188093b User Manual
188093b User Manual
Controllers
PC54 and PC55
Notice
This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1995. No part
of this document may be photocopied, reproduced, or translated to another language without the prior written
consent of Nordson Corporation. The information contained in this publication is subject to change without
notice.
Trademarks
100 Plus, Blue Box, ChromaFlex, CleanSleeve, CleanSpray, Control Coat, Cross-Cut, Easy Coat, Econo-Coat,
Flow Sentry, Isocoil, Isocore, Iso-Flo, Nordson, the Nordson logo, PRX, Pro-Flo, RBX, Ready-Coat, Rhino,
Select Coat, Select Cure, Shur-Lok, Smart Spray, System Sentry, Thread Coat, Tribomatic, and Versa-Spray are
registered trademarks of Nordson Corporation.
CPX, CanWorks, Excel 2000, PowderGrid, Pulse Spray, SCF, Versa-Coat, Versa Screen, and Package of
Values are trademarks of Nordson Corporation.
Table of Contents
Run Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Hardware Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Keyboard Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Increasing Dir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Run Up Qty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Pgm Sel Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Index
Safety
Section 1
Safety
S Read and become familiar with this Safety section prior to installing,
operating, maintaining, or repairing the unit.
S Read and follow the warnings which appear within the text and are
related to specific tasks.
2. Safety Symbols The following symbols are used to warn against dangers or possible
sources of danger. Become familiar with them! Failure to heed a
warning could lead to personal injury and/or damage to the unit or other
equipment.
4. Intended Use The unit is designed and intended to be used only for the purpose
described in the Description section. Uses not in accordance with that
section or as described in this document are considered unintended uses
and not in accordance with governing regulations.
The following actions of the owner or operator of the unit are some, but
not all, examples of unintended use which would permit Nordson to claim
it is not responsible for personal injury or property damage arising from
such unintended use:
5. Installation and Electrical WARNING: Failure to follow the safety procedures can result in
injury or death.
Connections
S Cables which run outside the unit must regularly be checked for wear
or damage.
S Prior to start-up of the unit, check to make sure all safety guards and
safety equipment are in place and functioning properly.
S Keep parts of the body or clothing away from rotating parts. Do not
wear loose articles of clothing when operating or servicing units with
rotating parts. Take off wrist watches, rings, necklaces, or similar
pieces of jewelry and pin up or cover long hair before performing any
work on or with the unit.
S To carry out measurements on work pieces, switch off the unit and
wait until it comes to a standstill.
S The possibility that electrical potentials may remain in the unit after
the unit was de-energized
Action in the Event of Unit If the unit malfunctions, switch it off immediately.
Malfunction
S Turn the circuit breaker or main power switch OFF.
Danger of Burns Contact with hot melt materials or hot areas of the unit may produce a
severe skin burn.
S Always wear protective clothing which safely covers all exposed parts
of the body.
In case of burns:
7. Maintenance/Repair Allow only qualified personnel to perform the procedures described in this
document. When performing such tasks, wear protective clothing, and
equipment.
WARNING: Even when the circuit breaker or main power
switch is OFF, the unit is still electrically energized. Complete
the following steps prior to maintenance or repair:
S If the unit energizes, repeat the disconnect, lock out, and tag
procedure. Re-test the unit.
7. Maintenance/Repair S Follow the specific instructions provided in this manual to relieve the
(contd.) system pressure in the entire unit.
S Only use parts which do not compromise the safety of the unit. Only
use genuine Nordson parts.
8. Cleaning NOTE: Always refer to the material manufacturer’s Material Safety Data
Sheet (MSDS) or material information sheet before working with any
material.
S Never use an open flame to clean the unit or components of the unit.
S Use only cleaning fluids designed or intended to be used with the hot
melt material being used in the unit. Never use paint fluids under any
circumstances.
S Note the flash point of the cleaning fluid used. Only use a controlled
heating method to heat fluids.
9. Thermoplastic Hot Melt NOTE: Always refer to the material manufacturer’s Material Safety Data
Sheet (MSDS) or material information sheet before working with any hot
Material melt material.
10. Equipment and Material Dispose of equipment and materials used in operation and cleaning
according to local regulations.
Disposal
Description
Section 2
Description
1. Introduction
5940300
S “On” and “off” points can be adjusted instantly from the keypad
Controller and Keypad PC50 Series controllers consist of two main components, the controller
and the keypad/display, both housed within a cabinet. The controller
contains the microprocessor, associated circuitry, and all of the I/O
circuits.
5
1
5940394
PC50 Series controllers are available in two models, the PC54 and the
PC55. See Section 7, Specifications for a listing of each controller’s
capabilities.
4 5
5940282
Fig. 2-3 Controller Keypad and Display and Program Menu Tree and Program Listing
1. Display 3. Power ON/OFF and FAULT 5. Operator Created Program Listing
2. Keypad indicators
4. Program Menu Tree
3. Keypad Description
Display Screen
S Press SEL key when cursor is on “MENU” to enter Menu Tree and
5940297
initiate programming. See Figure 4-1.
Fig. 2-4 Display Screen
Cursor Keys
Use to:
5940293
SEL S ESC exits from current menu level to previous menu, or aborts
numeric entry.
S SEL enters a new menu level; toggles a value; and selects an output
ESC HLP group if multiple groups with different offsets are used.
S HLP shows help regarding menu selection and what keys to press.
5940294 Use this key if unsure what to do.
Fig. 2-6 ESC, SEL and HLP Keys
3. Keypad Description
(contd.)
Numeric Keys
S ENT must be pressed to enter the value; entry will flash until ENT is
pressed.
4. Basic Terminology The following terms, used throughout this manual, are defined to provide
understanding of PC50 Series controller installation, programming and
operation:
Channels Each Channel (CHN) in a PC50 Series controller contains “on” and “off”
setpoints for one 360 revolution of the resolver shaft. There are two
types of channels:
Setpoints “Setpoints” are the points within one rotation of the resolver at which a
channel turns on or off. Setpoints are programmed into a channel
through the keypad/display. PC50 Series controllers can turn any given
channel on and off multiple times within one rotation.
Duration A “duration” is the “on” period between the time a channel is turned on
and off. The “on” setpoint is the leading edge of the duration, and the
“off” setpoint is the trailing edge. Adhesive is applied to the substrate
during the duration. When multiple pairs of setpoints are programmed
into one channel, the channel is said to have multiple durations.
4. Basic Terminology
(contd.)
NOTE: The PC54 can have up to 8 inputs; the PC55 can have up to 16
inputs.
Output Groups and Operating Output channels can be combined into “Output Groups”, and each Output
Modes Group can be associated with an input terminal in different “Operating
Modes”.
S PC54 controllers have three different Operating Modes.
S PC55 controllers have six different Operating Modes.
See Output Groups and Operating Modes in this section.
5. Standard Features
Scale Factor Users can program the number of increments per revolution, or “Scale
Factor”.
S PC54 controllers have a resolution of 2-1024 increments per
revolution.
S PC55 controllers have a resolution of 2-4096 increments per
revolution.
Examples of possible linear distance applications include:
- the scale factor may be set to define increments in terms of linear
distance, such as one increment equals 0.1I of travel
- for an application (with the PC55 controller only) in which one
revolution of the resolver equals 24I of linear travel, a scale factor
of 2400 results in increments equal to 0.01I of travel
Examples of having the controller display position in degrees include:
- the scale factor may be set at 360 (for both the PC54 and the
PC55) allowing programming in 1 degree increments
- the scale factor may be set at 3600 (PC55 only) allowing
programming in 0.1 degree increments
Programming Access Two levels of programming access are provided: Operator and Master.
Each level is assigned a password which must be entered, to allow
programming at that level. Careful use of programming access levels
provides key personnel with required flexibility in controller programming,
while protecting settings against accidental/unauthorized changes. The
Operator and Master levels can be activated on an individual keypad
through hardware terminals on the back.
Speed Enable/Disable Minimum/maximum speed ranges can be programmed into the controller.
Each power output module can be linked, (through ANDing, see CHN
ANDing Menu) with the minimum or maximum speed range.
Min Speed ANDing The Min Speed ANDing selection is used to link (AND) programmed
outputs to either of two speed ranges programmed into the controller.
Typically, outputs are ANDed with either speed range such that the
output is disabled unless the machine speed is within the range.
Timed Outputs Timed outputs, like standard outputs, are programmed to turn on and off
at specific points during resolver rotation. Once a timed output is on, it
remains on for a specified time period regardless of RPM. However, if
the programmed off position is reached before the the time period
passes, the output turns off. Timed outputs can be used to provide a
constant volume of adhesive over a wide range of machine speed.
5. Standard Features
(contd.)
Gun Compensation Gun Compensation advances the setpoints for gun output as machine
speed increases, providing greater accuracy, higher production speeds,
and reduced downtime for machine adjustment.
6. Optional Features See Section 8, Options for a description of options available on PC50
Series controllers. Insert instruction sheets for any purchased options in
the Options section of this manual for future reference.
7. System Configuration
and Preprogramming
Considerations
NOTE: Output Groups, Operating Modes, Offset, and Gun
Compensation are discussed in this section to provide operators with
PC50 Series controller set up and programming considerations. These
topics should be thoroughly read and completely understood prior to any
programming attempts.
Conditional Operation
S The device being controlled is allowed to function only if an input
signal occurs. In adhesive application, photoeyes are used to
sense the presence of a product immediately before adhesive
application occurs. If the product is not present, the gun is not
enabled to turn on at its programmed setpoints.
Phase Adjustment
S The device being controlled must maintain a certain relationship
to other devices on the machine. For example, web converting
lines such as disposable diaper machines usually have several
machine sections, each performing a different operation on a
continuous web of material. As line speed increases, the phase
relationships between different machine sections adjust,
compensating for stretching of the web material. To keep a
device synchronized within its machine section, a sensor is used
to detect a registration mark on a component such as shaft or
disk. The sensor signal “resets” the position of the device each
revolution, ensuring that the device operates at the correct
position on the web of moving material.
PC50 Series controller programming links input signals from sensors or
other devices to the controller’s output channels. The controller’s output
channels can remain separate or they can be combined together into
groups. Each Output Group can then be assigned to an Operating Mode.
The Operating Mode controls the interaction between the output group
channel, its input terminal and its output channel(s).
NOTE: PC54 controllers have two inputs which can be associated with
two Output Groups. PC55 controllers have six inputs, allowing output
channels to be divided into as many as six group channels.
