Process Sentry

Process Sentryt PLC Controller
Customer Product Manual

Part 1615366-01
Issued 01/19
For parts and technical support, call the Industrial Coating

Systems Customer Support Center at (800) 433-9319 or
contact your local Nordson representative.
This document is subject to change without notice.
Check http://emanuals.nordson.com for the latest version.
NORDSON CORPORATION • AMHERST, OHIO • USA

tents
Table of Contents
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . 1 Optional Controller Configurations . . . . . . . . . . . . 64
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Part ID Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . 65
Regulations and Approvals . . . . . . . . . . . . . . . . . . 1 Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Segment Volumes . . . . . . . . . . . . . . . . . . . . . . . . 68
High-Pressure Fluids . . . . . . . . . . . . . . . . . . . . . 2
Pre−Pressure Setup . . . . . . . . . . . . . . . . . . . . . . . . . 69
Fire Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Halogenated Hydrocarbon Solvent Hazards . 4 Pro-Meter S PLC Dispenser . . . . . . . . . . . . . . . . . . 70
Action in the Event of a Malfunction . . . . . . . . . . . 5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Robot Interface/Communication Ethernet . . . . . . 71
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . 8 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 PS PLC Controllers . . . . . . . . . . . . . . . . . . . . . . . . . 74
Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operator Interface, Screens and Setup . . . . . . . . 10
User Login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
System Status . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Program Screen . . . . . . . . . . . . . . . . . . . . . . . . . 20
Heating Screen (If equipped) . . . . . . . . . . . . . . 44
Temperature Control Unit (TCU) (If equipped) 52
Pumps Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Diagnosis Screen . . . . . . . . . . . . . . . . . . . . . . . . 55
Fault Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Statistics Screen . . . . . . . . . . . . . . . . . . . . . . . . . 58
Manual Operations . . . . . . . . . . . . . . . . . . . . . . . 59
Data Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Product Manuals . . . . . . . . . . . . . . . . . . . . . . . . . 62
Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Contact Us Notice
Nordson Corporation welcomes requests for information, comments, and This is a Nordson Corporation publication which is protected by copyright.
inquiries about its products. General information about Nordson can be Original copyright date 2019. No part of this document may be
found on the Internet using the following address: photocopied, reproduced, or translated to another language without the
http://www.nordson.com. prior written consent of Nordson Corporation. The information contained
Address all correspondence to: in this publication is subject to change without notice.
Nordson Corporation Trademarks
Attn: Customer Service Pro-Meter, Nordson, and the Nordson logo are registered trademarks of
555 Jackson Street Nordson Corporation.
Amherst, OH 44001 Process Sentry is a trademark of the Nordson Corporation.
Pro−Meter is a registered trademark of the Nordson Corporation.
All other trademarks are the property of their respective owners.
Part 1615366-01 E 2018 Nordson Corporation

Change Record i
Change Record
Revision Date Change
01 01/19 Initial Release.
E 2018 Nordson Corporation Part 1615366-01

ii Change Record

Process Sentryt PLC Controller 1
Process Sentryt PLC Controller
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
S using incompatible materials

S making unauthorized modifications
S removing or bypassing safety guards or interlocks
S using incompatible or damaged parts
S using unapproved auxiliary equipment
S 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.

2 Process Sentryt PLC Controller
Personal Safety
To prevent injury follow, these instructions.
S Do not operate or service equipment unless you are qualified.

S 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.
S 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.
S 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.
S 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.
S 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.
S Obtain and read Safety Data Sheets (SDS) for all materials used.
Follow the manufacturer’s instructions for safe handling and use of
materials, and use recommended personal protection devices.
S Make sure the spray area is adequately ventilated.
S 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 SDS 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:
S Go to an emergency room immediately.

S Tell the doctor that you suspect an injection injury.
S Show them this card
S Tell them 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.
S 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.
S 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.
S Do not smoke, weld, grind, or use open flames where flammable
materials are being used or stored.
S Do not heat materials to temperatures above those recommended by
the manufacturer. Make sure heat monitoring and limiting devices are
working properly.

