Fiber Optic Module. Customer Product Manual Part B02

Transcription

1 Fiber Optic Module Customer Product Manual Issued 3/08 For parts and technical support, call the Industrial Coating Systems Customer Support Center at (800) or contact your local Nordson representative. This document is subject to change without notice. Check for the latest version. NORDSON CORPORATION AMHERST, OHIO USA

2 Table of Contents Safety... 1 Qualified Personnel... 1 Intended Use... 1 Regulations and Approvals... 1 Personal Safety... 2 High-Pressure Fluids... 2 Fire Safety... 3 Halogenated Hydrocarbon Solvent Hazards. 4 Action in the Event of a Malfunction... 4 Disposal... 4 Description... 5 Specifications... 5 Related Equipment and Manuals... 5 Operation Description... 6 Installation... 7 Module Installation... 7 Wiring... 7 Cable Installation... 8 Rotary Atomizer Connection... 8 Cutting the Cable to the Desired Length... 9 Fiber Optic Module Connection... 9 Adjusting Sensor Sensitivity Fiber Optic Module Test Test Procedure Speed Tables in. Unloaded Cup, 1/2-in. OD Tubing in. Unloaded Cup, 3/8-in. OD Tubing in. Unloaded Cup, 1/2-in. OD Tubing in. Unloaded Cup, 3/8-in. OD Tubing in. Unloaded Cup, 1/2-in. OD Tubing in. Unloaded Cup, 3/8-in. OD Tubing Troubleshooting Repair Parts Optional Fiber Optic Cable Kit Contact Us Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General information about Nordson can be found on the Internet using the following address: Address all correspondence to: Nordson Corporation Attn: Customer Service 555 Jackson Street Amherst, OH Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 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 Nordson and the Nordson logo are registered trademarks of Nordson Corporation Nordson Corporation

3 Fiber Optic Module 1 Fiber Optic Module Safety Read and follow these safety instructions. Task- and equipment-specific warnings, cautions, and instructions are included in equipment documentation where appropriate. Make sure all equipment documentation, including these instructions, is accessible to persons operating or servicing equipment. Qualified Personnel Equipment owners are responsible for making sure that Nordson equipment is installed, operated, and serviced by qualified personnel. Qualified personnel are those employees or contractors who are trained to safely perform their assigned tasks. They are familiar with all relevant safety rules and regulations and are physically capable of performing their assigned tasks. Intended Use Use of Nordson equipment in ways other than those described in the documentation supplied with the equipment may result in injury to persons or damage to property. Some examples of unintended use of equipment include using incompatible materials making unauthorized modifications removing or bypassing safety guards or interlocks using incompatible or damaged parts using unapproved auxiliary equipment operating equipment in excess of maximum ratings Regulations and Approvals Make sure all equipment is rated and approved for the environment in which it is used. Any approvals obtained for Nordson equipment will be voided if instructions for installation, operation, and service are not followed Nordson Corporation

4 2 Fiber Optic Module Personal Safety To prevent injury follow these instructions. Do not operate or service equipment unless you are qualified. Do not operate equipment unless safety guards, doors, or covers are intact and automatic interlocks are operating properly. Do not bypass or disarm any safety devices. Keep clear of moving equipment. Before adjusting or servicing moving equipment, shut off the power supply and wait until the equipment comes to a complete stop. Lock out power and secure the equipment to prevent unexpected movement. Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or servicing pressurized systems or components. Disconnect, lock out, and tag switches before servicing electrical equipment. While operating manual spray guns, make sure you are grounded. Wear electrically conductive gloves or a grounding strap connected to the gun handle or other true earth ground. Do not wear or carry metallic objects such as jewelry or tools. If you receive even a slight electrical shock, shut down all electrical or electrostatic equipment immediately. Do not restart the equipment until the problem has been identified and corrected. Obtain and read Material Safety Data Sheets (MSDS) for all materials used. Follow the manufacturer s instructions for safe handling and use of materials, and use recommended personal protection devices. Make sure the spray area is adequately ventilated. To prevent injury, be aware of less-obvious dangers in the workplace that often cannot be completely eliminated, such as hot surfaces, sharp edges, energized electrical circuits, and moving parts that cannot be enclosed or otherwise guarded for practical reasons. High-Pressure Fluids High-pressure fluids, unless they are safely contained, are extremely hazardous. Always relieve fluid pressure before adjusting or servicing high pressure equipment. A jet of high-pressure fluid can cut like a knife and cause serious bodily injury, amputation, or death. Fluids penetrating the skin can also cause toxic poisoning. If you suffer a fluid injection injury, seek medical care immediately. If possible, provide a copy of the MSDS for the injected fluid to the health care provider Nordson Corporation

