire size External sensor/actor supply Internalpowerconsumption(8VDC) Weight (without terminal block) Dimensions (W x H x D) Order information Accessories*

A A A

ms ms

mm2 mA kg mm

MT-X8 MT-X16 8 16 70 % 70 % Optocoupler isolation between input terminals and internal power for all modules. 24 V DC (25 %) 24 V DC (25 %) 0.7 0.7 1 1 1 1 Electronic Electronic All modules have one or two status LEDs per input. LED LED 8 16 All modules can be fitted with screw type or cache clamp terminal blocks (see accessories). 0.75 2.5 0.75 2.5 24 V DC (30 mA) 24 V DC (30 mA) 25 30 0.16 0.17 56 x 114 x 60 56 x 114 x 60 68896

MT-X4Y4T 4 100 % 4 Transistor 4 24 V DC (25 %) 24 V DC (-1 %) 24 V DC (25 %) 0.7 0.5 4 < 50 A 14 0.05 Electronic LED 8 0.75 2.5 24 V DC (20 mA) 35 0.22 56 x 114 x 60 124625

Art. no. 68893 Terminal MT-X8-TBS, no. 68894 blocks MT-X8-TBC, no. 68895

MT-X16-TBS, no. 68897 MT-X16-TBC, no. 68898 MT-X4Y4T-TBS, no. 124626 MT-X16-PTBS, no. 69400 MT-X4Y4T-TBC, no. 124627 MT-X16-PTBC, no. 69397 * Description of the terminal blocks: TBS=screw type terminal block, TBC=cache clamp terminal block, PTBS=screw type terminals with potential terminal, PTBC=cache clamp terminals with potential terminal

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Communications Modules PROFIBUS/DP MT Modules
Digital output modules
MT-Y8T2
OUT DC24V 2A Y1 Y2 Y3 Y4 OUT DC24V 2A Y5 Y6 Y7 +24V

SPECIAL FUNCTION MODULES

Y0

ERR US

UI

MT-Y8T2

The digital output modules of the MT series facilitate the evaluation of process data (contacts, limit switches, etc.) via a PROFIBUS/DP master. Modules with 4, 8 and 16 inputs are supplied. The digital output modules supply different function elements for the customisation to the required control functions.

A Q
BASICS

Special features:
For the 16-type modules potential terminal blocks in three-wire technique are available. The output modules provide transistor outputs rated at 0.5 A and 2 A, and relay outputs with up to 3 A (AC). The driving power supplying the sensors and actors (except relay output) is directly fed into the module. Connection of the sensory circuits in three-wire technique Standard potential isolation between process and module Two selectable types of connecting terminals: screw type and cache clamp terminals
MT-Y8R5 8 Relay 1 24 / 110 / 230 V DC, AC 250 V AC 5A(AC12)/3A(AC15)/1.0A(DC13) 5A(AC12)/3A(AC15)/0.2A(DC13) 5A(AC12)/3A(AC15)/0.1A(DC13) 10 ms 5 ms 8 0.75 2.5 24 V DC (20 mA) Max. 120 0.325 112 x 114 x 60 124628 MT-Y8R5-TBSLR, no. 125534 MT-Y8R5-TBCLR, no. 125533

06 07 U01U02 00 01 02 03 04 05

06 07 U01U02 00 01 02 03 04 05

14 15 0V 0V 08 09 10 11 12 13

14 15 0V 0V 08 09 10 11 12 13

PE PE PE PE PE PE PE PE PE PE

PE PE PE PE PE PE PE PE PE PE

Specifications Outputs Output type Common terminal arrangement Isolation Output voltage range Output voltage (actor supply) Max. switching voltage Switching capacity conf. EN60947/5/1 per output per group Leakage current at OFF OFF ON Response time ON OFF Short circuit protection Status display for outputs Error indicator I/O points Connection terminal Applicable wire size External sensor/actor supply Internalpowerconsumption(8VDC) Weight (without terminal block) Dimensions (W x H x D) Max. current Order information Accessories* at 24 V at 110 V at 220 V A A ms ms

mm2 mA kg mm

MT-Y8T MT-Y16T MT-Y8T2 MT-Y4R 8 16 8 4 Transistor Transistor Transistor Relay 8 8 4 1 Optocoupler isolation between input and output terminals and internal power for all modules. 24 V DC (-1 %) 24 V DC (-1 %) 24 V DC (-0.5 %) 24 / 110 / 230 V DC, AC 24 V DC (25 %) 24 V DC (25 %) 24 V DC (25 %) 250 V AC 2 A (AC15) / 1.3 A (DC 13) 2 A (AC15) / 0.25 A (DC 13) 2 A (AC15) / 0.1 A (DC 13) 0,5 0,5 2 4 4 4 <50 A <50 A 6 A 0.14 0.14 0.3 10 ms 0.05 0.05 0.08 5 ms Electronic Electronic Electronic All modules have one or two status LEDs per output. LED LED 8 16 8 8 All modules can be fitted with screw type or cache clamp terminal blocks (see accessories). 0.75 2.5 0.75 2.5 0.75 2.5 0.75 2.5 24 V DC (20 mA) 24 V DC (20 mA) 24 V DC (20 mA) 24 V DC (20 mA) 35 60 35 Max. 45 0.16 0.16 0.18 0.175 56 x 114 x 60 56 x 114 x 60 56 x 114 x 60 56 x 114 x 60 68902 MT-Y16T-TBS, no. 68903 MT-Y16T-TBC, no. 68904 MT-Y16T-PTBS, no. 69399 MT-Y16T-PTBC, no. 69398 68905 MT-Y8T2-TBS, no. 68906 MT-Y8T2-TBC, no. 68907 68908 MT-Y4R-TBS, no 69401 MT-Y4R-TBC, no. 69402

Art. no. 68899 Terminal MT-Y8T-TBS, no. 68900 blocks MT-Y8T-TBC, no. 68901

* Description of the terminal blocks: TBS=screw type terminal block, TBC=cache clamp terminal block, PTBS=screw type terminals with potential terminal, PTBC=cache clamp terminals with potential terminal

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SPECIAL FUNCTION MODULES PROFIBUS/DP MT Modules Communications Modules

A Q
BASICS
CH1

Analog input/output modules

MT-4DAV
OUT 0...10V CH3 CH2 CH4 +24V US

UO

MT-4DAV

Analog input modules of the MT series convert analog process data like pressure, temperature, etc. into digital values that are sent to the PROFIBUS/DP master. The analog output modules convert the digital values sent from the PROFIBUS/DP master into an analog voltage signal. This signal can be used to control valves, inverters, servomotors, etc.

Special features:
4 separately parameterisable channels per module Voltage, current, and temperature evaluation (MT-4AD) can be set via parameter. The driving power supplying the sensors and actors is directly fed into the module. With the analog input module current, voltage, and 4-wire PT100 inputs can be operated in parallel Two selectable types of connecting terminals: screw type and cache clamp terminals Standard potential isolation between process and module

06 07 UO UO 00 01 02 03 04 05

06 07 UO UO 00 01 02 03 04 05

14 15 0V 0V 08 09 10 11 12 13

14 15 0V 0V 08 09 10 11 12 13

PE PE PE PE

Specifications Module type No. of channels Analog input Resolution of digital output Resolution of digital input Analog output voltage Input resistance current voltage Max. input current Max. output load I/O characteristics

k V mA

Max. resolution Overall accuracy in % of the measurement range Max. conversion time Isolation Connection terminal External sensor/actor supply Applicable wire size Internal power consumption (8 V DC) Weight Dimensions (W x H X D) Order information Accessories

mm2 mA kg mm

MT-4AD MT-4DA Analog input module Analog output module 4 4 -10 V +10 V, -20 mA +20 mA, 4 20 mA, -180 +600 C (PT100) 16 bits binary (incl. sign) 16 bits binary (incl. sign) -10 +10 V, 0 +20 mA 176 50 15 30 750 Analog input Digital output Digital input Analog output -10 +10 V -4000 +4000 -20 +20 mA -4000 +4000 - 2000 +2000 -10 +10 V 4 20 mA 0 +4000 0 2000 0 +20 mA -180 +600 C -1800 +6000 2.5mV 5A 5V 4 A 10 A 0.125 C 50 mV (-10 +10 V) 80 A (-20 +20 mA) 76 A (4 20 mA) 4.2 C (-180 +600 C) 50 ms/channel 1 ms/4 channels Optocoupler isolation between input terminals and internal power All modules can be fitted with screw type or cache clamp terminal blocks (see accessories). 24 V DC (50 mA) 24 V DC (50 mA) 0.75 1,5 0.75 1,5 80 0.225 0.225 76 x 114 x 60 56 x 114 x 60 124643

MT-4DAV Analog output module 4 16 bits binary (incl. sign) 0 10 V DC 750 Digital input Analog output 0 4000 0 10 V

2.5 mV

1 ms/channel

30 mV (0 +10 V)

24 V DC (120 mA) 0.75 1,5 60 0.22 76 x 114 x 60 68912

Art. no. 68909

Terminal Screw type terminal block MT-4AD-TBS, no. 68910 Screw type terminal block MT-4DA-TBS, no. 124645 Screw type terminal block MT-4DAV-TBS, no. 68913 blocks Cache clamp terminal block MT-4AD-TBC, no. 68911 Cache clamp terminal block MT-4DA-TBC, no. 124644 Cache clamp terminal block MT-4DAV-TBC, no. 68914

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Communications Modules PROFIBUS/DP MC Modules
Digital input, output, and combined modules acc. to IP67
The digital I/O modules of the MC series support the evaluation of process signals (contacts, limit switches, etc.) directly on the machine via a PROFIBUS/DP master. The sensors and actuators are connected via plug-type/screw terminals. Different modules with 16 inputs max. and 8 outputs max. as well as a combined I/O module with 8 inputs and 4 outputs are available.

SPECIAL FUNCTION MODULES

A Q
BASICS

DI2 DI3 DI6 DI7

DI0 DI1 DI4 DI5

D02 D03

D00 D01
MC-DP X8Y4
IN OUT RN INT 0 1 2 3 I/O 4 5 6 7

Special features:
The driving power for the sensors and actuators is supplied directly on the module. Connection of the sensory circuits in 3-wire cabling. Standard electrical isolation between process and control via optocoupler. Overload and short-circuit protection.