Fire Safety (contd)

S Provide adequate ventilation to prevent dangerous concentrations of
volatile particles or vapors. Refer to local codes or your material SDS
for guidance.
S Do not disconnect live electrical circuits when working with flammable
materials. Shut off power at a disconnect switch first to prevent
sparking.
S 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.
S Shut off electrostatic power and ground the charging system before
adjusting, cleaning, or repairing electrostatic equipment.
S Clean, maintain, test, and repair equipment according to the instructions
in your equipment documentation.
S 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 SDS 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:
S Disconnect and lock out system electrical power. Close hydraulic and
pneumatic shutoff valves and relieve pressures.
S 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.

Description
See Figure 1 and refer to Table 1.
The Process Sentry (PS) PLC controller uses signals from a robot or cell
controller to control the material dispensing process. A constant bead size
can be maintained by adjusting the material dispensing rate for changes in
robot speed.
The controller can be configured with various options for dispensers and
system interfaces. The PS PLC controller also:
S displays recover procedures if faults are detected,

S communicates faults to the robot controller,
S stores SPC and fault data, and
S controls material temperature of four independent zones (integrated
temperature control unit (TCU) model only).
Table 1 Major Components

Item Description
Alarm Tower: Alerts the operator that a fault condition exists within the system
S RED — Major Fault, Immediate Action
1
S AMBER — Minor Fault
S GREEN — Ready
2 Display Screen (Available in 10− or 15−in.)
3 Start Button
4 Stop Button
5 Programming Port
6 TCU (if equipped)

PS PLC with TCU

1
2
PS PLC without TCU
1
3
4
3
5
4
6
Figure 1 Process Sentry PLC Controller

Specifications
Item Description
1615339 480 VAC, 3 phase, 60 HZ, 7 full−load amperes (FLA)
1615340 480 VAC, 3 phase, 60 HZ, 7 FLA
1615341 120 VAC, 1 phase, 60 HZ, 15 FLA
1615342 120 VAC, 1 phase, 60 HZ, 15 FLA
1615343 480 VAC, 3 phase, 60 HZ, 7 FLA
1615344 480 VAC, 3 phase, 60 HZ, 7 FLA
1615345 480 VAC, 3 phase, 60 HZ, 11 FLA
1615346 480 VAC, 3 phase, 60 HZ, 11 FLA
1615347 480 VAC, 3 phase, 60 HZ, 8 FLA
1615348 480 VAC, 3 phase, 60 HZ, 8 FLA
1615349 120 VAC, 1 phase, 60 HZ, 25 FLA
1615350 120 VAC, 1 phase, 60 HZ, 25 FLA
1615351 480 VAC, 3 phase, 60 HZ, 8 FLA
1615352 480 VAC, 3 phase, 60 HZ, 8 FLA
1615353 480 VAC, 3 phase, 60 HZ, 8 FLA
Theory of Operation
The robot sends a flow rate command that is proportional to the speed of
the robot. This voltage can be a 16-bit word in the case of an Ethernet I/O
system. The voltage controls the speed of the servomotor, which in turn
controls the material flow rate, allowing the dispensed bead to remain
constant through corners. The material dispensing rates can be changed.
The Bead Size feature controls the percentage of the robot analog signal to
the servomotor. It also eliminates the need to change the robot program
due to changes in the material dispensing rates. Increasing the bead size
value increases the rate dispensing material. Decreasing the bead size
value decreases the rate of dispensing material.
NOTE: A different bead size can be entered for each Part ID. A Global
bead size can be entered if the bead size applies to all Part IDs.
Alarms
The PS PLC controller alerts the operator when a fault occurs by lighting the
alarm tower. The status screen will also flash the graphic of the faulted
system component, allowing the user to quickly access help information for
the fault by simply selecting the flashing icon. The fault help screen
provides a description of the fault, the corrective action needed, and how to
contact Nordson for assistance. A fault log screen displays a list of the most
recent faults.

Security
Features and changeable settings are locked to prevent accidental changes
in process. User name and passwords, and/or USB flash drives, are
needed to make changes.
Installation
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
WARNING: The PS PLC contains electrical connections that can be fatal.