5 Fiber Optic Module 3 The National Spray Equipment Manufacturers Association has created a wallet card that you should carry when you are operating high-pressure spray equipment. These cards are supplied with your equipment. The following is the text of this card: WARNING: Any injury caused by high pressure liquid can be serious. If you are injured or even suspect an injury: Go to an emergency room immediately. Tell the doctor that you suspect an injection injury. Show him this card Tell him what kind of material you were spraying MEDICAL ALERT AIRLESS SPRAY WOUNDS: NOTE TO PHYSICIAN Injection in the skin is a serious traumatic injury. It is important to treat the injury surgically as soon as possible. Do not delay treatment to research toxicity. Toxicity is a concern with some exotic coatings injected directly into the bloodstream. Consultation with a plastic surgeon or a reconstructive hand surgeon may be advisable. The seriousness of the wound depends on where the injury is on the body, whether the substance hit something on its way in and deflected causing more damage, and many other variables including skin microflora residing in the paint or gun which are blasted into the wound. If the injected paint contains acrylic latex and titanium dioxide that damage the tissue s resistance to infection, bacterial growth will flourish. The treatment that doctors recommend for an injection injury to the hand includes immediate decompression of the closed vascular compartments of the hand to release the underlying tissue distended by the injected paint, judicious wound debridement, and immediate antibiotic treatment. Fire Safety To avoid a fire or explosion, follow these instructions. Ground all conductive equipment. Use only grounded air and fluid hoses. Check equipment and workpiece grounding devices regularly. Resistance to ground must not exceed one megohm. Shut down all equipment immediately if you notice static sparking or arcing. Do not restart the equipment until the cause has been identified and corrected. Do not smoke, weld, grind, or use open flames where flammable materials are being used or stored. Do not heat materials to temperatures above those recommended by the manufacturer. Make sure heat monitoring and limiting devices are working properly Nordson Corporation

6 4 Fiber Optic Module Fire Safety (contd) Provide adequate ventilation to prevent dangerous concentrations of volatile particles or vapors. Refer to local codes or your material MSDS for guidance. Do not disconnect live electrical circuits when working with flammable materials. Shut off power at a disconnect switch first to prevent sparking. Know where emergency stop buttons, shutoff valves, and fire extinguishers are located. If a fire starts in a spray booth, immediately shut off the spray system and exhaust fans. Shut off electrostatic power and ground the charging system before adjusting, cleaning, or repairing electrostatic equipment. Clean, maintain, test, and repair equipment according to the instructions in your equipment documentation. Use only replacement parts that are designed for use with original equipment. Contact your Nordson representative for parts information and advice. Halogenated Hydrocarbon Solvent Hazards Do not use halogenated hydrocarbon solvents in a pressurized system that contains aluminum components. Under pressure, these solvents can react with aluminum and explode, causing injury, death, or property damage. Halogenated hydrocarbon solvents contain one or more of the following elements: Element Symbol Prefix Fluorine F Fluoro- Chlorine Cl Chloro- Bromine Br Bromo- Iodine I Iodo- Check your material MSDS or contact your material supplier for more information. If you must use halogenated hydrocarbon solvents, contact your Nordson representative for information about compatible Nordson components. Action in the Event of a Malfunction If a system or any equipment in a system malfunctions, shut off the system immediately and perform the following steps: Disconnect and lock out system electrical power. Close hydraulic and pneumatic shutoff valves and relieve pressures. Identify the reason for the malfunction and correct it before restarting the system. Disposal Dispose of equipment and materials used in operation and servicing according to local codes Nordson Corporation

