MXCO001L084A0195

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Key Decrease values Key Channel up Key Channel down LED Enter key Enter key Indication lamp Collective fault (red) Indication lamp Switched On (white) Indication lamp Ready (green) Key Test Key Manual/Automatic mode Key Increase motor/pump speed
23. 24. 25. 26. 27. 28. 29. 30. 31.
Key Decrease motor/pump speed LED Motor(s) On Key Motor(s) On/Off Illuminated symbol Manual mode Key Motor pre-selection LED Motor preselected Illuminated symbol Motor On Display Motor/Pump speed Display Pressure (Option)

Only MC units

Refer to separate unit manual for key description 1
Fig. 2 Additional control panel MC
3. Illuminated symbol Inert gas supply 4. Key Purge (inert gas flush) 5. Illuminated symbol Inert gas bottle empty

002159

1. Key Heating off 2. Key Heating on
A pressure sensor can be installed for each pump stream. The control system offers the option of displaying both pump stream pressures. There are two display lines for each motor on the motor control panel (Fig. 3). In the second line of each display, the pressure of the second pump stream and all parameters relevant for this pump stream are shown.
6. Control Panel for Double Stream Pumps

bar psi

Fig. 3

002353

Motor control panel for 1 motor
If the system contains a control panel for double stream pumps, the software automatically activates the functions needed for the double stream pumps. If the system uses an analog module to compile pressure, both pressure displays are activated for each motor.
The indication lamps and the optional indicator beacon show the operating modes: Collective fault, Switched on and Ready for operation. The switching of the indicator beacon is carried out differently depending on the unit series. For certain series and special versions, the indicator beacon may contain further lamps. The functioning is described in the manual for the unit/system.
7. Indication Lamps and Indicator Beacon

17 Red

18 White

Mmin bar psi C F

19 Green

MXCO054L067A1295

Fig. 4
(Also refer to Fig. 1 for position numbers)
Indication lamp Red (17) Collective fault
Message(s) Overtemperature message from control system Overtemperature shutdown by control system, e.g. channel 2 Undertemperature during operation Ambient temperature too high Temperature sensor short circuit Temperature sensor interruption Speed alarm (special function) Memory error Coupling fault (special function) Underpressure alarm (special function) Overpressure alarm (special function) Safety valve opened (special function) Other error messages (Refer to service display Error)

Function / possible setting Threshold value switch (Pilot voltage in % at which the motor stops) Threshold value switch (Pilot voltage in % at which the motor starts) Reverse mode (Speed at which the motor rotates in reverse after switching off)
Setting range OFF or 1.0 to 100 % pilot voltage OFF or 1.0 to 100 % pilot voltage OFF or 1.0 to 100 min-1
Factory setting OFF OFF OFF
Notes Index 94 Option Index 95 Option Index 86 Option

SLo Shi drS

Reverse mode (Period in which the motor rotates in reverse after switching off)

0.5 to 25 seconds

0.5 seconds

Index 87 Option

Adapting speed to special gearbox

1.0 to 250 min-1

100 min-1
Index 83 Special function may be activated

Speed alarm

OFF or 2 to 10 min-1
Index 81 Only on units with actual speed compiling

Con CoF C1 C2 CLr Adr

Inert gas control (injection period) Inert gas control (interval) Forcibly actuated inert gas injection Forcibly actuated air exhaust (vacuum pump) Return values to factory setting Field bus address of unit
OFF or 2 to 120 seconds 2 to 120 minutes 2 to 240 seconds OFF or 2 to 240 seconds no / yes 2 to 126
5 seconds 30 minutes 30 seconds 60 seconds no 10
Con: Index 35 CoF: Index 36 The parameters Con, CoF, C1 d l i h and C2 are only in the system if the selector switch S 11 of the central module is set to B. They t l d l i t t B Th are used only for certain units in the series MC. Index 9 Only with option PROFIBUS DP
Operation by electrostatically-charged persons can lead to improper functioning of the control system.

1. Operation Overview

Displays
Refer to Overview of Displays and Diagnosis Program in technical appendix.

C / F status display

Decimal point Lit when the displayed channel is heating.

MXCO004L050A0295

Switching on/off immediate temperature setback
Switching ON: Press key 10; SPL blinks in display 4 and the LED in the key lights. Switching OFF: Press key 10 or wait until the setback period has expired (if the setback period is longer than 9.99 hours, the temperature setback is not automatically ended). Note: The temperature setback can also be switched on via the XS 2 interface. When the temperature setback is switched on, SPL blinks in displays 4 and 30 (Fig. 1). A setback period is ineffective in this case. Note: The Automatic Temperature Setback After Motor Standstill is ended by pressing key 25 (Fig. 1) on the motor part. Press key 25 for approx. 2 seconds.

Overtemperature shutdown The shutdown depends on the setting of the DIP switch S 8.8 on the temperature control panel board (Refer to Technical Appendix for Temperature Part). Activation When the overtemperature shutdown value is reached or Shutdown temperature was exceeded for more than 120 seconds / temperature increased Switch on/off unit

Deactivation

Ambient temperature too high Activation Deactivation
Electrical cabinet internal temperature is higher than 60 C (140 F) for more than 120 seconds Switch on/off unit
Temperature sensor interruption Activation Deactivation Interruption for more than 5 seconds Eliminate fault
Temperature sensor short-circuit (not for Fe-CuNi sensors) Activation Deactivation Short-circuit for more than 5 seconds Eliminate fault
Undertemperature during operation Activation Actual temperature goes below temperature setpoint minus undertemperature value for more than 10 seconds Actual temperature exceeds temperature setpoint minus 3 C (5.4 F) for more than 5 seconds

Automatic deactivation

Overtemperature Activation Actual temperature exceeds temperature setpoint plus overtemperature value for more than 10 seconds Actual temperature goes below temperature setpoint plus 3 C (5.4 F) for more than 5 seconds
Memory error Activation The memory of the displayed temperature channel is probably defective. Replace corresponding module if this occurs again. Switch on/off unit
The bar graph indicates in which range the temperature is currently located for all activated channels. The sensitivity and deviation value (at which temperature deviation the next LED lights) can be set on a DIP switch. The DIP switch S 3 is located on the bar graph board (see Technical Appendix of the Temperature Part, Bar Graph). The setting affects all bar displays.

8. Bar Graph (Option)

Channels 1 to 12
1 red 2 yellow 3 yellow 4 green 5 yellow 6 yellow 7 red

MXCO038L050A0595

Fig. 12
1. Red (3rd deviation upward) 2. Yellow (2nd deviation upward) 3. Yellow (1st deviation upward) 4. Green (no deviation) 5. Yellow (1st deviation downward) 6. Yellow (2nd deviation downward) 7. Red (3rd deviation downward)
Operation by electrostatically-charged persons can lead to improper functioning of the control system. Alteration of values and parameters can be blocked (see Technical Appendix of the Motor Part, Central Module, DIP Switch S 6 ).

Switch on motor

First press key 27 on the appropriate motor panel (motor is pre-selected, LED in key 27 is lit). Then press key 25 (motor is switched on, LED in key 25 and illuminated symbol 29 are lit). Switch off one motor Press only key 27 on the corresponding motor panel. Switch off all motors Press only key 25. Switch off automatic temperature setback Press only key 25 for approx. 2 seconds. Displays Refer to Display Overview and Service Display.

The motor startup protection prevents the motors from starting up after the initial heating phase or after a system error. When the startup protection is activated, LED 24 in key 25 blinks. To switch the motors back on: Press key 25 or, with external control via interface, activate the input Release all motors once.
WARNING: On units with the option Reverse mode, the motor rotates in reverse after being switched off (for the set time at the set speed).
7. Switching OFF Motor(s)

Switch Off one Motor

Press key 27 of the corresponding motor panel. The LED Motor preselected turns off.

