GD-500 Bead Detection System

GD-500 Bead Detection System Customer Product Manual Issued 4/08 NORDSON CORPORATION DULUTH, GEORGIA USA www.nordson.com

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: http://www.nordson.com. Address all correspondence to: Nordson Corporation Attn: Customer Service 11475 Lakefield Drive Duluth, GA 30097 Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2008. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Nordson Corporation. The information contained in this publication is subject to change without notice. Trademarks AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, CleanSleeve, CleanSpray, ColorMax, Color-on-Demand, Control Coat, Coolwave, Cross-Cut, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber, DuraPail, Dura-Screen, Durasystem, Easy Coat, Easymove Plus, Ecodry, Econo-Coat, e.dot, EFD, ESP, e stylized, ETI, Excel 2000, Fillmaster, FlexiCoat, Flex-O-Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, HDLV, Heli-flow, Helix, Horizon, Hot Shot, icontrol, iflow, isocoil, Isocore, Iso-Flo, itrax, Kinetix, Lean Cell, Little Squirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, Microcoat, Micromark, MicroSet, Millennium, Mini Squirt, Mountaingate, MultiScan, Nordson, OptiMix, Package of Values, Pattern View, PermaFlo, Plasmod, Porous Coat, PowderGrid, Powderware, PRIMARC, Printplus, Prism, ProBlue, Prodigy, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, RBX, Rhino, Saturn, Scoreguard, Seal Sentry, Select Charge, Select Coat, Select Cure, Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, SureBead, Sure Clean, Sure Coat, Sure-Max, Tracking Plus, TRAK, Trends, Tribomatic, TrueBlue, Ultra, Ultrasaver, UpTime, u TAH, Vantage, Veritec, VersaBlue, Versa-Coat, Versa-Screen, Versa-Spray, Walcom, Watermark, and When you expect more. are registered trademarks of Nordson Corporation. Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AquaCure, ATS, Auto-Flo, AutoScan, Best Choice, Blue Series, Bowtie, Bravura, Check Mate, ClassicBlue, Classic IX, Controlled Fiberization, Control Weave, CountourCoat, CPX, CScan, Cyclo-Kinetic, DispensLink, DropCure, Dry Cure, DuraBraid, DuraCoat, Easy Clean, EasyOn, EasyPW, Eclipse, e.dot+, Emerald, Encore, E-Nordson, Equi=Bead, FillEasy, Fill Sentry, Fluxplus, Get Green With Blue, GreenUV, G-Net, G-Site, idry, ion, Iso-Flex, itrend, Lacquer Cure, Maxima, MicroFin, MicroMax, Mikros, MiniBlue, MiniEdge, Minimeter, MonoCure, Multifil, Myritex, OptiStroke, Partnership+Plus, PatternJet, PatternPro, PCI, Pinnacle, Powder Pilot, Powercure, Precise Coat, Process Sentry, Pulse Spray, Quad Cure, RediCoat, Ready Coat, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Signature, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit, Sure Brand, SureFoam, SureMix, SureSeal, SureWrap, Swirl Coat, Tempus, TinyCure, Trade Plus, ThruWave, UltraMax, Ultrasmart, Universal, ValveMate, VersaDrum, VersaPail, Vista, Web Cure, and 2 Rings (Design) are trademarks of Nordson Corporation. Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes, could lead to violation of the owners rights. All rights reserved

Table of Contents i Table of Contents Safety........................................................ 1 Qualified Personnel............................................. 1 Intended Use.................................................. 1 Safety Alert Symbols........................................... 2 Regulations and Approvals...................................... 2 Personal Safety................................................ 2 Fire Safety.................................................... 3 Action in the Event of a Malfunction............................... 3 Equipment Disposal............................................ 3 System Overview............................................. 4 System Components........................................... 6 GD-500 Controller........................................... 6 GD-500 Sensor.............................................. 7 Trigger..................................................... 8 Encoder.................................................... 8 Installation................................................... 9 Required Equipment............................................ 9 Unpack the GD-500 Sensor...................................... 9 Dimensions.................................................... 10 GD-500 Controller........................................... 10 GD-500 Folding Carton Sensor................................ 10 GD-500 Corrugated Sensor................................... 11 Mounting Guidelines............................................ 11 Mount the GD-500 Sensor....................................... 12 Folding Carton System....................................... 12 Corrugated System.......................................... 14 Mount the GD-500 Controller.................................... 15 Cable Connections............................................. 16