Specifications Inputs Outputs Output type Isolation Input voltage (sensor supply) Rated output voltage Output voltage (actor supply) Max. switching voltage Max. input current per output Max. current per group Leakage current at OFF OFF ON Response time ON OFF Short circuit protection Status display for outputs Error indicator I/O points Connection terminal Applicable wire size External sensor/actor supply Internal power consumption (8 V DC) Weight (without termninal block) Dimensions (W x H x D) Order information

A A A A ms ms

mm2 mA kg mm

MC-DPX8 MC-DPX16 8 16 Optocoupler isolation between input terminals and internal power 24 V DC (25 %) 24 V DC (25 %) < 0.1 <0.1 1 1 1 1 Electronic Electronic All modules have one status LEDs per output. LED LED 8 16 All modules can be fitted with screw type or cache clamp terminal blocks. 0.75 2.5 0.75 2.5 24 V DC (100 mA) 24 V DC (100 mA) 80 80 0.47 0.47 62 x 217.5 x 70.5 62 x 217.5 x 70.5 127211

MC-DPY8 8 Transistor 24 V DC (25 %) 24 V DC (-1 %) 24 V DC (25 %) 2 2 10 at 055 C, 16 at 040 C <10 A 0.5 0.5 Electronic LED 8 0.75 2.5 24 V DC (100 mA) 80 0.47 62 x 217.5 x 70.5 127209

MC-DPX8Y4 8 4 Transistor 24 V DC (25 %) 24 V DC (-1 %) 24 V DC (25 %) 2 <0.1 2 10 bei 055 C, 16 bei 040 C <10 A 0.5 0.5 Elektronisch

16

24 V DC (100 mA) 80 0.47 62 x 217.5 x 70.5 127210

Art.-Nr. 127208

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SPECIAL FUNCTION MODULES DeviceNet Network Communications Modules

A Q
BASICS

Data Communications
The DeviceNet represents a cost-effective solution for the network integration of low-level terminal equipment. Up to 64 devices including a master can be integrated in one network.

Daisy Chain AnS/QnAS with master DN91 I/O Modules e.g. from third party manufacturers Frequency inverter

Structure
Due to the supported tree structure of the data line, a T-junction can be installed in any place. It has to be considered that the overall extension must not exceed 500 m. Using repeaters increases the overall extension to 3 km.

Trunk Line / Drop Line AnS/QnAS with master DN91 Frequency inverter I/O Modules e.g. from third party manufacturers

Cable types
For the data exchange a cable with two shielded twisted-pair cables is used.

Parameterization
Parameterization is done with the configuration software SyCon from Ver. 2.0.6.2 by the Hilscher company.

Communications
The bus accessing method CSMA/NDA ensures an extremely fast and efficient access of the link devices to the bus. Based on the Producer/Consumer network model this method ensures greater determinism of all data. The slave modules communicate via the following methods: Polling Bit strobe Change of state Cyclic Information at a size of 8 bytes per data packet can be transmitted. Packets exceeding these 8 bytes are fragmented automatically.

Cabel Outline diameter Inside wire for data (blue / white) Inside wire for power supply (red / black) Trunkline Dropline Max. distance Max. distance incl. Repeater m m mm

Thick Cable 12.2 18AWG19x30 zinc plated 15AWG19x28 zinc plated Yes Yes 500 3000

Thin Cable 6.9 24AWG19x36 zinc plated 22AWG19x34 zinc plated Yes Yes 500 3000

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Communications Modules DeviceNet Master Module
CAN based network for low level terminals
A1SJ71DN91
RUN L. RUN MS NS

SPECIAL FUNCTION MODULES

The DeviceNet represents a cost-effective solution for the network integration of low-level terminal equipment. Up to 64 devices including a master can be integrated in one network.
AA

A Q
BASICS

Special features:
Up to 64 devices including a master station can be configured within one network. The positions of master and slave stations are user-selectable. Transfer rates of 125, 250 and 500 kBaud. Distances of up to 500 m. Communication methods Polling Bit strobe Change of state Cyclic

DeviceNet

RS-232-C

A1SJ71DN91

Specifications Module type Applicable PLC series Nodes per network Stations per network Max. number of slave stations Communications volume Communication speed I/O communication Message communication Cabel length

A1SJ71DN91 Master MELSEC AnS/QnAS series Group 2 Client 0 up to 63 63 2048 adresses (256 bytes) 240 bytes 500 m 125 kBaud 250 m 250 kBaud 100 m 500 kBaud mA 26.5 32 mA 240 kg 0.23 mm 130 x 34.5 x 93.6 Art.-No. 124373 Configuration software SyCon from Fa. Hilscher

Network power consumption I/O points Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information Accessories

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SPECIAL FUNCTION MODULES The Network with Actuator Sensor Interface Communications Modules

A Q
BASICS

Data transfer
The AS interface is an international standard for the lowest field bus level. The network suits versatile demands, is very flexible and particularly easy to install. Controlled are Sensors Actors I/O units Gateways

AnS/QnAS

Slaves

Slaves

Structure
ASI networks can be configured in any random tree structure. Up to 2 repeaters are supported providing a maximum communication distance of 300 m. Terminating resistors are not needed.

Cable types
A special coded 2-wire cable or a round cable is required. When using a flat cable the modules are connected to the cable via push-through connections while the coding ensures a reverse protection.

Slaves

Specifications Network management Cabling Data transfer rate Bus cycle time Max. overall distance Slave units per master Repeaters per network

AS interface Master/Slave Coded twisted-pair cable (unshielded) kBit/s 167 5 ms m 100 (300 with Repeater) 31 2

Data exchange
The AS interface supports the connection of conventional sensors and actors following the master-slave principle.

Administration
The I/O points are assigned electronically through the bus connection or through the PLC program of the AnS/QnAS controller.

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Communications Modules AS Interface Module A1SJ71AS92
AS Interface master for AnS-/QnAS-CPUs
A1SJ71AS92
RUN U ASI ERR.

SPECIAL FUNCTION MODULES

MODE

The A1SJ71AS92 serves as master module for the connection of the AnS/QnAS series to the AS Interface system. The A1SJ71AS92 can control up to 62 slave units (31 per channel) with up to 4 inputs and 4 outputs each per address. The addresses of the slave devices across the AS Interface are assigned automatically by the master.

A Q
BASICS

SET

Special features:
ASI1+ ASI1+ ASI1ASI1ASI2+ ASI2+ ASI2ASI2-

Up to 62 slave units can be configured across two networks. Up to 496 digital inputs/outputs can be driven via the master. Communications via AS-I conform coded flat cable or round cable Highly efficient error securing system Automatic data exchange with the PLC

A1SJ71AS92

Specifications Module type Application range Max. number of slave stations to be controlled Assignable I/O points Data transfer rate I/O refresh time Communications method Error handling Transmission method distance

A1SJ71AS92 Master MELSEC AnS/QnAS series 31 x 2 Max. 2 x124 inputs, 2 x 124 outputs 167 kBaud Max. 5 ms APM modulation Parity check Bus 100 m (300 m with repeater) Acc. to IEC62026-2 (yellow cable), round cable 32 ASI power supply (30.5 V DC) mA 100 kg 0.3 mm 130 x 34.5 x 93.6 Art. no. 129936 External AS-I power supply: ASI-PS-2.8, art. no.: 130259

ASI network cable Assigned I/O points External power supply Power consumption Weight Dimensions (W x H x D) Order information Accessories

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SPECIAL FUNCTION MODULES MELSEC AnS Pulse Catch Module Pulse Catch Module

A Q
BASICS

Digital pulse catch

A1SP60
0 1 2 3 4 5 6 7

8 9 A B C D E F

A1SP60
0 1 2 3 4 5 6 7

8 9 A B C D E F

The A1SP60 is a digital input module capable of detecting narrow pulses independently of the program cycle time.

Special features:
1 2 3 4 5 6 7 8
9

0 1 2
0 1 2 3 4 5 6 7 8 9 A B C D E F

3 4 5 6 7
COM

8 9 A
B

10 11 12 13 14 15 16 17 18 19 20

C D E F
COM

DC NC NC
DC24V 7mA A1SP60

Possibility of working with pulse function or with normal input function In the case of the pulse function, it is ensured that a signal applied at the input (>0.5 ms) is caught. By means of DIP switches, it is possible to specify, in groups of 4 input points, whether they are used as normal input points or with pulse catch. Galvanic isolation between process and controller by means of an photocoupler is a standard feature

Specifications Input points Rated input voltage Operating voltage range Max. input points simultaneous ON resistance Input current voltage Switch ON current voltage Switch OFF current OFF ON Response time ON OFF Min. input pulse width Status display of inputs Isolation No. of occupied I/O points Connection terminal Applicable wire size Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information

V DC V DC k mA V mA V mA ms ms ms

mm2 mA kg mm

A1SP60 16 24 19.2 26.4 100 % ca. 3.3 ca. DC 7 DC 13 DC 3.5 DC 6.5 DC 1.7 0.5 1.0 0.5 LED All modules fitted with photocoupler isolation between input terminals and internal circuit. 16 The module is fitted with a terminal block with 20 screw terminals. 0.75 1.5 55 0.19 34.5 x 130 x 93.6

Art. no. 33197

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MELSEC AnS/QnAS
Interrupt Module MELSEC AnS Interrupt Module
Branching to subroutines
A1SI61
0 1 2 3 4 5 6 7

SPECIAL FUNCTION MODULES

8 9 A B C D E F

A1SI61
0 1 2 3 4 5 6 7

The A1SI61 is suitable for applications in which it is necessary to respond very rapidly to events.
8 9 A B C D E F

A Q
BASICS

Special features:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

0 1 2
0 1 2 3 4 5 6 7 8 9 A B C D E F
CO - +

3 4 5 6 7
COM

8 9 A
B

C D E F
M

Every input in this module is assigned a pointer which serves as a branch mark for a subroutine. If an interrupt/alarm signal is applied at an input, the PLC program is interrupted after it has worked through the current statement and a subroutine assigned to the input is first processed. Galvanic isolation between process and controller by means of an photocoupler is a standard feature Only one A1SI61 can be installed to one PLC system

NC NC
DC12V 4mA DC24V 8mA A1SI61

Specifications Input points Rated input voltage Operating voltage range Max. input points simultaneous ON resistance Input current voltage ON current voltage OFF current OFF ON Response time ON OFF Status display of inputs Isolation method No. of occupied I/O points Connection terminal Applicable wire size Internal power consumption (5 V DC) Weight Dimensions (W x H x D) Order information

V DC V DC k mA V mA V mA msec msec

mm2 mA kg mm

A1SI61 16 12 / 24 10.2 26.4 100 % ca. 2.7 ca. DC 4 / 8 DC 9 DC 3 DC 4 DC 1 0.2 0.2 LED All modules fitted with photocoupler isolation between input terminals and internal circuit. 32 The module is fitted with a terminal block with 20 screw terminals. 0.75 1.5 57 (all points ON) 0.2 34.5 x 130 x 93.6

Art.no. 33195

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ACCESSORIES MELSEC AnS Dummy Modules Dummy Modules

A Q
BASICS

Place keeper and mechanical protection

A1SG62
0 1 2 3 4 5 6 7

8 9 A B C D E F

The dummy modules protect unused slots on the base unit from foreign bodies and reserve I/O addresses.

Special features:
The A1SG62 has 16 simulation switches by means of which digital inputs can be set and reset. Indication of the status of the inputs/outputs by means of LEDs.