Switch Off all Motors

Press key 25. The LED Motor(s) on turns off.
8. Set Speed (Manual Mode)
To prevent excessive wear, the motor/pump speed should not continuously fall below 5 min-1 (rpm) or continuously exceed 80 min-1 (rpm). The speed setpoint can be adjusted in steps of 0.1. The actual speed display is shown in steps of 1.0. Changing speed directly:
1. Press key 27 for approx. 2 seconds (until in display 30, P blinks). 2. Increase value with key 22 or decrease with key 23. The speed setpoint can also be changed in the menu (parameter rSP); proceed as described under Setting parameters.
Fig. 16 Details from Fig. 1
5.0 min-1 1.0 to 100 min1
To prevent excessive wear, the motor/pump speed should not continuously fall below 5 min-1 (rpm) or continuously exceed 80 min-1 (rpm). Changing rhi directly:

27 M24 30

9. Setting Speed (Automatic Mode)
1. Press key 27 for approx. 2 seconds (until P blinks in display 30 and rhi blinks in display 31). 2. Increase value with key 22 or decrease with key 23.
rhi increases (decreases) as soon as the motor speed is increased (decreased). The motor speed can be increased until rhi=100 min1 (rpm).
Fig. 17 Details from Fig. 1
rhi can also be changed in the menu; then proceed as described under Setting Parameters.
Factory setting (rhi): Setting range (rhi): 80 min-1 1.0 to 100 min1
Speed Parameters in Automatic Mode
Via interface XS 5 (without Profibus)
The parameters rLo, rhi and Uhi function in automatic mode (Refer to Parameter Overview). 1. Select automatic mode (Refer to Selecting Manual or Automatic Mode). 2. Set parameters: rhi Refer to Setting Speed (Automatic Mode) - direct change or refer to Setting Parameters rLo Refer to Setting Parameters Uhi Refer to Setting Parameters 3. Determine pilot voltage via interface XS 5.
Via interface XS 5 (with Profibus)
1. Select automatic mode (index 72, bit 1=1) 2. Select pilot voltage via interface XS (analog signal) (index 60, bit 10=1) 3. Set parameters: Set Limit maximum pump speed (index 79) Set Limit minimum pump speed (index 80) Set Limit pilot voltage/machine speed (Index 78) 4. Determine pilot voltage via interface XS 5.

Control system CS 20 PAH = Pressure Monitoring for Overpressure (when Pressure Controlled) PAL = Pressure Monitoring for Underpressure (when Pressure Controlled)
Parameter Overview (contd.)
Overpressure and underpressure values are differential values. Pressure monitoring serves to indicate underpressure or overpressure and, if necessary, to stop all motors on overpressure. PAL = Underpressure: If the pressure value falls below the alarm limit (setpoint minus underpressure value) for more than 10 seconds, PAL appears in display 30 (Fig. 1), and the red indication lamp Collective fault lights up (error number 242). If the alarm limit is below 0 bar (e.g. setpoint = 2 bar, PAL = 3 bar), no underpressure alarm can be triggered (Refer to example). PAH = Overpressure: If the pressure value exceeds the alarm limit (setpoint plus overpressure value) for more than 20 seconds, PAH appears in display 30 (Fig. 1), and the red indication lamp Collective fault lights up (error number 241). If the alarm limit is exceeded for more than 60 seconds, the motors are all stopped and the green indication lamp Ready for operation goes off (error number 240). Underpressure and overpressure monitoring can each be deactivated for individual motors by setting the parameter to less than 2 % (display OFF). The relay outlets indicate No underpressure or No overpressure. The error indications PAL and PAH can be reset by switching the motors on/off. It is then possible to see which motor set off the pressure alarm.

PAL PAH

Factory setting:
Note: Special function Note: PAH corresponds to Phi, and PAL corresponds to Plo when speed controlled.
OFF or 2.0 % to 30 % of pressure measuring range upper limit

Example:

p [bar] 100 %

PAH PAL

Up to 100 bar: 0.1 steps Over 100 bar: steps of 1

100 System pressure [%]

SPL = Temperature Setback after Motor Standstill
SPL is the time after which the automatic temperature setback after motor standstill begins. The temperature is then decreased to the value of parameter SPL (setback temperature) set in the temperature part.
OFF 15 to 240 minutes Steps of 1
Note: The function Temperature setback is only switched on if the value of SPL is within the setting range range. Note: E d temperature setback: P Note End t t tb k Press k 25 f approx. 2 seconds. key for d
PdS = Second Display for Double Stream Pumps
When both double and single stream pumps are used, the second pressure display can be switched off with the parameter PdS (pressure display). The parameter can be called up only in the second line.

Hours.minutes since last switching on
Hours the corresponding motor was released Inputs of digital module 1 hexadecimally coded (refer to Service display di and do and Digital Module ) Other digital modules possible (display then di 2, di 3 etc., according to selector switch position / module number) Outputs of digital module 1 hexadecimally coded (refer to Service display di and do and Digital Module ) Other digital modules possible (display then di 2, di 3 etc., according to selector switch position / module number) Pilot voltage input 0 to 10 VDC or 0 to 160 VDC (display in percent) Field bus type Profibus DP available

00 to FF

0 to 100
Display / meaning Current actual speed NOTE: Only when pressure controlled. Memory of the last 10 unit faults (refer to Table Service Display Error) Software version
Value range 0 to 100 min-1

001 to 255

0.00 to 999
Setting of DIP switch S 6 on the central module (refer to Code of DIP Switch S 6 )
Control system CS 20 Service Displays di and do
Display di shows the levels of the inputs, and display do shows the switching state of the outputs of the digital module hexadecimally coded (Also refer to Service Displays). The b can be mistaken for a 6. The digital module has 8 inputs and 8 outputs. This means that there are 256 possible combinations of inputs/outputs. The following binary table can be used to assist in translation of the signals (an example has been shaded).
Code 9 A b C d E F OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON Inputs/outputs 5 to OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON ON ON 6 OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON 5 OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON A b C d E F Code
Inputs/outputs 1 to OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON 3 OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON ON ON 2 OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON 1 OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON
OFF = input/output open; ON = input/output closed

Code of DIP Switch S 6

Example
The codification for 00 to FF can be found in the above chart.
Code OFF = switch open ON = switch closed OFF Switch positions 5 to ON 6 ON 5 OFF b
Code 4 ON OFF = switch open ON = switch closed Switch positions 1 to OFF 2 ON 1 ON
The error displays can be shown in the service display of the motor part (Refer to Service Displays). Errors which do not appear in display 30 (e.g. r_d) are displayed as error numbers in display 31 of motor panel 1.

Service Display Error

When faults are caused by situations not described here, Nordsons customer service can help.

Error Error number

Failure of a module: In most cases, the module is defective. But the following faults are also possible: Contact fault in voltage supply Fuse(s) on the module defective Incorrect or fluctuating operating voltage A selector switch on a module was moved while the unit was o erating. operating.
All modules f il within a few seconds. Possible cause: d l fail ithi f d P ibl roblem LED s There may be a problem with the CAN bus system. The yellow LEDs on the modules will then be lit. In such cases it is recommended to replace all modules and boards (including the control panel board) as well as all CAN bus cables as the communication in the CAN anel bus system ist most likely disrupted. Reset of a module: A reset usually occurs as a result of external disturbances. Possible causes: External, inductive loads (e g solenoid valves) without recovery diodes or varistors External (e.g. Level of interference to the power cables (e.g. plug connector XS 2) too high ( g g ) g The unit was operated by an electrostatically charged person Incorrect or fluctuating operating voltage Short interruption in operating voltage supply supply.
Corrective action: Use shielded power cables, change cable path, switch inductive loads ower ath, with recovery diodes or varistors. Resetting error messages Failure and Reset: Switch ff h S i h off the unit f at l i for least 10 seconds. d
Overpressure alarm by pressure monitoring. The value of parameter Phi or PAH was exceeded for longer than 60 seconds (Refer to Operating the Motor Part, Parameter Overview). The error message Phi appears in display 30 of the corresponding motor panel. All motors are stopped.
Reset overpressure alarm (switch motor off/on), then check the following: Is the safety valve dirty or clogged? Is the safety valve incorrectly set? Is the safety valve defective? Is the pneumatic safety valve (option) pressurized too high? Is the value of parameter Phi below or too close to the safety valve setting?
Overpressure alarm by pressure monitoring. The value of parameter Phi or PAH was exceeded for longer than 20 seconds (Refer to Operating the Motor Part, Parameter Overview). The error message Phi appears in display 30 of the corresponding motor panel.
Reset overpressure alarm (switch motor off/on), then check the following: Is the safety valve dirty or clogged? Is the safety valve incorrectly set? Is the safety valve defective? Is the pneumatic safety valve (option) pressurized too high? Is the value of parameter Phi below or too close to the safety valve setting? Is the safety valve dirty or clogged? Is the safety valve incorrectly set? Is the safety valve defective? Is the pneumatic safety valve (option) pressurized too low? Is the value of parameter Plo above or too close to the safety valve setting? Is the tank empty? Is the pump block of the gear pump worn? Is the pump defective? Is the safety valve dirty or clogged? Is the safety valve defective?