ii Table of Contents Setup........................................................ 18 GD-500 Controller Operator Panel................................ 18 Operator Panel Buttons and LEDs............................. 19 Operational Overview........................................... 20 Service Menu Setup Procedures................................. 23 Run Mode.................................................. 23 Sensor Trigger Offset (STO)................................... 24 Calibration Samples.......................................... 25 Minimum Tolerance.......................................... 26 Maximum Tolerance.......................................... 28 Sensitivity Threshold......................................... 29 Encoder Ratio............................................... 29 Language................................................... 30 Software Version............................................. 30 Return to Run Mode.......................................... 30 When to Adjust Service Settings................................. 30 Dynamic Calibration Mode Setup Procedure....................... 31 Calibrate the GD-500 System from the GD-500 Controller Operator Panel............................. 31 Calibrate the GD-500 System from the LogiComm Touch-screen Panel................................ 32 Learn Pattern Setup on the LogiComm Touch-screen Panel.......... 33 Glue Sensor Input Set-up..................................... 33 Excess Sensor Input Set-up................................... 33 Maintenance.................................................. 36 Parts List..................................................... 37 GD-500 Parts for Folding Carton Machines........................ 37 GD-500 Parts for Corrugated Machines........................... 38

GD-500 Bead Detection System 1 GD-500 Bead Detection System Safety Read this section before using the equipment. This section contains recommendations and practices applicable to the safe installation, operation, and maintenance (hereafter referred to as use ) of the product described in this document (hereafter referred to as equipment ). Additional safety information, in the form of task-specific safety alert messages, appears as appropriate throughout this document. WARNING: Failure to follow the safety messages, recommendations, and hazard avoidance procedures provided in this document can result in personal injury, including death, or damage to equipment or property. 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

2 GD-500 Bead Detection System Safety Alert Symbols The following safety alert symbol and signal words are used throughout this document to alert the reader to personal safety hazards or to identify conditions that may result in damage to equipment or property. Comply with all safety information that follows the signal word. WARNING: Indicates a potentially hazardous situation that, if not avoided, can result in serious personal injury, including death. CAUTION: Indicates a potentially hazardous situation that, if not avoided, can result in minor or moderate personal injury. CAUTION: (Used without the safety alert symbol) Indicates a potentially hazardous situation that, if not avoided, can result in damage to equipment or property. 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. All phases of equipment installation must comply with all federal, state, and local codes. 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 any 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.

GD-500 Bead Detection System 3 If you receive even a slight electrical shock, shut down all electrical 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. 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. Fire Safety To avoid a fire or explosion, follow these instructions. 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. Provide adequate ventilation to prevent dangerous concentrations of volatile materials or vapors. Refer to local codes or your material MSDS for guidance. Do not disconnect live electrical circuits while working with flammable materials. Shut off power at a disconnect switch first to prevent sparking. Know where emergency stop buttons, shut off valves, and fire extinguishers are located. 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. 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 electrical power. Close pneumatic shutoff valves and relieve pressure. Identify the reason for the malfunction and correct it before restarting the equipment. Equipment Disposal Dispose off equipment and materials used in operation and servicing according to local codes.

4 GD-500 Bead Detection System System Overview This manual describes the installation, connection, setup, and operation of the GD-500 controller and sensor when used with the LogiComm control system. The GD-500 sensor monitors liquid adhesive applications, such as side-seem, wheel-pot, or extrusion gluing, for too much or too little adhesive. A keypad and an LCD display allows alarm thresholds to be set in order to prevent weak bonds or squeeze-out. The sensor has an automatic calibration feature to aid in establishing accurate maximum and minimum settings. When used with the LogiComm system, defective products can be tracked through the machine and ejected or marked for later ejection. There are several configurations of GD-500 systems to target specific applications. This includes sensor versions for the Folding Carton and Corrugated machines. The controller and sensor cable are the same for all configurations, but the sensor geometry and brackets are optimized for each application. See Figure 1 for a system overview.