0 1 2 3 4 5 6 7 8 9 A B C D E F DUMMY POINT SW1 SW2

P OINT 16 32 48 64
A1SG 62

SETTING
SW1 SW2 SW1 SW2 SW1 SW2 SW1 SW2

Specifications I/O points Application Current consumption Weight Dimensions (W x H x D) Order information

A1SG60 16 Used to protect any vacant slot from dust. mA kg 0.08 mm 34.5 x 130 x 93.6 Art. no. 26596

A1SG62 Max. 64 (16, 32, 48 or 64 can be selected by DIP-switches) Used to reserve I/O points for a later to install I/O module. 60 0.13 34.5 x 130 x 93.6 30030

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Cables, Converters Connection Cable
Connection cable for subracks The connection cables A1SC01B, A1SC03B, A1SCO12B and A1SC30B are used for connecting main base units to the extension base units. They have been cut to the correct length for each application. The A1SC05NB cable is used for connecting MELSEC A series extension base units to AnS/QnAS series main base units. Connection of a base unit of the AnS/QnAS series to an A870GOT operator panel is also possible.

ACCESSORIES

A Q
BASICS

Specifications For extension base units Length Ohmic resistance R of the cable Order information

A1SC01B type MELSEC AnS/QnAS mm 55 0.020 Art. no. 24979

A1SC03B MELSEC AnS/QnAS 330 0.021 24980

A1SC12B MELSEC AnS/QnAS 1200 0.055 24981

A1SC30B MELSEC AnS/QnAS 3000 0.121 24982

A1SC60B MELSEC AnS/QnAS 6000 0.182 68294

A1SC05NB MELSEC A to AnS/QnAS, AnS/QnAS to A870GOT 450 0.037 24983

Adapter Cable
Assembled cable with D-SUB plug
The cable A32CBL is used for connecting the modules AX82 and AY82 of the MELSEC A series and the modules A1SX81 and A1SY81 of the MELSEC AnS series.

Specifications Connection cable for Inputs/outputs Length Order information

A32CBL type AX82, AY82 (MELSEC A), AnS) A1SX81, A1SY81 (MELSEC 32 m 3 Art. no. 3895

A32CBL-5m AX82, AY82 (MELSEC A), A1SX81, A1SY81 (MELSEC AnS) 32 5 56052

Interface Converter CR01-R2/R4 SET and CR01-R4/R4

This module is a signal amplifier with photocoupler isolation for RS422 signals. It is used to connect a PLC with external devices like operation panels or a personal computer, especially when a potential isolation is required and when the wiring length takes more than 15 meters.

Specifications Interface converter Order information

CR01-R4/R4 RS422 RS422 Art. no. 56173

CR01-R2/R4 SET RS422 RS232 56172

MITSUBISHI ELECTRIC

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MELSEC AnS/QnAS
ACCESSORIES MELSEC AnS Memory Cassettes Memory Medias

A Q
BASICS

MELSEC AnS memory cassettes The AnSCPUs all have a permanently installed RAM with 8 k, 14 k, 30 k or 60 k steps. EPROM and EEPROM memory cassettes are available for permanent storage.

The EPROMs are programmed via the A6WA-28P (A1SNMCA-8KP) or A2SWA-28P (A2SNMCA-KP) with the aid of MELSEC MEDOC plus.

A1SMCA -2KE

Specifications Memory cassette For CPU type Memory capacity Order information

A1SNMCA2KE type EEPROM A1SH kbyte 8 instructions 2 k Art.no. 68835

A1SNMCA8KE EEPROM A1SH 20 8k 68834

A1SNMCA8KP EPROM A1SH 20 8k 68832

A2SMCA14KP EPROM A2SH 32 14 k 38066

A2SNMCA30KE EEPROM A2SH 64 30 k 68831

A2SMCA30KP EPROM A2AS 64 30 k 54922

A2SMCA60KE EPROM A2AS 128 60 k 68000

MELSEC AnS Adapter Units

EPROM write adapter
The write adapters A2 SWA-28P and A6 WA-28P are used for writing on the memory cassettes A2S(N)MCA-KP and A1SMCA- of the MELSEC AnS series.

Specifications For memory cassettes Order information

A2 SWA-28P type A2SMCA-14KP/30KP Art. no. 38069

A6 WA-28P A1SMCA-8KP 24987

MELSEC QnAS Memory Cards

MELSEC QnAS memory cards The QnASCPUs all have a permanently installed RAM. This memory can be extended with a variety of PCMCIAmemory cards.
MITSUBISHI
SRAM CARD
INSERT

The combination cards (with two memory types) have a non-volatile EEPROM memory which is programmable by MELSEC MEDOC plus.

LOCK

Specifications Memory Memory capacity Order information

Q1MEM1MS type Card 1 MB SRAM Art.no. 64197

Q1MEM2MS Card 2 MB SRAM 64196

Q1MEM256SE Card 128 kB SRAM, 128 kB EEPROM 64193

Q1MEM512SE Card 256 kB SRAM, 256 kB EEPROM 64204

Q1MEM1MSE Card 512 kB SRAM, 512 kB EEPROM 68031

80

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Battery, Fuses, Cover Battery A6BAT
The A6BAT lithium cell battery is already installed in every MELSEC A series memory cassette. The battery protects the data in the cassette RAM when the power supply is switched off or in the event of power failures. It has a service life of around five years.

ACCESSORIES

A Q
BASICS

Specifications Voltage Backup time during power failure Dimensions ( x H) Order information

A6BAT V DC 3,6 A3NMCA-0 : 10800 h A3NMCA-40: 1400 h mm 16 x 30 Art. no 4077

Fuses
The output modules A1SY22, A1SY80 and A1SY81 are equipped with dedicated fuses for device protection.

Specifications For module Rating Type Order information

HM50C A1SY22 5A Solder fuse Art. no 38361

LM50 A1SX80 5A Plug fuse 32301

LM32 A1SY81 3.2 A Plug fuse 32303

Dust Cover
If I/O devices are mounted on an extension base unit, then the first module on the extension base unit should be equipped with a dust cover.

Specifications Material Dimensions (W x H) Order information

Dust Cover Plastics mm 44 x 129 Art. no. 32299

MITSUBISHI ELECTRIC

81

MELSEC AnS/QnAS
ACCESSORIES Local System Extension Set for the MT Series Network Accessories

A Q
BASICS

For the extension of the MT series to a second connecting level the local system extension MT-LE and the connecting cable MT-LE-CBL50 are required. The extension and the cable are available only as complete set, which is called MT-LE-SET.

Specifications Application Cable length Dimensions (W x H x D) Order information

MT-LE-SET MT series m 0.5 mm 22.5 x 97 x 36 Art.no. 69759

ProfiConT Profibus Connector

The ProfiCon bus connector plug is designed for connecting DIN 19245 standard Profibus components with data transfer rates of up to 12 Mbaud. The connector is available with a selectable termination resistor.
Specifications Data rate 12 Mbit/s Terminator Order information ProfiConT supported Yes (selectable) Art. no. 87035

82

on ProfiC

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Terminal Assignments MELSEC AnS/QnAS Power Supply Modules
A 1S61PN
POWER

TERMINALS + DIMENSIONS

A Q
BASICS

MITSUBISHI

INPUT 100-240VAC 105VA 50/60Hz

OUTPUT 5VDC 5A

A1S61PN NC NC

A1S62PN +24V 24G

A1S63P

FG (FG) (FG)

(LG)

(LG) LG +24G INPUT 24G

INPUT 100-240VAC

INPUT 100-240VAC

MELSEC AnS/QnAS Digital Input Modules

A1SX10EU

120VAC 7mA 50/60 Hz

V9

A1SX10EU

MELSEC AnS/QnAS Digital Output Modules

A1SY18AEU

A1SY28EU

120/240VAC 7mA 0.6A

A1SY18AEU

A1SY28EU

MITSUBISHI ELECTRIC

83

MELSEC AnS/QnAS
TERMINALS + DIMENSIONS MELSEC AnS Analog Input/Output Modules Terminal Assignments

A Q
BASICS
C H 1

RUN OFFSET

GAIN

C H 2 C H 3

C H 4 C H 5

C H 6

V+ COM I+ V+ COM I+ V+ I+ V- ISLD V+ I+ V- IV+ I+ V- ISLD V+ I+ V- IAG

(FG)

INPUT 24VDC D/A A/D 0~10 V 0~20 mA

2 3

MELSEC AnS Counter, Timer and Positioning Modules

A1ST60
Y0 Y1 Y2 Y3 Y4 Y5 Y6 Y7 X0 X1 X2 X3 X4 X5 X6 X7

78

901

TIM. SET

456

SET UP T0 T1 T2 T3 T4 T5 T6 T7
A1ST60
105 1E 105 1E 105 1E 105 1E 105 1E 105 1E 105 1E 105 1E

84

23

ON OFF

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Terminal Assignments MELSEC AnS/QnAS Interface Modules
A1SJ71UC24-R2 A1SJ71UC24-R4 A1SJ71UC24-R2-S2 A1SJ71UC24-R4-S2

TERMINALS + DIMENSIONS

A1SJ71QC24-R2
RUN ERR. C.R/W NEU C/N ACK P/S PRO NAK SIO SD.W. SD RD
CH1
ERROR

A1SJ71QC24
SW.E. NEU ACK NAK SD.W. SD RD ERR. C/N P/S PRO SIO RUN ERR. C.R/W NEU C/N ACK P/S PRO NAK SIO SD.W. SD RD
CH1
ERROR

CH2

SW.E. NEU ACK NAK SD.W. SD RD

ERR. C/N P/S PRO SIO

A Q
BASICS

CH2

DISPLAY STS ERR

X10
456 901

AC
X1
456

DISPLAY
STS ERR
X10
4 56 901

CC
X1
4 56

CH1
456
23

CH2
456 4 56
789 F 01

CH1
23

CH2
4 56
789 F 01

23

SW

CH1/2 1 9 2 10 3 11 4 12 5 6 7 8 ON CH1 RS-232-C

SW

CH1/2 1 9 2 10 3 11 4 12 5 6 7 8 ON CH2 RS-422/485

SDA SG SDB FG RDA NC RDB

A1SJ71UC24-R2 A1SJ71UC24-R4 A1SJ71UC24-R2-S2 A1SJ71UC24-R4-S2

A1SJ71QC24-R2

CH2 RS-232-C

CH1 RS-232-C

A1SJ71QC24

MELSEC AnS/QnAS Communications Modules

A1SD51S-BAL

A1SD51S-BAL

MELSEC AnS/QnAS Communications Modules for Ethernet and MELSECNE4T Networks

A1SJ71E71-B2-S3
UN RDY

A1SJ71E71-B5-S3
RUN RDY BSY B1 B2 B3 B4 B5 B6 B7 B8 RAM CHK RAM ERR. ROM CHK ROM ERR. S.C. S.C.ERR COM.ERR: FROM/TO

A1SJ71QE71-B2
RUN RDY BSY B1 B2 B3 B4 B5 B6 B7 B8 CPU R/W TRAN. S TRAN. R FTP SW ERR. COM.ERR. TEST TEST ERR.

A1SJ71QE71-B5
RUN RDY BSY B1 B2 B3 B4 B5 B6 B7 B8 CPU R/W TRAN. S TRAN. R FTP SW ERR. COM.ERR. TEST TEST ERR.