Blinking D9 D 10 Yellow Green Lit Flickering

DIP Switch S 7

Switch 1 ON 2 OFF 3 OFF 4 ON 5 ON 6 ON 7 ON 8 OFF Channel number of temperature control panel board (other channel numbers not permitted) Function

DIP Switch S 8

Switch 1 OFF ON OFF ON 2 OFF OFF ON ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF No leading channel Channel 1 is leading channel (refer to table DIP switch S 8, switch 6) Channel 2 is leading channel (refer to table DIP switch S 8, switch 6) Channel 3 is leading channel (refer to table DIP switch S 8, switch 6) Setting by channel deactivated (only SE and offset displayed) -factory settingSetting by channel activated Predefined control parameter (parameter sets) accessible, if Setting by Channel is activated with DIP switch S 8, switch 3 Predefined control parameter (parameter sets) blocked No function No function Refer to table DIP switch S 8, switch 6 Refer to table DIP switch S 8, switch 6 Inert gas control OFF (only for MX) Inert gas control ON (only for MX) Immediate shutdown when overtemperature shutdown value OFF is reached. -factory settingNOTE: If the highest temperature setpoint is reduced by 30 C (54 F) or more, shutdown may occur. Shutdown when the shutdown temperature has been exceeded for more than 120 seconds and the temperature continues to rise. Function
Control system CS 20 DIP Switch S 8, Switch 6
The leading channel is determined by switches 1 and 2 of the DIP switch S 8 (Refer to DIP Switch S 8). The initial heating behavior of the channels is determined by switch 6 of the DIP switch S 8.
Initial heating behavior All channels heat independently of one another (no start up control) The leading channel heats up first. The other channels do not begin to heat until the leading channel has reached a temperature of 50 C (90 F) below its temperature setpoint. The other channels can not exceed the actual temperature of the leading channel during the initial heating phase until the leading channel has reached a temperature of 10 C (18 F) below its temperature setpoint. All channels heat up simultaneously with the leading channel, but they can not exceed the actual temperature of the leading channel until the leading channel has reached a temperature of 10 C (18 F) below its temperature setpoint. Channel 1 heats simultaneously with the leading channel, but it can not heat to a higher temperature than that of the leading channel. The other channels do not begin to heat until the leading channel has reached a temperature of 50 C (90 F) below its temperature setpoint. The other channels can not exceed the actual temperature of the leading channel during the initial heating phase until the leading channel has reached a temperature of 10 C (18 F) below its temperature setpoint. All channels heat up simultaneously with the leading channel, but they can not exceed the actual temperature of the leading channel until the leading channel has reached a temperature of 10 C (18 F) below its temperature setpoint. Channels 1 and 2 heat at the same time as the leading channel. However, channels 1 and 2 can not heat higher than the leading channel. The other channels do not begin to heat until the leading channel has reached a temperature of 50 C (90 F) below its temperature setpoint. The other channels can not exceed the actual temperature of the leading channel during the initial heating phase until the leading channel has reached a temperature of 10 C (18 F) below its temperature setpoint. All channels heat up simultaneously with the leading channel, but they can not exceed the actual temperature of the leading channel until the leading channel has reached a temperature of 10 C (18 F) below its temperature setpoint.

Basic Settings (Switches 1 and 2)
Switch 1 ON Switch 2 OFF Basic setting Standard setting 1 (Factory setting) LED (refer to Fig. 12) LEDs 3 and 5 LEDs 2 and 6 LEDs 1 and 7 OFF ON Standard setting 2 LEDs 3 and 5 LEDs 2 and 6 LEDs 1 and 7 OFF ON OFF ON Bar graph switched off Deviation values can be individually set on switches 3 to 8 (see Setting deviation values) LEDs light at: 3 C (5.4 F) temperature deviation One-half over-/undertemperature value Over-/Undertemperature value 5 C (9 F) temperature deviation 10 C (18 F) temperature deviation 15 C (27 F) temperature deviation
Setting Deviation Values (Switches 3 to 8)
By adjusting DIP switches 3/4, 5/6 and 7/8, the temperature deviation at which the LEDs light can be set. The deviation values are added together (see Band Widths).
Switch 3 OFF ON OFF ON Switch 5 OFF ON OFF ON Switch 7 OFF ON OFF ON Switch 4 OFF OFF ON ON Switch 6 OFF OFF ON ON Switch 8 OFF OFF ON ON LEDs 3 and 5 light at a temperature deviation of: 1 C (1.8 F) 2 C (3.6 F) 3 C (5.4 F) 4 C (7.2 F) LEDs 2 and 6 light at a temperature deviation of: 1 C (1.8 F) 3 C (5.4 F) 5 C (9 F) 10 C (18 F) + value of LED's 3 / 5 + value of LED's 3 / 5 + value of LED's 3 / 5 + value of LED's 3 / 5 Band width 2 to 14 C (to F) C (3.6 25.2 F) Band width 1 to 4 C (to F) C (1.8 7.2 F) Band width
LEDs 1 and 7 light at a temperature deviation of: 2C (3.6 F) 4 C (7.2 F) 8 C (14.4 F) 16 C (28.8 F) + value of LED's 3 / 5 + value of LED's 2 / 6 + value of LED's 3 / 5 + value of LED's 2 / 6 + value of LED's 3 / 5 + value of LED's 2 / 6 + value of LED's 3 / 5 + value of LED's 2 / 6
4 to 30 C (7.2 to 53 F) C (F)
7. Temperature Comparison Measuring Point

XXPN064L096A1198

Fig. 35
The temperature comparison measuring point is attached to a top hat rail in the electrical cabinet of the hot melt applicator and is connected to the plug connector X1 of the temperature control module. The connections are labeled with numbers: cable terminal 1 of temperature comparison measuring point to cable clamp 1 of plug connector, etc.
1. Central Module with Digital Input/Output
The central module with digital input/output is a combination of central module, digital module and possibly field bus communication module. The field bus communication module is present only in control systems with PROFIBUS DP (option). The analog input on the central module must be aligned (Refer to Aligning Pilot Voltage ).

No collective coupling fault Level 0 VDC Function Coupling fault Notes When a coupling fault occurs, CLU (error number 64) appears in display 30 (Fig. 1). When a coupling fault occurs, the motors continue to rotate in order for the coupling to engage The error message remains engage. even after the coupling has engaged until it is reset via the corresponding digital input or the automatic reset is activated via the corresponding digital input.

No coupling fault

Coupling fault Motor 1 to 6 Level 0 VDC Function No coupling fault Notes When a coupling fault occurs, CLU (error number 64) appears in display 30 (Fig. 1). When a coupling fault occurs, the motors continue to rotate in order for the coupling to engage The error message remains engage. even after the coupling has engaged until it is reset via the corresponding digital input or the automatic reset is activated via the corresponding digital input.

Coupling fault

Reset coupling fault statically Level 0 VDC 24 VDC Function An indicated coupling fault is not automatically reset. The error message CLU and error number remain. An indicated coupling fault is automatically reset when the coupling has re-engaged. The error message CLU and error number are deleted. Notes
Reset coupling fault through flank At this input, a flank of 0 VDC to 24 VDC must appear to reset a coupling fault. The fault is only reset when the input Coupling fault no longer indicates a coupling fault. NOTE: To deactivate the startup protection, this flank must be set once after the initial heating phase or after an error indication.
No unit specific alarm (e.g. fuse alarm) Level 0 VDC 24 VDC Function At least one fuse has been activated All fuses are OK Notes When there is 0 VDC at the input, all motors are stopped and the output Unit specific alarm is activated (error number 244) 244).
Pressure monitoring Level 0 VDC 24 VDC Function Pressure monitoring not active Pressure monitoring active Notes See Operating the motor part, parameter overview, Plo and PAL = pressure monitoring for underpressure Phi and PAH = pressure ressure under ressure, ressure monitoring for overpressure.
Pressure build-up Level 0 VDC 24 VDC Function Pressure build-up not active, normal unit function. Pressure build-up active. The respective motor runs at the speed set in parameter rhi until the corresponding safety valve has opened (see Input safety valve motor 1 to 6 open ). With open safety valve, the motor runs at a speed of 5 min-1. If the safety valve closes again, the corresponding motor continues to run at the speed set in parameter rhi until the safety valve opens again. When all safety valves have opened once, the output Pressure build-up complete is closed. Notes This function serves to maintain a certain pressure in the application system even at machine standstill The pneumatic standstill. safety valves must be set to the desired pressure. Function only together with special safety valve which is equipped with an electrical contact.