7 Fiber Optic Module 5 Description The Nordson Fiber Optic Module is used to convert an optical speed signal from a Nordson rotary atomizer into a square wave electrical signal which can be used by a RPM indicator or PLC controller to monitor and control rotary atomizer turbine speed. Figure 1 Fiber Optic Module Specifications Height: Width: Depth: Mounting (0.32-in. holes): (width, center to center) (height, center to center) Weight: Power Requirements: Fiber Optic Cable Length 22.9 cm (9.00 in.) cm (8.0 in.) 5.08 cm (2.0 in.) cm (7.25 in.) 25.1 cm (9.88 in.) 2.95 kg (6.5 lb) 15 Vdc, 100 ma max m (40 ft) Related Equipment and Manuals The following Nordson equipment is used with the Fiber Optic Module: Fiber Optic Cable RPM Indicator Rotary Atomizer The RA-20 Rotary Atomizer is equipped with a visible-light transmitter that sends light pulses through the fiber optic cable to the Fiber Optic Module. Refer to the manuals included with the above equipment for more information on the installation and operation of the optional fiber optic speed sensing system Nordson Corporation

8 6 Fiber Optic Module Operation Description Figure 2 Fiber Optic Module Operation 1. Magnets 2. Visible light transmitter 3. Fiber optic cable 4. Photoelectric sensor The fiber optic module is connected to the rotary atomizer by an optional 12 meter (40 ft) long fiber optic cable. The length of the cable allows the module to be mounted outside the spray area in a non-hazardous environment. One end of the fiber optic cable is connected to a ferrule secured by a set screw to the rotary atomizer interface plate and the other end is connected to the photoelectric sensor in the fiber optic module. A visible light transmitter assembly is installed in the rotary atomizer interface plate. The transmitter contains a coil and LED. Magnets embedded in the turbine wheel generate a pulsating current in the coil as they rotate past it. The LED converts the current into pulses of visible light. The fiber-optic cable transmits the pulses of light to the fiber-optic module. The light pulse is converted by the photoelectric sensor in the module into a 0-15 Vdc square wave output. For open-loop (manual) speed control, this output is used by a display device such as the RPM Indicator to display turbine speed. The operator manually adjusts air flow and pressure to control the turbine speed. For closed-loop (automatic) speed control, this output is used by a PLC controller and voltage-to-pressure or current-to-pressure transducers and regulators to monitor and control turbine speed Nordson Corporation

9 Fiber Optic Module 7 Installation WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. WARNING: Relieve system pressure and remove and lock out all pneumatic, hydraulic, and electrostatic inputs before connecting the fiber optic cable to the rotary atomizer. CAUTION: Do not use solvents to clean the fiber-optic cable. Solvent will damage the fiber-optic core. Use a clean, soft cloth to clean the cable. Module Installation Use 1 / 4 inch fasteners to mount the module on a rigid, permanent mounting surface in a non-hazardous environment. Make sure that the switches on the photoelectric sensor are properly set. Wiring See Figure 3 for wiring. The module requires 15 Vdc, 100 ma maximum power. TB1-5 and 6 are open collector output, NPN, 50 ma maximum current, load sinking. Output turns on when light becomes marginal. BLACK SENSOR BLUE PINK BROWN Resistor:124 OHMS 1 / 4 W (+12 NC) GND GND SIG GND TB1 FIELD WIRING Figure 3 Manual Operation Terminal Block Connections 2008 Nordson Corporation