A1SJ71QBR11

A1SJ71LP21
PW PC REM. SW.E. D.LINK M/S.E. T.PAS. PRM E. F.E. R.E. CPU R/W
RUN MNG S.MNG

CRC OVER AB.IF TIME DATA UNDER SD RD

23

MODE

789 F 01

MODE

7 89 F 01

ON OFF SW1 SW2 SW3 SW4

AUI
78

AF
SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8
456 901
23

OFF ON
8 9A
BCD 345
EF

AE
SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8
0 12
67

OFF ON
7 8

456

X100

456

NETWORK NO. 78
78 23 23

DISPLAY L R

(F.L.)
901

(R.L.)

GR.NO. ST.NO. X10

456

78 23

456

78 23

MODE 0:ONLINE(A.R) 2:OFFLINE

FRONT SIDE

+12 12G FG
A1SJ71E71-B2-S3

+12V 12G FG 1OBASE2

A1SJ71QE71-B2

INPUT 12VDC
IN

OUT

(FG)
A1SJ71QE71-B5

A1SJ71E71-B5-S3

A1SJ71QBR11

A1SJ71QLP21

MITSUBISHI ELECTRIC

45 23

67

MODE

89

CD AB

23

10BASE

X1

456

78

23

MODE 0:ONLINE 1:ONLINE 2:TEST1 3:TEST2 4:TEST3

MODE 0:ONLINE 1:ONLINE 2:TEST1 3:TEST2 4:TEST3 5:TEST4

MODE 0:ONLINE 1:ONLINE 2:TEST1 3:TEST2 4:TEST3 5:TEST4

X10

456

456

78

X1

ON SW OFF 1 REM PC 2 N.ST MNG D.S.M P.S.M 3 PRM D.PRM ST. SIZE 4 5 8,16,32,64 6 LB/LW SIZE 2, 4, 6, 8K 7 8

OFF ON SW 1 2 3 4 5 6 7 8

901

901

STATION NO.

STATION NO.

2 3

2 3

2 3

2 3

7 8

7 8

7 8

7 8

AB

AB

AB

AB

CDE

CDE

CDE

CDE

E R R O R

901
2 3

901 901 901 901 901

01 EF

85

MELSEC AnS/QnAS
TERMINALS + DIMENSIONS MELSEC AnS/QnAS Communications Modules for MELSECNET Networks Terminal Assignments

A Q
BASICS

A1SJ71QLP21
PW PC REM. SW.E. D.LINK M/S.E. T.PAS. PRM E. F.E. R.E. CPU R/W
RUN MNG S.MNG

A1SJ72QLP25
CRC OVER AB.IF TIME DATA UNDER SD RD E R R O R
RUN DUAL D.LINK T.PASS WAIT F.E. PW HOLD RMT.E. SW.E. ST.E. PRM.E R.E. CRC E OVER R AB.IF R TIME DATA O UNDER R SD RD

A1SJ72QBR-15
RUN PW HOLD RMT.E. D.LINK SW.E. T.PASS ST.E. WAIT PRM. CRC OVER AB.IF TIME DATA UNDER SD RD

E R R O R

AB
RESET STATION NO. 78 X10
456 456

X100

456

NETWORK NO. 78
78 23 23

DISPLAY L R

456

(F.L.)
901

(R.L.)

456

RESET STATION 78 NO. X10

456

DISPLAY L R (F.L.) (R.L.)

SW Setting OFF ON 1 QnA A 2 3 OFF 4 5

DISPLAY L R
SW Setting OFF ON QnA A OFF

X10

456

78 23

78

X1

89A

8 9A

GR.NO. ST.NO. X10

456

78 23

BC D 345

BCD 345

456

78 23

67

X1

456

78 23

MODE 0:ONLINE(A.R.) 2:OFFLINE

MODE 0:ONLINE(A.R.) 2:OFFLINE

MODE 0:ONLINE(A.R) 2:OFFLINE

FRONT SIDE

IN

OUT
A1SJ71QLP21

MELSEC AnS/QnAS Communications Modules for I/O-Link, Profibus, CC-Link, DeviceNet and AS Interface
A1SJ71PB96F A1SJ71PB92D A1SJ61BT11
RUN ERR. MST S MST LOCAL CPU R/W L RUN L ERR. SW M/S PRM TIME LINE SD RD
E R R O R

MELSEC AnS/QnAS Pulse Catch and Interrupt Modules, Co-Processor module

SPAC20
RUN

MB

FG FG

+24 0V

FG FG

D01 +A01 0V -A01

+24 +A02 D02 -A02 D03 +A03 0V +24 -A03 SV0 +AI0 -AI0 AG0
8 9 9 8 7 7 6 6 5 5

SELECT
WD TIME WDR OFF NO BUS W. START NO I/O ON 1 2 3 4 5 6

D05 0V

+DI0 SV1 -DI0 +AI1 +DI1 -AI1 -DI1 AG1 +DI2 SV2 -DI2 +AI2 +DI3 -AI2

RS-232C

-DI3 AG2 +DI4 SV3 -DI4 +AI3 +DI5 -AI3 -DI5 AG3

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10

D04

RUN STOP RESET

+24 +A00 D00 -A00

1 1

86

45 23

67

MODE

89

CD AB

OFF ON SW 1 2 3 4 5 6 7 8

FRONT SIDE

IN

OUT

A1SJ72QBR-15

67

MODE

MODE

A1SJ71PB96F

A1SJ71PB92D

23

23

ON SW OFF 1 REM PC 2 N.ST MNG D.S.M P.S.M 3 PRM D.PRM ST. SIZE 4 5 8,16,32,64 6 LB/LW SIZE 2, 4, 6, 8K 7 8

X1

X1

23

23

901 901 901 901 901

SW 1 2 3 4 5 OFF ON

1 2 3 4 5

78

SW 1 2 3 4 5 OFF ON

901

901 901
012

901

EF

EF

0 12

01 EF

A1SJ61QBT11
RUN ERR. MST S MST LOCAL CPU R/W L RUN L ERR. SW M/S PRM TIME LINE SD RD
E R R O R

A1SJ71DN91
RUN L. RUN MS NS

A1SJ71AS92
RUN U ASI ERR.

STATION NO. MODE X 10 X 1

OFF ON M/L S MST

STATION NO. MODE X 10 X 1

OFF ON M/L S MST

AA
MODE
DeviceNet

SET
CLEAR HOLD 1 4 CLEAR HOLD 1 4

B RATE
0 1 2 3 4 156K 625K 2.5M 5M 10M 0 1 2 3 4

B RATE
156K 625K 2.5M 5M 10M

ASI1+ ASI1+ ASI1ASI1ASI2+ ASI2+

RS-232-C

NC DA NC DB NC DG NC SLD NC (FG) (FG) SLD DG DB DA

NC NC NC NC NC

ASI2ASI2-

A1SJ71DN91

X
0 1 2 3 4 5

WDT BOOT SD/RD FROM/TO BATT L PS L

SPAC20

MITSUBISHI ELECTRIC

MELSEC AnS/QnAS
Terminal Assignments MELSEC I/O Link Decentralised Digital Input/Output Modules
AJ55TB3-4D
1 3 5 7 9 11 13 15

TERMINALS + DIMENSIONS

DATA
2

FG
4

+24V
6

I/024A
8

X0
10

X1
12

X2
14

X3
16

A Q
BASICS

DG

24G

I/024B COMB COMA COMB COMA COMB

AJ55TB32-4DR
1 3 5 7 9 11 13 15

DATA
2

FG
4

+24V
6

I/024A
8

X0
10

X1
12

Y0
14

Y1
16

DG

24G

I/024B COMB COMA COM1 COM1 COM2

AJ55TB2-4R
1 3 5 7 9 11 13 15

DATA
2

FG
4

+24V
6

I/024V
8

Y0
10

Y1
12

Y2
14

Y3
16

DG

24G

I/024G COM1 COM1 COM1 COM1 COM2

AJ55TB3-8D
1 3 5 7 9 11 13 15 17 19 21 23

DATA
2

FG
4

+24V
6

I/024A
8

X0
10

X1
12

X2
14

X3
16

X4
18

X5
20

X6
22

X7
24

DG

24G

I/024B COMB COMA COMB COMA COMB COMA COMB COMA COMB

AJ55TB32-8DR
1 3 5 7 9 11 13 15 17 19 21 23

DATA
2

FG
4

+24V
6

I/024A
8

X0
10

X1
12

X2
14

X3
16

Y0
18

Y1
20

Y2
22

Y3
24

DG

24G

I/024B COMB COMA COMB COMA COMB COM1 COM1 COM1 COM2

AJ55TB2-8R
1 3 5 7 9 11 13 15 17 19 21 23

DATA
2

FG
4

+24V
6

I/024V
8

Y0
10

Y1
12

Y2
14

Y3
16

Y4
18

Y5
20

Y6
22

Y7
24

DG

24G

I/024G COM1 COM1 COM1 COM1 COM1 COM1 COM1 COM1 COM2

AJ55TB3-16D
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39

DATA
2

FG
4

+24V
6

I/024A
8

X0
10

X1
12

X2
14

X3
16

X4
18

X5
20

X6
22

X7
24

X8
26

X9
28

XA
30

XB
32

XC
34

XD
36

XE
38

XF
40

DG

24G

I/024B COMB COMA COMB COMA COMB COMA COMB COMA COMB COMA COMB COMA COMB COMA COMB COMA COMB

AJ55TB32-16DR
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39

DATA
2

FG
4

+24V
6

I/024A
8

X0
10

X1
12

X2
14

X3
16

X4
18

X5
20

X6
22

X7
24

Y0
26

Y1
28

Y2
30

Y3
32

Y4
34

Y5
36

Y6
38

Y7
40

DG

24G

I/024B COMB COMA COMB COMA COMB COMA COMB COMA COMB COM1 COM1 COM1 COM1 COM1 COM1 COM1 COM2

AJ55TB2-16R
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39

DATA
2

FG
4

+24V
6

I/024V
8

Y0
10

Y1
12

Y2
14

Y3
16

Y4
18

Y5
20

Y6
22

Y7
24

Y8
26

Y9
28

YA
30

YB
32

YC
34

YD
36

YE
38

YF
40

DG

24G

I/024G COM1 COM1 COM1 COM1 COM1 COM1 COM1 COM1 COM2 COM3 COM3 COM3 COM3 COM3 COM3 COM3 COM4

MITSUBISHI ELECTRIC

87

MELSEC AnS/QnAS
TERMINALS + DIMENSIONS CC-Link Decentralised Digital Input/Output Modules Terminal Assignments

A Q
BASICS

MITSUBISHI

AJ65BTB1-16D
RD L ERR.