No coupling fault Switching state Open Closed Function Coupling fault not yet reset No coupling fault Notes See inputs Coupling fault
No motor fault Switching state Open Closed Function General motor fault No motor fault Notes Speed alarm, motor overtemperature, coupling fault
Motor fault Motor 1 to 6 Switching state Open Closed Function No fault in the corresponding motor Fault in the corresponding motor Notes The relay picks up when there is a fault in the corresponding motor (e g speed fault coupling fault motor overtemperature) (e.g. fault, fault, overtemperature).
No collective fault Switching state Open Closed Function Error, unit is not ready for operation Unit ready for operation Notes
Motors ready for operation Switching state Open Closed Function Unit not ready for operation Unit ready for operation Notes The relay picks up when: - no fault indication present ll t th t l l l t d - all motors on the control panel are pre-selected - all motors on the control panel are set to automatic mode.
Motor rotates in manual mode (Motor 1, Motor 2 etc.) Switching state Open Closed Function The corresponding motor is not in manual mode or doesnt rotate The corresponding motor is in manual mode and rotates Notes
No unit specific alarm, (e.g. fuse alarm) Switching state Open Closed Function At least one fuse has been activated All fuses are OK Notes See input Unit specific alarm
No overpressure Switching state Open Closed Function Overpressure or pressure monitoring not active No overpressure Notes See input Pressure monitoring
No overpressure is being activated if pressure monitoring is g g active and no overpressure alarm present. The output is switched off if pressure monitoring is not active.
No underpressure Switching state Open Closed Function Underpressure or pressure monitoring not active No underpressure Notes See input Pressure monitoring No underpressure is being activated if pressure monitoring is g g active and no underpressure alarm present. The output is switched off if pressure monitoring is not active.
Pressure build-up ready Switching state Open Closed Function Pressure build-up not yet ready Pressure build-up ready Notes See input Pressure build-up
Safety valve open (Motor 1, Motor 2 etc.) Switching state Open Closed Function Safety valve open Safety valve closed (normal operating mode) Notes See input Safety valve open
All safety valves are closed (for all motors) Switching state Open Closed Function Safety valve open Safety valve closed (normal operating mode) Notes Relay contact closes when all safety valves have closed.
In addition to the digital module that is part of the central module with digital input/output, units with special functions can have additional separate digital modules. The levels/switching states of the inputs and outputs can be shown in hexadecimal code in the service display of the motor part (Refer to service displays di and do ).

3. Digital Module (contd.)

D4 D3 D2 D1

X5 MXCO026L089B0200
Fig. 37 Separate digital module
Fuses (Separate Digital Module)
Fuse F 1 Operating voltage of digital module electronics F 2 Operating voltage for external components F 3 Operating voltage for external components Value 1 AT Order Number P/N 285 957
LEDs (Separate Digital Module)
Number D1 Color Red State Lit Meaning A software reset has occured. It can be caused by a brief loss of voltage supply or e.g. by strong, external interfering impulses or glitches (EMC). See also reset of various modules (error number 217 to 239, Service Display Error) Problems with CAN bus hardware. Check and, if necessary replace CAN bus and modules/boards. A CAN bus command could not be sent. Check or replace: CAN bus cable, central module and digital module. Valid data are being transmitted or received via CAN bus. Input 1 (X 1 / Pin 2) is active Input 2 (X 1 / Pin 3) is active Input 3 (X 1 / Pin 4) is active Input 4 (X 1 / Pin 5) is active Input 5 (X 1 / Pin 6) is active Input 6 (X 1 / Pin 8) is active Input 7 (X 1 / Pin 9) is active Input 8 (X 1 / Pin 10) is active Output 1 (X 4 / Pin 1 and 2) is active Output 2 (X 4 / Pin 3 and 4) is active Output 3 (X 4 / Pin 5 and 6) is active Output 4 (X 4 / Pin 7 and 8) is active Output 5 (X 5 / Pin 1 and 2) is active Output 6 (X 5 / Pin 3 and 4) is active Output 7 (X 5 / Pin 5 and 6) is active Output 8 (X 5 / Pin 7 and 8) is active Fuse F 2 Operating voltage of external components is correct Fuse F 1 Operating voltage of electronics is correct Fuse F 3 Operating voltage of external components is correct
Blinking D2 D3 D4 D5 D6 D7 D8 D9 D 10 D 11 D 12 D 13 D 14 D 15 D 16 D 17 D 18 D 19 D 20 D 21 D 50 Yellow Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Lit Flickering Lit Lit Lit Lit Lit Lit Lit Lit Lit Lit Lit Lit Lit Lit Lit Lit Lit Lit Lit
DIP Switch S 2 (Separate Digital Module)

For double stream pumps (motor control panel shown in Fig. 3 is used):
Pressure sensor pump stream A, pump 1 Pressure sensor pump stream B, pump 1
Analog inputs 3 and 4 Pin Function Analog input 4 B) Reference potential Supply voltage for external components Analog input 3
Level 0 to 10 VDC / 0 to 20 mA 0 VDC +24 VDC 0 to 10 VDC / 0 to 20 mA 0 VDC +24 VDC
Notes Pressure sensors for motor/pump 3 / 4. The input voltage is displayed with a corresponding factor in the pressure display of motor 3 / 4. ressure dis lay For factor see selector switch S 1. g Pilot voltage for motor 3 / 4 when selector switch S 1 is set to position 7.
Reference potential Supply voltage for external components
Pressure sensor pump stream A, pump 2 Pressure sensor pump stream B, pump 2
Analog inputs 5 and 6 Pin Function Analog input 6 B) Reference potential Supply voltage for external components Analog input 5 A) Reference potential Supply voltage for external components Level 0 to 10 VDC / 0 to 20 mA 0 VDC +24 VDC 0 to 10 VDC / 0 to 20 mA 0 VDC +24 VDC Notes Pressure sensors for motor/pump 5 / 6. The input voltage is displayed with a corresponding factor in the pressure display of motor 5 / 6. ressure dis lay For factor see selector switch S 1. g Pilot voltage for motor 5 / 6 when selector switch S 1 is set to position 7.
For double stream pumps (motor control panel available as shown in Fig. 1):
Pressure sensor pump stream A, pump 3 Pressure sensor pump stream B, pump 3
Analog inputs 7 and 8 Pin Function No function Level 0 to 10 VDC / 0 to 20 mA 0 VDC +24 VDC 0 to 10 VDC / 0 to 20 mA 0 VDC +24 VDC Notes -
NOTE: Special function. Only with PROFIBUS DP. The selector switch S 1 of the analog module is set to position 8. NOTE: The four level signals are connected to the PROFIBUS interface directly, without evaluation.

7. Level Monitoring

Analog Inputs with Digital Function
The first three inputs of the analog module are not switched with analog signals; they are switched with relay outputs. The levels are 0 VDC or 24 VDC. The protective switching of the analog inputs internally limits the voltage to 10 VDC. As a switching threshold for recognizing the input state, voltages higher than 5 VDC are considered high levels and voltages lower than 5 VDC are considered low.

Control System CS 20 for Bulk Melters BM 20 / BM 200

Manual P/N C English

NORDSON ENGINEERING GMBH D LNEBURG D GERMANY
Note This manual applies to the entire Bulk Melters BM 20 / BM 200 with CS 20 series.
Order number P/N = Order number for Nordson products
Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2000. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Nordson Corporation. The information contained in this publication is subject to change without notice.