Group Input
Output Terminal Group
Group TB 1, (Figure 3-13) Channel
1 1 91
2 2 92
Group Input
Output Terminal Group
Group TB1, (Figure 3-14) Channel
1 9 91
2 10 92
3 11 93
4 12 94
5 13 95
6 14 96
When combining output channels into Output Groups, specific rules must
be followed:
S Output channels are assigned to Output Groups sequentially.
Output Group 1 begins with output channel 1 and includes the
specified number of output channels; Output Group 2 begins with
the next output channel and continues sequentially for its
specified number of output channels; and so on. The last Output
Group automatically includes all remaining output channels.
S With the PC55, six Output Groups or as few as one Output Group,
can be established.
S With the PC54, two Output Groups or as few as one Output
Group, can be established.
S More than one Output Group can be assigned to the same
Operating Mode.
Operating Mode 0
Programming
Operating Mode 1
Once the position is reset, the input terminal has no effect until it is turned
off and the resolver reaches the leading edge of a duration programmed
3 into the corresponding group channel. See Table 2-1 and Table 2-2 for
5940332
input terminal and group channel assignments.
Fig. 2-9 Operating Mode 1 - Typical
Setup
1. Group Channel Duration
2. Input Signal
3. Output Channel Duration
NOTE: Operating Mode 1 can be used to automatically adjust phase
relationships between machine sections. Another use is in applications
where some machine sections run multiple cycles per resolver revolution.
S The group position resets at the leading edge of the input terminal
signal, regardless of how long the terminal is on (item 2, Figure
2-9).
S Output channel setpoints are always enabled (item 3, Figure 2-9).
S Duration (item 1, Figure 2-9) in Group Channel re-arms the
terminal .
Possible Applications:
S Machines with Multiple Cycle Ratios - Some machines have different
sections that run at different cycle ratios per overall machine cycle.
For example, one portion of a machine may complete several cycles
while another section makes only one cycle. By using Mode 1 or 2, it
is possible for some output groups to cycle multiple times while others
cycle once.
S Web Converting Machines - Disposable diapers, medical pads, office
folders, and similar products. Mode 1 can automatically change the
timing of individual machine sections to compensate for changes in
phase relationships between sections.
1 1 4 2 3 7
6
8 5 5 5
9
2
5940311
One resolver provides the position information needed for all sections of
the machine, regardless of their phase relationship.
Application Specifics
S The group position resets at the leading edge of the input terminal
signal, regardless of how long the terminal is on.
S Once a reset occurs, the input terminal has no effect until it is
de-energized and the leading edge of a duration in the
corresponding group channel re-arms the terminal.
S When the position of a group resets, the position of the
corresponding group channel also resets.
S On start-up, the input terminal is armed and the group position is
the same as the value programmed in SHAFT POSITION, Section
4, Programming. When powered down, the group’s current
position setting is lost.
S Either edge of a duration in the group channel can re-arm the
input terminal. If the resolver shaft is rotating in the forward
direction (position is increasing as shaft rotates) the “on” edge of
the duration re-arms the terminal. If the shaft is rotating in the
reverse direction (position decreasing as shaft rotates), the “off”
edge of the duration re-arms the terminal.
S Each program in the controller can have different setpoints for
output channels and the corresponding group channel.
S MIN SPEED ANDing and REM ENAB ANDing can be used with
outputs in an Operating Mode 1 group.
Programming
See Tables 2-1 and 2-2 for input terminal and group channel assignments
while reviewing programming steps.
3. Jog the machine to the point where the group input terminal
energizes. Using this point as a reference, program setpoints into the
output channels in the group.
Operating Mode 2
Application Specifics
S Outputs are enabled and the group position resets at the leading
edge of the input terminal signal, regardless of how long the
terminal is on.
S Once a reset occurs, the input terminal has no effect until it
de-energizes and the leading edge of a duration in the
corresponding group channel re-arms the terminal.
S When the position of a group resets, the position of the
corresponding group channel also resets.
S On power up, outputs are disabled, the input terminal is armed,
and the group position is the same as the value programmed in
SHAFT POSITION, Section 4, Programming.
S Either edge of a duration in the group channel can re-arm the
input terminal. If the resolver shaft is rotating in the forward
direction (position is increasing as shaft rotates) the “on” edge of
the duration re-arms the terminal. If the shaft is rotating in the
reverse direction (position decreasing as shaft rotates), the “off”
edge of the duration re-arms the terminal.
S Each program in the controller can have different setpoints for
output channels and the corresponding group channel.
S MIN SPEED ANDing and REM ENAB ANDing can be used with
outputs in a Operating Mode 2 group.
3 4
2
5
6
7 5940272
Application Example
Programming
See Tables 2-1 and 2-2 for input terminal and group channel assignments
while reviewing programming steps.
2. Use OFFSET to program the “Preset” value for any Operating Mode 2
Output Groups.
3. Jog the machine to the point where the group input terminal will
energize. Using this point as a reference, program setpoints into the
output channels in the group.
Operating Mode 3
Description
NOTE: Use Operating Mode 3 where outputs should be active only while
a sensor or limit switch is on.
2
5940274
Application Specifics
S The group channel for a group operating in Mode 3 has no effect.
S Each program in the controller can have different setpoints for
output channels in the group.
S MIN SPEED ANDing and REM ENAB ANDing can be used with
outputs in a Mode 3 group.
S The machine position for a Mode 3 group can be set through
OFFSET programming.
Programming
2. Use OFFSET to program the absolute offset value for any Operating
Mode 3 groups.
2
1
3
5 4
5940273
Application Example
Adhesive application occurs only while the photo-eye sees the top edge
of a carton. Adhesive application stops when crushed or improperly
erected cartons cause the photoeye to lose sight of the carton’s top edge.
Operating Mode 4
Application Specifics
S The leading edge of the signal from the input terminal must occur
during the duration in the group channel. If the leading edge
occurs before the duration, the outputs are not enabled.
S Each program in the controller can have different setpoints for
output channels and the corresponding group channel.
S Either edge of a duration in the group channel can disable the
outputs. If the resolver shaft is rotating in the forward direction
(position is increasing as shaft rotates) the “on” edge of the
duration disables the outputs. If the shaft is rotating in the reverse
direction (position decreasing as shaft rotates), the “off” edge of
the duration disables the outputs.
S MIN SPEED ANDing and REM ENAB ANDing can be used with
outputs in an Operating Mode 4 group.
S Machine position for an Operating Mode 4 group can be set
through OFFSET programming.
Programming
See Tables 2-1 and 2-2 for input terminal and group channel
assignments.
2. Use OFFSET to program the absolute offset value for any Operating
Mode 4 Output Groups.
3. Jog the machine to the point where the group input terminal
energizes. Program a duration in the group channel that turns on a
little earlier than this point, and off a little later. The shorter the
duration, the narrower the portion of the machine cycle in which the
input signal enables the outputs.
NOTE: The leading edge of the duration in the group channel disables
the output channels in the group.
Application Example
3
2
5 4
5940276
The adhesive gun is enabled for one machine cycle only if the sensor
detects the leading edge of a carton during the duration programmed in
the group channel. If a carton is missing (item 1) or incorrectly
positioned, (item 5) the gun does not activate.
Operating Mode 5
Application Specifics
S Regardless of its programmed “off” point, the duration in the group
channel ends as soon as any of the outputs in the group turn on.
S Each program in the controller can have different setpoints for
output channels and the corresponding group channel.
S MIN SPEED ANDing and REM ENAB ANDing can be used with
outputs in an Operating Mode 5 group. Use MIN SPEED ANDing
to prevent the First Cycle Enable terminal from re-activating the
outputs while the machine is stopped.
S The machine position for an Operating Mode 5 group can be set
through OFFSET programming.
Programming
See Tables 2-1 and 2-2 for input terminal and group channel
assignments.
2. Use OFFSET to program the absolute offset value for any Operating
Mode 5 Output Groups.
3. Jog the machine to the point where the group input terminal
energizes. Program a duration in the group channel that will be on
during any portion of the input terminal signal. The smaller the
overlap between the input signal and the group channel duration, the
narrower the portion of the machine cycle in which the input signal
enables the outputs.
Application Example
3
2
5 5940338
The adhesive gun (item 3) is enabled for one machine cycle if the sensor
(item 2) detects a carton during the duration programmed in the group
channel. If a carton is missing (item 1) the gun does not activate.
If the line stops, the gun is disabled immediately. The gun is re-enabled
on the same machine cycle by depressing the pushbutton (item 4) while
the product sensor is ‘on’.
Offset
Menu Path
1
2
1. Output Group
2. Group Position = Shaft Position + ABS
Offset
3 3. Absolute Offset Value for This Group
5940339
Offset (contd.)
EXAMPLE:
Assume that an Output Group controls a gun on a cartoning
machine and that the scale factor is 360_ (1 increment equals 1
degree). When jogging the machine and viewing POS on the
controller display, it is evident that the gun opens at 347 and closes
at 22 when using the position set through SHAFT POSITION.
By using the OFFSET function for this group, and adding 13 to the
shaft position, the gun opens at a group position of 0 and closes at
35. Although the group position has been “offset” by 13, the gun
still opens at 347 and closes at 22, in terms of shaft position.
1
2
1. Output Group
2. Group Position = PRE + Change Since
Last Reset
3. Group Preset Value (If Group is
Mode 1 or 2)
3
5940340
Device Placement
1
For gun compensation to work most effectively, the device being
controlled by the output channel should be located on the machine in a
position where the product moves past the device at a constant speed.
(Figure 2-21) In the case of a gun, if the gun is ON when the speed is
changing, adhesive distribution may be inconsistent from carton to carton
at varying machine speeds.
3 5940341
Pull In/Drop Out Gun Gun pull in/drop out allows assigning different adhesive gun
Compensation compensation values for the leading and trailing edges of the adhesive
application duration. Consequently, machine operators can precisely
define, within a targeted area, how close to the front and back edges
(leading/trailing edges) adhesive is applied.
1. If the gun’s ON and OFF response times are known, jog the parent
machine line to determine ON and OFF setpoints at zero line speed.
2. Estimate gun response times for ON and OFF and enter them
through the GUN COMP function. The ON timing value controls Pull
In, while the the OFF timing value controls Drop Out.
3. Start the parent machine and run product through the adhesive
station at a fixed speed. Adjust each gun compensation value as
required for proper application. This can be done while the line is in
motion.
4. Once the ON and OFF setpoints are programmed, vary the line
speed to confirm proper operation at all speeds. Fine tune the GUN
COMP values if necessary.
NOTE: GUN COMP must be set to zero, for both Pull In and Drop Out,
while establishing the setpoints.
1. Run the line at a fixed speed, setting the gun ON and OFF operating
setpoints as required. Write down the programmed ON and OFF
setpoints.
