ISC2 Series Induction Dryers Customer Product Manual Issued 01/15 For parts and technical support, call the Finishing Customer Support Center at (800) 433-9319. This document is subject to change without notice. Check http://emanuals.nordson.com/finishing for the latest version. NORDSON CORPORATION AMHERST, OHIO USA
tents Table of Contents Safety... 1 Qualified Personnel... 1 Intended Use... 1 Regulations and Approvals... 2 Personal Safety... 2 High-Pressure Fluids... 3 Fire Safety... 4 Halogenated Hydrocarbon Solvent Hazards. 5 Action in the Event of a Malfunction... 5 Disposal... 5 Description... 6 Features... 6 Induction Dryer Components... 7 Theory of Operation... 8 Specifications... 9 Manufacturing Data Code... 9 Operating Parameters... 9 Power Supply Requirements... 9 System Weight (Crated)... 9 Installation... 10 Inspection... 10 Lift Points... 10 System Positioning and Mounting... 11 Flow Direction and Power Supply... 11 Clearances... 11 Mounting and Line Connections... 12 Coil Tray Installation... 13 System Wiring... 13 Schematics and Wiring Diagrams... 13 Power Input... 14 External Interlock... 15 Connecting the External Interlock... 15 Disabling the External Interlock... 16 Optional Status Contact... 16 Motion Sensor... 16 Return Shipping Instructions... 17 Domestic/USA... 17 Export... 17 Setup... 18 Preparation... 18 Language Selection... 19 Option Setup... 21 Restore System Defaults... 21 Motion Sensor Sensitivity Adjustment... 22 Timer and Motion Sensitivity Settings... 23 Motion Timer Setting... 23 Motion Detect Sensitivity Setting... 23 External Interlock Activation... 24 External Interlock Timer Setting (Optional).. 24 Temperature Offset Setting... 25 Alarm and Temperature Display Settings... 26 Product Temperature Setpoint... 26 Temperature Alarm Delay... 26 Temperature Display Selection... 27 Phase Control Select... 27 Line Speed Monitor Select... 28 Operation... 29 Operator Controls... 29 Startup... 30 ISC2 Run Mode... 31 Adjusting the Temperature Setpoint... 31 High and Low Alarms... 32 Faults... 32 Navigation Screen... 33 Shutdown... 33 Maintenance... 34 Monthly... 34 Quarterly... 34 Troubleshooting... 35 Repair... 37 Air Filter Replacement... 37 Parts... 38 Temperature Conversions... 38 Celsius Fahrenheit Temperature Table... 38 Conversion Equations... 38 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: http://www.nordson.com. Address all correspondence to: Nordson Corporation Attn: Customer Service 555 Jackson Street Amherst, OH 44001 Trademarks Nordson, the Nordson logo, and idry are registered trademarks of Nordson Corporation. Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2014. 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. 2014 Nordson Corporation
Change Record i Revision Date Change 01 01/15 New Release Change Record 2014 Nordson Corporation
ii Change Record 2014 Nordson Corporation
ISC2 Series Induction Dryers 1 ISC2 Series Induction Dryers 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 2014 Nordson Corporation
2 ISC2 Series Induction Dryers 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. WARNING: Never disarm any diagnostic or interlock devices including but not limited to the following: Current sensor Overtemperature switches Air pressure switches Power supply door safety switch Disarming these devices will void the warranty and may cause personal harm or equipment failure. 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. 2014 Nordson Corporation
ISC2 Series Induction Dryers 3 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. 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. 2014 Nordson Corporation
4 ISC2 Series Induction Dryers 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. 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. 2014 Nordson Corporation
ISC2 Series Induction Dryers 5 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. 2014 Nordson Corporation
6 ISC2 Series Induction Dryers Description The ISC2 Series induction systems provide simple, efficient, and uniform drying of side seam coatings and bottom spray coatings. The systems use solid state induction heating to generate heat within the can body, drying the coatings at various line speeds dependent on quantity of coil tray units. Coil trays can be mounted in any position for maximum versatility. 1 M ISC2 Coil Tray Operator Control Pedestal Power Supply Figure 1 ISC2 Series Induction Dryer Features Instant on/off Energy savings Reliability Small footprint Temperature monitor When the line starts, heating within the can body starts instantly. Since heat is created directly within the can surface, there is no thermal inertia. When the line stops, heating instantly stops or continues per the preset time. Solid state induction heating is extremely efficient. Most of the power consumed is directly realized as heat in the can body. When the line stops, almost no power is consumed. The solid state design of the dryers minimizes downtime. Fewer moving parts equals less wear items. Due to the high efficiency of induction drying, the dryer is much smaller than a conventional oven. An infrared sensor, located on the last coil tray, determines the temperature of the can body. The temperature is displayed on the operator terminal. 2014 Nordson Corporation