Trademarks

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, Millenium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson, OmniScan, Opticoat, Package of Values, Pattern View, PluraFoam, Porous Coat, PowderGrid, Powderware, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, PRX, RBX, Rhino, S. design stylized, Saturn, SC5, 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, Watermark, When you expect more. are registered trademarks of Nordson Corporation. ATS, Aerocharge, Auto-Flo, AutoScan, BetterBook, Chameleon, CanNeck, Check Mate, COLORMAX, Control Weave, Controlled Fiberization, CPX, E-Nordson, EasyClean, Eclipse, Equi=Bead, Fillmaster, Gluie, Ink-Dot, Iso-Flex, Kinetix, Maxima, MicroFin, Minimeter, Multifil, OptiMix, PluraMix, Primarc, Prism, Process Sentry, PurTech, Pulse Spray, Seal Sentry, Select Series, Sensomatic, Shaftshield, Spectral, Spectrum, Sure Brand, Swirl Coat, Vista, Walcom, 2 Rings (Design) are trademarks T of Nordson Corporation. Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes, could lead to violation of the owners rights.

COV_EN_458374C

CS04 Issued 12/01
E 2001 Nordson Corporation All rights reserved

Table of Contents

Overview
1. Safety. 1 2. Intended Use. 1 Unintended Use. 1 Residual Risks. 1 3. Manual References. 1 4. PROFIBUS DP. 2 General Information. 2 Plug Connectors. 2 Installation. 2 Transmission Speed. 3 Guidelines. 3 Definition of Terms. 3 Host. 3 Stand Alone Mode. 3 Remote Mode. 3 5. Pressure Control (Option). 3 6. Functions. 4 Melt Platen Position Recognition. 4 Drum almost empty. 4 Drum empty. 4 Interface XS 2. 4 Speed Control with Two Applications. 5 7. Control Panel. 6 8. Indication Lamps and Indicator Beacon (Accessory). 7 9. Overview of Settings. 9 Temperature Part. 9 Motor Part. 10

P/N 458374C

1. Operation Overview. 12 2. Display Overview. 13 Overview of Parameters Set by Channel. 14 3. Basic Settings. 15 Startup Control with Leading Channel. 15 Temperature Display, Selecting Celsius or Fahrenheit. 15 Switching Scan Mode On/Off. 15 Selecting Control or Measuring Mode. 16 Switching Channel On/Off. 16 4. Switching Immediate Temperature Setback On/Off. 17 5. Setting Temperature. 18 Recommended values. 18 6. Setting Parameters. 19 Setting Parameters by Channel. 19 Example of selecting parameter set. 19 Return Parameter to Factory Setting. 19 Parameter Overview. 20 SPL = Setback temperature. 20 h SPL = Setback period. 20 Lo = Undertemperature value / interlock. 20 Hi = Overtemperature-value. 20 OFF = Overtemperature shutdown. 20 Pid = Predefined control parameters. 20 On = Regulation ratio (display). 21 SE = Service display. 21 7. Automatic Fault Displays. 21
Operating the Temperature Part

Operating the Motor Part

1. Operation Overview. 24 2. Display Overview. 25 3. Basic Settings. 26 Select Manual or Automatic Mode. 26 4. Test. 26 5. Switching ON Motor(s). 27 Motor Startup Protection. 27 6. Switching OFF Motor(s). 28 Switching Off One Motor. 28 Switching Off All Motors. 28 7. Setting Speed (Manual Mode). 28 8. Setting Speed (Automatic Mode). 29 Speed Parameters in Automatic Mode. 29 9. Switching Automatic Temperature Setback On/OFF. 30 10. Setting Parameters. 31 Returning Parameters to Factory Setting. 31 Parameter Overview. 31 ruP = Increase speed. 31 rLo = Motor speed at 0 % pilot voltage. 32 rhi = Motor speed at pilot voltage Uhi. 32 Uhi = Pilot voltage at which the motor rotates constantly at rhi. 32 rLo, rhi and Uhi, graphic illustration. 32 SPL = Temperature setback after motor standstill. 33 rPU = Adapting speed to special gearbox. 33 Adr = Field bus address of system. 33 11. Service Displays. 34 Service Displays di and do. 36 Code of DIP Switch S 6. 36 Service Display Error. 37

Interface XS 2

The standard assignment of interface XS 2 is described in the separate manual Bulk Melters.
Control System CS 20 for BM 20 / BM 200 Speed Control with Two Applications
NOTE: Does not apply to systems with piston pumps. Also refer to Central Module with Digital Input/Output, Selector Switch S11 and Plug connector X11.
The set speed can be changed with the parameter ruP (refer to table) on bulk melters where two applications are supplied. NOTE: To prevent excessive wear, the motor/pump speed should not continuously fall below 5 min-1 (rpm) or continuously exceed 80 min-1 (rpm). Input Release Motor for Application 1 No No Yes Yes Release Motor for Application 2 No Yes No Yes Set speed + Set speed x ruP / min-1 (rpm) Set speed Speed for motor/pump 1 Output* Release Release Application head Application head for Application 1 for Application 2 No release No release Release Release No release Release No release Release
* The output is active when all requirements have been met (Refer to Switching ON Motor(s)).

Example

Set speed: 45 min-1 (rpm) ruP (factory setting): 100 % When both applications are active, the pump speed is calculated as follows: 45 min-1 + 45 min-1 x 100 % / 100 = 90 min-1 (rpm) If the calculated speed is higher than 100 min-1 (rpm), error number 71 is displayed as long as both applications are active (Refer to Service Display Error). The pump is running at 100 min-1 (max. speed). NOTE: The alarm and ready indications are not influenced.
The control panel is divided into motor and temperature parts. The elements found in the dotted line box are also referred to as the motor panel in the following description (up to 2 motor panels per control system are possible second motor is optional). The motor/pump speed is indicated with the SI-unit min -1 (equivalent to rpm).

7. Control Panel

Motor part

Temperature part

Motor panel 26

bar x10 psi

Fig. 1
11 Channel allocation Display Temperature channels Display Temperature setpoint Display Actual temperature Illuminated symbol Degrees Celsius (C) Illuminated symbol Degrees Fahrenheit (F) Decimal point Heating on LED Temperature setback on Key Temperature setback On/Off Key Increase values

002446

Key Decrease values Key Channel up Key Channel down LED Enter key Enter key Indication lamp Collective fault (red) Indication lamp Switched On (white) Indication lamp Ready (green) Key Test Key Manual/Automatic mode Key Increase motor/pump speed
Key Decrease motor/pump speed LED Motor(s) On Key Motor(s) On/Off Illuminated symbol Manual mode Key Motor pre-selection LED Motor pre-selected Illuminated symbol Motor On Display Motor/Pump speed Display Pressure (Option)
8. Indication Lamps and Indicator Beacon (Accessory)
The indication lamps and the indicator beacon available as an accessory show the operating modes Collective fault, Switched on and Ready. In addition, there is a yellow light on the indicator beacon that indicates the states Drum almost empty and Drum empty.

Red White Green

DGCO217L067A0299

Fig. 2

(Also refer to Fig. 1 for position numbers)
Indication lamp Red (17) Collective fault
Message(s) Overtemperature message from control system Overtemperature shutdown by control system, e.g. channel 2 Undertemperature during operation Ambient temperature too high Temperature sensor short circuit Temperature sensor interruption Memory error Other error messages (Refer to service display Error)
Notes Display 5: Hi blinking Displays 3, 4 and 5: 2 blinking Display 5: Lo blinking Displays 3, 4 and 5: AM bIE nT blinking Display 5: S blinking Display 5: E blinking Displays 4 and 5: Error blinking Display 30: Err indicated Display 31: Error number indicated
Indication lamp White (18) Turned on Green (19) Ready for ope a o operation
Message(s) After switching on the unit and during the initial heating phase, only the white indication lamp is lit The green indication lamp does not light until all channels have reached their temperature setpoints and when the following conditions have been met: Release Unit must be bridged or activated Temperature setback may not be switched on
Notes If, after the initial heating phase (1 hour and longer), the green indication lamp is not lit: Refer to manual Bulk Melters, section Troubleshooting.
Refer to manual Bulk Melters, section Installation, XS 2 Interface Refer to section Temperature Setback in this manual and to section Installation, Interface XS 2 in the manual Bulk Melters.

The melt platen has reached the upper switch. Drum is not empty
Indicator beacon (accessory) Yellow (blinking) Yellow (remains lit)
Message(s) Indication Drum almost empty Indication Drum empty
Notes The customer can utilize the signals Drum almost empty and Drum empty via the interface XS 2.
The possible settings and parameters described here are not available for every bulk melter (Refer to column Notes). NOTE: The indexes in the column Notes indicate the corresponding position in the separate communication data list. These references can be ignored when a control system CS 20 without PROFIBUS is used.