B RATE
01 2 3 4

PW L RUN SD

STATION NO.
X10 X1

0 1 2 3 4 5 6 7 8 9 A B C D E F

01 901 2 2 8 3 3 7 6 54 6 54

AJ65BTB1-16DT
1 DA 2 DB 3 DG 4 5 +24V 6 (FG) 7 24G 8 X0 9 24G X1 10 X2 11 X3 12 X4 13 X5 14 X6 15 X7 16 17 NC 18 Y8 19 Y9 20 YA 21 YB 22 YC 23 YD 24 YE 25 XF 26 COM2+ 27 CLT2+

SLD

COM1+

AJ65BTB2-16D
1 DA 2 DB 3 DG 4 5 +24V 6 (FG) 7 24G 8 NC 9 11 13 X2 14 COMB 15 17 19 X6 20 COMB 21 X7 22 NC 23 25 27 XA 28 COMB 29 31 33 XE 34 COMB 35 37 24G NC COMB 10 12 X0 X1 COMB X3 16 18 X4 X5 COMB NC 24 26 X8 X9 COMB XB 30 32 XC XD COMB XF 36 COMA

AJ65BTB1-16T
1 DA 2 DB 3 DG 4 5 +24V 6 (FG) 7 24G 8 Y0 9 24G Y1 10 Y2 11 Y3 12 Y4 13 Y5 14 Y6 15 17 19 Y9 20 YA 21 YB 22 YC 23 YD 24 YE 25 XF 26 COM227 CLT2+ CLT1+ Y7 16 18 COM1Y8

SLD

SLD

1 DA 2 DB

3 DG 4

5 +24V 6

7 24G 8 (FG)

11

13 Y2 14

15

17

19 Y6 20

21

23

25

27 YA 28

29

31

33 YE 34

35

37

1 DA 2 DB

3 DG 4

5 +24V 6

7 24G (FG)

CTL+ COMB 24G 10 12 Y0 Y1

COMB Y3 16 18 Y4 Y5

COMB COMD Y7 22 24 26 COMA Y8 Y9

COMD YB 30 32 YC YD

COMD YF 36 COMC

SLD

CTLG

COMB

COMB

COMD

COMD

SLD

1 DA 2 DB

3 DG 4

5 +24V 6

7 24G 8 (FG)

9 24G X1 10 X0

11 X3 12

13 X5 14

15 X7 16

17 NC 18 X8

19 X9 20

21 XB 22

23 XD 24

25 XF 26

27 NC COM

1 DA 2 DB

3 DG 4

5 +24V 6

7 24G (FG)

SLD

X2

X4

X6

COM

XA

XC

XE

SLD

CC-Link Decentralised Digital Input/Output Modules and Special Function Modules

MITSUBISHI
PW RUN L RUN SD RD L ERR. B RATE STATION NO.
X10 X1

MITSUBISHI
CH. 1 A B DEC PRE F ST. EQU1 EQU2 CH. 2 A B DEC PRE F ST. EQU1 EQU2

AJ65BT-D62D
PW RUN L RUN SD RD L ERR.

01 901 01 2 28 2 3 3 7 3 4 6 54 6 54

CH. OFFSET UP RESET

01 2 3 4
SET

GAIN DOWN

AJ65BT-64DAI
1 DA 2 DB 3 DG 4 5 +24V 6 (FG) 7 24G 8 TEST 9 HLD/ CLR 24G 11 13 15 17 19 21 23 25 27 HLD/ CH1 CH2 CH3 CH4 CLR I+ I+ I+ I+ 10 12 14 16 18 20 22 24 26 TEST COM COM COM COM

AJ65BT-D62D
1 DA 2 DB 3 DG 4 5 +24V 6 (FG) 7 24G 9 11 13 15 17 19 21 23 25 27 CH1 CH2 EQR CH1 CH1 CH2 CH2 CH2 CH1 CH2 24G A ( A ) B ( B ) COM A ( A ) B ( B ) PRST F. ST EQR2 EQR2 COM 10 12 14 16 18 20 22 24 26 CH1 CH1 CH1 CH1 CH2 CH2 CH1 CH2 +12 CH2 A ( A ) B ( B ) PRST F. ST A ( A ) B ( B ) COM EQR1 EQR1 24V 8

SLD

SLD

AJ65BT-64DAV
1 DA 2 DB 3 DG 4 5 +24V 6 (FG) 7 24G 8 9 HLD/ CLR 24G 10 11 13 15 17 19 21 23 25 27 HLD/ CH1 CH2 CH3 CH4 CLR V+ V+ V+ V+ 12 14 16 18 20 22 24 26 COM COM COM COM
AX1 AX2 B RATE PW RUN L RUN SD RD L ERR. STATION NO.
X10 X1

MITSUBISHI

AJ65BT-D75P2-S3

SLD

TEST

TEST

AJ65BT-64AD
1 DA 2 DB 3 DG 4 5 +24V 6 (FG) 7 24G 8 TEST 9 11 13 15 17 19 21 23 25 27 CH1 CH2 CH3 CH4 SLD SLD FG1 COM COM V+ V+ V+ V+ 12 14 16 18 20 22 24 26 CH1 CH2 CH3 CH4 TEST SLD AG I+ I+ I+ I+ COM COM

10

SLD

AJ65BT-64RD3
1 DA 2 DB 3 DG 4 5 +24V 6 (FG) 7 24G 8 NC 9 A1 10 B1 11 b1 12 SLD 13 SLD 14 NC 15 A2 16 B2 17 b2 18 NC 19 A3 20 B3 21 b3 22 SLD 23 SLD 24 NC 25 A4 26 B4 27 b4

SLD

AJ65BT-D75P2-S3
1 3 DA DG 2 DB 4 5 +24V 6 (FG) 7 24G

AJ65BT-64RD4
1 DA 2 DB 3 DG 4 5 +24V 6 (FG) 7 24G 8 a1 9 A1 10 B1 11 b1 12 SLD 13 SLD 14 a2 15 A2 16 B2 17 b2 18 a3 19 A3 20 B3 21 b3 22 SLD 23 SLD 24 a4 25 A4 26 B4 27 b4

SLD

SLD

AJ65BT-68TD
1 DA 2 DB 3 DG 4 5 +24V 6 (FG) 7 24G 8 9 11 13 15 17 19 21 23 25 RTD 26 NC 27 RTD

MITSUBISHI
CH1 + CH2 + CH3 + CH4 + CH5 + CH6 + CH7 + CH8 + 10 12 14 16 18 20 22 24 CH2 CH3 CH4 CH5 CH6 CH7 CH8 NC

AJ65BT-R2
PW RUN L RUN SD RD L ERR.

Y00 Y01 Y02 Y03 Y04 Y05 Y06 Y07 Y08 Y09 YA YB YC YD YE YF NC NC CLT+ CLT-

Y10 Y11 Y12 Y13 Y14 Y15 Y16 Y17 Y18 Y19 Y1A Y1B Y1C Y1D Y1E Y1F NC NC COM COM

AJ65BTB1-16D

AJ65BTC1-32T

X00 X01 X02 X03 X04 X05 X06 X07 X08 X09 X0A X0B X0C X0D X0E X0F NC NC COM COM

X10 X11 X12 X13 X14 X15 X16 X17 X18 X19 X1A X1B X1C X1D X1E X1F NC NC NC NC

AJ65BTB2-16R

AJ65BTC1-32D

B RATE STATION NO.

X10 X1

01 901 01 28 2 2 3 3 7 3 4 6 54 6 54

RING PLS CH. 1 2 CH. 1 2

RESET

01 901 01 28 2 2 3 7 3 3 4 6 54 6 54

MODE RESET

B RATE STATION NO. RS-232-C SD RD ERR.

X10 X1

XC XD YC YD

01 901 01 28 2 2 3 7 3 3 4 6 54 6 54

SLD

CH1 -

MODE SW2 1

3 4 5 6 7 8

RESET
ON

RS-232-C

I/O

AJ65BT-R2
1 DA 2 DB 3 DG 4 5 +24V 6 (FG) 7 24G 1 XC 2 COM1 3 XD 4 NC 5 YC 6 7 YD

SLD

COM2

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Dimensions Base Units
Type A1S32B-E A1S33B-E A1S35B-E A1S38B-E A1S38HB A1S52B-S1 A1S55B-S1 A1S58B-S1 A1S65B-S1 A1S68B-S1
X (in mm) 220 255 325 430 430 155 260 365 315 420

TERMINALS + DIMENSIONS

A Q
BASICS

130

CPUs and Power Supply Modules

130

54,5

6,5

AnS: 93,6 / QnAS 110

130

54,5

6,5

93,6

Digital and Special Function Modules

130

34,5

6,5

93,6

130

69,5

6,5

71,6 93,6

22

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TERMINALS + DIMENSIONS Profibus/DP MT Modules Dimensions

A Q
BASICS

56

76

60

116,2

116,2

114

114

96

60

41,5

22,5

36

97

116,2

114

Profibus/DP MC Modules

0 1 2 3

4 5 6 7

IN OUT RN INT I/O

62

MC-DP X8Y4

41,5

86

206,5 217,5

14,5 45 70,5

90

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Dimensions Profibus/DP Compact I/O Modules
MITSUBISHI AJ95TB2-16T
RUN BF DIA L1+ L2+ STATION NO. X10 X1

TERMINALS + DIMENSIONS

A Q
BASICS

0 1 2 3 4 5 6 7 8 9 A B C D E F

80

BUS TEMINATION

DP I / F

IN (FG) 24V L1+ (+C) X0 X1 X2 X3 X4 X5 X6 X7 1,21 22 31,32 3 4 5 6 7 8 9 10 2,41 42-60 24G L1G (-C) X0 X1 X2 X3
TB3-16D

IN X8 X9 XA XB XC XD XE XF 13 14 15 16 17 18 19 20

ON

X4 X5 X6 X7

X8 X9 XA XB

XC XD XE XF

197,4

46,5

MELSEC AnS/QnAS Decentralised Input/Output Modules

Type AJ55TB3-4D AJ55TB3-8D AJ55TB3-16D AJ55TB32-4DR AJ55TB32-8DR AJ55TB32-16DR AJ55TB2-4R AJ55TB2-8R AJ55TB2-16R
X (in mm) 82 114 177 82 114 177 82 114 177

45

66

CC-Link Decentralised Input/Output Modules and Special Function Modules

2 x 4,5
MITSUBISHI

AJ65BT-64DAI
PW RUN L RUN SD RD L ERR.

B RATE STATION NO.

X10 X1

01 901 01 2 28 2 3 3 7 3 4 6 54 6 54

CH. OFFSET UP RESET

01 2 3 4
SET

Bx

GAIN DOWN

1 DA 2

5 7 9 11 13 15 17 19 21 23 25 27 DG +24V 24G 4 6 8 10 12 14 16 18 20 22 24 26 DB SLD (FG)

Ax A

9,5

I/O Modules
Type A Ax B Bx C

Analog modules AJ65BTAJ65BT64DAV/DAI 68TD

151.9 142.9 65 56 63 151.9 142.9 65 56 63

Special Funktion Modules AJ65BT64RD3/4

151.9 142.9 65 56 63

AJ65BTB1- AJ65BTB2- AJ65BTC1- AJ65BTB1- AJ65BTB1- AJ65BTC1- AJ65BTB2- AJ65BT16D 16D 32D 16DT 16T 32T 16R 64AD
151.9 142.9 65 56 46 197.4 188.4 65 56 46 165 156 65 56 46 151.9 142.9 65 56 46 151.9 142.9 65 56 46 165 156 65 56 46 197.4 188.4 65 56 46 151.9 142.9 65 56 63

AJ65BTD62
151.9 142.9 65 56 63

AJ65BTAJ65BTD75P2-S3 R2
170 161 80 71 63.5 170 161 80 71 63.5

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PROGRAMMING Programming and Documentation Software for Standard Personal Computers Software

A Q
BASICS

With the MELSoft software family Mitsubishi Electric offers efficient software packages helping to reduce programming and setup times to a high degree. The MELSoft software family provides instant access, direct communications, compatibility, and open exchange of variables.