GD-500 Bead Detection System 5 Figure 1 System components 1. LogiComm control module 2. Touch-screen panel 3. GD-500 controller 4. LogiComm cable 5. Trigger 6. GD-500 sensor (folding carton version) 7. Encoder

6 GD-500 Bead Detection System System Components The GD-500 bead detection system requires the following components: GD-500 controller GD-500 sensor Trigger Encoder LogiComm control system (control module and touch-screen panel) GD-500 Controller The GD-500 controller is an adhesive detection unit that works in conjunction with the GD-500 sensor to detect the amount of liquid adhesive on different materials, such as paper, carton, etc. The GD-500 controller contains an operator panel that allows for programming and operation. Figure 2 GD-500 controller showing the connector panel 1. GD-500 controller 3. Connector panel 2. Operator panel

GD-500 Bead Detection System 7 GD-500 Sensor The GD-500 sensor measures the amount of liquid adhesive on the substrate as it passes between the sensor arms. GD-500 Sensor for Folding Carton Machines Figure 3 GD-500 sensor for folding carton machines 1. Power input/signal output connector 2. Sensor measuring points 3. Sensor arms 4. Shock absorber and mounting bolts

8 GD-500 Bead Detection System GD-500 Sensor for Corrugated Machines Figure 4 GD-500 sensor for corrugated machines 1. Power input/signal output connector 2. Sensor measuring points 3. Sensor arms 4. Shock absorber and mounting bolts Trigger The trigger signal is transmitted from the photocell to the GD-500 and then to the LogiComm trigger input for product tracking and for displaying the measurement result on the touch-screen panel. Encoder The GD-500 sensor uses the LogiComm encoder signal from the Encoder Repeater output on the LogiComm master bank. By default the GD-500 controller is set for a ratio of 1 pulse/mm, but other ratios can be set through the GD-500 controller menus.

GD-500 Bead Detection System 9 Installation WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. This section describes the following instructions: Mount the GD-500 sensor and controller Connect the GD-500 sensor to the LogiComm control module NOTE: The sensor is IP56 (NEMA 4) rated. Required Equipment Make sure that the following items are available for installation: GD-500 controller GD-500 sensor Mounting brackets GD-500 controller and sensor interconnect cable LogiComm interface cable Trigger and trigger cable GD-500 controller key GD-500 manual Unpack the GD-500 Sensor 1. Carefully unpack the contents of the box. Exercise care to prevent equipment damage during unpacking. 2. Inspect for any damage that may have occurred during shipping. Report any damage to your Nordson representative.

10 GD-500 Bead Detection System Dimensions The dimensions of the GD-500 controller and the sensors are as follows: GD-500 Controller Figure 5 1. Magnet location GD-500 controller dimensions GD-500 Folding Carton Sensor Figure 6 Folding carton sensor dimensions

GD-500 Bead Detection System 11 GD-500 Corrugated Sensor Figure 7 Corrugated sensor dimensions Mounting Guidelines Observe the following guidelines when installing the GD-500 sensor: Make sure that the mounting location provides sufficient clearance for easy access to the connectors and the associated cables. Select a location to provide access to the operator panel for programming. The sensor is designed to operate between 0 and 50 C (32 and 122 F). The sensor arms must be kept free of dirt, dust, and adhesive.

12 GD-500 Bead Detection System Mount the GD-500 Sensor The GD-500 sensor must be mounted on the bracket assembly. Proper mounting of the adhesive sensors is important to obtain optimum operation of the liquid adhesive detection system. Folding Carton System Figure 8 1. GD-500 sensor 2. GD-500 arms 3. Lower guide bar Mounting the sensor and trigger on a folding carton bracket assembly 4. Protection bars 5. Trigger 6. Folding carton bracket assembly 7. Adapter for wheel pot 8. Straight line mounting bar 9. Adjustment arm

GD-500 Bead Detection System 13 See Figure 8. 1. Mount the sensor assembly (bracket, sensor, and trigger) on the machine using one of the following methods: For straight line gluing use the straight-line mounting bar (shipped installed) For wheel pot installation install the wheel pot mounting adaptor (shipped un-installed). 2. Make sure that the sensor arms are protected by the protection bars of the bracket to avoid damage to the sensor. 3. Align the opening in the bracket so the product passes freely through the opening. The lower guide bar must be at the same height as the belt of the machine. 4. Align adhesive pattern with the optimum sensing point on the sensor, marked by a dot on the short sensor arm. 5. Align the reference point of the trigger with the sensor, as shown below: Figure 9 Trigger reference line