ISC2 Series Induction Dryers 7 Induction Dryer Components See Figure 2. Coil tray Component Motion sensor Operator control pedestal Control enclosure/ power supply Temperature sensor Description Contains the induction coils with high flow cooling fans. A laser sensor that monitors the movement of the can body at the entrance to the coil tray. The controller will only apply power to the induction coil when the motion sensor detects product moving through the induction dryer. Contains the operator touch screen interface with all the operator control functions, including warnings and faults. The console includes an Emergency Stop, Power, and Off pushbuttons. Contains the system controller (PLC), cooling air filters and fan, power inverter devices, and control circuit boards. Senses the product temperature at the exit end of the last coil tray. Product Flow Temperature Sensor Operator Control Pedestal Motion Sensor Coil Tray Control Enclosure/Power Supply Figure 2 ISC2 Series Induction Dryer (shown with one coil tray) 2014 Nordson Corporation
8 ISC2 Series Induction Dryers Theory of Operation The induction coil is connected to the power supply, and the can bodies travel below or above the coil. When the power supply applies an alternating current, the coil generates an alternating magnetic field that cuts through the side seam or dome of the can bodies dependent on the application. This results in large eddy currents circulating within the can bodies. The resistance to this circulating current results in heat that cures the applied coating. In steel cans, there is also heat from magnetic hysteresis. Careful coil and power supply design ensure close control of heating rates and uniformity. Power to the induction coils and distance between the coils and the can bodies is adjusted during setup to provide the desired temperature of can bodies exiting the induction dryer. In some cases, an infrared temperature sensor can be used to provide over or under temperature safety shutdowns. Accuracy of infrared sensing depends on matching the emissivity of the product to the sensor. A laser motion sensor is mounted at the front of the unit to constantly monitor line movement. If the line stops, power to the induction coil is stopped. When the line restarts, the inverter is immediately restarted. WARNING: Never disarm any diagnostic or interlock devices including but not limited to the following: Current sensor Over temperature switches Air pressure switches Power supply door safety switches Disarming these devices will void the warranty and may cause personal harm or equipment failure. 2014 Nordson Corporation
ISC2 Series Induction Dryers 9 Specifications Manufacturing Data Code Serial Number: BK X X X X X X X year month Operating Parameters Ambient temperature range: Humidity: Elevation (altitude): 5 45C (40 112F) 0 70% for full system functionality Less than 1524 m (5000 ft) Above 1524 m (5000 ft) system must be de-rated contact your Nordson representative Power Supply Requirements 360-480 Vac 50 Hz or 440-480 Vac 60 Hz, 3 phase Voltage is preset at factory per specification NOT FIELD ADJUSTABLE Class J Bussmann TCF fusing required System Weight (Crated) Varies, 363-635 kg (800-1400 lb) 2014 Nordson Corporation
10 ISC2 Series Induction Dryers Installation WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Inspection The ISC2 system is shipped assembled in a kit form. The coil trays must be installed by the customer. Unpack and carefully inspect all components for obvious shipping damage and shortages. If any damage or shortages are observed, notify the shipper and your Nordson representative immediately. NOTE: A 5 / 16 -in. hex wrench is required to unlock and lock the control enclosure doors. Lift Points The ISC2 power supply requires a lift truck to remove it from the crate. See Figure 3 for lift points. The individual coil trays and operator control pedestal can be manually removed from the crate. Lift Points Figure 3 Lift Points for ISC2 Power Supply 2014 Nordson Corporation