The MELSoft family comprises: Programming packages like GPP/WIN and MELSEC MEDOC plus Network configuration software MELSEC ProfiMap Visualization software MX SCADA Software for a dynamic data exchange like MXChange Various development software for operator terminals (refer to the Technical Catalogue HMI)

GPP/WIN is recommended as a costeffective beginners package for the A/Q series. This package offers a quick and easy introduction to programming. For structured programming the IEC1131 conform programming software MELSEC MECOC plus is recommended. For detailed information please order our separate MELSoft brochure.

GPP/WIN
GPP/WIN is the standard programming software for the MELSEC A/Q series and combines all functions of MELSEC MEDOC with the user guidance of Microsoft Windows. With GPP/WIN you can comfortably create PLC programs alternatively in the form of Ladder Diagrams or Instruction Lists. Both forms of representation can be toggled easily during operation. Besides efficient monitoring and diagnostics functions GPP/WIN features an offline simulation of any PLC type from the FX0S to the Q4AR. This software provides all the Windowsspecific advantages and is especially suited to all MELSEC PLCs. GPP/WIN can be run under Windows 95 and Windows NT.

Software Series Language Disk type Included accessory Order information

MM GPP/WIN All MELSEC PLCs English / German CD ROM Converter Art. no. 126047

All MELSEC PLCs English / German CD ROM 126048

MELSEC MEDOC plus

MELSEC MEDOC plus provides all functions of the pre-mentioned programs and meets the programming standard for the future: IEC 1131.3. This makes MELSEC MEDOC plus ready for the programming standard of the future and offers in addition the basis for the on-leading programming of the MELSEC A and Q series. MELSEC MEDOC plus can be run under Windows 3.11 and Windows 95/98. The software is supplied complete with an SC-09N serial interface cable.

Software Series Language Disk type Order information

S-Set AnS(H), AnAS, AnUS, FX family English / German CD ROM Art. no. 126810

Q-Set All MELSEC PLCs English / German CD ROM 126811

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Software PROGRAMMING Network Configurations Software, Visualization Software and Software for Dynamic Data Exchange MELSEC ProfiMap
MELSEC ProfiMap V3.0 is a user friendly configurations software for open networks like MAP 3.0/ETHERNET and PROFIBUS/DP or PROFIBUS/FMS. The software package is a 32 bit application for Windows 95 and Windows NT4.0. Configuration of all PROFIBUS modules for the MELSEC Ans/QnAS and A/Q series is possible.
Software

A Q
BASICS

Due to the supported extended user parameters of a GSD file, easy parameter setting of PROFIBUS/DP slave devices is possible even for third party devices. The new ProfiMap V3.0 enables the download of all configuration data via an overriding network.

ProfiMap 3.0 CD-Set Supported master modules for the Mitsubishi Profibus/DP: A1SJ71PB92D, AJ71PB92D Profibus/FMS: A1SJ71PB96F, AJ71PB96F MELSEC AnS/QnAS and A/Q series MAP3.0/Ethernet: AJ71M56EF2 Language English Configuration cable ProfiCab is included Disk type CD ROM Order information Art. no. 128585

ProfiMap 3.0 CD Profibus/DP: A1SJ71PB92D, AJ71PB92D Profibus/FMS: A1SJ71PB96F, AJ71PB96F MAP3.0/Ethernet: AJ71M56EF2 English ProfiCab is not included CD ROM 128586

MELSEC MX SCADA
MELSEC MX SCADA is a process visualisation system that can handle everything from simple installations to complex production control systems. The software package can administer up to 100000 obSoftware Series Language Disk type Order information

jects. A variety of interfaces are supported, including ETHERNET. The software runs under Windows 95 and Windows NT and is available in a variety of different versions geared to the objects to be handled.
Run-time version All MELSEC PLC English CD ROM On request DEMO version All MELSEC PLC English CD ROM 65135

Development version All MELSEC PLC English CD ROM Art. no. On request

MELSEC MX Change
MELSEC MXChange is integrated in the MELSOFT family as the heart of automation. The software package consists of a Server and a Super Projekt Manager, other automation programs can be connected to. Since MXChange operates across a network, any variable once declared can be used by all other systems connected to the database.
Software Language Executable tags Disk type Order information MXChange Network English 10.000 CD ROM Art. no. 129639

Through this method following the principle define once and use anywhere the development time can even be decreased drastically. The software runs under Windows 95 and Windows NT.

Stand-alone English 10.000 CD ROM 129640

Stand-alone English 500 CD ROM 129641

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PROGRAMMING Graphical Programming for Closed-loop Control Systems Software

A Q
BASICS

MELSEC IDR BLOK

IDR-BLOK is a user-friendly development tool for programming closed-loop applications using PLC technology. Configuring a controlled system couldnt be simpler you just assemble it graphically by placing function blocks on the screen and the integrated compiler than generates the code for the PLC. The open design means that the user can intervene and change the control parameters at any time with the PLC program. Additional function blocks for autotuning, fuzzy logic and ATHC are available in combination with the run-time module IDR10F-ADU. IDR-BLOK turns a sequential logic controller into a multi-loop controller. It is the closed-loop programming software package for all AnSH/QnAS* controllers (*QnAS only in combination with a co-processor module). The software runs under Windows 95/98 and Windows NT.

Software CPU Application mit Co-Prozessor* Max. used blocks per application Language Disk type Order information

Full version Compact version AnSH (AnN)* AnAS, QnAS (AnU, AnA, QnA)* 1.024 64 English CD ROM 129665

Demo version

16

Art. no. 129666

on request

* For the AnN, AnU, AnA and QnA series the following accessories are required: connection cable A1SC05NB (art.no. 24983) and extension base unit A1S52B-S1 (art.no. 39667).

RUN-Time Products for IDR BLOK

To use the IDR-BLOK software the hereafter described run-time modules are necessary. These modules are available as single modules or within a bundle package. The IDR function module IDR10F is an integrated necessary part of the run-time package. It provides supervisory functions for the customer with digital output watch dog alarm signals and protects the process control against unexpected troubles. The A1SD51S-IDR is a co-processor module which is a standard MELSEC high-speed communication module A1SD51S with a preloaded IDR BLOK interpreter.

IDR10F
0 1 2
WDT

0 1 2 3 4 5 6 7 8 9 A B C D E F

RUN S.ERR. PROG. MTSE P1.RUN P1.ERR P2.RUN P2.ERR

6

A 1SD51S-IDR

CH1 SD CH1 RD CH2 SD CH2 RD CH3 SD CH3 RD M.PRO.

RUN STOP RES.

SW 1 2 3 4 5 6 7 8 9 10 11 12

CH1(RS-232-C)

CH2(RS-232-C)

A1SD51S-IDR

78 9 A

94

BCDE

Specifications Shipping contents Program features Function blocks Additional functions

IDR10F-STD 1 x IDR10F-STD Max. 1024 34.5 x 130 x 93.6 Art. no. 125359

IDR10F-ADV 1 x IDR10F-ADV Max. 1024 Fuzzy logic, GAT, ATHC 34.5 x 130 x 93.6 129658

ON

IDR bundle 1 IDR-BLOK software, 1 x IDR10F-STD, 1 x A1SD51S-IDR Max. 1024 IDR-BLOK 4.10 34.5 x 130 x 93.6 87511

FRONT SIDE CH3 TERMINATOR R O R S P S ' E ' 4 N 4 8 2 5 2

Software Module dimensions Order information

IDR bundle 2 IDR-BLOK software, 1 x IDR10F-ADV, 1 x A1SD51S-IDR Max. 1024 Fuzzy logic, GAT, ATHC IDR-BLOK 4.10 34.5 x 130 x 93.6 on request

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MELSEC AnS/QnAS
Software Co-Processor Module SPAC20
MELSEC SPAC20
The SPAC20 is a co-processor module for special process applications and high-end process control. It is the ideal supplementation for the IDR BLOK Software. Furthermore self-developed control applications can be realized with C programming language.

PROGRAMMING

A Q
BASICS

SPAC 20
RUN

X
0 1 2 3 4 5

WDT BOOT SD/RD FROM/TO BATT L PS L

FG

MB RUN STOP RESET

FG

0V

D00 -A00 D01 +A01 0V -A01

+24 +A00

Special features:
C programmed users tasks Communication with PLC processor via fast back plane bus Real-time execution Special non-linear processes with fast FUZZY controller Integrated fast digital and analog inputs and outputs Stand-alone possibility

SELECT
WD TIME WDR OFF NO BUS W. START NO I/O ON 1 2 3 4 5 6

D04 D05 0V

+AI0 -AI0 AG0

+DI0 SV1 -DI0 +AI1 +DI1 -AI1 -DI1 AG1 +DI2 SV2 -DI2 +AI2 +DI3 -AI2

RS-232C

-DI3 AG2 +DI4 SV3 -DI4 +AI3 +DI5 -AI3 -DI5 AG3

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9

SV0

SPAC2 0

Specifications Working environment Processor Memory Peripheral communication Number Response time Voltage Digital Nominal input current inputs Max. input voltage range Frequency meters Galvanic isolation Number Nominal current Digital outputs Protection Galvanic isolation Number Sampling rate Resolution Analog Galvanic isolation inputs Voltage Current Optional Piggy back modules Number Refresh rate Resolution Analog Galvanic isolation outputs Voltage Current Protection From the back plane Power External voltage supply Current Programmable with Order information Accessory

SPAC 20 MELSEC AnS/QnS or AnU/QnA* series PLCs or as stand alone device without CPU 40 MHz Texas Instruments TMS 320C32 DSP with floating point 2 MB RAM battery backed-up, 2 MB FLASH RS232C, up to 56 Kbaud 6 < 20 s in high-speed mode 24 V (OFF < 5V, ON > 12V) 7.7 mA -24 V bis +40 V 4 digital inputs can be used as frequency meters (up to 20 kHz each) Separate for each channel, no common 6 0.5 A Short-circuit, thermal overload, reverse polarity Between each pair of outputs and A-BUS 4 80 s in fast mode, 160 s in normal mode 16 bits Between analog common and A-BUS -10 V to +10 V DC -20 mA to +20 mA Pt-100/Pt-1000, R100/R1000 , separate galvanic isolation 420 mA 4 80 s in fast mode, 160 s in normal mode 12 Bit + sign in voltage mode, 12 bit in current mode Between analog common and A-BUS 10 V DC 0/4 to 20 mA Short-circuit in voltage mode Approx. 0.4 A at 5 V DC 24 V DC (20 %) Approx. 15 mA for digital outputs; up to 200 mA for analog I/O board IDR BLOK and/or TI C programming language Clamp type terminal blocks, Piggy back module Pt-100/Pt-1000 or R100/R1000 , Piggy back module separate galvanic isolated analog input channels 420 mA, IDR BLOK programming tool, TI development tools for C language programming

Art. no. on request

* Connection to the MELSEC AnU/QnA series is only possible via extension base unit A1S52B-S1

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9

+24

0V

-A03

D03 +A03

D02 -A02

+24 +A02

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MELSEC AnS/QnAS
PROGRAMMING Hand-held Programming Unit A7PU Programming Unit EPROM Writer Cables

A Q
BASICS

The hand-held programming unit A7PU is used for the MELSEC A controllers. The programming unit can be mounted directly on the controller or connected by a cable.