Disconnect and lock out electrical power before making connections.
Read and understand this entire section before performing actions. Contact
a Nordson representative regarding these procedures if necessary.
NOTE: Refer to the Optional Controller Configurations section for

additional data that is applicable to this controller configuration.
1. Unpack the PS PLC controller and inspect it for dents, scratches,

corrosion, or other physical damage. If there is any visible damage, call
a local Nordson representative immediately.
2. Install the PS PLC controller as close to the robot controller as possible.
Guidelines
Refer to the following guidelines:
S Hard wire the controller to a dedicated power supply to provide safe

operation and reduce interference from electrical noise.
S Install all electrical connections to local code.
S Install a locking disconnect switch or breaker in the service line ahead of
any electrical equipment.
S Electrical, fluid, and air connections are dependent upon application
requirements. Use the System Layout and Interconnect drawings
provided with the system documentation for all connections.
S Make sure there is enough slack in all hose and cable routings to allow
for proper system operation.
NOTE: Most of the critical setup parameters that are described in this
section are configured prior to shipment. The information on
enabling/disabling pump and TCU is provided for reference and should
not be needed during a typical installation.

Operator Interface, Screens and Setup

Use this section to configure the main menu screens. Use the touchscreen
to navigate between the menu screens.
NOTE: Refer to the Optional Controller Configurations section for

additional data that is applicable to this and other controller
configurations.
Select the screen to choose one of the main menus.
Table 2 System Status Screen

Item Description Function
1 User Login Login and/or change users
2 Test Points Menus used to verify that the robot signals are being
sent and received by the controller. Green is active,
gray is inactive
3 System Status Appears as the default screen; displays the system
configuration
4 Program Screen Menus used to set up and configure system
parameters and access control screens for the
pumps, temperature controls, etc
5 Heating Screen/TCU Screen Menus allow user to set up heating and/or cooling
options (if equipped)
6 Pumps Screen Menus to set up and configure pump settings
7 Diagnosis Screen Shows fault information, buttons to view fault logs,
fault status and allows faults to be reset
8 Fault Reset Resets all faults
9 Statistics Screen Shows usage statistics since last performed
maintenance
10 Manual Operations Menus allow user to perform different manual
operations
11 Data Log Provides log of operation tasks
12 Product Manuals Allows access to online versions of the Operator’s
Manuals
13 Back Moves the system back one page
14 Stop Purging Stops a system purge
15 Start Purging Starts a system purge

1 2 3 14 15
4 5 6 7 8 9 10 11 12 13
Figure 2 System Status Screen

User Login
See Figure 3.
Use the User Login to:
S Login/Logout
S Check Security Level
S Check current or last user
Figure 3 User Login Screen

Test Points
Refer to Table 3 and see Figures 4−9.
These screens are used to verify the state of I/O signals to and from the
robot and peripheral devices (pump stand, TCU). The screen displays
depend on the system configuration.
Select buttons on the left to toggle through the available I/O screens.
When an Input/Output is active, the box to the left is green. When the
Input/Output is inactive, the box to the left is gray.
Table 3 Test Points Screen

Item Description Setting
1 System I/O Opens system input/output test point screen
2 Pumps I/O Opens pumps test point screen
3 Remote Meter I/O Opens remote meter test point screen
4 All Inputs From Robot Opens inputs from robot test point screen
5 All Outputs To Robot Opens outputs to robot test point screen
6 Vision I/O Opens Vision test point screens. (If equipped)
Figure 4 Test Point Screens (1 of 6)

Figure 5 Test Point Screen (2 of 6)



Servo Status Screen

See Figure 10.
Touch anywhere on the text listing the servo information on the Remote I/O
screen (see Figure 6) to access the Servo Status screen.
When an Input/Output is active, the box to the left is green. When the
Input/Output is inactive, the box to the left is gray.
Press the CLOSE button to close the screen.
Figure 10 Servo Status Screen

System Status
See Figure 11.
The System Status screen is the default screen displayed at power-up.
This screen shows the layout of major system components including

material supply pumps, the applicator, and the controller itself. Each
component image can flash red when a fault condition occurs involving that
component. When an image or applicator is flashing, selecting the flashing
image or View Faults takes the user to the View Faults screen where
detailed information on the fault and recovery instruction appears.
The status screen also features indicators for the status of digital inputs and
meter pressure.
NOTE: The actual system configuration may differ from the view on
Figure 11.