2. Increase the line speed, adjusting the gun ON and OFF operating
setpoints to restore proper application.
Since a shaft at 1 RPM rotates 0.006_/ms, this shaft requires (0.05/0.006), or 8.3 ms
to rotate 0.05_. This speed compensation value is 8.3.
Since a shaft at 1 RPM rotates 0.006_/ms, this shaft requires (0.025/0.006), or 4.2
ms to rotate 0.05_. This speed compensation value is 4.2.
6. Once new ON and OFF setpoints are programmed for the line
running at constant speed, vary the line speed, confirming proper
adhesive application at all speed ranges.
Negative Gun Compensation Normal gun compensation advances an output channel’s setpoints,
compensating for a fixed response time in the device being controlled.
Some applications require negative gun compensation to retard the
setpoints in an output channel.
Figure 2-22 illustrates a basic sensor gating scheme, in which the signal
from the sensor reaches the controller only when the output channel from
the controller is turned on.
1 3
1. PC50 Series Controller
2. PC50 Series Controller Output
Channel
3. Sensor
2 5940342
9. Controller Initial While performing initial programming refer to Figure 4-1, Program Menu
Tree. The tree shows the path to each major program grouping and
Programming selections available within each group.
Installation
Section 3
Installation
2. Installation
Resolver Installation The resolver must be mounted to the parent machine and then wired to
the controller. Various other wiring connections may be required,
depending on the required number of inputs and outputs to the controller.
5940300
No provision need be made for physically rotating the resolver shaft with
respect to the machine shaft. PC50 Series controllers are easily
programmed to set any resolver position as the 0 position.
Figures 3-2, 3-3 and 3-4 provide dimensional information for the three
most commonly used resolvers.
Ambient Temperature
Resolver Wiring
NOTE: Resolver cables supplied with the resolver are a special type,
consisting of three individually twisted/shielded pairs with a common
braid shield, insuring that reliable position information is being received
by the controller. See Figures 3-5 and 3-6. Using other cable types
could degrade the accuracy of the position signals, making them more
susceptible to electrical noise.
Cables for non-stainless resolvers are shipped with one end soldered to
the resolver connector and the other end screwed into the controller
connector. See Figure 3-5.
Remove the controller connector if routing the cable through areas where
the connector won’t fit. Run the cable from the resolver back to the
controller cabinet.
The shield is connected at both ends of the cable to prevent damage due
to electrostatic discharge. If electrical noise problems are suspected
when the control is in operation, call your Nordson Representative for
advice regarding shielding.
The cable used with the stainless steel resolvers does not have a
connector at the resolver end because screw terminals are used inside
that resolver. When routing this cable, start at the controller end and run
the plain end of the cable to the resolver. When properly connected, both
ends of the cable shield will be connected. If electrical noise problems
are suspected when the control is in operation, call your Nordson
Representative for advice regarding shielding.
NOTE: The resolver cable illustrated in Figure 3-5 has a ring lug on a
green shield wire at the resolver end. Attach the ring lug to one of the
resolver connector strain relief screws as a protection against static
discharge through the resolver cable.
GR Green White
Black White
BK Black
Red Black Black (P/W) WHITE
RD
Black Red Black (P/W) RED
BK
White Black Red
WT
Black Black (P/W) GREEN
BK Green Green
SH
Shield
Shield
5940302
Fig. 3-6 Cable for Stainless Steel Resolver (with Terminal Strip Connections)
NOTE: The resolver cable illustrated in Figure 3-6 has a spade lug
connected to the shield at the resolver end. Attach the lug to the
grounding stud on the cover plate of the resolver.
Controller Installation Mount the controller cabinet in a suitable location on the parent machine.
The cabinet flanges are pre-drilled for mounting on a panel. Leave
sufficient room on each side of the cabinet for wiring access. Resolver
and serial communication access is provided on the left side of the
cabinet. Input/ power cables are installed on the left hand side of the
cabinet. System power wiring and input/output wiring access is provided
by knockouts on both sides of the cabinet.
2
5
5940308
Module Mounting A phillips head screw holds each module in place. Individual modules
can be removed and installed without affecting the other modules on the
unit.
2 1
3 1. Module
2. Phillips head screw
3. Module operating lamp
5940279
DIP Switches NOTE: If installing a PC55 controller that is purchased separately (not in
a cabinet), set the DIP switches on the side of the controller and keypad
to their proper positions before mounting the units in a panel. See DIP
Switch Settings in this section for DIP switch information.
NOTE: Changing from 240 VAC to 120 VAC service requires installing
additional jumpers on the terminal strip per schematics and wiring
1 diagrams in Section 5, Troubleshooting and Repair and replacing fuses
5940393
F1 and F2 with customer supplied 2 amp Slo Blo fuses.
Fig. 3-9 AC Power Connection to
Controller Power Supply
1. AC Power Supply In (w/Strain
Relief)
2. Input Power Wiring Terminal Strip
Electrical power is supplied to the controller as illustrated in the
schematics in Section 5, Troubleshooting and Repair.
Connect a 240 VAC or 120 VAC power cable to the controller’s terminal
strip as illustrated in Figure 3-9 and per the schematics and diagrams in
Section 5, Troubleshooting and Repair. Provide a strain relief for the
wires at the cabinet.
2
1. TB 8 20-30 VDC connection from DC
power supply
2. Main Power Fuse (1 1/4 A Slo-Blo)
1
5940307
Terminal Blocks
All terminal blocks can be unplugged from the controller. Each block is
keyed so it cannot be plugged into the wrong socket. All terminals are
labelled on each block. Controller general arrangement and location of
the terminal blocks are illustrated in Figure 3-11 (PC54) and Figure 3-12
(PC55).
Input Terminals
6 8
7
2 3
9
12 13
10 11 14 15
5940343
1 7
8
9 10 11
2
3 4
12
15 16
13 14 17 18 19
5940262
Sinking or Sourcing
NOTE: PC54 Controllers have one input terminal strip (TB 1). See
Figure 3-11. PC55 Controllers have two input terminal strips (TB 3 and
TB 1). See Figure 3-12.
NOTE: Two wire DC sensors can also be used, but may require a load
resistor in parallel with the input.
Figure 3-13 and Figure 3-14 illustrate current sourcing output, with
positive (+) VDC being switched. Figure 3-15 and Figure 3-16 illustrate
a current sinking output, with DC common being switched.
1. TB 1 (Inputs 1-8)
2 1
2. TB 2 (Aux Power for Inputs)
3. Switch or Relay Contact (Connect to
desired input 1-8)
4. Sourcing Module - (PLC or other
electronic output Connect to desired
+VDC input 1-8)
5. Three (3) wire DC Sensor with current
sourcing output (PNP)
3
Terminal Function
1 Group 1 Input
2 Group 2 Input
4 DC COM
7 First Cycle Enable
8 Remote Enable
5 5940345
1. TB 3 (Inputs 1-8)
2. TB 2 (Aux Power for Inputs)
3. TB 1 (Inputs 9-16)
4. Switch or Relay Contact (Connect to
desired input 1-16)
1 2 3 5. Sourcing Module - (PLC or other
electronic output Connect to desired
input 1-16)
6. Three (3) wire DC Sensor with current
sourcing output (PNP)
4 9 Group 1 Input
10 Group 2 Input
11 Group 3 Input
12 Group 4 Input
5 13 Group 5 Input
16 Remote Enable
2 1. TB 1 (Inputs 1-8)
1 2. TB 2 (Aux Power for Inputs)
3. Switch or Relay Contact. (Connect to
desired input 1-8)
4. Sinking Module - (PLC or other
electronic output. Connect to desired
input 1-8)
5. Three (3) wire DC Sensor with current
3 sinking output (NPN)
Terminal Function
1 Group 1 Input
2 Group 2 Input
4
7 First Cycle Enable
+VDC 5
8 Remote Enable
5940344
1. TB 3 (Inputs 1-8)
2. TB 2 (Aux Power for Inputs)
3. TB 1 (Inputs 9-16)
1 2 3 4. Switch or Relay Contact. (Connect to
desired input 1-16)
5. Sinking Module - (PLC or other
electronic output. Connect to desired
input 1-16)
6. Three (3) wire DC Sensor with current
sinking output (NPN)
Terminal Function
9 Group 1 Input
10 Group 2 Input
11 Group 3 Input
13 Group 5 Input
5 14 Group 6 Input
The following are the input terminals and their corresponding functions:
When all program select inputs are off, the “Default” program becomes
active as programmed through DEFAULT PROGRAM function.
Mode 5 uses this input to allow the machine to resume a cycle after being
stopped in mid-cycle. See Section 4, Programming for details.
Any output (except Run UP) can be ANDed with this input through
OUTPUT ENABLE ANDing. ANDed outputs operate only when this input
is on. This output can be used in conjunction with Speed Enable/Disable
and output modes.
PC54 Controller
PC55 Controller
Program Notes
BCD Format
S For BCD, calculate the program selected by adding the values for
each of the inputs that are on. For example, if inputs 5, 3, and 1 are
On, Program 15 is active (10 + 4 + 1).
S Only three of the normal four BCD digits for 10’s are used.
S Nine (9) is the largest valid value for the units digit. A units digit
combination larger than 9 sets the units digit to 9.
Binary Format
S For Binary, calculate the program selected by adding the values for
each of the inputs that are on. For example, if inputs 5, 3, and 1 are
On, Program 21 is active (16 + 4 + 1).
NOTE: Nordson eight position Gray Code program enable and program
select switches are available as options for PC50 Series controllers. See
Section 8, Options for program enable and program select switch
installation instructions.
Output Modules
NOTE: The load device to be driven must match the output type.
Power output modules directly switch inductive loads and resistive loads.
Each output module has two dedicated terminals and therefore does not
share any common signal with the other modules. This allows AC and
DC modules to be mixed on the same controller.
NOTE: The modules do not supply the power for the load; they simply
switch it.
TB 6
5 6 7 8 9
AB A B A B AB AB 1. TB 6 (Outputs 5-9 with 9 being Run
Up, or AC/DC)
TB 6 2. TB 7 (Outputs 1-4)
9
1
8
TB 7
7 1 2 3 4
6 AB A B A B AB
5 2
4
3
2
1
TB 7
5940326
TB 10 TB 6
8 7 6 5 13 14 15 16 17
AB A B A B AB AB A B A B AB AB 1. TB 6 (Outputs 13-15 with 16 & 17
being Run Up, or AC/DC)
2. TB 10 (Outputs 5-8)
1
2 17 3. TB 9 (Outputs 1-4)
8 16
7 15 TB 6 4. TB 7 (Outputs 9-12)
TB 10 6 14
5 13
4 12
TB 9 3 11 TB 7
2 10
1 9
23 4
TB 9 TB 7
4 3 2 1 9 10 11 12
AB A B A B AB AB A B A B AB
5940263
AC Output
2 1
L1 4 L2
1. Neutral
2. Hot
3. Module Terminals
3
5 4. Varistor
5. Load
6
6. R-C Suppressor
5940287
NOTE: Although most applications will not require the varistor or R-C
suppressor shown in Figure 3-22, when switching devices are in series or
parallel with the AC module, voltage spikes may damage the module.