Programming takes the form of an instruction list. The unit is suitable for minor program changes directly on the machine.

A 7P

ING RAMM PROG

UNIT

T MN
NS

TES

PRM F INC K F D MR L = P P BIN V OR E AND 9 MC F OR A ANB 5 RST 0 R MC B ORB 6 SFT 1 MPP R W W

NO

WR RD A * G V MO M B B /

D TO C
A

D RET J

DEC K

I O

MPS X
P

H N + S LD C T

BCD U AND D

END Z SFT SSN CL OUT 3 STPSTP+ SP

LDI 8

PLS 7 CJ 2

SET 4

T CM

Specifications General specifications Ambient temperature Ambient relative humidity (non-condensing) Power supply Current consumption Display Character display Keyboard Cable, is adjoined Weight Dimensions (W x H x D) Oder information

A7PU Conform to basic components of AnS/QnAS 0 40 C 85 % 5 V DC (from PLC) mA 300 LCD 16 x 2 54 keys J1, to connect a standard cassette-player kg 0.5 mm 188 x 79 x 44.5 Art. no. 3922

A6WU EPROM Writer

The EPROM writer A6WU is used for transfering the PLC programs of the MELSEC AnS controller to the EPROM memory cassette. Conversely, existing programs on the memory cassette can be written into the CMOS RAM of the controller and program comparisons can be carried out.

A 6W
OM P-R

IT R UN ITE WR

RES F E D C 8 4 0 9 5 1 A 6 2 B 7 3 CLR NEXT P DIS PASS GO

A6WU Order information Art. no. 3921

T CM

Connecting Cable
The cables AC30R4 and AC300CR4 are used for connecting the hand-held programming unit to the controller. The cable AC 30WU is used for connecting the EPROM writer.

Specifications Connecting device Length Order information

AC 30R4 A7PU m 3 Art. no. 3930

AC300CR4 A7PU 30 3928

AC 30WU A6WU 3 15033

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Teaching Unit Teaching Unit AD71TU
The AD71TU teaching unit is used for setting parameters and entering position data for the AD71 and AD72 positioning modules. Position parameters are read and written via the handy units integrated RS422 interface.
1TU D7

PROGRAMMING

This unit is often used for on-site system setup and commissioning. An additional interface is provided for the connection of a standard cassette recorder for data storage.

A Q
BASICS

Specifications General specifications Ambient temperature Storage temperature Power supply Power consumption Display type Display format Keypad Cassette recorder cable Programming software Programming cable Weight Dimensions(WxHxD) Order information

V mA

kg mm

AD71TU Conforms to MELSEC A series basic components 0 40 C -20 C 50 C DC 5 (by positioning module) 0.3 LCD 16 characters x 2 lines Membrane keypad, 30 keys J1, for connection of a standard cassette recorder SW0-AD71PE, art. no. 4191 AC30R4, art. no. 3930 0.45 79x188x23

Art. no. 4193

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MITSUBISHI ELECTRIC EUROPE B.V. Factory-Automation / German Branch Gothaer Str. 8 D-40880 Ratingen Fax: +49 2102 486-112
Order declaration
Pos. Number Item (type) Article number

Company: Street: Address: Phone: Fax:

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Department: . . . . . . . . . . . . . . . . . . . . .

Description

Remarks

Notes when ordering: When ordering, please use only the type designations and order numbers shown in this catalogue.

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INDEX
A80BD(E)-J61BT13 . . . . . . . . . . . . . . . . . . . . . 59 AJ55TB2-16R . . . . . . . . . . . . . . . . . . . . . . . . . . 63 AJ55TB2-4R. . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 AJ55TB2-8R. . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 AJ55TB3-16D . . . . . . . . . . . . . . . . . . . . . . . . . . 62 AJ55TB32-16DR . . . . . . . . . . . . . . . . . . . . . . . 62 AJ55TB32-4DR. . . . . . . . . . . . . . . . . . . . . . . . . 62 AJ55TB32-8DR. . . . . . . . . . . . . . . . . . . . . . . . . 62 AJ55TB3-4D . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 AJ55TB3-8D . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 AJ65BT-62D . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 AJ65BT-62D-S1 . . . . . . . . . . . . . . . . . . . . . . . . 55 AJ65BT-64AD . . . . . . . . . . . . . . . . . . . . . . . . . . 52 AJ65BT-64DAI . . . . . . . . . . . . . . . . . . . . . . . . . 53 AJ65BT-64DAV . . . . . . . . . . . . . . . . . . . . . . . . 53 AJ65BT-64RD3. . . . . . . . . . . . . . . . . . . . . . . . . 54 AJ65BT-64RD4. . . . . . . . . . . . . . . . . . . . . . . . . 54 AJ65BT-68TD . . . . . . . . . . . . . . . . . . . . . . . . . . 56 AJ65BTB1-16D. . . . . . . . . . . . . . . . . . . . . . . . . 50 AJ65BTB1-16DT. . . . . . . . . . . . . . . . . . . . . . . . 50 AJ65BTB1-16T . . . . . . . . . . . . . . . . . . . . . . . . . 51 AJ65BTB2-16D. . . . . . . . . . . . . . . . . . . . . . . . . 50 AJ65BTB2-16R . . . . . . . . . . . . . . . . . . . . . . . . . 51 AJ65BTC1-32D. . . . . . . . . . . . . . . . . . . . . . . . . 50 AJ65BTC1-32T . . . . . . . . . . . . . . . . . . . . . . . . . 51 AJ65BT-D62 . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 AJ65BT-D75P2-S3. . . . . . . . . . . . . . . . . . . . . . 57 AJ65BT-R2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 AJ95TB2-16T . . . . . . . . . . . . . . . . . . . . . . . . . . 66 AJ95TB3-16D . . . . . . . . . . . . . . . . . . . . . . . . . . 66 AJ95TB32-16DT. . . . . . . . . . . . . . . . . . . . . . . . 66 MC-DPX16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 MC-DPX8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 MC-DPX8Y4 . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 MC-DPY8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 MT-4AD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 MT-4DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 MT-4DAV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 MT-DP12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 MT-DP12E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 MT-X16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 MT-X4Y4T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 MT-X8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 MT-Y16T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 MT-Y4R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 MT-Y8R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 MT-Y8T. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 MT-Y8T2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Counter modules A1SD61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 A1SD62E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 CPU modules A1SHCPU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 A2SHCPU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 A2SHCPU-S1 . . . . . . . . . . . . . . . . . . . . . . . . . . 14 A2ASCPU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 A2ASCPU-S1. . . . . . . . . . . . . . . . . . . . . . . . . . . 15 A2ASCPU-S30 . . . . . . . . . . . . . . . . . . . . . . . . . 15 A2ASCPU-S60 . . . . . . . . . . . . . . . . . . . . . . . . . 15 A80BDE-A2USH-S1 . . . . . . . . . . . . . . . . . . . . 17 Q2ASCPU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Q2ASCPU-S1 . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Q2ASHCPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Q2ASHCPU-S1 . . . . . . . . . . . . . . . . . . . . . . . . . 16 Digital input/output modules A1SX10EU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 A1SX20EU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 A1SX80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 A1SX80-S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 A1SX81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 A1SY10EU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A1SY14EU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A1SY18AEU . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A1SY22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A1SY28EU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A1SY68A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A1SY80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A1SY81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Dummy modules A1SG60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 A1SG62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Interface modules A1SD51S(-BAL) . . . . . . . . . . . . . . . . . . . . . . . . 33 A1SJ71C24-PRF . . . . . . . . . . . . . . . . . . . . . . . . 30 A1SJ71QC24-R2 . . . . . . . . . . . . . . . . . . . . . . . 32 A1SJ71QC24. . . . . . . . . . . . . . . . . . . . . . . . . . . 32 A1SJ71UC24-R2 . . . . . . . . . . . . . . . . . . . . . . . 30 A1SJ71UC24-R4 . . . . . . . . . . . . . . . . . . . . . . . 30 A1SJ71UC24-R2-S2 . . . . . . . . . . . . . . . . . . . . 31 A1SJ71UC24-R4-S2 . . . . . . . . . . . . . . . . . . . . 31 Network descriptions ASI-Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . 75 CC-Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 DeviceNet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 ETHERNET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 MELSECNET/B . . . . . . . . . . . . . . . . . . . . . . . . . 46 MELSECNET/10 . . . . . . . . . . . . . . . . . . . . . . . . 38 MELSECNET (II) . . . . . . . . . . . . . . . . . . . . . . . . 43 MELSEC I/O-Link . . . . . . . . . . . . . . . . . . . . . . . 60 PROFIBUS/DP. . . . . . . . . . . . . . . . . . . . . . . . . . 64 Positioning modules A1SD70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 A1SD71-S2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 A1SD75P1-S3. . . . . . . . . . . . . . . . . . . . . . . . . . 28 A1SD75P2-S3. . . . . . . . . . . . . . . . . . . . . . . . . . 28 A1SD75P3-S3. . . . . . . . . . . . . . . . . . . . . . . . . . 28 Pulse catch and interrupt modules A1SP60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 A1SI61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Power supply modules A1S61PN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 A1S62PN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 A1S63P. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Software MELSEC IDR BLOK. . . . . . . . . . . . . . . . . . . . . . 94 MELSEC MEDOC GPP/WIN. . . . . . . . . . . . . . 92 MELSEC MEDOC plus. . . . . . . . . . . . . . . . . . . 92 MELSEC MX Change . . . . . . . . . . . . . . . . . . . 93 MELSEC MX SCADA . . . . . . . . . . . . . . . . . . . . 94 MELSEC ProfiMap . . . . . . . . . . . . . . . . . . . . . . 94 Timer module A1ST60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Accessories Adapter cable for extension base units . 79 Battery A6BAT . . . . . . . . . . . . . . . . . . . . . . . . . 81 Connecting cable A32CBL. . . . . . . . . . . . . . 79 Connecting cable for programming unit 96 Dust cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 EPROM-/EEPROM memory cassettes. . . . 80 EPROM adapter units . . . . . . . . . . . . . . . . . . 80 EPROM writer A6WU . . . . . . . . . . . . . . . . . . . 96 Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Hand-held programming unitA7PU . . . . 96 Interface converter . . . . . . . . . . . . . . . . . . . . 79 Memory cards . . . . . . . . . . . . . . . . . . . . . . . . . 80 Profibus connector . . . . . . . . . . . . . . . . . . . . 82 System adapter set for MT series . . . . . . . 82 Teaching unit AD71TU . . . . . . . . . . . . . . . . . 97 Analog input/output modules A1S62DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 A1S62RD3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 A1S62RD4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 A1S63ADA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 A1S64AD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A1S64TCRT-S1 . . . . . . . . . . . . . . . . . . . . . . . . . 24 A1S64TCTT-S1 . . . . . . . . . . . . . . . . . . . . . . . . . 24 A1S66ADA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 A1S68AD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A1S68DAI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 A1S68DAV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 A1S68TD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Base and extension units A1S32B-E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 A1S33B-E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 A1S35B-E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 A1S38B-E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 A1S52B-S1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 A1S55B-S1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 A1S58B-S1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 A1S38HB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 A1S65B-S1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 A1S68B-S1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Communications modules A1SJ51T64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 A1SJ61BT11 . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 A1SJ61QBT11 . . . . . . . . . . . . . . . . . . . . . . . . . 49 A1SJ71AP21 . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 A1SJ71AR21 . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 A1SJ71AS92 . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 A1SJ71AT21B. . . . . . . . . . . . . . . . . . . . . . . . . . 47 A1SJ71BR11 . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 A1SJ71DN91 . . . . . . . . . . . . . . . . . . . . . . . . . . 73 A1SJ71E71-B2-S3 . . . . . . . . . . . . . . . . . . . . . . 36 A1SJ71E71-B5-S3 . . . . . . . . . . . . . . . . . . . . . . 36 A1SJ71LP21 . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 A1SJ71LP21GE. . . . . . . . . . . . . . . . . . . . . . . . . 39 A1SJ71PB92D . . . . . . . . . . . . . . . . . . . . . . . . . 65 A1SJ71PB96F . . . . . . . . . . . . . . . . . . . . . . . . . . 65 A1SJ71QBR11 . . . . . . . . . . . . . . . . . . . . . . . . . 40 A1SJ71QE71-B2. . . . . . . . . . . . . . . . . . . . . . . . 37 A1SJ71QE71-B5. . . . . . . . . . . . . . . . . . . . . . . . 37 A1SJ71QLP21. . . . . . . . . . . . . . . . . . . . . . . . . . 40 A1SJ71QLP25. . . . . . . . . . . . . . . . . . . . . . . . . . 41 A1SJ71QLR21. . . . . . . . . . . . . . . . . . . . . . . . . . 40 A1SJ72QBR15 . . . . . . . . . . . . . . . . . . . . . . . . . 41 A1SJ72T25B . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 A7BDE-J71AP21 . . . . . . . . . . . . . . . . . . . . . . . 45 A7BDE-J71AR21 . . . . . . . . . . . . . . . . . . . . . . . 45 A70BDE-J71QBR13. . . . . . . . . . . . . . . . . . . . . 42 A70BDE-J71QLP23 . . . . . . . . . . . . . . . . . . . . . 42 A70BDE-J71QLP23GE . . . . . . . . . . . . . . . . . . 42 A70BDE-J71QLR23 . . . . . . . . . . . . . . . . . . . . . 42