ISC2 Series Induction Dryers 11 System Positioning and Mounting Flow Direction and Power Supply ISC2 coil trays are non-directional. 1. After coil trays are positioned on the line, install the motion sensor on the leading edge of first coil tray. NOTE: On lines with conveyor speed greater than 15 m/minute (16 ft/minute) the motion sensor should be positioned up stream. 2. Install infrared sensor on the trailing edge of the last coil tray. 3. For systems with multiple coil trays, coil trays are numbered to facilitate wiring. Place on line accordingly. 4. Place the power supply within 3 m (10 ft) of the first coil tray. Install leveling pads on the power supply, making sure there is a minimum clearance of 50 mm (2 in). under the power supply for air flow. Clearances Coil trays Provide clearance around coil tray cooling fans. Do not obstruct or limit free air to the fans or coil tray exhaust Power supply Clear any obstruction from blower intake (filters) and vents on the top and bottom of the cabinet Provide 1 m (39 in.) of clearance at the rear of the power supply to remove the access panel for power and interlock connections and repairs Provide 1 meter (39 in.) of clearance in front of the power supply to open the enclosure doors Provide a minimum clearance of 50 mm (2 in.) under the power supply 2014 Nordson Corporation
12 ISC2 Series Induction Dryers Mounting and Line Connections Coil trays Mount on adjustable mounts above or below the conveyor with the can bodies Make wiring connections using the wiring schematic in the addendum Power supply Install within 3 m (10 ft) of the first coil tray Operator control pedestal Pre-wired Anchor to floor in desired location 2014 Nordson Corporation
ISC2 Series Induction Dryers 13 Coil Tray Installation 1. Connect the coil wiring to the terminals (1) located in the junction box (4) on lid of the coil tray (2). 2. Use the wiring schematics in the addendum to complete wiring connections. CAUTION: Do not block air intake (3) or exhaust (6) air flow. 1 2 3 4 5 6 Figure 4 ISC2 Coil Tray 1. Terminals 2. ISC2 coil tray 3. Inlet air 4. Junction/terminal box 5. Mounting rail (both sides) 6. Exhaust air (both sides) System Wiring Schematics and Wiring Diagrams Refer to the addendum to this manual for system schematics and wiring diagrams. 2014 Nordson Corporation
14 ISC2 Series Induction Dryers Power Input See Figure 5 for connections. Service requirement is 360-480 Vac 50 Hz or 440-480 Vac 60 Hz, 3 phase at 50 A. Class J fusing required. Systems are preset for voltage & frequency at the factory. Verify supply voltage with wiring schematics in the addendum. WARNING: If plant supply is not through current-limiting Class J 50 A fusing, customer is required to follow arc flash hazard criteria and label appropriately. WARNING: Install a locking breaker or disconnect in the electrical supply line ahead of the system so all power to the induction system can be disconnected and locked out when repairs are made. All electrical connections must be made according to code, including a proper ground connection. Failure to observe this warning could result in severe personal injury or death from electrical shock. WARNING: DANGER! Line terminals remain live even with the power supply main disconnect locked out in the Off position. Line power is supplied to the system through a 3 / 4 -in. (1.9 cm) conduit fitting in the lower left-hand corner of the dryer exit end. NOTE: The wire gauge must be copper and comply with local and national electrical codes. 1. Route three #6 AWG (13.3 mm 2 ) wires to the input terminal block (TBL) on the input side of the line filter. 2. Route one #6 AWG (13.3 mm 2 ) ground wire to the cabinet grounding terminal (PE) located next to the input terminal block. L1 L2 L3 Ground Figure 5 Power and Ground Connections/Line Terminals 2014 Nordson Corporation
ISC2 Series Induction Dryers 15 External Interlock The external interlock is an optional connection that indicates to the dryer that the production line is running. When the interlock is used, the dryer controller will not apply power to the induction coil if there is no interlock signal. CAUTION: Nordson engineering recommends that the external interlock be connected and enabled. Without the interlock, a random trip of the line motion sensor may cause the controller to apply power to the coil while the line is stopped, which could overheat stationary can bodies near the coil. Connecting the External Interlock The external interlock requires an external 24 Vdc source at 100 ma to power an internal relay coil (refer to Note below). The external 24 Vdc power source is not referenced to the dryer ground. The interlock indicates to the dryer system that the production line is running. Without this signal, the controller will not apply power to the induction coil. NOTE: The interlock relay coil is relay CR4 (IDEC part number RY22S). Additional relay voltages are available through an IDEC distributor. 1. Locate the interlock terminal behind the control enclosure doors, in front of the control panel on the right side. 2. See Figure 6. Drill a hole or use a knockout tool to bring the interlock cable into the enclosure. Install a properly sized strain relief or conduit connector in the knockout. 3. Connect the interlock wiring to the terminal TB31-T and TB32-B. 1 2 Figure 6 External Interlock and Status Contact Connections 1. External internal terminal TB31-T 2. Status contact terminal TB32-B 2014 Nordson Corporation