Run Up Output
2
(+) 1. Run Up Load Device
1
2. Run Up Positive Voltage
3 3. Module Terminals
4. Run Up Negative Voltage
(--)
4
5940289
6
3 1. DC Common
+
2. Load
4
3. Positive VDC
4. Module Terminals
5. Zener Diode
2 6. Reverse Bias Diode
5
1 (--) 5940288
3 + 6 1. DC Common
5
4 2. Load
1
3. Positive VDC
4. Module Terminals
5. Zener Diode
2 (--)
6. Reverse Bias Diode
5940346
3. Keypad Wiring
Number of Keypads One or two keypads may be connected to a PC54 controller as shown in
Figure 3-26.
2 11
1 3 12 4 5 6 8 9
7
X W Z Y + -- S E1 E2 C S -- + W X Y Z E1 E2 C S -- + W X Y Z
10 10
Bk Wh Bk Gn Rd Bk Bk Rd Wh Bk Gn Bk Bk Rd Wh Bk Gn Bk
5940264
Programming Enable The terminal block on the back of each keypad includes terminals to
select Master or Operator level programming access for that keypad.
These terminals can be temporarily jumpered during set-up to allow entry
of programming access codes, or they can be switched with a variety of
devices including mechanical switches, relay contacts, and PLC DC
outputs. See PASSWORDS in the programming section for details on
programming access.
2 3
1
1. Master Program Enable
2. Operator Program Enable
E1 E2 C S -- + W X Y Z 3. Enable Common
4. Switch (To E1 or E2)
5. Sourcing Device (To E1 or E2)
5940291
2 3
1
1. Master Program Enable
2. Operator Program Enable
E1 E2 C S -- + W X Y Z 3. Enable Common
4. Switch (To E1 or E2)
5. Sinking Device (To E1 or E2)
5
5940292
4. Controller/Keypad DIP
Switch Configurations
DIP Switches Each keypad and controller has a DIP switch as shown in Figures 3-29
and 3-30.
Controller Settings The address settings on the controller DIP switch apply to a network
connecting the controller to a PLC or other system host. When the DIP
switch is set to zero, the default address programmed through the
COMMUNICATIONS function takes effect. Whereas the DIP switches
can set a maximum address of ‘7’, the COMMUNICATIONS function can
establish much higher address numbers. These settings are not related
to communications with the keypads.
Two sets of termination switches are included on the controller. One set
establishes the termination value for an RS-485 network connecting the
controller to a PLC or other system host. It does not apply to an RS-232
network. The other termination switches apply to the keypad network.
See Figures 3-31, 3-32 and 3-33 for guidelines and sample settings.
2 3
1
B0 B1 B2 4 5 6 7
4 1 Off
0 On 5
6 8
7
9
11
10
PLC or
SYSTEM
HOST
5940347
Keypad Settings The address and termination settings on the keypad DIP switch apply to
the RS-485 network that connects it to the controller. See Figures 3-31,
3-32 and 3-33 for guidelines and sample settings.
0 1
2
B0 3
B1 4
6 B2 5
B3
On Off
7
8
10
11 12
PLC or
SYSTEM
HOST
5940265
1
2
1 2 3 4 56
1 2 3 4 5 6 7 5940266
1 2 3
1 23 456
1 2 3 456
1 2 3 4 5 6 7
5940286
Fig. 3-32 DIP Switch Settings - Two Keypads with Controller in Middle
1. Keypad DIP Switches 2. Controller Keypad DIP Switches 3. Keypad DIP Switches
Termination: ON and Address: 0 Termination: OFF (Switches 6 & 7) Termination ON and Address: 1
1 2 3
1 2 3 4 56
1 2 3 4 56
1 2 3 4 5 6 7
5940285
Fig. 3-33 DIP Switch Settings - Two Keypads with Controller on End
1. Keypad DIP Switches 2. Keypad DIP Switches 3. Controller Keypad DIP Switches
Termination: ON and Address: 1 Termination Off and Address: 0 Termination: ON (Switches 6 & 7)
DB- 9F Port Serial communication to a PLC or other system host is provided through
a DB-9 female connector. See Figures 3-11 and 3-12 for location. This
connector can be wired for RS-232 or RS-485 communications.
RS-232 RS-232 can connect only a single PC50 Series controller to a system
host.
1
1. Data Terminal Ready (Not Used)
2
2. Transmit Data to Host
3 3. Receive Data From Host
4. Clear to Send (Not Used)
4 5. Signal Common
5
5940348
5. Communications Wiring
(contd.)
RS-485 RS-485 can be used for “multi-drop” networks where more than one
controller could be connected to the system host.
1
1. Receive Data From Host (--)
2. Transmit Data to Host (--)
2
3. Transmit Data to Host (+)
3 4. Receive Data From Host (+)
4 5. Signal Common
5
5940351
6. Initial Programming
Bench Test Test the PC50 Series controller, prior to installation, following the steps
below:
1. Verify that output modules are plugged into the controller beginning
with Position 1. See Figures 3-20 and-21.
5. Set the keypad DIP switch to address ‘0’ and termination “ON,” as
shown in Figure 3-30.
NOTE: Factory default for the PC54 is for all outputs to be in Mode 2.
NOTE: Supply a trigger for the PC54 input terminals 1 and/or 2. See
Table 2-1. Since only 2, 3, and 5 Operating Modes are available on the
PC54, an input signal is required to test the controller.
When experimenting with the controller, note that the LED on an output
module lights when that output channel is turned on. By hand-turning the
resolver shaft and watching the module LED’s, you can observe the
effects of programming setpoint values.
6. Initial Programming
(contd.)
Machine Setup After installing the unit, program the following set up information into the
controller before attempting any other programming:
Programming
Section 4
Programming
1. Introduction This section provides the basic steps required for programming PC50
Series controllers. Explanations for controller functions and capabilities
are provided in Section 3, Description. PC50 Series controller installation
and initial testing is provided in Section 3, Installation.
ESC SEL
Password
Setpoints
Setup Menu Gun Compensation
Timed Outputs (PC 55 only)
ESC SEL Offsets
Speed Enable/Disable
(If Outputs are Run Up
divided into Groups) Stitch
Channel Copy
Program Copy
Default Program
Enable Codes
ESC SEL
Output Groups
Communications Menu
ESC SEL
5940352
2. Initial Programming Specific set up information, generally related to controller firmware and
system interface physical characteristics must be initially programmed
(contd.)
into the controller before other system configuration information can be
entered.
Main Screens On power-up, or after five minutes of keypad inactivity, the controller
displays one of two main screens. The screen that is displayed depends
on whether one, or multiple, output groups are programmed and whether
each output group has its own position in the machine cycle or if all
groups share one position in the machine cycle.
1
2
1. Active Program
2. Machine Speed
3. Machine Position
3
5940354
Fig. 4-2
1
1. Group Position
2. Group Selection
3. Menu Tree Entry
3 2
5940355
Fig. 4-3
Active Program
The PC54 controller can store 16 programs in its memory. The PC55 is
capable of storing 64 programs in its memory. The “active program”
(item 1, Figure 4-2) is the program currently controlling the output
channels.
If hardware inputs are not used, the Active Program is the program
specified through the DEFAULT PROGRAM function.
Machine Speed
Toggle RPM
Enter the Menu Tree from the Main Screen by moving the cursor to
“MENU”, then pressing the SEL key.
Password
Menu Path
Entering a Password
Clearing a Password
Hardware Menu Initial programming of the controller begins with selections in this menu.
Upon completion, other items are programmed through the
CONFIGURATION MENU. PASSWORDS and SETPOINTS are other
programmed selections, but are selections off the main menu tree.
Keyboard Quantity
The KEYBOARD QTY screen shows the number of keypads with which
the controller will communicate.
Menu Path
NOTE: If KEYBOARD QTY is set to ‘2’, but only one keypad is physically
connected, Menu Tree operation will be very slow. Change KEYBOARD
QTY to ‘1’ to restore normal Menu Tree speed.
Changing Direction
Pressing SEL toggles the value of increasing direction. The new value
begins flashing. Pressing the ENT key confirms the selection.
Scale Factor
Menu Path
NOTE: The scale factor on PC54 controllers ranges from 2-1024. PC55
controllers have a scale factor ranging from 2-4096.
NOTE: When the scale factor is changed, all programmed setpoints are
recalculated, converting them to the new scale factor. The
keypad/display is inoperative until the calculations are complete.
Shaft Position
Menu Path
Programming
Use the INC/DEC keys or the numeric keys, followed by ENT to change
shaft position.
Run Up Qty
Menu Path
Use the numeric keys to enter ‘0’, ‘1,’ or ‘2’ for the number of modules
installed in the controller. Run Up output module(s) are required to
generate the Run Up output signal(s).
Each output can be offset and scaled by different values. See RUN UP
OUTPUT for details.
Menu Path
This screen allows you to specify the format for the hardware Program
Select inputs on:
The Program Select inputs can operate in Binary, BCD or Gray Code
formats as shown in Figures 3-18 and 3-19.
Use the SEL key to toggle the input format.
Setpoints
Menu Path
5 4
5940358
Channel to Edit
Use the numeric keypad and ENT to select the channel to program.
Use the left and right arrow keys to move between the ON and OFF
setpoints.
S If a channel has more than one duration, you may view the other
durations by pressing the right cursor key when viewing the OFF
setpoint, or by pressing the left cursor key when viewing the ON
setpoint.
S If a channel contains no durations, the ON and OFF setpoints are
1 5940359 ‘0’. (item 1)
S If a channel is always on, both the ON and OFF setpoints are ‘1’.
Fig. 4-7 Channel Display
Setpoints (contd.)
Adding a Duration
You may add a new duration to a channel by pressing the SEL key when
the cursor points to either the ON or the OFF setpoint.
The display changes to show blank ON and OFF (item 1) setpoints; the
1 cursor (item 2) will point to the ON setpoint. Enter the ON setpoint
through the numeric keypad, then press the ENT key or the right cursor
to move to the OFF setpoint. Enter the OFF setpoint through the numeric
keypad, then press the ENT key.