Figure 11 System Status Screen (4 of 4)

Program Screen
Refer to Table 4 and see Figure 12.
Use the Program Screen to configure the system parameters to access

control screens for the pumps and the TCU. The following provide a
description.
NOTE: The display screen will vary depending on the security level,
configuration used and the robot interface.
Table 4 Program Screen and Security Level

Description Default Maintenance Supervisor
Clock X X X
Simulation Mode X X X
Lamp Test X X X
Part ID Set−up X X
PM Set−up X X
Pre−Pressure Set−up X X
Delay Timers X X
Signals I/O Trace X X
Fault Set−up X X
Purge X X
Temperature/TCU
X X
Set−up
Devices Enabled X
Pump Stand Set−up X
Pro−Meter® S Set−up X
Vision Setup X

X.XX
X.XX
XX.XXX
X.XX
Figure 12 Program Screen

Clock
See Figure 13.
The time and date used on the Process Data screen and in the stored SPC
and fault logs are based on a clock that runs on the PS PLC controller
board.
Click/touch the Set button to set the time. The HMI clock will synchronize
with the PLC clock once an hour.

Figure 13 Clock Synchronization Screen

Part ID Setup
NOTE: When on the Part ID Setup screen, any part can be brought up
by clicking in the Part−ID Setup box and inputting the number. Operator
can also scroll through the parts by using the arrows to the right of the
box.
NOTE: The amount of available parts and segments available varies

according to the system configuration. Refer to the Optional Controller
Configurations section for additional data and screens that are
applicable to the system configurations.
Table 5 Part ID Setup Screen

Item Description Setting 1 Setting 2
1 Part ID Setup Variable Arrows to Scroll
2 Pro−Meter S Prepressurization Setpoint Variable —
3 Target Volume Variable —
4 High Volume Fault (1−99%) Variable —
5 Low Volume Fault (1−99%) Variable —
Major
6 High Instantaneous Pressure Variable Minor
Disabled
Major
7 Low Instantaneous Pressure Variable Minor
Disabled
Major
8 Low Average Pressure Delta Variable Minor
Disabled
Loads current part average pressure
9 Teach Pressure Average into average pressure First in First Out
(FIFO)
Enabled
10 Dynamic Pre−Pressure —
Disabled
11 Bead Size (1−100%) Variable —

1
9
2
10
3
11
4
12
5
13
6
14
7
15
Figure 14 Part ID Set−up Screen

Preventative Maintenance Set−up

See Figure 15.
To change the maintenance intervals select the box to the right of the
following settings and input the desire maintenance interval.
S Pump Strokes
S Gun Cycles
S Vol (Volume) Dispensed Liters
NOTE: The maintenance intervals are dependant on the material being
used. Some materials will require a decrease in strokes, cycles or
volume intervals and some may be capable of increased intervals.
Figure 15 PM Set−up Screen

Delay Timers
See Figure 16.
Set the times for the following setting to between 0−2.000 seconds.
S Meter On Delay
S Gun On Delay
S Gun Off Delay
S Inlet Low Pressure
S Inlet High Pressure
Figure 16 Delay Timers Screen

Fault Setup
See Figure 17.
Set faults to MAJOR, MINOR or DISABLED.
NOTE: These faults will vary depending on the robot interface used.
Figure 17 Fault Set−up Screen

Signals I/O Trace

See Figure 18.
Shows the Analog Signals and the Timing Sequence of the robot interface.
Figure 18 Signals I/O Screen

Purge
See Figure 19.
Set the time and amounts for:
S Dispense Time (in seconds)