16 ISC2 Series Induction Dryers Disabling the External Interlock If the external interlock will not be used, set the ISC2 system to run with the signal from the motion sensor only. 1. Use the touch screen to go to the Navigation screen. 2. Select Options to go to the Options Setup screen. 3. Select the External Run Signal button to toggle it to Ignored. Optional Status Contact See Figure 6. The status contact provides a Dryer Ready signal. It is used in conjunction with the customer interlock. The contact indicates when the dryer is off or in a fault condition. The contact is off when: The dryer is turned off. Any fault on the operator control is activated. Status contact connection: Terminal 32 output contact (output) Motion Sensor See Figure 7. The motion sensor requires field mounting and should be located close to the entry end of the coil tray (coil tray number 1 for systems with multiple trays.) On lines with conveyor speed greater than 15 m/minute (50 ft/minute) the motion sensor should be positioned up stream to ensure the coil tray is on prior to a can body entering the induction field. Adjust the motion sensor sensitivity as described on page 22. Figure 7 Motion Sensor Position 2014 Nordson Corporation
ISC2 Series Induction Dryers 17 Return Shipping Instructions If required to return the ISC2 system, use the packing and shipping instructions below. Refer to Page 10 for lift points. Domestic/USA 1. Remove interconnect wiring from coil trays and individually wrap and pack each coil tray. 2. Remove the leveling pads and place the power supply on a heavy duty shipping skid. Bolt the power supply to the skid through the leveling pad mounting holes. 3. Secure the operator control pedestal to the skid. 4. Wrap the system with plastic wrap or shrink wrap. Export Prepare the system as described in the Domestic/USA return shipping instructions. In addition, perform the following: 1. Fully crate the system with all sides protected with 13 mm ( 1 / 2- in.) minimum OSB material or equivalent. 2. If shipping by ocean freight, add silica gel to the shipping crate. 2014 Nordson Corporation
18 ISC2 Series Induction Dryers Setup WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Setup consists of the following: Motion sensor sensitivity adjustment Language selection Motion timer setting Optional external interlock timer setting Temperature offset Alarm settings Optional phase control select Optional line speed monitor NOTE: The screens used during setup can be locked from the Options screen, which is a password protected screen. If setup screens are not accessible, contact your Nordson representative. Setup normally needs to be performed at initial startup. Refer to System Controls on page 29 for an overview of the controls used for setup. WARNING: The dryer contains high voltages which can be fatal. Do not touch any electrical terminals or connections inside the enclosure while the dryer is powered up. Do not attempt to operate the dryer with the coil tray lid open or removed. Preparation 1. Make sure the production line is ready to start. For motion sensor sensitivity adjustment, can bodies must be running through the dryer. 2. Turn the main disconnect to the ON position. 3. Press the POWER button on the operator panel. The dryer powers up. 2014 Nordson Corporation
ISC2 Series Induction Dryers 19 Language Selection English is the default operator interface language. Other languages available are: Spanish, French, Portuguese, German, Italian, and Dutch. 1. Press the green POWER button on the operator terminal to turn on the dryer. 2. See Figure 8. The Nordson idry splash screen appears, then the ISC2 Run screen. Figure 8 ISC2 Run Screen 3. Touch the Menu button in the lower right-hand corner to bring up the Navigation screen. Figure 9 Navigation Screen 4. Touch the Language button to bring up the Language Selection screen. The current language is displayed at the top. 2014 Nordson Corporation
20 ISC2 Series Induction Dryers 5. Touch the applicable language button to select the desired language. 6. Touch the MENU button to return to the Navigation screen. Figure 10 Language Selection Screen 2014 Nordson Corporation
ISC2 Series Induction Dryers 21 Option Setup NOTE: The Options Setup screen is password-protected by default. This screen should only be accessed by qualified personnel. For the password, contact your Nordson representative. To get to the Options Setup screen, select the Config button on the Navigation screen (Figure 9). Enter the password on the keypad and touch the Ent key. The Option Setup screen appears. See Figure 11. The Options Setup screen allows the user to change settings on the setup screens, enable the external interlock, or restore system defaults. Toggle any of the buttons to ON/OFF to control access for the various screens and functions. NOTE: The Allow Force Outputs function and the PLC I/O Display screen are reserved for Nordson service only. Figure 11 Option Setup Screen Restore System Defaults The default power up state is set to Keep Current Values. To restore all settings to the factory defaults, toggle the button to Restore Sys Defaults Next Powerup, and then cycle the ISC2 system power. NOTE: System setup will be required after restoring system to factory defaults. 2014 Nordson Corporation