2 5940360
If ON and OFF setpoints for a duration are visible on the screen and SEL
is pressed to program a new duration, the original duration remains in the
output channel. If the ON or OFF setpoints being entered overlap an
existing duration in the channel, “Error: Duration Overlap” is displayed on
the screen.
Changing Setpoints
Change a setpoint value by entering a new value using the numeric keys,
followed by ENT, or increase/decrease the setpoint value with the INC
and DEC keys.
Duration Modes
The Duration Mode controls how the INC and DEC keys modify
setpoints. There are three modes; EDG (edge), DUR (duration), and
CHN (channel.)
Change the Duration Mode by pressing the SEL key when the cursor
points to the Duration Mode.
S In EDG mode, the INC and DEC keys affect the selected ON or
OFF setpoint only.
S In DUR mode, both ON and OFF setpoints are incremented or
decremented simultaneously.
S In CHN mode, all ON and OFF setpoints for all durations in the
channel are incremented or decremented simultaneously.
Setpoints (contd.)
The same logic applies if OFFSET is used for individual output groups.
Program the offsets before establishing setpoints for the channels in the
groups.
Gun Compensation
Menu Path
When GUN COMP MODE is selected, the data entry screen illustrated in
Figure 4-9 appears.
1
2
1. Output Channel
3 2. Pull in (10.5 ms shown)
3. Drop out (20 ms shown)
5940361
Programming
To change output channels, move the cursor to the channel number and
enter a new channel number or use the INC or DEC keys.
To change gun comp values, use the numeric keys or INC and DEC. To
enter tenths of milliseconds, use the decimal point. When entering even
milliseconds, the decimal point is not needed. (For example, when “12”
is entered and ENT pressed, the resulting value is 12.0.)
Menu Path
Any four outputs can be programmed to time out rather than remain on
until an OFF setpoint is reached. This makes the output duration
constant regardless of machine speed. If the OFF setpoint is reached
before the specified time has elapsed, the timing will be aborted and the
output will turn off immediately.
1. Channel
1
2. Time Duration
2
5940362
Once an output times out, it will not turn on until the next output pulse is
reached. Each timed output can have a unique time delay length.
Offsets
NOTE: Group Position Display (GRP POS DISP) must be set to “EACH”
to assign different offset groups through OFFSET programming.
Menu Path
Offset Programming
Screens
1
2
1. Output Group
2. Group Position = Shaft Position + ABS
Offset
3 3. Absolute Offset Value for This Group
5940363
1 2
1. Output Group
2. Group Position = PRE + Change
Since Last Reset
3. Group Preset Value (If Group is in
Operating Mode 1 or 2)
3
5940364
S Direct Entry - Enter the offset directly by moving the cursor to ABS
and entering the offset value on the numeric keypad, followed by
ENT.
Programming Preset
Speed Enable/Disable
Menu Path
Programming
Use the numeric keys and ENT to change values for SPEED LEVEL,
LOW RPM, and HIGH RPM.
Run Up
Menu Path
This function assigns OFFSET and HIGH RPM values to output positions
for Run Up modules.
Module Number
The following table shows the relationship between the Run Up module
number on the screen and the module position on the controller back.
See Figures 3-20 and 3-21 for an illustration of Run Up module
positions.
NOTE: When two Run Up outputs are used, the two outputs can have
different values for OFFSET and HIGH RPM.
Run Up (contd.)
RUN UP OUTPUT
1 1. Max Output
2. Offset
3. High RPM
2 3
RPM 5940366
Fig. 4-14
High RPM
Run Up High RPM is the resolver speed at which full scale output occurs.
High RPM is programmed in whole RPM. When this speed is reached,
the Run Up output signal level is at full scale (10 VDC or 20 mA).
Increasing speed beyond the High RPM will not increase the RUN UP
output beyond full scale.
To program High RPM, move the cursor to “Hi” and enter the number
using the numeric keys, then press ENT.
Offset
Run Up Offset is the signal level output when the resolver is at zero
RPM. This allows the minimum signal to be greater than zero volts or
4 mA.
To program RUN UP Offset, move the cursor to “Of”, use the numeric
keys to enter the calculated Offset value, then press ENT.
Stitch
Menu Path
Programming
DURATION ON OFF
1 0 50
2 100 150
3 200 250
4 300 350
5 400 450
6 500 550
7 600 650
8 700 750
9 800 850
10 900 950
Programming (contd.)
1
1. Program to Add Stitch Pattern to:
Enter Number, Then SEL to Go to Next
Screen
2 2. Channel to Add Stitch Pattern to:
Enter Number, Then SEL to Go to Next
Screen
3. “On” Time of Leading Edge of First
Duration:
3 Enter Number, Then ENT and SEL to
Go to Next Number
4. OFF Time of Trailing Edge of Last
Duration:
4 Enter Number, Then ENT and SEL to
Go to Next Screen
5. Total Number of Durations to be
Added:
Enter Number, Then ENT and SEL to
5 Go to Next Screen
6. Length of Each Duration to be Added:
Enter Number, Then ENT and SEL to
Go to Next Screen
6 7. Move Cursor to EXECUTE, Then
Press SEL to Generate Stitch Pattern.
To Review Values Before Executing,
Move Cursor to Top Row and Press
SEL as Needed.
8. COMPLETE Indicates Stitch Pattern
Has Been Generated.
7
5940367
Fig. 4-15
5940368
Channel Copy
Menu Path
1
1. Program Containing Channel to Copy.
Enter Number, Press ENT, then SEL
5940433
Fig. 4-17
1
1. Channel Being Copied From. Enter
Number, Press ENT, then SEL
5940434
Fig. 4-18
1
1. Destination Channel Being Copied to.
Enter Number, Press ENT, then SEL
5940435
Fig. 4-19
1
1. Move Cursor to Execute, then Press
5940436
SEL
Fig. 4-20
Fig. 4-21
Program Copy
Menu Path
1
1. Program to be Copied From
5940369
Fig. 4-22
1
1. Destination Program to be Copied to
5940370
Fig. 4-23
Fig. 4-24
Fig. 4-25
Programming
Default Program
Menu Path
The Default Program is the program that controls the output channels
when terminals 3-6 of TB 1 on the PC54 or terminals 1-8 of TB 3 on the
PC55 (Program Select terminals) are “off”. See Figures 3-13 and 3-14.
NOTE: The PC54 controller can store 16 programs in its memory. The
PC55 is capable of storing 64 programs in its memory.
Programming
Use the numeric keys to enter the number of the program designated as
the Default program, then press ENT.
Output Status
Menu Path
At the MAIN SCREEN:
- Press SEL
- Scroll down to I/O STATUS MENU. Press SEL.
- Scroll down to OUTPUT STATUS. Press SEL.
The screen(s) display the On/Off state of the output channels. The 0
indicates Off; the 1 indicates On.
1 2
5940373
3 4
5940374
3. Input/Output Status
Menu (contd.)
Input Status
Menu Path
The input status screen displays the On/Off status of the DC inputs on
Terminal Blocks TB 1 and TB 3 (for PC55 controllers only), (see Figure
3-13 and Figure 3-16).
1 Inputs are numbered 1 through 16, but only 8 inputs are shown at one
2
time. The On/Off status is shown under the input number. The 0
indicates Off; the 1 indicates On.
Selecting Inputs
3 5940375 View inputs 1-8 (for PC54 and PC55 controllers).
Setpoint Use
Menu Path
Firmware Version
Menu Path
5. Config Menu Sub-menus falling under the CONFIG MENU include: HARDWARE
MENU, DISPLAY MENU, ENABLE CODES, CHN ANDing MENU,
OUTPUT GROUPS and COMMUNICATIONS MENU. Many of these
sub-menus require access only during original controller programming.
Hardware Menu Selections within the HARDWARE MENU were provided earlier in this
section under Initial Programming
Display Menu
RATE SET UP
Menu Path
The Rate Setup function allows you to configure the RPM display on the
Main Screen. Three parameters can be programmed:
S Rate—The ratio of displayed RPM to actual resolver RPM. This
ratio is a fraction consisting of a multiplier (MPY) (item 1, Figure
4-29) over a divider (DIV) (item 4, Figure 4-29).
2
S Units— (item 3, Figure 4-29) The Main Screen can label the
1 resolver speed as Revolutions Per Minute (RPM), Bags Per
Minute (BPM), Cartons Per Minute (CPM), or Inches Per Minute
(IPM).
S Decimal Points—The controller divides the Rate by 1, 10, 100, or
1000 to display 0, 1, 2, or 3 decimal places, respectively (item 2,
Figure 4-29).
4 3
5940376
Programming
S Units-Move the cursor to the “Units” field and use SEL to toggle
between values.
S MPY & DIV-Move the cursor to MPY or DIV and use the numeric
keys followed by ENT to enter a value.
S DP-Move the cursor to DP and use SEL to toggle between values.
TOGGLE RPM
Menu Path
After a certain speed the Position digits scroll too fast to read. Toggle
RPM allows setting the resolver rpm at which the Position display on the
Main Screen disappears. At speeds below the Toggle RPM setting, the
Position display is visible; at speeds above the Toggle RPM setting, the
1 Position does not display.
5940377
Programming
Use the numeric keys and ENT to enter an RPM setting at which Position
display will blank out. Use INC and DEC to change an existing value.
Menu Path
Screen
1 2
1. Active Program
2. Machine Speed
3. Machine Position =
Shaft Position + Offset
4 3 4. To enter Menu Tree, press SEL when
5940379
cursor is here
Fig. 4-32
Fig. 4-33
To enter the Menu Tree (item 3, Figure 4-33) put the cursor at MENU and
press SEL.
Programming
Enter the GRP POS DISP function and press SEL to toggle between
“ONE” and “EACH”.
NOTE: GRP POS DISP must be set to “EACH” to assign different offsets
to groups through OFFSET programming.
Enable Codes
Menu Path
Programming
Each programming level can have only one password. That password is
stored in the controller and applies to all keypads connected to that
controller.
If one keypad in a two keypad system is enabled, the other keypad will
continue to operate in the “Normal Display” mode.
If both keypads in a two keypad system are enabled, each keypad will
operate at the programming level enabled on it. One keypad may be
Operator enabled, while the other keypad may be Master enabled.
Programming Level
Normal
Display Operator Master
Can Be Enabled By . . .