10 8 Fiber Optic Module Cable Installation When installing the cable observe the following: Provide a protected path for the fiber optic cable. Do not twist the fiber optic cable or bend the cable around a radius of less than one inch. Install the fiber optic module in such a manner that, when the fiber optic cable is connected, it will not be subject to undue stress or kinking. Rotary Atomizer Connection 1. Remove the outer cover of the rotary atomizer. Refer to your rotary atomizer manual for procedures. 2. See Figure 4. Loosen the set screw (4) and remove the plug from the mounting hole on the interface plate (5). 3. Route 3 / 8 in. air tubing (7) between the fiber optic module and the rotary atomizer to protect the fiber optic cable. 4. Push the fiber optic cable (2) through the tubing. You may need to coat the cable with baby powder to get it through the tubing. 5. Guide the end of the fiber optic cable through the 3 / 8 in. bulkhead union (6) included with the cable kit. 6. Route the end of the fiber optic cable through the threaded hole in the atomizer rear mounting plate (1) labeled SPEED CABLE, then thread the bulkhead union into the hole and plug the tubing into the union. 7. Install the cable ferrule (3) on the end of the cable, then insert the ferrule into the mounting hole in the interface plate (5). 8. Tighten the set screw (4) to secure the ferrule. 9. Bundle the cable tubing with the other rotary atomizer air tubing. To Fiber-Optic Module Figure 4 Fiber Optic Cable Installation - Rotary Atomizer 1. Rear mounting plate 4. Set screw 2. Fiber optic cable 5. Interface plate 3. Cable ferrule 6. 3 / 8 in. bulkhead union 7. 3 / 8 in. air tubing 2008 Nordson Corporation

11 Fiber Optic Module 9 Cutting the Cable to the Desired Length Determine the desired length of the fiber optic cable before connecting it to the fiber optic module. Cut the cable in a smooth motion to avoid a rough cut, which will result in lowered transmission ability. Do not use any of the cutting holes in the cable cutter more than once. 1. See Figure 5. Insert the fiber optic cable into the cable cutter. 2. Firmly push down on the blade until the cable is completely cut. 3. If the cable cut is rough, insert the cable into a unused cutting hole and cut a little more off the end of the cable. Figure 5 Cutting the Cable with a Cable Cutter Fiber Optic Module Connection WARNING: Do not install the fiber optic module in an environment classified as hazardous. Improper installation may lead to an explosion, fire, destruction of property, or death. 1. See Figure 6. Remove the module cover. 2. Remove the small strain relief cap (5) and slide it over the fiber optic cable (4). Insert the cable end through the strain relief. NOTE: To connect the air tubing used to protect the fiber optic cable to the fiber optic module, you can replace the strain relief shown in Figure 6 with a 3/8 in. tube bulkhead fitting. 3. Remove the cap (3) and plug (1) from the photoelectric sensor (2). 4. Slide the cap over the cable end. 5. Insert the cable end into the plug until the cable end projects from the plug approximately 1 / 4 inch. 6. Install the cable end and plug into the sensor. 7. Screw the cap onto the sensor and tighten it snugly. 8. Tighten the strain relief cap (5) to grip the cable Nordson Corporation

12 10 Fiber Optic Module Figure 6 Connecting the Cable to the Fiber Optic Module 1. Plug 2. Photoelectric sensor 3. Cap 4. Fiber optic cable 5. Strain relief Adjusting Sensor Sensitivity 1. Turn on the rotary atomizer bearing air. Rotate the atomizer. 2. Turn the sensitivity knob on the photoelectric sensor counter-clockwise until it stops. 3. If the red LED is blinking: Turn the knob 1 / 4 turn clockwise. If the red LED is not blinking: Turn the knob clockwise until the light comes on, then turn the knob another 1 / 4 turn clockwise. Fiber Optic Module Test WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. WARNING: Avoid contact with high speed rotating parts. Before starting the rotary atomizer, make sure no personnel or equipment are touching the atomizer cup. Warn personnel to stay clear. The following are general instructions to test the fiber optic module operation. Air pressures given in these instructions are initial settings for testing and may be adjusted for optimum performance Nordson Corporation