S Purge Speed (in cc’s/second)
S Purge Volume (in cc’s)
Figure 19 Purge Screen

Electric Heat Setup (If equipped)/

Temperature Conditioning Unit (TCU) Setup (If equipped)
Electric Heat Setup (If equipped)
Click/touch the Temperature Setup button on the Program Screen to access

the Heat Setup screen.
Table 6 Electric Heat Setup Screen

Description Setting
Enabled
Auto Setback
Disabled
Enabled
Auto Shut Off
Disabled
Time to Auto Setback in Minutes Variable
Time to Auto Shut Off in Minutes Variable
Soak Time in Minutes Variable
Figure 20 Heating Screen

TCU Setup (If equipped)
Table 7 TCU Setup Screen

Description Heat Cool
Proportional Gain (Kp) Variable Variable
Integral Gain (Ki) 1/s Variable Variable
Derivative Time (Kd) s Variable Variable
Loop Update Time Sec. Variable Variable
Output Cycle Time Sec. Variable Variable
Temperature Offset to Start Variable Variable
Description Setting 1 Setting 2
Major
Low Temperature Fault °F Variable Minor
Disabled
Major
High Temperature Fault °F Variable Minor
Disabled
Soak Time in Minutes Variable —
Auto Off Time Minutes Variable —
Click/touch Enable Shut Down
Shut Dn Enabled
Shut Down Enabled/Disabled
Click/touch Shut Down
Disable Shut Dn Disabled

Figure 21 TCU Setup Screen

Devices Enabled
Devices Enabled gives to access a list of devices, the status of those

devices and the ability to ENABLE/DISABLE the devices.
Table 8 Devices Enabled Screen

Item Description Setting
1 Settings Column Enable or Disable features
Green indicates an enabled feature
2 Status Column
Yellow indicates a disabled feature
Overrides the purge bucket detected
3 Purge Bucket Overridden
requirement for purging

1 2 1 2
Figure 22 Devices Enabled Screen

Pump Stand Setup

Table 9 Pump Stand Setup Screen

Description Setting
Pump Stroke Volume in CC’s Variable
Material Per Drum in Gallons Variable
Enabled
Auto−Depressurize
Disabled
Time to Auto−Depressurize in Minutes Variable
Depressurize Timeout in Seconds Variable
Runaway Prox Trip Point (Pulses per Minute) Variable
Major
Runaway Fault Minor
Disabled
Major
One Drum Empty Minor
Disabled
Major
Filter Plugged Minor
Disabled
Pumps per Stand Variable

Figure 23 Pump Stand Setup Screen

Simulation Mode
Refer to Table 10 and see Figure 24. After inputting the simulation variables,
click/touch the Run Simul. button to run the simulation.
Table 10 Simulation Type Setup Screen

Constant Cycle — —
S Set Time 1−99 Sec. Variable —
S Set Spd cc per sec. Variable —
Up/Down Cycle — —
Multiple On/Off — —
S Set Spd 1 cc per sec. Variable —
Constant —
Step Up —
Simulation Type Step Down —
Multiple —
Disabled —
Press to Start Run Simul. —
Simul. Running —
Target Volume Variable —
Pre−Pressure Setpoint Variable —
Major
High Volume Fault (1−99%) Variable Minor
Disabled
Major
Low Volume Fault (1−99%) Variable Minor
Disabled
Major
High Instantaneous Pressure Variable Minor
Disabled
Major
Low Instantaneous Pressure Variable Minor
Disabled
Major
Low Average Pressure Delta Variable Minor
Disabled
Major
Dynamic Pre−Pressure — Minor
Disabled

Figure 24 Simulation Type Setup Screen

Pro−Meter S PLC Setup
Table 11 Pro−Meter S PLC Setup Screen

Description Setting
Refill After Number of Parts Variable
Meter Size in CC’s Variable
Screw Pitch in Inches Variable
Setpoint
Part Pre−Pressure by
Dynamic
Major
Air Pocket Diagnostic Minor
Disabled
Air Pocket Trip Size % Variable
Air Pocket Max Purge Limit Variable
Meter Transducer Range Variable
Refill Timeout in Seconds Variable
Pre−Pressure Timeout in Seconds Variable
Meter Over Pressure Limit in PSI Variable
Major
Meter Not Full Minor
Disabled
Major
Segment High Volume Minor
Disabled
Major
Segment Low Volume Minor
Disabled
Jog Speed CC’s per Second Variable
Pressurize Speed CC’s per Sec. Variable
Depressurize Speed CC’s per Sec. Variable
Depressurize Settings in PSI Variable
Daub Speed CC’s per Second Variable
Refill Speed CC’s per Second Variable