14 GD-500 Bead Detection System Corrugated System Figure 10 Mounting the sensor and trigger on a bracket assembly for corrugated machines 1. Corrugated market bracket assembly 2. Sensor 3. Sensor arms 4. Protection bars 5. Lower guide bar 6. Trigger

GD-500 Bead Detection System 15 See Figure 10. 1. Mount the sensor assembly (bracket, sensor, and trigger) on the machine. 2. Make sure that the sensor arms are protected by the protection bars of the bracket to avoid damage to the sensor. 3. Align the opening in the bracket so the product passes freely through the opening. The lower guide bar must be at the same height as the belt of the machine. 4. Align adhesive pattern with the optimum sensing point on the sensor, marked by dots on the short sensor arm. 5. Align the the reference point of the trigger with the sensor so that the flap can be tracked at the same time. See the following figure: Figure 11 Trigger reference line Mount the GD-500 Controller Install the controller using the magnets. The magnets are installed on the back of the controller.

16 GD-500 Bead Detection System Cable Connections Figure 12 Cable connections

GD-500 Bead Detection System 17 Connector Name Connecting Device 1. S (Sensor) Connects from the GD-500 controller to the GD-500 sensor. 2. Tin (Trigger in) Connects from the GD-500 controller to a trigger (photocell). The following connectors (items 3, 4, and 5) are bundled together as a single harness: 3. Tout (Trigger out) Connects from the GD-500 controller to any Trigger input connector on the control module. The harness is connected to Trigger B1 on the control module, as shown in Figure 12. 4. Enc (Encoder) Connects from the GD-500 controller to the Encoder Repeater connector on the Master I/O panel of the control module. 5. LC (LogiComm) Connects from the GD-500 controller to two Sensor input connectors on the Verification panel of the control module. 5a. Glue Connects to the Glue sensor input. The harness is connected to Sensor B1, as shown in Figure 12. 5b. Excess Connects to the Excess sensor input. The harness is connected to Sensor B2, as shown in Figure 12. 6. Port Nordson use only.

18 GD-500 Bead Detection System Setup GD-500 Controller Operator Panel Use the operator panel to program the system for operation. Refer to Operator Panel Buttons and LEDs for details on the component functionality. Figure 13 Operator panel 1. Display panel 2. Operator panel buttons

GD-500 Bead Detection System 19 Operator Panel Buttons and LEDs Button Name Function Dynamic calibration and Run Menu button Button: Press this button for 2 seconds for the system to activate Dynamic Calibration mode. LED: Turns green to indicate that the system is in run mode, and turns yellow during dynamic calibration. Decrease value button Increase value button Service Menu button Button: Press this button decrease the value of a parameter. LED: Not used. Button: Press this button increase the value of a parameter. LED: Turns green to indicate a trigger signal. Button: 1. Press this button for 2 seconds to activate the Service menu. 2. Press this button to scroll through the menu screens. LED: Turns yellow to indicate that the system is ready for setup.

20 GD-500 Bead Detection System Operational Overview The GD-500 system monitors the amount of liquid adhesive on a product by measuring the dielectric coefficient of the material passing between the sensor arms. The dielectric measurement is directly related to the amount of adhesive on the carton or other substrate. The GD-500 controller learns the correct amount of adhesive during an automated dynamic calibration process, see item 7 in Figure 14. The alarm levels are then set to monitor the upper (MAX) and lower (MIN) deviations from the calibration level. Figure 14 Calibration and tolerance settings 1. Machine direction 2. Carton 3. Glue flap 4. Glue bead 5. Trigger 6. Sensor signals a: Glue input b: Excess input 7. Calibration 8. Flap

GD-500 Bead Detection System 21 There are two outputs from the GD-500 that connect to LogiComm sensor inputs: Glue and Excess. The Glue sensor input provides a signal to LogiComm when glue is detected. The Excess sensor input provides a signal to LogiComm when too much glue is detected (above the MAX limit). For additional details on Glue and Excess refer to Cable Connections under Installation. Also see item 6 in Figure 14 for the status of the two inputs at different signal levels. Figure 15 Glue and Excess output settings as it appears on the Monitor screen of the touch-screen panel The sensor is also sensitive enough to read the change in dielectric measurement due to the carton passing between the sensor arms, see item 8 in Figure 14.