Keypad Terminal ------ Yes (E 2) Yes (E1)
Password ------ Yes Yes
Menu Item Access
Password Enter Enter Enter
Setpoints View Program Program
Setup Menu
Gun Comp View Program Program
Timed Outputs (PC55 Only) View Program Program
Offsets View Program Program
Speed Enable/Disable View Program Program
Run-Up View Program Program
Stitch ------ ------ Program
Channel Copy ------ ------ Program
Program Copy ------ ------ Program
Default Program View Program Program
NOTES: 1 KEYBOARD QTY can be programmed only through the keypad whose address
is ‘0’.
Menu Path
Programming
Press the SEL key to toggle the ANDing to L1, L2, or OFF.
Operation
S Any number of output channels can be ANDed to a single SPEED
ENABLE/DISABLE level.
S MIN SPEED ANDing and REMOTE ENABLE ANDing can be
combined for any given output channel.
S When MIN SPEED ANDing is activated for a channel, it applies to
that channel in all programs.
Using Channels as Motion Detectors
Menu Path
Programming
Output Groups
Menu Path
1
2 1. Selected Output Group
2. Number of Output Groups
3. Mode of Selected Output Group
4. Number of Channels in Selected
Output Group
4 3
5940381
Establishing Groups
Programming
Begin by moving the cursor to GRP QTY, then entering the number of
Output Groups desired, followed by ENT.
Next, move the cursor to GRP and enter ‘1’ followed by ENT.
Move the cursor to CHNS and enter the number of output channels to be
included in Group 1, followed by ENT.
Move the cursor to MODE and enter the operating mode for the Output
Group from zero to five, followed by ENT.
Move the cursor back to GRP and repeat the steps for each group being
programmed.
NOTE: When output channels are divided into Output Groups, the
appearance of the Main Screen changes slightly. See MAIN SCREEN for
details.
Menu Path
Purpose
This function sets the communications type, controller address, and baud
rate for communicating with a host computer.
Type
Address
Use the numeric keys to enter the Address, then press ENT.
Baud Rate Use SEL to toggle between the available baud rates. The baud rate must
match that of the host computer. Available baud rates are 4,800, 9,600,
19,200 and 38,400.
6. Test Menu
Memory Tests
Menu Path
Programming
Perform one of the memory test functions by using the numeric keys to
enter a function number, then pressing SEL.
Test Functions
Function 7000 Clears all setpoints and configuration settings from the controller’s EEPROM.
After clearing the settings, the controller reloads the factory default settings.
Function 7001 Clears all configuration settings from the controller’s EEPROM, including all
programming performed through the SETUP Menu and CONFIG Menu on the
Menu Tree. When finished, the controller reloads the factory default settings.
Function 7002 Clears all setpoints from the controller’s EEPROM, including any ON/OFF
setpoints programmed through SETPOINTS. All other settings are preserved.
Function 7998 The Watchdog Timer monitors controller microprocessor operation, shutting the
controller down if any internal malfunction is detected. The controller may
continue if the Watchdog Timer fails, but subsequent malfunctions or irregularities
may go undetected.
Function 7998 tests the Watchdog Timer. When operating properly, the controller
resets. If the controller does not reset, failure has occurred and the controller
must be replaced.
Section 5
Troubleshooting and Repair
1. Controller Diagnostics
Status LED The yellow Status LED on the controller (Figure 5-1) blinks in various
patterns, indicating the controller status.
1 2 5940382
Normal Operation
Internal Errors
If the LED blinking pattern is “on” for a second, followed by one or more
quick blinks “off,” the controller is experiencing internal errors. The
specific error is indicated by the number of “off” blinks:
If any of the above four patterns occur, power cycle the controller. If the
pattern occurs again, remove the controller from service and return it to
Nordson.
If either of these two patterns occur, check for loose connections and fix
any obvious noise problems. If the problem persists, remove the
controller from service and return it to Nordson.
2. Keypad Diagnostics
Keypad Fault LED If the Fault LED on the keypad lights, turn the controller off, then back on.
If the keypad Fault LED does not go off, the keypad microprocessor has
malfunctioned. Return the keypad to the factory.
1. Power Indicator
2. Fault Indicator
2
5940383
Keypad Diagnostics The Keypad includes a series of diagnostics that show the status of
various keypad functions.
To start the diagnostics, turn the controller off, then restart the controller
while pressing any key on the keypad.
NOTE: After each display, press the down arrow, then press SEL. A
new screen appears. Press the up or down arrows to return to the menu.
5940384
Fig. 5-3
2. The Fault LED blinks on, then off, at one second intervals.
5940385
Fig. 5-4
5940386
Fig. 5-5
5940387
Fig. 5-6
5940388
Fig. 5-7
5940389
Fig. 5-8
7. The screen displays a unique key number for each key pressed.
Press the ‘hidden key’ on the keypad face, just below HLP to exit.
5940390
Fig. 5-9
1
2 5940391
3. Resolver
Troubleshooting
Mechanical Problems If the resolver is generating erratic RPM or position readings, or the
position appears to be shifting periodically with respect to the machine
cycle, check the mechanical coupling between the resolver and the
machine.
If the coupling is not slipping, loosen the coupling and rotate the resolver
shaft in both directions with sudden, jerky motions. If the controller
displays unusual position or RPM readings, the resolver may be need to
be replaced.
Electrical Problems Section 2, Installation provides installation procedures for the resolver
and cables. If any wire in one of the three individually shielded pairs
becomes disconnected, “ERROR: Resolver Not Connected” is displayed
on the keypad screen.
1. Verify that the electrical connections at each end of the resolver cable
are secure.
4. General Troubleshooting
NOTE: Controllers and keypad/displays cannot be repaired in the field.
If a unit fails, do not disassemble it. Return the defective unit to Nordson
for replacement.
NOTE: See Figures 5-12 and 5-13 for the PC 50 Series controller
cabinet general arrangement and the cabinet wiring diagram.
Controller & keypad dead Main fuse blown. Check main fuse.
Keypad dead, but controller LED’s Incorrect wiring between keypad Check wiring between keypad and
are on. and controller. controller.
Keypad Fault LED “On”. Keypad microprocessor has Turn the controller off and back on.
malfunctioned. If the keypad Fault LED does not
go off, return the keypad to the
factory.
Menu operation slow on keypad KEYBOARD QTY programming Check KEYBOARD QTY
display. incorrect. programming. If it is set for two
keypads, but only one is
connected, menu operation will be
very slow.
4. General Troubleshooting
(contd.)
Problem Possible Cause Corrective Action
ERROR: Analog Malfunction. This is a non-fatal error, indicating Replace the controller.
the controller’s internal analog chip
is not working. A bad or missing
RUN UP module will not cause this
message.
ERROR: RESOLVER NOT Resolver or resolver cable failure. See Resolver Troubleshooting in
CONNECTED message. this section.
POS (position) moves opposite to INCREASING DIR programmed Check INCREASING DIR for the
machine direction. incorrectly for the correct direction correct direction of rotation.
of rotation.
POS (position) does not match Incorrect OFFSET. Once set, the Verify that OFFSET is correct.
machine position. offset value should not change.
Serial communications not Type, baud rate, and address Check communication
working incorrectly set in Communication programming to be sure type,
programming. baud rate, and address are
correctly set.
DIP switches for the Be sure the DIP switches for the
controller-to-host communications controller-to-host communications
are set incorrectly. are set correctly.
4. General Troubleshooting
(contd.)
Outputs cycling regularly at Incorrect program number is active. Check that the correct program
incorrect machine positions. number is active.
Erratic Operation Watchdog Timer test described Run the Watchdog Timer test
under Memory Tests in Section 4, described under Memory Tests in
Programming. Section 4, Programming.
RUN UP output not working. RUN UP QTY and RUN UP Output Check that RUN UP QTY and
are programmed incorrectly. RUN UP Output are programmed
correctly.
4. General Troubleshooting
(contd.)
AC/DC module not working. Incorrect program number is active. Check that correct program
number is active.
Too small a value in Timed Output. Too small a value will not turn on
output module.
Fuse Tester Figure 5-11 shows location of the fuse test socket and LED used to test
TR5 style fuses. PC 50 Series controllers are shipped with a spare 4A
fuse mounted in the test socket.
2 1
1. 250 mA TR 5 for power to Inputs TB 2
3 2. LED Lights if Fuse in Test Socket
Good
3. Test Socket w/Spare 4 A TR 5 Fuse
5940269
6. Electrical Schematics
and Wiring Diagrams
2 4
3
10
9
6
1
11
12
8
5940439
7. Electrical Schematics NOTE: Controllers are shipped configured for 240 VAC service.
and Wiring Diagrams WARNING: Disconnect equipment from the line voltage.
PC 50 Series Controllers with Install 240 VAC input power to the terminal strip as illustrated in Figure
240 VAC Service 5-13.
+24V
24 VDC 1 24V
POWER COM
SUPPLY
L1
240 VAC
2 L2
GND
3
F1
4
-- OUT + OUT
A
J1
B
F2
-- + G
PATTERN CONTROLLER
NOTE: Fuses F1 and F2 are 1 amp Slo Blo for 240 VAC service.
PC 50 Series Controllers with NOTE: Controllers are shipped configured for 240 VAC service.
120 VAC Service
WARNING: Disconnect equipment from the line voltage.
To reconfigure for 120 VAC service, remove J1 (see Figure 5-13) from
terminals A and B, then install J2 from F1 to terminal B and J3 from F2 to
terminal A as shown in Figure 5-14. Route the 120 VAC service to the
terminal strip as illustrated in Figure 5-14.
NOTE: Replace fuses F1 and F2 with customer supplied 2 amp Slo Blo
for 120 VAC service.
+24V
24 VDC 24V
POWER 1
COM
SUPPLY
L1
120 VAC
2 L2
GND
3
F1
4 J2
-- OUT + OUT
A
J3
F2
-- + G
PATTERN CONTROLLER
Parts
Section 6
Parts
Using the Illustrated Parts List Numbers in the Item column correspond to numbers that identify parts in
illustrations following each parts list. The code NS (not shown) indicates
that a listed part is not illustrated. A dash (--) is used when the part
number applies to all parts in the illustration.
The six-digit number in the Part column is the Nordson Corporation part
number. A series of dashes in this column (- - - - - -) means the part
cannot be ordered separately.
The Description column gives the part name, as well as its dimensions
and other characteristics when appropriate. Indentions show the
relationships between assemblies, subassemblies, and parts.
The number in the Quantity column is the quantity required per unit,
assembly, or subassembly. The code AR (As Required) is used if the
part number is a bulk item ordered in quantities or if the quantity per
assembly depends on the product version or model.
Letters in the Note column refer to notes at the end of each parts list.
Notes contain important information about usage and ordering. Special
attention should be given to notes.