Figure 25 Pro−Meter S PLC Setup Screen

Vision Setup (if equipped)

Table 12 Vision Setup Screen

Description Setting/Action
Enable Vision 1 Enables Vision
Disable Vision 1 Disables Vision
Vision 1 Enabled/Disabled Vision Status
Major
Vision 1 Inspection Fail Minor
Disabled
Major
Vision 1 Not Responding Minor
Disabled
Major
Vision 1 Not in Automatic Minor
Disabled
Major
Vision 1 Disabled Minor
Disabled
Major
Vision 1 Bypass Mode Minor
Disabled
Major
Vision 1 Learn Mode Minor
Disabled
Opens up a remote desktop screen to the vision
Vision Unit 1 Setup
PC. Refer to the Vision software manual.

Figure 26 Vision Setup Screen

Heating Screen (If equipped)

The following section provides a description of the Heating Screen menu.
NOTE: The number of heating zones varies according to each system

configuration.
NOTE: The menu options and accessibility are subject to security level.
Table 13 System Temperatures Screen

System Temps Opens system temperatures screen
Manually Start Heater Press to manually start the heaters
Manually Stop Heater Press to manually stop the heaters
System Heater Started Manually Manual start is active, press to switch to auto start
System Heater Auto Start Auto start is active, press to switch to manual start
System Heaters Are On Press to turn the heaters off
System Heaters Are Off Press to turn the heaters on
Enable Auto Start System Heaters Press to enable system heaters auto start
Disable Auto Start System Heaters Press to disable system heaters auto start
Auto Start is Disabled Auto start is inactive, press to enable auto start
Auto Start is Enabled Auto start is active, press to disable auto start
Temperature Setpoints Opens temperature setpoints screen
Setback Setpoints Opens setback setpoints screen
High Temp Setpoints Opens high temperature setpoints screen
Low Temp Setpoints Opens low temperature setpoints screen
PID Settings Opens PID settings screen

System Temps
See Figure 27.
Access the System Temperatures screen to set the temperatures to change

temperatures for all active zones.

configuration.
Figure 27 System Temperature Screen

Temperature Setpoints
See Figure 28.
Access the Temperature Setpoints button on the System Temperatures

screen to change temperatures for all active zones.
To change the individual temperatures for the active zones, click/touch in

the box to the right of each zone and input the desired temperature. To
change the temperature setting for active zones at once, put the desired
temperature into the box to the right of Mass Setpoint and click/touch the
Send Mass Setpoint To All Zones button.

configuration.
Figure 28 Temperature Setpoints Screen

Setback Setpoints
See Figure 29.
Access the Setback Setpoints button on the System Temperatures screen

to change temperatures for all active zones.
The setback temperature is the temperature that the active zones go back
to when the activity timer times out.
To change the individual temperatures for all active zones, click/touch in the
box to the right of each zone and input the desired temperature. To change
temperatures for all active zones, put the desired temperature into the box
to the right of Mass Setpoint and click/touch the Send Mass Setpoint To All
Zones button.

configuration.
Figure 29 Setback Setpoints Screen

High Temp Setpoints

See Figure 30.
Access the High Temp Setpoints button on the System Temperatures

screen to change temperatures for all active zones..

change temperatures for all active zones, put the desired temperature into
the box to the right of Mass Setpoint and click/touch the Send Mass
Setpoint To All Zones button.

configuration.
Figure 30 High Temperature Setpoints Screen

Low Temp Setpoints

See Figure 31.
Access the Low Temp Setpoints button on the System Temperatures screen
to change temperatures for all active zones.

change temperatures for all active zones, put the desired temperature into
the box to the right of Mass Setpoint and click/touch the Send Mass
Setpoint To All Zones button.

configuration.
Figure 31 Low Temperature Setpoints Screen

PID Settings
See Figure 32.
Click/touch the PID Settings button on the System Temperatures screen to

change the Kp, Ki, Kd and Loop time for the active zones.
The names of the zones can also be changed by clicking/touching under the
current zone name and inputting the new name.

configuration.