9. Overview of Settings

Temperature Part
Parameter Function / possible setting
NOTE: means that the function is switched off. Do this by setting the value to > 9.99.
Setting range Refer to manual Bulk Melters, Section Specifications 5 to 100 C (9 to 180 F) 0.05 to 9.99 hours 5 to 30 C (9 to 54 F) 5 to 30 C (9 to 54 F) 70 to 260 C (158 to 500 F); 70 to 280 C (158 to 536 F) with high temperature units Factory setting Dependent on system 50 C (off) 10 C 10 C Notes Index 154 Index 166 Index 163 Index 164 Only display
Temperature setpoint for each channel

SPL h SPL Lo Hi OFF

Temperature setback (setback value) Temperature setback (setback period) Undertemperature value Overtemperature value Overtemperature shutdown
Predefined control parameters

SLO, nor, FA1, FA2

SLO: Slow controlled system nor: Normal controlled system FA1: Fast controlled system FA2: Fast controlled system
Service display (sensor type) Select temperature display in C or F Return parameters to factory setting
Pt, FEC, ni C / F no / yes

Only display

The parameters marked with an asterisk (*) are not available for system models with piston pumps. NOTE: OFF means that the function is switched off. Do this by setting value to 0 (zero).

Motor Part

Parameter
Function / possible setting Speed setpoint for each motor panel (manual mode) Speed at 0% pilot voltage Speed at pilot voltage Uhi Speed increase in one pump, two guns/applications Pilot voltage in % at which the motor rotates at speed rhi. If the pilot voltage exceeds Uhi, the speed remains constant at rhi. Period after motor standstill at which the temperature setback is automatically switched on Adapting speed to special gearbox Return values to factory setting Filed bus address of system
Setting range 1.0 to 100 min-1 (rpm)
Factory setting 5.0 min-1 (rpm)
Notes Index 75 Index 80 Special function may be activated Index 79 Index 78 Special function may be activated

rSP* rLo* rhi* ruP* Uhi*

1.0 to 100 min-1 (rpm) 1.0 to 100 min-1 OFF or 1.0 to 250 % 0 to 100 % pilot voltage
1.0 min-1 (rpm) 80 min-1 (rpm) 100 % 100 %

Factory setting: Setting range:
Dependent on system For maximum operating temperature, refer to manual Bulk Melters, section Specifications.

Recommended values

The values stated in the tables are general values determined by experience; deviation may prove necessary.
Heating zone / temperature / time Melt platen Undertemperature value Overtemperature value Temperature setback value (Standby) Setback period Application head (accessory) Heated hose (accessory) Setting 10 C 10 C 10 to 30 C As needed As needed Prescribed processing temperature(s) Prescribed processing temperature below prescribed processing temperature below set processing temperature above set processing temperature

6. Setting Parameters

1. Press key 13 or 14 until the desired parameters appear in displays 3 and/or 4. 2. Press and hold key 16 (in display 5, P blinks) and use key 11 to increase value or key 12 to decrease value. Pressing once changes the value by 1, holding the key changes the value faster. NOTE: With the parameters SPL, Hi and Lo, all of which can be set individually for each channel, three lines appear in the display when at least one channel has a setting that differs from the others. A setting that applies to all channels is usually sufficient.
Setting Parameters by Channel
Refer to DIP switch S 8 on the temperature control panel board.
Example of selecting parameter set
1. Press and hold keys 11 and 12, then press key 16 until the display blinks. 2. Press key 13 or 14 until the desired channel is displayed. NOTE: Channels that are switched off are automatically skipped. 3. Press key 11 or 12 until Pid is displayed. 4. Select parameter set (Refer to previous section, Setting Parameters) 5. Press and hold keys 11 and 12, then press key 16 at the same time to leave the menu. NOTE: If no keys are pressed for approx. 2 minutes, the program automatically returns to the normal display.
Return Parameter to Factory Setting
1. Press key 13 or 14 until parameter CLr appears in display 4. 2. Press and hold key 16 (in display 5, P blinks) and set displayed value from no to yes, using key 11 or 12. 3. Release all keys. The temperature parameters (with the exception of temperature setpoint values) will be reset to factory settings. NOTE: The value will be no again after resetting.
Parameter Overview SPL = Setback temperature h SPL = Setback period
The temperature setback serves to protect the hot melt material and to save energy during breaks in production. After the setback period has expired, the heating is automatically switched back on, but not automatically if the setback period has been set to higher than 9.99 hours. After 9.99 hours, three dashes appear in display 5 (Fig. 1).

Returning Parameters to Factory Setting
1. Press and hold keys 22 and 23 and press key 27 for approx. 2 seconds. Displays 30 and 31 blink. 2. Press key 22 or 23 until display 30 shows CLr and display 31 shows no. 3. Press and hold key 27 (in display 31, P and no blink). 4. Press key 22 or 23 until display 31 shows YES. 5. Release key 27 (after approx. 2 seconds display 31 shows no). All settings have now been returned to factory settings. 6. End Returning parameters to factory settings: Press and hold keys 22 and 23 and press key 27 for approx. 2 seconds.

Parameter Overview

Also refer to Setting Parameters.

ruP = Increase speed

Speed increase with two applications ruP Factory setting: 100 % Setting range: OFF, 1.0 to 250 % Setting increments: 0.1-steps Above 100 %: 1.0-steps Note: The parameter appears after the parameter rhi.
Parameter Overview (contd.)
rLo = Motor speed at 0 % pilot voltage
See rLo, rhi and Uhi, graphic illustration
Factory setting: Setting range: Setting increments:
1.0 min-1 (rpm) 1.0 to 100 0.1-steps min-1 (rpm)
Note: Functions only in automatic mode Note: Special function may be activated; DIP switch S 6 on the central module
rhi = Motor speed at pilot voltage Uhi
80 min-1 (rpm) 1.0 to 100 min-1 (rpm) 0.1-steps
Note: Functions only in automatic mode
Uhi = Pilot voltage at which the motor rotates constantly at rhi
Pilot voltage at which the motor rotates at speed rhi. If the pilot voltage exceeds Uhi, the speed remains constant at rhi. See rLo, rhi and Uhi, graphic illustration
100 % pilot voltage 0 to 100 % pilot voltage 0.1-steps
Note: Functions only in automatic mode Note: Special function may be activated. DIP switch S 6 on the central module
rLo, rhi and Uhi, graphic illustration
rLo = 1 min-1 / rhi = 75 min-1 / Uhi = 100 % 100 Motor speed in min-1 Motor speed in min-rLo = 25 min-1 / rhi = 100 min-1 / Uhi = 100 % Motor speed in min-1 rLo = 20 min-1 / rhi = 70 min-1 / Uhi = 100 % 100 Motor speed in min-rLo = 1 min-1 / rhi = 90 min-1 / Uhi = 60 % 80 100

Canceling diagnosis program: 1. Confirm error with key 13 or 14. 2. Press key 13 or 14 to end.
NOTE: The unit, application heads and heated hoses (and air heaters, if present) must be cold; the diagnosis program expects an increase in temperature of 10 C (18 F) in every channel within 10 minutes. NOTE: Unused channels must be switched off (set the temperature setpoint to less than 40 C (104 F).
Activating the Diagnosis Program
Activate: 1. Switch off the unit. 2. Press keys 13 and 14 simultaneously and switch the unit back on.

MXCO019S024A0295

Fig. 17
All segments of the digital displays now light up for approx. 2 seconds. A decimal point running through all displays indicates that the diagnosis program is active. Test phase 0 begins.