22 ISC2 Series Induction Dryers Motion Sensor Sensitivity Adjustment WARNING: Due to laser radiation exposure, do not look directly into the laser beam or its reflection from can bodies. Doing so could result in serious eye injury. See Figure 12. 1. The focal point is adjustable between 30-60 mm from the sensor face. 2. Adjust the distance screw for optimum distance and observe the reception indicator. LED Operating Indicator Green LED Reception Indicator Yellow Distance / Gain Adjustment Figure 12 Motion Sensor Module 2014 Nordson Corporation
ISC2 Series Induction Dryers 23 Timer and Motion Sensitivity Settings See Figure 13. The settings for motion timer, motion detect sensitivity, and external interlock timer can be adjusted by selecting the applicable field on the Motion Timer screen, using the keypad to enter the desired setting, and selecting Ent to save the setting. Motion Timer Setting The motion timer setting delays turning off the coil power when can motion stops. This keeps power to the coil trays and allows the last can body to travel the length of the system with power on. To determine the recommended setting, measure the time it takes for a can body to pass through the entire system from the start of the first coil tray to the end of the last coil tray. This time value is the motion timer setting. Figure 13 Motion Timer Motion Detect Sensitivity Setting The motion detect sensitivity setting adjusts the time cycle of the motion pulses from the motion sensor. This can be useful for various line speeds. The factory default setting is 30. This setting must be field selected and adjusted while the line is running. Make adjustments in increments of 20 and observe results until the power runs steady without interruption with the can present. 2014 Nordson Corporation
24 ISC2 Series Induction Dryers External Interlock Activation The external interlock must be wired and activated before setting the timer. Refer to the Installation section for information on wiring. The following procedure details the settings required to use the interlock. 1. From the Navigation screen (Figure 9), select the Config button to bring up the Option Setup screen. This screen is password protected. 2. Select the Ext Interlock Fault Mode button to toggle the mode to ON. 3. Select the External Run Signal button to toggle the mode to Monitored. 4. Touch the Back button to return to the Navigation screen. Figure 14 Option Setup Screen External Interlock Timer Setting (Optional) The external interlock timer starts when a run signal is received from the customer line. If the motion sensor does not detect motion before the timer expires, the alarm relay state will change and activate a customer supplied external alarm. The timer setting is dependent on the line speed and is useful to detect a line jam prior to the induction heating system. 2014 Nordson Corporation
ISC2 Series Induction Dryers 25 Temperature Offset Setting See Figure 15. Temperature offset is used to alter the display temperature versus the input temperature. This is used to match the temperature to a master handheld temperature probe, or to alter the temperature output when using infrared type sensors when emissivity needs to be adjusted for various metal types. The Temperature Offset screen can be password-protected. 1. From the Navigation screen (Figure 9), select the Temp Offset button to bring up the Temperature Offset screen. 2. Select the Temperature Offset field and use the keypad to set the desired offset. Touch Ent to save the setting. Figure 15 Temperature Offset and Power Limits Screen 2014 Nordson Corporation
26 ISC2 Series Induction Dryers Alarm and Temperature Display Settings See Figure 16. From the Navigation screen, select Temp Setup to bring up the Temperature Display and Alarm screen. This screen can be password-protected. Select the applicable setting, then use the keypad to enter the desired setting. Select ENT to save the setting. Figure 16 Temperature Display and Alarm Screen Product Temperature Setpoint The product temperature setpoint defines when an alarm fault is issued and the dryer is shut down if the product temperature increases to the Alarm High Setpoint or deceases to the Alarm Low Setpoint. The factory default settings: for each is to 20 C (36 F). Alarm low setpoint: 20 C ( 36 F) Alarm high setpoint: 20 C (36 F) NOTE: When setting the Alarm Low Setpoint, the minus sign is automatically populated in the field. Temperature Alarm Delay The temperature alarm delays the activation of a temperature fault if the Alarm High or Alarm Low setpoints are exceeded. The factory default setting is five seconds. 2014 Nordson Corporation