22 GD-500 Bead Detection System Operational Overview (contd) To eliminate false signals from the carton, the sensitivity is adjusted, see Figure 16. If the sensitivity threshold level is set too high, the glue output will sense the board or the glue, and will not change at all. If the sensitivity threshold level is set too low, the glue output will change as soon as the edge of the board enters between the sensor arms. The correct sensitivity setting is shown in the following figure: Figure 16 Sensitivity threshold setting 1. Machine direction 2. Carton 3. Glue flap 4. Glue bead 5. GD-500 sensor 6. Sensor signal a: Sensitivity level high b: Sensitivity level correct c: Sensitivity level low 7. Glue output signal a: Sensitivity level high b: Sensitivity level correct c: Sensitivity level low

GD-500 Bead Detection System 23 Service Menu Setup Procedures Once the system is installed, power on the LogiComm System and then power up the GD-500 controller and sensor. NOTE: The GD-500 system gets power from the 24 VDC output of the LogiComm Sensor input. Run Mode The system will start up in Run Mode. The Run button LED will turn green to indicate that the system is in Run Mode. Begin the setup procedure by pressing for two seconds. You will enter the Service menu, and the Service menu button LED will turn yellow.

24 GD-500 Bead Detection System Sensor Trigger Offset (STO) Press to move to the STO setting menu. Enter the STO distance in millimeter by pressing or. Refer to Figure 17 to determine the STO distance. Figure 17 STO settings 1. Machine direction 2. Carton 3. Glue flap 4. Glue bead 5. Trigger 6. GD-500 sensor 7. STO 8. Sensor signal 9. Trigger signal NOTE: The default STO value is 30 mm. For the Folding Carton bracket in standard mounting, the STO distance is approximately 30 mm (1.18 in.). For the Corrugated bracket the STO distance is approximately 34 mm (1.33 in.).

GD-500 Bead Detection System 25 Calibration Samples Press to move to the Calibration Samples menu. This setting determines how many pieces the sensor will measure when performing a calibration, refer to Figure 14 for calibration and tolerance settings. The sensor will calculate the average measurement of the programmed number of samples. Press or to select a number between 1 and 10. The typical setting is five.

26 GD-500 Bead Detection System Minimum Tolerance Press to move to the Minimum Tolerance menu. Minimum tolerance is the amount below the calibrated signal level where the glue output signal will no longer indicate the presence of glue. Press or to select minimum tolerance. The default setting is 15% and the range is 0 100%. Figures 18 and 20 and the corresponding LogiComm Sensor touch-screen panel screens show two examples of minimum tolerance defects. Figure 18 Minimum tolerance settings Example 1 showing low glue amount or not enough glue 1. Not enough glue or low glue amount 2. Sensor signal 3. Maximum setting See Example 1 settings as it appears on the touch-screen panel: 4. Calibration 5. Minimum setting Figure 19 Bead error screen

GD-500 Bead Detection System 27 Figure 20 Minimum tolerance settings Example 2 showing broken glue bead 1. Broken glue bead 2. Sensor signal 3. Maximum setting 4. Calibration 5. Minimum setting See Example 2 settings as it appears on the touch-screen panel: Figure 21 Bead error screen

28 GD-500 Bead Detection System Maximum Tolerance Press to move to the Maximum Tolerance menu. Maximum Tolerance is the amount above the calibrated signal level where the max output signal will indicate excess glue. Press or to select maximum tolerance. The default setting is 15% and the range is 0 100%. See Figure 22 and the corresponding LogiComm Sensor touch-screen panel screen for an example of a maximum tolerance defect caused by excess glue. Figure 22 1. Heavy glue bead 2. Sensor signal Maximum tolerance setting 3. Maximum setting 4. Calibration 5. Minimum setting See the excess glue settings as it appears on the Monitor screen of the touch-screen panel: Figure 23 Excess glue settings

GD-500 Bead Detection System 29 Sensitivity Threshold Press to move to the Sensitivity Threshold menu. The Sensitivity Threshold setting sets the overall range of the sensor signal. Refer to Figure 16 for the correct sensitivity threshold setting. Press or to select sensitivity setting. The default setting is 50% and the range is 1 99%. NOTE: Press gain) and press signal gain). to increase the Sensitivity Threshold (reduces the signal to reduce the Sensitivity Threshold (increases the Encoder Ratio Press to move to the Encoder Ratio menu. The Encoder Ratio setting sets the number of pulses per millimeter of the encoder. Press or to select encoder ratio. The default setting is 1.0 pulses per mm. The range is 1.0 20.0 pulses per mm.