Test phase 0

Tests the Solid-State-Relays and the temperature sensors. Testing the Solid-State-Relays: A Solid-State-Relay which is not controlled is checked to find out whether the temperature still increases. If in one channel the temperature increases by 10 C (18 F) within 10 minutes, the illustrated error code appears. Display 3: Test phase 0 Display 4: Error code P (heating zone heats although not controlled). Display 5: Number of the channel / heating zone

Fig. 18

Testing the temperature sensors: Temperature sensors are tested for interruptions and short-circuits (no short-circuit for Fe-CuNi-sensor). Display 3: Test phase 0 Display 4: Error code E (interruption) Display 5: Number of the channel / heating zone

Fig. 19

Display 3: Test phase 0 Display 4: Error code S (short-circuit) Display 5: Number of the channel / heating zone

Fig. 20

When execution of test phase 0 is error-free, the diagnosis program automatically goes to test phases 1 to n.
Control System CS 20 for BM 20 / BM 200 Test Phases 1 to n
Checks whether heating zones 1 to n (n= number of highest channel that is switched on) are being heated. The heaters are controlled for 10 minutes. The temperature must increase by 10 C (18 F) within this period; if this does not happen, an error code is displayed. If the temperature increases within 10 minutes, the program switches automatically to the next channel. Display during the test phase: Display 3: Test phase 1 (Channel / Heating zone 1 is tested) Display 4: Channel / Heating zone 1 has been tested for 40 seconds. Display 5: Actual temperature is 30 C (86 F).

Fig. 21

Error: Heating zone does not heat Display 3: Test phase 1 (Channel / Heating zone 1 is tested) Display 4: Error code E (Heating zone does not heat) Display 5: Number of the channel / heating zone

Fig. 22

Possible faults: Fuse(s) defective Solid-State-Relay defective Temperature sensor defective Damaged cable Polarity of Fe-CuNi-sensor interchanged Heating defective Error: Wrong heating zone heats Display 3: Test phase 1 (Channel / Heating zone 1 is tested) Display 4: Error code H (wrong heating zone heats) Display 5: Number of the heating zone which is heated (wrong heating zone)

Switch 1 ON 2 OFF 3 OFF 4 ON 5 ON 6 ON 7 ON 8 OFF Channel number of temperature control panel board (other channel numbers not permitted) Function

DIP Switch S 8

WARNING: The DIP switches S 8.1 and S 8.2 must be set to OFF (no leading channel) in changeover systems.
Switch Function 8 No leading channel Channel 1 is leading channel (refer to table DIP switch S 8, switch 6) Channel 2 is leading channel (refer to table DIP switch S 8, switch 6) Channel 3 is leading channel (refer to table DIP switch S 8, switch 6)

1 OFF ON OFF ON

2 OFF OFF ON ON
OFF ON OFF ON OFF OFF ON X OFF
Setting by channel deactivated (only SE and offset displayed) -Factory settingSetting by channel activated Predefined control parameter (parameter sets) accessible, if Setting by Channel is activated with DIP switch S 8, switch 3. - Factory setting Predefined control parameter (parameter sets) blocked -Factory settingNote: Do not adjust! Refer to table DIP switch S 8, switch 6 Refer to table DIP switch S 8, switch 6 No function Immediate shutdown when overtemperature shutdown value OFF is reached.
NOTE: If the highest temperature setpoint is reduced by 30 C (54 F) or more,
shutdown may occur. ON Shutdown when the shutdown temperature has been exceeded for more than 120 seconds and the temperature continues to rise. -Factory setting-
Control System CS 20 for BM 20 / BM 200 DIP Switch S 8, Switch 6
The leading channel is determined by switches 1 and 2 of the DIP switch S 8 (Refer to DIP Switch S 8). The initial heating behavior of the channels is determined by switch 6 of the DIP switch S 8.
Initial heating behavior All channels heat independently of one another (no start up control) The leading channel heats up first. The other channels do not begin to heat until the leading channel has reached a temperature of 50 C (90 F) below its temperature setpoint. The other channels can not exceed the actual temperature of the leading channel during the initial heating phase until the leading channel has reached a temperature of 10 C (18 F) below its temperature setpoint. All channels heat up simultaneously with the leading channel, but they can not exceed the actual temperature of the leading channel until the leading channel has reached a temperature of 10 C (18 F) below its temperature setpoint. Channel 1 heats simultaneously with the leading channel, but it can not heat to a higher temperature than that of the leading channel. The other channels do not begin to heat until the leading channel has reached a temperature of 50 C (90 F) below its temperature setpoint. The other channels can not exceed the actual temperature of the leading channel during the initial heating phase until the leading channel has reached a temperature of 10 C (18 F) below its temperature setpoint. All channels heat up simultaneously with the leading channel, but they can not exceed the actual temperature of the leading channel until the leading channel has reached a temperature of 10 C (18 F) below its temperature setpoint. Channels 1 and 2 heat at the same time as the leading channel. However, channels 1 and 2 can not heat higher than the leading channel. The other channels do not begin to heat until the leading channel has reached a temperature of 50 C (90 F) below its temperature setpoint. The other channels can not exceed the actual temperature of the leading channel during the initial heating phase until the leading channel has reached a temperature of 10 C (18 F) below its temperature setpoint. All channels heat up simultaneously with the leading channel, but they can not exceed the actual temperature of the leading channel until the leading channel has reached a temperature of 10 C (18 F) below its temperature setpoint.

Leading channel No leading channel Channel 1

Switch 6 OFF / ON OFF

Channel 2

Channel 3

X1, X2 CAN bus (Refer to central module)
One unit may have several temperature control modules. Refer to Selector Switch S 1.
4. Temperature Control Module

Ni 120

For temperature sensor Ni 120.
Board Voltage control of temperature control module

P1 D23 D24 D25

D10 D11 D12 D13 D14 D15

DGCO227L134A0399

Fig. 27
Control System CS 20 for BM 20 / BM 200 LEDs
Number D 10 Color Green State Lit Meaning
Heater output of the first channel (plug connector X4) of this temperature control module is switched on. Depending on how switch S 1 is set on the control module, the first channel of this temperature control module is 1, 7, 13, 19, 25, 31, 37 or 43. Heater output of the second channel (plug connector X4) of this temperature control module is switched on. Depending on how switch S 1 is set on the control module, the second channel of this temperature control module is 2, 8, 14, 20, 26, 32, 38 or 44. Heater output of the third channel (plug connector X4) of this temperature control module is switched on. Depending on how switch S 1 is set on the control module, the third channel of this temperature control module is 3, 9, 15, 21, 27, 33, 39 or 45. Heater output of the fourth channel (plug connector X4) of this temperature control module is switched on. Depending on how switch S 1 is set on the control module, the fourth channel of this temperature control module is 4, 10, 16, 22, 28, 34, 40 or 46. Heater output of the fifth channel (plug connector X4) of this temperature control module is switched on. Depending on how switch S 1 is set on the control module, the fifth channel of this temperature control module is 5, 11, 17, 23, 29, 35, 41 or 47. Heater output of the sixth channel (plug connector X4) of this temperature control module is switched on. Depending on how switch S 1 is set on the control module, the sixth channel of this temperature control module is 6, 12, 18, 24, 30, 36, 42 or 48. A software reset has occurred. It can be caused by a brief loss of voltage supply or e.g. by strong, external interfering impulses or glitches (EMC). See also reset of various modules (error number 217 to 239, Service Display Error) Problems with CAN bus hardware. Check and, if necessary replace CAN bus and modules/boards. A CAN bus command could not be sent. Check or replace: CAN bus cable and temperature control module. Valid data is being transmitted or received via CAN bus.

1. Ensure that switch S 15 is set to ON (factory setting). 2. Operate parent machine at max. speed. 3. Display Uin for Motor 1 (see Service Displays). 4. Set Uin with potentiometer R 18 to 100 (100% pilot voltage).
Aligning pilot voltage input 0 to 160 VDC
1. Set switch S 15 to OFF. 2. Operate parent machine at max. speed. 3. Display Uin for Motor 1 (see Service Displays). 4. Set Uin with potentiometer R 42 to 100 (100% pilot voltage).

Switch S 15

OFF ON Input voltage 0 to 160 VDC pilot voltage Input voltage 0 to 10 VDC pilot voltage (factory setting)

Potentiometer R 18, R 42

R 18 R 42 Align pilot voltage input 0 to 10 VDC (Refer to Aligning Pilot Voltage ) Align pilot voltage input 0 to 160 VDC (Refer to Aligning Pilot Voltage)

DIP Switch S 1

Switch 1 ON 2 ON 3 OFF 4 ON Channel and module number of the central module (other switch positions not permitted) Function

DIP Switch S 6

Switch 1 OFF ON OFF ON 2 OFF OFF ON ON OFF ON OFF 7 8 Factory setting, values and parameters are displayed and can be altered. Service display can also be activated. Values and parameters are displayed and can be altered. Service display cannot be activated. Values and parameters can only be displayed; they cannot be altered. Only the software version number and the DIP switch positions on the central module can be displayed. No function No function Automatic mode: If the speed setpoint is below 1.0 min-1 or below rLo, the motor runs at 1 min-1 or at speed rLo. Manual mode: No function ON Automatic mode: If the speed setpoint is below 1.0 min-1 or below rLo, the motor does not run. Manual mode: No function (Factory setting) OFF ON Parameters rLo and Uhi are activated Parameters rLo and Uhi are factory set and cannot be changed (rLo = 1.0 min-1, Uhi = 100 % pilot voltage) Function

DIP Switch S 12

Switch 1 OFF 2 ON 3 OFF 4 ON 5 ON 6 ON Channel number of the digital module (other channel numbers not permitted) Function
Control System CS 20 for BM 20 / BM 200 Button S 3
Pressing the button activates a software reset.