ISC2 Series Induction Dryers 27 Temperature Display Selection Touch the display field to toggle between C (Celsius) or F (Fahrenheit). Phase Control Select Systems including the optional phase control power system must select Phase Control On from the Option Setup screen (Figure 14). Standard control systems use pulse width modulation (PWM). If the phase control is not installed on system, the Phase Control Off must be selected on the option screen or the system will not function. This will be preset at the factory to accommodate system configuration. 1. Select the Config button (password protected) on the Navigation menu screen. 2. See Figure 17. On the Option Setup screen, select the Phase Control button to toggle to ON or OFF, depending on the system setup. 2014 Nordson Corporation
28 ISC2 Series Induction Dryers Line Speed Monitor Select See Figure 17. Power output to the coil trays can be controlled by the ISC2 system or remotely. Systems including the line speed monitor option utilize a 4 20mA input signal to control the power output into the coil trays. The line speed monitor can be turned on/off per requirements. With the line speed monitor off, the system will operate by the percentage of power preset in the ISC2 Run Screen. With line speed monitor on the output power is determined by the 4-20mA. signal supplied by customer. Line Input Gain and Line Input Offset can be used to calibrate the system if supplied process signal varies from 4 20mA. The ISC2 Run screen provides a message indicating if the line speed monitor is ON. With the line speed monitor on, the percentage of power selection becomes a multiplier function (1 100%). When set at 100% with a command signal of 4 20mA: 4mA corresponds to 0% power 20mA corresponds to 100% power Setting can be monitored on the ISC2 Run screen under Power Output With the percentage of power set below 100% the command signal is multiplied by the percentage of the power preset. See the following as an example. Percentage of power set at 50% (multiplier = 0.5) Command signal of 12mA (50% of range) Therefore, 0.5 x 0.5 = 0.25 (25% power output) Figure 17 Line Speed Monitor 2014 Nordson Corporation
ISC2 Series Induction Dryers 29 Operation WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Operator Controls ISC2 controls consist of: Main disconnect (on power supply) Emergency stop switch Power pushbutton/indicator (Start) Off pushbutton (Stop) Operator interface Emergency Stop Power Off Operator Interface Figure 18 Operator Controls 2014 Nordson Corporation
30 ISC2 Series Induction Dryers Startup 1. Turn the main disconnect switch on the power supply to the ON position. 2. Check the following: Enclosure doors are closed and locked Rear access panel is fastened into place Emergency Stop switch is in the released position 3. Press the green Power pushbutton The Power indicator lights and the system run a self test. The operator interface displays the ISC2 Run screen. When the self test is complete, if no faults are detected, then the system is ready to operate. if a fault occurs during the test, select the Fault Page button. Refer to the Troubleshooting section on page 35. 4. Start the production line and run can bodies through the system. The system powers the induction coil and heats the can bodies whenever the motion sensor detects moving product. When the line stops, the dryer automatically stops heating. When the line begins to move again, heating will automatically restart. 2014 Nordson Corporation
ISC2 Series Induction Dryers 31 ISC2 Run Mode See Figure 19. The default operating mode is ISC2 run mode. The ISC2 RUN screen automatically appears when the dryer is turned on. 7 1 2 5 3 6 4 Figure 19 ISC2 Run Screen 1. Percent power bar graph 2. Percentage of power setpoint 3. Actual temperature bar graph 4. Actual temperature 5. Mode indicators 6. Up and down buttons 7. Setpoint temperature value Adjusting the Temperature Setpoint NOTE: The actual and setpoint temperature can be displayed in Celsius or Fahrenheit. To change the display, refer to page 27. The percentage of power must be adjusted to reach the desired setpoint. Refer to page 32 for information on protecting the setpoint. The percentage of power setpoint can be adjusted in two ways: Touch the Up () or Down () buttons to change the setpoint temperature one degree at a time. For larger adjustments, touch the setpoint temperature value (7). Enter the new setpoint using the keypad that appears, and select the Ent button to save the setting. NOTE: With systems utilizing Line Monitor Option, the percentage of power is controlled by a remote 4 20mA process signal. 2014 Nordson Corporation