13 Fiber Optic Module 11 Test Procedure Test the fiber optic module operation as follows: 1. Supply bearing air at 5.5 bar (80 psig) nominal (4.13 bar (60 psig) minimum) to the rotary atomizer turbine. 2. Apply power to the speed signal receiving device. WARNING: Maximum RA-20 turbine speed with 1.5 and 2 in. cups is 45,000 rpm (continuous operation); with 2.5 in. cups the maximum speed is 40,000 rpm (continuous operation). To avoid personal injury and equipment damage, do not exceed the maximum speed. 3. Adjust the TURBINE AIR pressure to obtain the expected speed as shown in the following tables. Choose the table that corresponds to your cup and tubing size. 4. Compare the display on the RPM indicator with the expected speed. 5. If the turbine speed is displayed and the speed is close to the expected speed, the fiber optic module is operating properly. If the turbine speed is not displayed, or the indicated speed is significantly different than the expected speed, stop the turbine by adjusting the turbine air to 0 bar/psi and applying turbine brake air. Refer to the Troubleshooting section. NOTE: The speeds obtained in in the following tables are based on turbine air supplied through the specified size and length of tubing. Speeds are based on a turbine spinning an unloaded cup with 5.5 bar (80 psi) bearing air applied. Speed Tables 1.5-in. Unloaded Cup, 1/2-in. OD Tubing PSI 1 = Turbine PSI at Flowmeter PSI 2 = Turbine PSI at Turbine (at rear plate inlet) RPM x 1000 NOTE: 1 / 2 -inch tubing was reduced to 3 / 8 -inch tubing at rear plate inlet. 25 ft 1 / 2 -in. O.D. tubing 50 ft 1 / 2 -in. O.D. tubing 75 ft 1 / 2 -in. O.D. tubing 100 ft 1 / 2 -in. O.D. tubing PSI 1 PSI 2 SCFM RPM PSI 2 SCFM RPM PSI 2 SCFM RPM PSI 2 SCFM RPM Nordson Corporation

14 12 Fiber Optic Module 1.5-in. Unloaded Cup, 3/8-in. OD Tubing PSI 1 = Turbine PSI at Flowmeter PSI 2 = Turbine PSI at Turbine (at rear plate inlet) RPM x ft 3 / 8 -in. O.D. tubing 50 ft 3 / 8 -in. O.D. tubing 75 ft 3 / 8 -in. O.D. tubing 100 ft 3 / 8 -in. O.D. tubing PSI 1 PSI 2 SCFM RPM PSI 2 SCFM RPM PSI 2 SCFM RPM PSI 2 SCFM RPM in. Unloaded Cup, 1/2-in. OD Tubing PSI 1 = Turbine PSI at Flowmeter PSI 2 = Turbine PSI at Turbine (at rear plate inlet) RPM x 1000 NOTE: 1 / 2 -inch tubing was reduced to 3 / 8 -inch tubing at rear plate inlet. 25 ft 1 / 2 -in. O.D. tubing 50 ft 1 / 2 -in. O.D. tubing 75 ft 1 / 2 -in. O.D. tubing 100 ft 1 / 2 -in. O.D. tubing PSI 1 PSI 2 SCFM RPM PSI 2 SCFM RPM PSI 2 SCFM RPM PSI 2 SCFM RPM Nordson Corporation

15 Fiber Optic Module 13 2-in. Unloaded Cup, 3/8-in. OD Tubing PSI 1 = Turbine PSI at Flowmeter PSI 2 = Turbine PSI at Turbine (at rear plate inlet) RPM x ft 3 / 8 -in. O.D. tubing 50 ft 3 / 8 -in. O.D. tubing 75 ft 3 / 8 -in. O.D. tubing 100 ft 3 / 8 -in. O.D. tubing PSI 1 PSI 2 SCFM RPM PSI 2 SCFM RPM PSI 2 SCFM RPM PSI 2 SCFM RPM in. Unloaded Cup, 1/2-in. OD Tubing PSI 1 = Turbine PSI at Flowmeter PSI 2 = Turbine PSI at Turbine (at rear plate inlet) RPM x 1000 NOTE: 1 / 2 -inch tubing was reduced to 3 / 8 -inch tubing at rear plate inlet. 25 ft 1 / 2 -in. O.D. tubing 50 ft 1 / 2 -in. O.D. tubing 75 ft 1 / 2 -in. O.D. tubing 100 ft 1 / 2 -in. O.D. tubing PSI 1 PSI 2 SCFM RPM PSI 2 SCFM RPM PSI 2 SCFM RPM PSI 2 SCFM RPM Nordson Corporation