Switch S 2

Switch position outward (factory setting) Switch position inward
The switch position first takes effect following a software reset.
Normal operation Switch position permitted only for Nordson personnel

Selector Switch S 11

Series BM Position 1 Function Single mode Notes Description of functions/special functions refer to Plug connectors.
The remaining switch positions have no function
Plug Connectors (Voltage Supply)
X1 Pin Voltage supply (central module) Function Input for operating voltage of electronics Reference potential for Pin 1 Input for operating voltage of external components Reference potential for Pin 3 Level +24 VDC 0 VDC +24 VDC 0 VDC Notes Both voltages are electrically isolated from one another and are led through the CAN bus cable. Pin 1 / 3 are fuse protected internally with 6.3 A (F3 and F4) and protected against reversing of polarity behind the fuses with a protective diode. rotected olarity rotective The operating voltage for the electronics may only be used for the boards/modules g g of the control system. The inputs/outputs of all boards/modules of the control system are operated with components. the operating voltage of external components All external components have the same reference potential (Pin 4).

Notes Bus cable shield Receipt/transmission line of data-P, B-line Data transmission potential Supply voltage to terminating resistors P Receipt/transmission line of data-N, A-line -

X 22 Pin 1 2

PROFIBUS shield Function Shield Shield Level Protective grounding PE / functional grounding Protective grounding PE / functional grounding Notes Bus cable shield Bus cable shield
3. Motor Control Panel Board

V3 V4 V26

002202

Fig. 31

Number V3 V4 V5 Color Green Yellow Red State Flickering Lit Lit Meaning Valid data are being transmitted or received via CAN bus. A CAN bus command could not be sent. Check or replace: CAN bus cable, central module and control panel board. A software reset has occurred. It can be caused by a brief loss of voltage supply or e.g. by strong, external interfering impulses or glitches (EMC). See also reset of various modules (error number 217 to 239, Service Display Error) Problems with CAN bus hardware. Check and, if necessary replace CAN bus and modules/boards. Fuse F 1 is OK

Blinking V 27 Green Lit

Control System CS 20 for BM 20 / BM 200 DIP Switch S 1
Switch 1 ON 2 OFF 3 ON 4 ON 5 ON 6 ON 7 ON 8 ON Function
Channel number of motor control panel board (other channel numbers not permitted)
The DIP switch S 2.3 on the motor control panel board can be used to select pressure display resolution of either 1 or 0.1 bar. If the measuring range of the pressure sensor is always greater than 100 bar, the pressure is always shown as a whole number. If the pressure display is set to psi, switch 2.3 has no function.
Switch Function 6 7 8 Parameter rPU not activated (factory setting) Parameter rPU activated (refer to Parameter overview) Motor present Piston pump present Resolution of all pressure displays is 0.1 bar Resolution of all pressure displays is 1.0 bar (factory setting)

1 OFF ON

2 OFF ON

3 ON OFF

X5 Internal plug
The analog module is present only when the drum melter is equipped with the option pressure control.
4. Analog Module (Option)

S4 S3 S6 S5 S8 S7 S10 S9

Fig. 32
Fuse F 1 Operating voltage of analog module electronics F 2 Voltage supply of analog module inputs F 3 Voltage supply of analog module inputs Value 1 AT Order Number P/N 285 957
Number V2 V3 V9 V 26 V 27 V 28 Color Green Green Green Green Yellow Red State Lit Lit Lit Flickering Lit Lit Meaning Fuse F 1 Operating voltage of electronics is correct Fuse F 2 Operating voltage of external components is correct Fuse F 3 Operating voltage of external components is correct Valid data are being transmitted or received via CAN bus. A CAN bus command could not be sent. Check or replace: CAN bus cable, central module and analog module. A software reset has occurred. It can be caused by a brief loss of voltage supply or e.g. by strong, external interfering impulses or glitches (EMC). See also reset of various modules (error number 217 to 239, Service Display Error) Problems with CAN bus hardware. Check and, if necessary replace CAN bus and modules/boards.

Blinking

V28 V27 V26

MXCO025L089A0595

Control System CS 20 for BM 20 / BM 200 Potentiometer R 48
NOTE: The potentiometer has been factory-set. Do not adjust! It was aligned to 80 % of the measuring range. For example:
S Measuring range 100 bar (1450 psi):
Input voltage 80 % = 8 VDC = 80 bar (1160 psi)
S Measuring range 400 bar (5800 psi):
Input voltage 80 % = 8 VDC = 320 bar (4640 psi).
Switch 1 ON 2 ON 3 OFF 4 ON 5 ON 6 ON Channel number of the analog module (other channel number not permitted) Function

Selector Switch S 1

Position 9 A to F Function Measuring range 10 bar (145 psi) (special function) 10 VDC at input = 10 bar in the display Measuring range 35 bar (507,5 psi) (special function) 10 VDC at input = 35 bar in the display Measuring range 100 bar (1450 psi) (factory setting) 10 VDC at input = 100 bar in the display Measuring range 400 bar (5800 psi) (special function) 10 VDC at input = 400 bar in the display Measuring range variable 1 to 680 bar (14.5 to 9860 psi) (special function) 10 VDC at input = 1 to 680 bar in the display No function No function No function No function No function

Jumper S 3 to S 10

Jumper position A: Input 0 to 20 mA (special function) Jumper position B: Input 0 to 10 VDC (factory setting) Notes Jumper S3 Jumper S4 Jumper S5 Jumper S6 Jumper S7 Jumper S8 Jumper S9 Jumper S10 Input 1 Input 2 Input 3 Input 4 Input 5 Input 6 Input 7 Input 8 See plug connector X6 See plug connector X5 See plug connector X4 See plug connector X3
CAN Bus (Refer to Central Module with Digital Input/Output)

Internal plug

X2 Pin 3 4
Voltage supply Level + 24 VDC + 24 VDC Reference potential Reference potential Function Pins 1/2 and 3/4 can be bridged. External components connected to the analog module are then supplied via the bus cable with 24 VDC for external components (see X 1 of the central module) module). Otherwise, an external 24 VDC voltage supply can b connected t Pin 2 and Pin 4. The external components of Oth i t l lt l be t d to Pi d Pi 4 Th t l t f the analog module can thereby be electrically separated from the rest of the control system. Pin Pi 2 (24 VDC t external components) i f to t l t ) is fuse-protected with a 1 A f t t d ith fuse.

X3 Input

Analog inputs 1 and 2 Pin 2 Function Analog input 1 Reference potential Supply voltage for external components Not in use Not in use Not in use Not in use Level 0 to 10 VDC 0 VDC + 24 VDC
Notes Pressure sensor for motor 1. The input si voltage is converted to bar or psi and displayed in the pressure display of the motor. -

X4 X5 X6

The motor module is used to trigger a frequency converter or a motor controller.

Relay output

X5 Pin 1 2
Analog input Function Not in use Level 0 to 10 V 0 VDC Notes
The motor speed is aligned on the motor module. NOTE: Alignment was carried out at the factory. Setting or alignment is only necessary after replacement of modules/boards or if alignment elements have been mistakenly adjusted. NOTE: If the speed at which the motor is normally operated during production (production speed) is known, the speed should not be aligned at 80 min-1 but at the production speed. 1. Set operating mode of the motor to manual mode (illuminated symbol manual mode must be lit). 2. Note the set motor speed (manual mode). 3. Set motor speed to 80 min-1 or the production speed. 4. Switch on the motor. 5. Set the motor speed to 80 min-1 or to the production speed with the potentiometer R8. 6. Set the motor speed back to the original value (step 2).
Aligning the Motor Module