Figure 32 PID Settings Screen

Temperature Control Unit (TCU) (If equipped)

The temperature control must be enabled before the PS PLC controller can
operate it. Perform the following to enable the temperature control:
1. Click/touch the Program Screen button.

2. Click/touch the Devices Enabled button.
3. Click/touch the Enable TCU button.
NOTE: The Enable TCU button (if equipped) will be in the Settings
column shown in Figure 22.
4. Click/touch the TCU Screen button.

5. Click/touch the Start TCU button to activate the TCU. The yellow
TCU is Off indicator will turn green and change to TCU is On indicating
that the TCU is on. Select BACK to go back to the Program screen.
Table 14 TCU Screen

Description Setting
Current Temperature F Variable
Setpoint Temperature F Variable
Conservation Min. Remaining Variable
Heat Output % Variable
Heater SSR OFF/ON
Cool Output % Variable
Cooling Solenoid OFF/ON
TCU is On
Start/Stop TCU
TCU is Off

Figure 33 TCU Screen

Pumps Screen
See Figure 34.
Click/touch the Pressurize/Depressurize Pumps button to change the

pressurize or depressurize the pumps. When the pumps are pressurized,
the indicator turns green and says Pumps Are Pressurized. Click/touch the
Pressurize/Depressurize Pumps button to depressurize the pumps. When
the pumps are depressurized, the indicator turns yellow and says Pumps
are Depressurized.
To switch between pumps, click/touch the Switch to Pump X button under

the applicable pump. The indicator below the pump turns green and
changes to display Pump X Active. Inactive pumps are yellow and display
Pump X Inactive.
Figure 34 Pump Stand Setup Screen

Diagnosis Screen
See Figure 35.
Click/touch the Diagnosis Screen button to access the Diagnosis Screen.
The Diagnosis Screen shows the highest priority fault and possible solutions
for that fault.
Description Action
Fault Reset Reset all faults
Fault Log Brings up Fault Log Screen
Fault Status Brings up Fault Status Screen
XXX
Figure 35 Diagnosis Screen

Fault Log Screen

Table 15 Fault Log Screen

Item Description Setting/Action
1 Value Fault list
2 QTY (Quantity) Displays amount of fault occurrences
3 Acc (Accumulative) Time Varies
4 Message Fault Description
Active Alarms
5 Display Mode Past Alarms
All Alarms
6 Silence Alarms Silences Alarms
7 Last Time Reset: Displays last reset date and time
8 Menu Navigation Scroll through the fault list
9 Print Print the fault list
10 Alarm History Alarm History screen
11 Close Exits the Fault Log screen
1 2 3 4
5 6 8 9 10 11
Figure 36 Fault Log Screen

Fault Reset
See Figure 37.
Select Fault Reset to clear the current faults.
NOTE: This only applies to non-self-clearing faults.
Select Fault Log/Fault Status to toggle between the fault log and help
screens.
Select Fault Log to view the history of faults by time and date (highest
priority is displayed).
Figure 37 View Faults Screen

Statistics Screen
Access Preventative Maintenance screen by using the Statistics Screen

button.
The Preventative Maintenance screen shows the pump and gun statistics
for preventative maintenance purposes and allows the counts to be reset.
Table 16 Preventative Maintenance Screen

Description Action
Pump A Strokes Since Last Maintenance Reset
Pump B Strokes Since Last Maintenance Reset
Gun On Cycles Since Last Maintenance Reset
Volume Liters Disp. Since Last Maintenance Reset
Figure 38 Preventative Maintenance Screen

Manual Operations
Click/touch the Manual Operations button to access the Manual Operations

screen. The Manual Operations screen allows the user to perform a few
tasks manually for maintenance purposes.
Table 17 Manual Operations Screen