PC50 Systems
RUN UP MODULES
- 188 091 0-10 VDC Run-Up Output Module -
- 188 092 4-20 mAmp Run-Up Output Module -
Power Supply
Keypad/Display and
Keypad /Display Cables
KEYPAD/DISPLAY CABLES
- 188 125 Cable, PC, Keypad/Display 2 ft.
- 188 081 Cable, PC, Keypad/Display 5 ft.
- 188 082 Cable, PC, Keypad/Display 10 ft.
- 188 083 Cable, PC, Keypad/Display 30 ft.
- 188 084 Cable, PC, Keypad/Display 50 ft.
- 188 085 Cable, PC, Keypad/Display 100 ft.
Terminal Blocks
Spare Parts
Specifications
Section 7
Specifications
PC50 Series Controller Cabinet Wall or machine mounting by bolts through cabinet flanges.
Mounting
Optional auxiliary keypad (PC55 only) may be
mounted up to 1000 feet from controller cabinet.
Input ON
State Voltage: 10-30 VDC
Program Select
Response: 100 ms typical (may be longer with large number
of setpoints)
Outputs
DC Outputs
Run Up Outputs
Number of Timed
Outputs: 4 maximum (PC55 only)
Options
Section 8
Options
1. Washdown Boot
Description The washdown boot, (P/N 188 105) a clear silicon rubber boot fitting over
and around the keyboard area, protects the keyboard during caustic
chemical washdown. The transparent and pliable boot, allows the
keyboard to be viewed and operated through it. In addition to preventing
contamination from harsh chemicals, the boot protects the keyboard from
grease, oil, dirt, and normal wear that could otherwise shorten keyboard
life.
Installing the Washdown Boot 1. Remove the nuts and regular black rubber gasket from the keyboard.
2. Carefully slip the silicone rubber boot over the keyboard. Slowly work
it over the mounting studs, being careful not to cause any tears in the
boot.
4. Install the keyboard into the panel. The nut tightening sequence is
important. Start with a corner of the unit, holding the rubber boot
snugly to the edge of the keyboard while bringing the nut to a finger
tightness. Select the next nut, again tightening while holding the boot
snugly to the keyboard edge. When all the nuts are in place, tighten
each nut a little more, tightening one at a time. The silicone rubber
tends to extrude from under the keyboard if the bolts are not
tightened in an even sequence or if they are over torqued.
NOTE: Applying too much torque to the nuts does not improve
sealing. Damage to the silicone rubber seal may occur.
2. Program Enable and Available as an option on PC50 Series controllers, program enable
(P/N 188 108) and program select (P/N 188 107) switches prevent
Select Switches unauthorized programming changes to the controller and allow remote
selection of the Active Program.
Program Enable Switch The switch is wired to the Master Program Enable terminal on the back of
the keyboard. A second switch may be wired to Operator Enable.
For the program enable switch, either sourcing or sinking wiring may be
used. Figures 8-1 and 8-2 illustrate keypad terminal block sinking and
sourcing wiring for programming enable.
1 2 3 5
1. Master Program Enable
E1 E2 C S -- + W X Y Z 2. Operator Program Enable
3. Enable Common
4. Switch (To E1 or E2)
5. Terminal Block on Keypad
4 5940291
1 2 3
5
1. Master Program Enable
E1 E2 C S -- + W X Y Z 2. Operator Program Enable
3. Enable Common
4. Switch (To E1 or E2)
5. Terminal Block on Keypad
4
5940292
Program Select Switch The program select switch, which allows remote control of the Active
Program, allows the operator to change programs but does not allow
changing setpoints in the output channels. The switch provides access
to 8 programs in the active program bank.
8
7 8
SINKING 1. Group 1 Input
6 7 TB1 2. Group 2 Input
6
5 GREEN
5
WHITE 3. Program Select 1
4 4
RED
3 3
2
4. Program Select 2
2 1 5. Program Select 3
C
1 6. Program Select 4
_
9 +
BLACK 7. First Cycle Enable
10 TB2 8. Remote Enable
11 9. Input Common
10. DC Power Out for Inputs
8 11. Chassis Ground
7 8
TB1 SOURCING
6 7
6
5 5
GREEN
WHITE
4 4
RED
3
3 2
1
2 C
1
_
9 +
10 TB2 BLACK
11 5940327
11
10 SINKING
1. Program Select 1
_ TB2 BLACK
9 2. Program Select 2
+
8 3. Program Select 3
7
C
8
4. Program Select 4
6 7 5. Program Select 5
6 TB3
5 5 6. Program Select 6
4 4
GREEN
3 7. Program Select 7
3 2 WHITE
2
1 RED
8. Program Select 8
9. Input Common
1
10. DC Power Out for Inputs
11 11. Chassis Ground
10 SOURCING
_ TB2
9 BLACK
+
8
C
7 8
6 7
5
6 TB3
5
4 4
3
GREEN
3 2
WHITE
1 RED
2
1 5940392
Insert the instruction sheet and diskette holder provided with the
communication package in Section 9, Communications for storage and
future reference.
Modbus Communication
Communications
Section 9
Communications
1. Introduction This section contains descriptions of and the operating requirements for
PC50 Series controller communications packages.
2. Modbus
Communications
NOTE: When using serial communications, the host device must be set
for seven (7) data bits, two (2) stop bits and no parity.
Data Organization The two types of data available through Modbus communications are
Discrete I/O and Registers.
In order to read the On and Off setpoints for a Duration, data must first be
written to the three index registers to specify which Duration is to be read.
EXAMPLE:
NOTE: Data Display registers will not accept mapping values until the
Map Limit register (40296) has been programmed with a value greater
than zero (0).
DOS Utilities On the diskette, furnished with the software package, are two (2) DOS
utilities for use with serial communications.
MODCMD. EXE
NOTE: When reading or writing to registers, use only the last three (3)
digits of the register.
S For example, to read or write to register 40305 (keyboard
quantity), type 305 when prompted. Do not enter 0305 or 40305.
MODMAP. EXE
Included with MODMAP. EXE is a text file called MAPPING. FMT which
can be opened in MODMAP and studied. This file explains the formats
used by MODMAP and includes a mapping example which can be
downloaded to a PC55 controller. The menus in MODMAP are
self-explanatory.
Modbus Register Map This section provides a list of PC55 controller addresses for Discrete I/O
elements and memory registers.
Discrete I/O
Inputs
10001 -- 10016 DC Inputs
These coils represent the status of the channel outputs. Forcing these
coils directly will set/clear the appropriate ORing and ANDing coils as
required.
Setting these coils to ‘1’ will force the corresponding channel Output Coil
ON.
Setting these coils to ‘1’ will force the corresponding Channel Output Coil
OFF.
Clears all OR and AND coils when set from ‘0’ to ‘1’ (edge active).
When ‘1’, this coil enables the creation of new Durations through writes to
the New Off Register. When this coil is ‘0’, writes to New Off Register do
not create a new Duration.
Creates a new Duration defined by the New On and New Off registers
when set from ‘0’ to ‘1’ (edge active). This coil is ignored if coil 302 is ‘1’.
When ‘1’, this coil will cause both edges of a Duration to move when
either the leading or trailing edge is changed by ‘1’ (incremented or
decremented).
When ‘1’, this coil will cause all edges of all Durations in a channel to
move when either the leading or trailing edge is changed by ‘1’
(incremented or decremented).
When ‘1’, this coil enables the auto increment feature on index registers.
This feature allows sequential reading of indexed values without
changing the index register.
Registers
These registers (017 -- 256) are used by the Mapping functions to display
individual instances of indexed data.
RPM
40257 RPM
Read only
Read/write
Values: 17 -- 256
Specifies the general purpose register used to display the position for the
output group specified by the Group Index Register.
Read/write
Values: 1 -- 6
40260 Position
Read only
Returns the current position for the output group specified by the Group
Index Register.
Registers (contd.)
Duration Programming
40261 Mapping
Read/write
Values: 17 -- 255
General Purpose Register used for mapping the On and Off values for
the Duration specified by the index registers. Two registers will be used;
the first contains the On value, the second contains the Off value.
Read/write
Values: 0 -- n
Returns the total number of Durations for all channels. Writing a value of
‘0’ to this register will erase all Durations. You can only write to this
register when the Stop register is ‘1’.
Read only
Values: 0 -- n
Read/write
Contains the current program number for Duration access. Writing to this
register resets the Channel Index Register and the Duration Index
Register to ‘1’. When this register is ‘0’, the current active program is
used for setpoint access and for mapping (setpoints mapped with a
program index of ‘0’ will automatically change when the active program
changes).
Read/write
Contains the current channel number for Duration access. Writing to this
register resets the Duration Index Register to ‘1’. This register is reset to
‘1’ when the Program Index Register is changed.
Registers (contd.)
Read/write
Values: 1 -- n
Contains the current Duration number for Duration access. This register
is reset to ‘1’ when the Program Index Register or Channel Index
Registers are changed.
40267 Duration On
Read/write
Duration On Value.
Read/write
40269 New On
Read/write
Writing to this register loads the On setpoint of a new Duration for the
program and channel specified by the index registers above.
Read/write
Writing to this register loads the Off setpoint of a new Duration for the
program and channel specified by the index registers above. The
Duration is stored when the Off value is written if the Duration Register
Enable Coil is set to ‘1’; otherwise the Duration is stored when the Create
New Duration Coil is changed from ‘0’ to ‘1’ (edge active).
Registers (contd.)
Default Program
40271 Default Program
Read/write
Gun Compensation
40272 Gun Comp Mapping
Read/write
Values: 17 -- 255
Read/write
Read/write
Values: 0 -- n (.1mS)
Read/write
Values: 0 -- n (.1mS)
Registers (contd.)
Timed Outputs
40276 Timed Output Mapping
Read/write
Values: 17 -- 255
Read/write
Read/write
Values: 0 -- n (1mS)
Offset
40279 Offset Mapping
Read/write
Values: 17 -- 256
Read/write
Values: 1 -- 6
Read/write
Registers (contd.)
Speed Enable/Disable
40282 Speed Enable/Disable Mapping
Read/write
Values: 17 -- 255
General purpose register is used for mapping low and high motion
detection values. Two registers are used; the first contains the low
motion detection rpm value, the second contains the high motion
detection rpm value.
Read/write
Values: 1, 2
Motion detection level index for high and low motion detection values.
Read/write
Values: 0 -- n
Min Speed low limit for the level specified by the index register.
Read/write
Values: 0 -- n
Max Speed high limit for the level specified by the index register.
Registers (contd.)