MITSUBISHI ELECTRIC

99

HEADQUARTERS

EUROPAN REPRESENTATIVES

EUROPAN REPRESENTATIVES

MITSUBISHI ELECTRIC EUROPE EUROPE B.V. German Branch Gothaer Strae 8 D-40880 Ratingen Phone: +49 (0) 21 02 / 486-0 Fax: +49 (0) 21 02 / 4 86-1 12 E mail: megfamail@meg.mee.com MITSUBISHI ELECTRIC ITALY EUROPE B.V. ITALIAN BRANCH Via Paracelso 12 I-20041 Agrate Brianza (MI) Phone: +39 039 6053 1 Fax: +39 039 6053 312 E mail: industrial@it.mee.com MITSUBISHI ELECTRIC SPAIN EUROPE B.V. SPANISH BRANCH Calle Joan Buscall, 24 E-08190 Sant Cugat del Valls Phone: +34 (9) 3 / 565 31 60 Fax: +34 (9) 3 / 589 15 79 E mail: industrial@sp.mee.com MITSUBISHI ELECTRIC UK EUROPE B.V. UK Branch Travellers Lane GB-Hatfield Herts. AL10 8 XB Phone: +44 (0) 1707 / 27 61 00 Fax: +44 (0) 1707 / 27 86 95 MITSUBISHI ELECTRIC JAPAN CORPORATION Mitsubishi Denki Bldg. 2-2-3 Marunouchi Tokyo 100-8310 Phone: +81 (0) 3 / 32 18 31 76 Fax: +81 (0) 3 / 32 18 24 22 MITSUBISHI ELECTRIC USA AUTOMATION 500 Corporate Woods Parkway Vernon Hills, IL 60061 Phone: +1 847 / 478 21 00 Fax: +1 847 / 478 22 83

GEVA GmbH AUSTRIA Wiener Strae 89 A-2500 Baden Phone: +43 (0) 2252 / 85 55 20 Fax: +43 (0) 2252 / 488 60 E mail: office@geva.co.at GETRONICS NV/SA BELGIUM Pontbeeklaan 43 B-1731 Zellik Phone: +32 (0) 2 / 467 17 51 Fax: +32 (0) 2 / 467 17 45 INEA CR d.o.o. CROATIA Drvinje bb HR-10000 Zagreb Phone: +385 (0) 1 / 366 71 40 Fax: +385 (0) 1 / 366 71 40 AUTOCONT s.r.o. CZECHIA Nemocnicni 12 CZ-70100 Ostrava 1 Phone: +420 (0) 69 / 615 21 11 Fax: +420 (0) 69 / 615 21 12 Louis Poulsen DENMARK Geminivej 32 DK-2670 Greve Phone: +45 (0) 43 / 95 95 95 Fax: +45 (0) 43 / 95 95 90 E mail: elpefa@elpefa.dk UTU ELEKTROTEHNIKA AS ESTONIA P.O. Box 4180 EE-0090 Tallinn Phone: +372 6 / 56 31 94 Fax: +372 6 / 56 38 36 E mail: utu@uninet.ee Beijer Electronics OY FINLAND Elannontie 5 FIN-01510 Vantaa Phone: +358 (0) 9 / 615 20 11 Fax: +358 (0) 9 / 615 20 500 E mail: info@elc.beijer.fi IP Systmes FRANCE 8, Rue Du Colonel Chambonnet F-69672 Lyon Bron Cedex Phone: +33 (0) 4 / 72 14 18 00 Fax: +33 (0) 4 / 72 14 18 01 E mail: info@ip-systemes.fr SANDSOFT HUNGARY 5 Rppenty Kz H-1139 Budapest Phone: +36 (0) 1 / 375 38 98 Fax: +36 (0) 1/ 3 75 06 88 MITSUBISHI ELECTRIC IRELAND EUROPE B.V. Westgate Business Park, Ballymount IRL-Dublin 24 Phone: +353 (0) 1 / 419 88 00 Fax: +353 (0) 1 / 419 88 90 CARPANETO & C. S.p.A. ITALY Via Ferrero 10 I-10090 Cascine Vica-Rivoli (TO) Phone: +39 011 / 959 01 11 Fax: +39 011 / 959 02 50 E mail: info.carpaneto@carpaneto.it

Getronics bv NETHERLANDS Industrial Automation Donauweg 10 NL-1043 AJ-Amsterdam Phone: +31 (0) 20 / 586 15 92 Fax: +31 (0) 20 / 586 19 27 E mail: info.algemeen@getronics.nl Beijer Electronics AS NORWAY Teglverksveien 1 N-3002 Drammen Phone: +47 (0) 32 / 24 30 00 Fax: +47 (0) 32 / 84 85 77 E mail: info@elc.beijer.no MPL Technology Sp. z.o.o POLAND ul. Wrocawska 53 PL-30011 Krakw Phone: +48 (0) 12 / 632 28 85 Fax: +48 (0) 12 / 632 47 82 E mail: mpl@krakow.ipl.net F. Fonseca Lda PORTUGAL Estrada de Taboeira 87/89, Esgueira P-3800 Aveiro Phone: +351 (0) 34 / 31 58 00 Fax: +351 (0) 34 / 31 58 04 E mail: amartins@ffonseca.com TUINGDOR ROMANIA 20, Fierarilor Street RO-72126 Bucaresti Phone: +40 (0) 1 / 211 98 01 Fax: +40 (0) 1 / 210 71 81 E mail: tuingdor@pcnet.ro INEA d.o.o. SLOVENIA Ljubljanska 80 SI-1230 Domale Phone: +386 (0) 1 / 721 80 00 Fax: +386 (0) 1 / 724 16 72 E mail: zoran.marinsek@inea.si Medicin y Control, S.A. SPAIN Gr. Via d. l. Corts Catalanes 133, 4 E-08014 Barcelona Phone: +34 (9) 3 / 422 77 00 Fax: +34 (9) 3 / 432 28 47 E mail: admin@mecco.org Beijer Electronics AB SWEDEN Box 325 S-20123 Malm Phone: +46 (0) 40 / 35 86 00 Fax: +46 (0) 40 / 93 23 01 E mail: info@elc.beijer.se ECONOTEC AG SWITZERLAND Postfach 282 CH-8309 Nrensdorf Phone: +41 (0) 1 / 838 48 11 Fax: +41 (0) 1 / 838 48 12 E mail: info@econotec.ch GTS TURKEY Fahri Gizden Sokak, Hacaloglu Apt. No. 22/6 TR-80280 Gayrettepe/Istanbul Phone: +90 (0) 212 / 267 40 11 Fax: +90 (0) 212 / 266 14 50 E mail: gts@turk.net

MIDDLE EAST REPRESENTATIVES

TEXEL Electronics Ltd. ISRAEL PO Box 6272 IL-Netanya 42160 Phone: +972 (0) 9 / 863 08 94 Fax: +972 (0) 9 / 885 24 30 E mail: texel_me@netvsion.net.il

EURASIAN REPRESENTATIVE

JV-CSC Automation UKRAINE Borisoglebskya St. 11 U-254070 Kiev Phone: +380 (4) 4 / 416 42 02 Fax: +380 (4) 4 / 463 63 93 E mail: csc-a@carrier.ki

Specifications subject to change. Art.-no. 59085-G, Printed in Germany 03/00

MITSUBISHI ELECTRIC EUROPE B.V.

FACTORY AUTOMATION

Gothaer Strasse 8 Phone: +49 2102 486-0 Fax: +49 2102 486-717 www.mitsubishi-automation.de megfamail@meg.mee.com D-40880 Ratingen Hotline: +49 2102 1805 000-765 /-766 Faxback: +49 2102 486-485 /-790 www.mitsubishi-automation.com