32 ISC2 Series Induction Dryers High and Low Alarms If the actual end temperature rises above the Alarm High setpoint or falls below the Alarm Low setpoint, the dryer will continue to operate for a preset period of time determined by the Temperature Alarm Delay. If the actual temperature is still above or below the alarm setpoint after the delay timer runs out, a system fault will occur. The dryer will automatically turn off and a fault indicator will appear on the operator interface. Faults See Figure 20. Select the Fault Page button to open the Fault screen. System faults are displayed in red. The problem must be corrected and the fault reset before the system can be restarted. Refer to the Troubleshooting section for fault descriptions and recommended corrections. Figure 20 Fault Screen 2014 Nordson Corporation
ISC2 Series Induction Dryers 33 Navigation Screen The Navigation screen provides access to the system settings, automatic and manual screens, and the operator language. Selecting the Menu button on any screen will open the Navigation screen. NOTE: Some screens are password protected. If they are protected, they can be opened, but the values they display cannot be changed. These screens are normally used for setup and testing. Figure 21 Navigation Screen Shutdown To shut down the dryer, press the Off pushbutton on the operator controls. NOTE: While it is possible to stop the dryer by pressing the Emergency Stop button or by switching the main disconnect switch to the Off position on the power supply, it is better to use the Off pushbutton on the operator controls to ensure a controlled shutdown. 2014 Nordson Corporation
34 ISC2 Series Induction Dryers Maintenance WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. WARNING: HIGH VOLTAGE! Disconnect and lockout all power to the dryer before working inside the coil tray or control enclosure. Failure to observe may result in fatal injury to personnel. WARNING: Never disarm any diagnostic or interlock devices, including but not limited to: Current sensor Overtemperature switches Air pressure switch(s) Power supply door safety switch Disarming these devices will void the warranty and may cause personal harm or equipment failure. The following parts of the dryer should be checked on the indicated schedule. Monthly Item Motion/Infrared sensor Cooling blower filter Coil trays Quarterly Item Electrical connections Electrical components Procedure Clean the sensor head lens with a clean, soft cloth. Inspect the blower filter for dust or obstruction. Replace the custom filter as needed. If the air flow is reduced, the system electronics can overheat and affect system reliability. End drying may also be affected by reduced air flow. Periodically inspect cooling fans on coil tray lid. Ensure the intake is free from dirt and obstruction. Procedure Check all wiring connections for loosening caused by vibration. Check for excessive dust and dirt. Vacuum if needed. 2014 Nordson Corporation
ISC2 Series Induction Dryers 35 Troubleshooting These troubleshooting procedures cover only the most common problems. If you cannot solve a problem with the information given here, contact your local Nordson representative for help. WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. WARNING: The dryer contains high voltages which can be fatal. WARNING: Never disarm any diagnostic or interlock devices including but not limited to: Current sensor Overtemperature switches Air pressure switch(s) Power supply door safety switch Disarming these devices will void the warranty and may cause personal harm or equipment failure. NOTE: Use the schematics provided with your system when performing troubleshooting procedures. Problem Possible Cause Corrective Action Main disconnect off Turn main disconnect switch to ON position. 1. Dryer will not turn on when POWER button is pressed 2. Can bodies not heating, RUN MODE ON 3. Can ends not heating, MOTION LED off Power supply door open EMERGENCY STOP switch pushed in Fuses F1A, 1B, or 1C open Fuses F1A, 1B, or 1C open Motion sensor lens dirty Motion sensor not focused 4. COILTRAY LID OPEN Not applicable for ISC2 system Close and lock door. Adjust door interlock switch if necessary. Pull switch out to release. Check the fuse indicators. If black, replace fuses. With power disconnected and locked out at an external breaker or disconnect switch, test the fuses and check for loose connections. Check the fuse indicators: If black, replace fuses. With power disconnected and locked out at an external breaker or disconnect switch, test the fuses and check for loose connections. Clean lens with a clean soft cloth. Perform distance adjustment. 2014 Nordson Corporation