16 14 Fiber Optic Module 2.5-in. Unloaded Cup, 3/8-in. OD Tubing PSI 1 = Turbine PSI at Flowmeter PSI 2 = Turbine PSI at Turbine (at rear plate inlet) RPM x ft 3 / 8 -in. O.D. tubing 50 ft 3 / 8 -in. O.D. tubing 75 ft 3 / 8 -in. O.D. tubing 100 ft 3 / 8 -in. O.D. tubing PSI 1 PSI 2 SCFM RPM PSI 2 SCFM RPM PSI 2 SCFM RPM PSI 2 SCFM RPM Nordson Corporation

17 Fiber Optic Module 15 Troubleshooting WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. WARNING: Hazardous voltages are present during troubleshooting procedures. Failure to observe safety precautions may result in serious injury or death. CAUTION: Printed circuit boards are susceptible to damage due to electrostatic discharge. Make sure you are electrically grounded while handling printed circuit boards. Use a grounding strap. This section contains troubleshooting procedures. These procedures cover only the most common problems that you may encounter. If you cannot solve the problem with the information given here, contact your local Nordson representative for help. Problem Possible Cause Corrective Action 1. RPM not displayed or is inaccurate 2. Power source not functioning Wiring between the fiber optic module and receiving device Check and repair loose connections or damaged wiring. 15 V not present Check wiring and the power source output. Repair or replace wiring or power source. Wiring between power source and fiber optic module Voltage is not toggling between 15 V and 0 V Check between GND and TB1-4 on the fiber optic module terminal block. Voltage should toggle between 0 and 15 Vdc as the cup spins. Replace the fiber optic module. Continued Nordson Corporation

18 16 Fiber Optic Module Problem 3. LED lights in fiber optic module do not illuminate Possible Cause Fiber optic cable or visible light transmitter damaged, or photoelectric sensor misadjusted or failed Corrective Action Remove the cover from the fiber optic module. With power applied, bearing air on, and turbine air off, slowly spin the atomizer turbine by hand. The red LED on the sensor should turn on (light sensed) and off as the cup is spun slowly. The red LED on the bottom of the sensor will turn on and remain on when power is applied. Remove the fiber optic cable from the fiber optic module. Spin the cup by hand with bearing air on and the turbine off. Look into the end of the fiber optic cable as the turbine is spun by hand. If a blinking light is seen, adjust the sensor. If the sensor cannot be adjusted, replace it. If a blinking light is not seen, remove the cable from the rotary atomizer and rotate the cup by hand while looking for a red blinking light from the visible light transmitter. If a light is seen, replace the cable. If no light is seen, replace the visible light transmitter. Repair Repair of the fiber optic module is limited to the removal and replacement of the photoelectric sensor. Refer to Parts for the sensor and the fiber optic cable kit part numbers and ordering information Nordson Corporation

19 Fiber Optic Module 17 Parts To order parts, call the Nordson Finishing Customer Support Center at (800) or contact your local Nordson representative. See Figure 7. Item Part Description Quantity MODULE, fiber optic, manual ENCLOSURE, fiber optic PANEL, enclosure, fiber optic SENSOR, fiber optic COVER, enclosure, fiber optic WASHER, lock BLOCK, terminal, 6 station STRIP, marker, 6 station FITTING, liquid-tight, in FITTING, liquid-tight, in RESISTOR, mf, 124, 0.25w, 1%, axl SCREW, pan, #6-32 x 0.50 in., steel, zinc WASHER, flat, x x in., zinc WASHER, lock, split, #6, steel, zinc SCREW, pan, #8-32 x in., steel, zinc WASHER, flat, x x in., zinc WASHER, lock, split, #8, steel, zinc PLATE, sensor SCREW, pan, #6-32 x 0.625, steel, zinc SCREW Nordson Corporation

20 18 Fiber Optic Module Figure 7 Fiber Optic Module Parts 2008 Nordson Corporation

21 Fiber Optic Module 19 Optional Fiber Optic Cable Kit Item Part Description Quantity Note KIT, cable, fiber optic, RA CABLE, fiber optic, RA-20 1 NS UNION, bulkhead, 3 / 8 -in. tube x 3 / 8 -in. tube, 1 plastic 1 Figure 8 Fiber Optic Cable Kit 2008 Nordson Corporation

22 20 Fiber Optic Module 2008 Nordson Corporation