30 GD-500 Bead Detection System Language Press to move to the Language menu. Press or to select the desired Language. The default setting is English. Software Version Press to move to the Software Version menu. The Software Version menu displays the current version of software installed in the GD-500 system. This screen is not programmable. Return to Run Mode Return to Run Mode by pressing off.. The Service menu button LED turns When to Adjust Service Settings Under normal operation, the Service menu settings do not change. After a product changeover the sensitivity may need to be adjusted for a different board material. The maximum and minimum settings may be changed for the requirements of different products.

GD-500 Bead Detection System 31 Dynamic Calibration Mode Setup Procedure Dynamic Calibration is the process that teaches the GD-500 controller the expected amount of adhesive by measuring the signal from the programmed number of products as they pass through the sensor. Dynamic Calibration can be started from the GD-500 controller operator panel or from the LogiComm touch-screen panel. Calibrate the GD-500 System from the GD-500 Controller Operator Panel To calibrate from the GD-500 controller operator panel follow these steps: 1. Start the Dynamic Calibration by pressing for two seconds, until the button LED turns from green to yellow. The display will change to Dynamic Calibration mode, see figure on the left. 2. Run the line normally, applying the desired adhesive pattern. The GD-500 controller display panel will show one bar on the screen for each product to be learned. As each product passes under the sensor, the bars will count down as each product is learned. When the programmed number of products has passed under the sensor, the system returns to Run mode.

32 GD-500 Bead Detection System Calibrate the GD-500 System from the LogiComm Touch-screen Panel To calibrate from the touch screen panel follow these steps: 1. On the Main Menu screen, select the sensor associated with GD-500 glue input (for e.g. B1). 2. Touch the Learn Pattern button on the Sensor Menu screen, and the following pop-up screen will appear: Figure 24 Initial learn pop-up screen 3. Touch the Calibrate button, then touch the OK button. The initial learn pop-up screen will change to the following: Figure 25 Calibration pop-up screen NOTE: Once the above pop-up screen appears, the calibration process has started in the GD-500 system. The GD-500 controller LEDs will change from green to yellow, and the display panel will change to Calibration mode, see figure under Calibrate the GD-500 Controller from the GD-500 Controller Operator Panel. 4. Touch the Cancel button to exit the Calibration pop-up screen. The GD-500 will complete the calibration process after learning the programmed number of products.

GD-500 Bead Detection System 33 Learn Pattern Setup on the LogiComm Touch-screen Panel The final step in setting up the GD-500 system is to configure the two pattern verification sensors on the LogiComm System. NOTE: It is recommended that you name the two sensors according to their function, for e.g. GD-500 Glue and GD-500 Excess. You can assign sensor names using the Sensor Names menu on System Setup Page 4. Glue Sensor Input Set-up The Glue sensor input is an input that is activated when the measured glue amount exceeds the programmed minimum threshold. This input is usually monitored using template gluing. Template gluing is a verification algorithm that compares the measured pattern to a learned template and alarms any defects outside of the programmed tolerance limit. To set up template verification for glue sensor input: 1. On the Main Menu screen, select the sensor associated with GD-500 glue input (for e.g. B1). 2. Touch the Inspection Parameters button. 3. Set the desired tolerance for the start and stop position of the glue pattern, typically using the All Beads settings. 4. Touch the OK button to exit this screen. Excess Sensor Input Set-up The Excess sensor input is usually best monitored using the maximum setting on a cumulative bead algorithm. Cumulative bead will identify a defective product any time the input is on for longer than the programmed maximum limit. The maximum limit should be set to the maximum allowed length of excess glue that is acceptable for the application. The minimum setting is not used for this function and should be set to zero. To set up maximum setting for excess sensor input: 1. On the Main Menu screen, select the sensor associated with GD-500 excess input (for e.g. B2). 2. Touch the Inspection Parameters button, and then touch the Cumulative Bead button to enable the settings 3. Define the measurement position in the Cumulative Bead pop-up screen using the Delay and Duration settings. 4. Set the minimum setting to zero and the maximum setting according to the application. NOTE: Alternately, the excess glue input can also be monitored using template verification as described in Glue Sensor Input Setup.