36 ISC2 Series Induction Dryers Problem 5. COOLING AIR FAIL fault 6. INVERTER OVER TEMP fault 7. PRODUCT TEMP HIGH fault 8. PRODUCT TEMP LOW fault Possible Cause Obstructed or dirty air filter Fuse F8 open Rear access panel loose or removed Rear access panel loose or removed Obstructed or dirty air filter Obstructed air flow under dryer Corrective Action Remove any obstructions that might impede air flow. Replace filter if dirty. Test fuse and replace if blown. Install access panel properly. Install access panel properly. Remove any obstructions that might impede air flow. Replace filter if dirty. Remove any obstructions that might impede air flow. % power setting too high Adjust setting. Refer to page 28. Increase target temperature setting. % power setting too low Adjust setting. Refer to page 28. Increase target temperature setting. Fuse F1B open 9. LINE PHASE LOSS fault Fuse F2A, F2B, F2C open 10. RF BOARD FAULT Occurs with one or more of following faults: Inverter Over Current, Tank Voltage High or Low, Inverter Out Of Lock 11. INVERTER OVER CURRENT fault 12. TANK VOLTAGE HIGH fault 13. TANK VOLTAGE LOW fault 14. INVERTER OUT OF LOCK fault 15. EXT INTLK TIMED-OUT fault Excessive current being drawn by tank circuit Excessive current draw in power processing circuitry for high frequency generator Line voltage low or loss of phase Tank circuit failure or incorrect product load RF board/driver failure Customer-supplied run signal present, but motion sensor does not activate Line jam. No product movement at dryer entrance Test fuse and replace if blown. Test fuses and replace if blown. DISCONNECT AND LOCKOUT POWER BEFORE PROCEEDING! Perform diagnostic test on power processing subsystems. DISCONNECT AND LOCKOUT POWER BEFORE PROCEEDING! Perform diagnostic test on power processing subsystems. DISCONNECT AND LOCKOUT POWER BEFORE PROCEEDING! Perform diagnostic test on power processing subsystems. DISCONNECT AND LOCKOUT POWER BEFORE PROCEEDING! Perform diagnostic test on power processing subsystems. DISCONNECT AND LOCKOUT POWER BEFORE PROCEEDING! Perform diagnostic test on power processing subsystems. Timer setting too short. Adjust timer to allow for line fill. Refer to page 26. Clear line jam so product resumes moving on the line. 2014 Nordson Corporation
ISC2 Series Induction Dryers 37 Repair WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. WARNING: HIGH VOLTAGE! Disconnect and lockout all power to the system before perfoming any of the procedures in this section. Failure to observe may result in fatal injury to personnel. Repair of the dryer consists mainly of replacing damaged or failed components. Most repairs require no more than basic tools. Electrical repairs should always be done by a qualified electrician with knowledge of high voltage systems. For help with repairs not covered in this manual, contact your Nordson representative. WARNING: Never disarm any diagnostic device, including but not limited to the current sensor, overtemperature switches, air pressure switch, or coil tray lid safety switches. Disarming diagnostic devices will void the warranty and may cause equipment failure. Air Filter Replacement See Figure 22. To replace the filter, pull it out of the right side of the holder. Figure 22 Filter Replacement 2014 Nordson Corporation
38 ISC2 Series Induction Dryers Parts Refer to the addendum to this manual for spare parts. To order parts, call the Nordson Finishing Customer Support Center at (800) 433-9319 or contact your local Nordson representative. Temperature Conversions Celsius Fahrenheit Temperature Table Conversion Equations Celsius Fahrenheit 50 122.0 51 123.8 52 125.60 53 127.40 54 129.20 55 131.00 56 132.80 57 134.60 58 136.40 59 138.20 60 140.00 61 141.80 62 143.60 63 145.40 64 147.20 65 149.00 66 150.80 67 152.60 68 154.40 69 156.20 70 158.00 71 159.80 72 161.60 73 163.40 74 165.20 75 167.00 76 168.80 77 170.60 78 172.40 79 174.20 80 176.00 Celsius to Fahrenheit: F = 9 / 5 x C + 32 Fahrenheit to Celsius: C = 5 / 9 x F - 32 2014 Nordson Corporation
Product: idry Induction Oven Models: ISC2 DECLARATION of CONFORMITY Description: This is an induction oven used for curing liquid or powder coating on the inside seam of a container (can) Assembly. Applicable Directives: 2006/42/EC (Machinery Directive) 2004/108/EEC (ElectroMagnetic Compatibility Directive) Standards Used for Compliance: EN12100-1 EN55011 NFPA79 EN60204 EN61000-6-2 UL508a EN61000-6-3 Principles: This product has been manufactured according to good engineering practices. The product specified conforms to the directive and standards described above. Hallie Smith-Petee Date : 12 Jan 2015 Engineering Manager Industrial Coating Systems Nordson Authorized Representative in the EU Person authorized to compile the relevant technical documentation. Contact: Operations Manager Industrial Coating Systems Nordson Deutschland GmbH Heinrich-Hertz-StraBe 42-44 D-40699 Erkrath DOC12027