Run Up Output
40286 Run Up Output Mapping
Read/write
Values: 17 -- 255
General purpose register used for mapping Run Up offset and high RPM
values. Two registers will be used; the first contains the Run Up offset
value, the second contains the high RPM value.
Read/write
Values: 1, 2
Run Up channel index for Run Up offset and high RPM values.
Read/write
Values: 0 -- 4095
Read/write
Values: 0 -- n
Registers (contd.)
Mapping Registers
40296 Map Limit
Read/write
Values: 0 -- 256
Read/write
Values: 0 -- 256
NOTE: Writing a ‘0’ to this register will delete all data mappings!
Registers (contd.)
Model Information
40300 Model
Read only
40301 Revision
Read only
Read only
Returns the number of output channels (8, 9, 16, 17, 25, etc.).
Read/write
Values: 1 -- n
Used as index for reading installed controller options through the Option
Register.
40304 Option
Read only
Values: 0 -- n
Registers (contd.)
Hardware Configuration
40305 Keyboard Quantity
Read/write
Values: 1, 2
Read/write
Values: 0 = CCW, 1 = CW
Specifies the resolver’s rotation direction (viewed from the shaft end) that
results in an increasing numerical display of position.
Read/write
Read only
Returns the current resolver shaft position, including the shaft offset.
Read/write
Registers (contd.)
Hardware Configuration
40310 Run Up Quantity
Read/write
Values: 0, 1, 2
Read/write
Read/write
Specifies how the program select inputs determine the active program.
Read/write
Values: 0 = Off, 1 = On
Read/write
Values: 1 -- 1091
Read/write
Values: 1 -- 63
Registers (contd.)
Display Configuration
40320 Rate Decimal Point Position
Read/write
Values: 0 -- 3
Read/write
Read/write
Values: 0 -- n
Read/write
Read/write
Values: 0 -- n
40328 Master ID
Read/write
Values: 0 -- n
Specifies the Master ID number used to enable the Master access level
for programming.
Registers (contd.)
Read/write
Read/write
Read/write
Read/write
Registers (contd.)
Group Programming
40336 Group Quantity
Read/write
Values: 1 -- 6
Read/write
Values 1--6
Read/write
Values: 0 -- n
Read/write
Values: 0 -- 5
Defines the operating mode for the output group specified by the Group
Index Register.
NOTE: Groups in mode ‘0’ do not need (or have) an enable input.
Registers (contd.)
Read/write
Read only
Read only
A value of ‘1’ in this register means that the EEPROM has been changed
(through the keyboard) since the last time this register was read.
Reading this register sets it to ‘0’.
3. Nordson Communication
Software Remove this page and insert the instruction sheet and diskette holder
provided with the optional Nordson Communication Software package.
Index
C E
Electrical
Channels, description, 2-5 AC output, 3-20
Cleaning, Safety instructions, 1-7 cabinet general arrangement, 5-11
controller DIP switch settings, 3-24
Communication controller fuse replacement, 5-10
baud rates, 7-3 controller outputs, 3-19
Modbus communication, 9-2 controller wiring, general, 3-8
programming, 4-42 controller/power supply wiring diagram, 5-12
software, 8-4 input terminal function, 3-15
software descriptions, 8-4 input terminals, 3-9
wiring, 3-27 keypad/display DIP switch settings, 3-24
keypad/display wiring, 3-22
Controller
output wiring, 3-19
bench test, 3-28 PC54 terminal locations, 3-10
cabinet installation, 3-6 PC55 terminal locations, 3-11
communication wiring, 3-27 power supply wiring, general, 3-8
DIP switch settings, 3-24 specifications, 7-1
dip switch settings, 3-7 terminal blocks, 3-9
initial programming, 3-28
input terminal functions, 3-15
input terminal wiring, 3-9
input wiring, 3-9
G
guidelines, 3-15 Gun Compensation
sinking or sourcing, 3-12 affect on operating modes, 2-26
keypad/display description, 2-2 calculating pull-in/drop-out, 2-28
module installation, 3-7 description, 2-8, 2-26
output modules, 3-19 guidelines, 2-26
PC 54 terminal locations, 3-10 leading/trailing edges, 2-27
PC 55 terminal locations, 3-11 negative gun compensation, 2-29
PC54 program select formats, 3-16 setting pull-in/drop-out, 2-27
PC55 program select formats, 3-17
program menu tree, 4-2
status LEDs, 5-1 I
terminal blocks, 3-9
troubleshooting, 5-1 Inputs
wiring, power supply, 3-8 description, 2-6
wiring, guidelines, general, 3-8 specifications, 7-2
terminals, wiring, 3-9
Installation
cabinet mounting, 3-6
D communication software, 8-4
communication wiring, 3-27
Durations controller bench test, 3-28
adding durations, 4-12 controller DIP switch settings, 3-24
adding multiple durations, 4-12 controller input wiring, 3-9
clearing a channel, 4-13 controller output wiring, 3-19
deleting durations, 4-13 controller power supply wiring, 3-8
description, 2-5 initial controller programming, 3-28
duration modes, 4-12 keypad/display DIP switch settings, 3-24
E 1995 Nordson Corporation 107 126A Manual 66-- PC50-- MA-- 01 (formerly 57-- 30)
All rights reserved
Issued 10/95
i-2 Index
Index (contd.)
I (contd.) O (contd.)
Installation (contd.) Operating Mode 2
keypad/display wiring, 3-22 application, 2-16
module mounting, 3-7 description, 2-16
program enable switch, 8-2 programming, 2-17
program select switch, 8-3 Operating Mode 3
programming enable, 3-23 application, 2-18
resolver, 3-2 description, 2-18
washdown boot, 8-1 programming, 2-18
Operating Mode 4
application, 2-20
K description, 2-20
programming, 2-21
Keypad/Display
communications test set up, 5-4 Operating Mode 5
description, 2-4, 2-5 application, 2-22
diagnostics, 5-2 programming, 2-22, 2-23
DIP switch settings, 3-24 Operation, specifications, 7-3
parts list, 6-4
program enable, 3-23 Options
wiring, 3-22 Nordson Communication Software description,
8-4
program enable switch, 8-2
program select switch, 8-3
M washdown boot, 8-1
Modbus Communication Output Groups
controller addresses, 9-4 combining output channels into output groups,
data organization, 9-2 2-11
DOS utilities, 9-3 establishing, 4-39
Modules Output Groups and Operating Modes
DC output, sourcing or sinking, 3-21 controller input signals, 2-9
parts lists, 6-2 description, 2-6
power output, 3-19 output channels, 2-6, 2-10
run up, 3-20 output group assignment to operating modes,
2-12
Motion ANDing, description, 2-7 output group programming, 2-10
Outputs, specifications, 7-2
O
Offset, description, 2-24
Operating Mode P
mode 0 description, 2-13
mode 1 description, 2-13 Parts Lists
keypad/display, 6-4
Operating Mode 0, programming, 2-13 keypad/display cables, 6-4
Operating Mode 1 output modules, 6-2
applications, 2-15 PC50 systems, 6-2
programming, 2-15 power supply, 6-3
Manual 66-- PC50-- MA-- 01 (formerly 57-- 30) 107 126A E 1995 Nordson Corporation
All rights reserved
Issued 10/95
Index i-3
Index (contd.)
P (contd.) P (contd.)
Parts Lists (contd.) Programming (contd.)
resolvers and resolver cables, 6-3 setpoints, 4-11
spare parts, 6-5 shaft position, 4-8
terminal blocks, 6-4 speed enable/disable, 4-19
Passwords stitch, 4-22
enable codes programming, 4-35 system testing, 4-43
program enable, 3-23 timed outputs, 4-16
programming access, 2-7 toggle rpm, 4-4, 4-32
Programs, description, 2-6
Power Supply
installation, wiring, 3-8 Pull-In/Drop-Out, description, 2-8
parts list, 6-3
Program Enable Switch, installation, 8-2
R
Program Select Switch, installation, 8-3
Resolver
Programming description, 2-1
active program, 4-4 dimensional information, 3-3
channel copy, 4-24 installation, 3-2
communications, 4-42 parts list, 6-3
default program, 4-26 troubleshooting, 5-5
enable codes, 4-35 wiring, 3-4
entering menu tree, 4-4
establishing output groups, 4-39 Run Up, description, 2-8
firmware version, 4-29
group position display, 4-33
gun compensation, 4-14 S
hardware menu, 4-6
increasing direction, 4-7 Safety
input status, 4-28 Cleaning, 1-7
keyboard quantity, 4-6 Installation and electrical connections, 1-4
machine speed, 4-4 Maintenance/Repair, 1-6
main screen description, 4-3 Operation, 1-4
menu tree, 4-2 Symbols, 1-2
min speed ANDing, 4-37 Thermoplastic, 1-8
offsets, 4-17 Scale Factor, description, 2-7
output groups, 4-39 Setpoints
output status, 4-27 adding a duration, 4-12
password, 4-5 adding multiple durations, 4-12
preprogramming considerations, 2-9 changing setpoints, 4-12
program copy, 4-25 clearing a channel, 4-13
program select mode, 4-10 deleting a duration, 4-13
rate set up, 4-30 description, 2-5
remote enable ANDing, 4-38 duration modes, 4-12
run up, 4-20
run up quantity, 4-9 Spare Parts, 6-5
scale factor, 4-7 Specifications
setpoint use, 4-29 communication, 7-3
E 1995 Nordson Corporation 107 126A Manual 66-- PC50-- MA-- 01 (formerly 57-- 30)
All rights reserved
Issued 10/95
i-4 Index
Index (contd.)
S (contd.)
Specifications (contd.)
inputs, 7-2
operation, 7-3
outputs, 7-2
physical, 7-1
Speed Enable/Disable, description, 2-7
Stitch, description, 2-6
System Configuration
controller input signals, 2-9
output groups and operating modes, 2-9
set up considerations, 2-9
T
Terminal
blocks, controller, 3-9
input terminal function, 3-15
locations
PC54, 3-10
PC55, 3-11
PC54 input terminal program select formats,
3-16
PC55 input terminal program select formats,
3-17
Terminal Blocks, parts list, 6-4
Timed Outputs, description, 2-7
Troubleshooting
communications port, 5-4
controller cabinet general arrangement, 5-11
controller diagnostics, 5-1
controller fuse and fuse tester, 5-10
controller/power supply wiring diagram, 5-12
general, 5-6
keypad diagnostics, 5-2
resolver, 5-5
status LED, 5-1
table, 5-6
W
Washdown Boot, installation, 8-1
Manual 66-- PC50-- MA-- 01 (formerly 57-- 30) 107 126A E 1995 Nordson Corporation
All rights reserved
Issued 10/95