34 GD-500 Bead Detection System Example of Glue and Excess Input Application The following figure shows an example of a GD-500 system application and the corresponding LogiComm sensor screens display the settings as it appears on the touch-screen panel. Figure 26 Example showing the glue and excess sensor input settings 1. Machine direction 2. Carton 3. Glue flap 4. Glue bead 5. GD-500 sensor Figure 27 Example showing the glue sensor input settings on the touch-screen panel

GD-500 Bead Detection System 35 Figure 28 Example showing the excess sensor input settings on the touch-screen panel

36 GD-500 Bead Detection System Maintenance The unit is virtually maintenance-free. Check cables regularly for damage. Replace damaged cables immediately. Clean the parts without using solvents. Remove adhesive splashes simply using a damp cloth. CAUTION: Do not use sharp tools to clean the sensor arms. Using sharp tools will damage the sensor arms.

GD-500 Bead Detection System 37 Parts List To order parts, call the Nordson Customer Service Center or your local Nordson representative. GD-500 Parts for Folding Carton Machines Part Description Quantity 7302492 GD500, FOLDING CARTON SYSTEM 7302435 GD500 CONTROL BOX 1 7302436 GD500 FOLDING CARTON SENSOR 1 7302438 GD500 SENSOR CABLE, 5 MTR 1 7302488 GD500, FOLDING CARTON BRACKET 1 7302489 GD500, SENSOR BRACKET 1 7302490 GD500, SIDE ADJUSTMENT BRACKET 1 7302491 GD500, ADAPTER PLATE, STRAIGHTLINE BR. 1 7301277 GD500 BRACKET, ADAPTER FOR WHEEL POT 1 311061 SCREW ALLENHEAD M8x12, DIN912,SS,A2,70 1 313611 WASHER, M5, DIN433, SS, A2 4 311043 SCREW ALLENHEAD M5x16, DIN912,SS,A2,70 4 7301990 PHOTOCELL, LA650, NPN/PNP 1 7302421 HARNESS, 10M, LOGICOMM, GD500 1 377219 CABLE, EXT. PHOTOCELL, LCOMM/LA404, 5M 1 311029 SCREW ALLENHEAD M3X20 DIN 912,SS, A2,70 2 311103 NUT HEX M3, DIN934, SS, A2, 70 2 313597 WASHER M3, DIN 433 2 313592 NUT HEX M6, DIN934, SS, A2 2 313612 WASHER, M6, DIN433, SS, A2 2

38 GD-500 Bead Detection System GD-500 Parts for Corrugated Machines Part Description Quantity 7302562 GD500, CORRUGATED SYSTEM 7302435 GD500 CONTROL BOX 1 7302437 GD500 CORRUGATED SENSOR 1 7302438 GD500 SENSOR CABLE, 5 MTR. 1 7300101 CORRUGATED STATION, GLUE DETECTION UNIT 1 7300074 CORR.BRACK. LAD MANIFOLD 1 7300076 CORR.BRACK. LAD SHAFT 2 7300043 LOCKING BOLT WITH SPRING M10 2 7301110 CGS, DETECTION, UPPER GUIDE ASSY 1 7301111 CGS, DETECTION, LOWER GUIDE ASSY 1 313605 WASHER, SPRING, M4, DIN 7980 2 311032 SCREW ALLENHEAD M4x8 DIN 912, BLACK, 8.8 2 7301109 CGS, DETECTION, BRACKET PHOTOCELL 1 313606 WASHER, SPRING, M5, DIN7980, ZINC PLATED 4 313544 SCREW ALLENHEAD M5x12, DIN912, 8.8, BLACK 4 7302446 HARNESS, 2M, LOGICOMM, GD500 1 377243 PHOTOCELL INLINER 1 7302454 CABLE, PHOTOC., DIN MALE 5P/M12, 5M, LCOM 1