Open Inlet Valve Maintained Opens the inlet valve
Open Outlet Valve Maintained Opens the outlet valve
Open Inlet Valve Momentary Temporarily opens the inlet valve
Open Outlet Valve Momentary Temporarily opens outlet valve
Jog Actuator Forward Moves the actuator forward
Jog Actuator Reverse Moves the actuator in reverse
Refill Meter Manually refills the meter
CC’s Remaining Variable
Pressure Variable
Purge Volume Variable
Drive Current Variable
Cont. Current Variable
10
11
12
Figure 39 Manual Operations Screen

Data Log
See Figure 40.
The Data Log screen shows a log of parts and segments and statistics for
each procedure performed. If a fault is shown in the Fault Code column,
click/touch fault number to access the Fault Decoder screen.
Scroll through the log by clicking/touching the Last Page, Page Up, and
Page Down buttons.
To access a specific data, click/touch to box under the Go to Data: field and
input the data number.
Figure 40 Data Log Screen

Fault Decoder Screen

See Figure 41.
On the Data Log Screen (see Figure 40), touch/click anywhere in the Fault
Code, 0=No Fault column to access the Fault Decoder Screen.
Input the fault code number from the Process Data Screen to see the faults.
Figure 41 Fault Decoder Screen

Product Manuals
See Figure 42.
The Product Manuals screen shows a list of drawings and manuals for the
system at the time of original equipment shipping. For revisions or updates,
consult emanuals.nordson.com.
Figure 42 Product Manuals Screen

Back
See Figure 43.
The Back button allows the user to go back one page at a time.
Figure 43 Back button

Operation
documentation.
1. Press the “START” button on the controller to power on the system.

2. Access the applicable heating screen (TCU or electric heat/if equipped)
and bring the zones to temperature.
3. Access the pump screen and pressurize the pumps.
4. When the screen indicates that the dispenser is ready, go to the
simulation screen and run a simulation or go to the manual operations
screen and manually purge the system.
Optional Controller Configurations

NOTE: Contact a Nordson representative regarding this data if
necessary.
The PS PLC controller can be configured for use with multiple components.
S TCU
S Pro-Meter S PLC Dispenser
S Vision Sensors
S Robot Interface/Communication Ethernet
NOTE: The PS PLC controller can also be configured for use with the
CP gun. Refer to the Controlled Pressure (CP) Gun manual for
instructions on configuration.
Refer to the following sections for additional data for each configuration.

Part ID Setup Screen

See Figure 44.
The amount of available parts and segments available varies according to

the system configuration. The part ID screen will also vary according to the
system configuration. The Target Volume, Fault Limits and Segment
Volumes (1-30 and 31-60) can be set by selecting the appropriate
button or field.
To change the Target Volume, click/touch the box to the right of the Part ID
and input the desired volume.
Figure 44 Part ID Setup Screen

Limits
Refer to Table 18 and See Figure 45.
Click/touch the change (CHG) button on the Limits column for the desired
Part ID to set the faults for each individual part.
Table 18 Limits Part ID Screen

Major
High Volume Fault (1−99%) Variable Minor
Disabled
Major
Low Volume Fault (1−99%) Variable Minor
Disabled
Major
High Instantaneous Pressure Variable Minor
Disabled
Major
Low Instantaneous Pressure Variable Minor
Disabled
Major
Minor
Low Average Pressure Delta Variable Disabled
Enabled
Disabled

Figure 45 Limits Screen

Segment Volumes
See Figure 46.
Click/touch the change (CHG) button under the Segment Volume (1−30 or
31−60 if available) for each part, then set the individual Segment Volume,
Segment Type, and High Vol %, Low Vol % for each Seg #.
Figure 46 Segment Target Volumes Part ID Screen

Pre−Pressure Setup
See Figure 47.
This screen is used on some configurations and is accessible if the system

is different than the Part ID Screen show in the Operator Interface, Screens
and Setup section.
Click/touch the box to the right of the Part ID and input the desire Setpoint
Pressure.
Figure 47 Pre−Pressure Setup Screen

Pro-Meter S PLC Dispenser
Installation
Configure the Robot Communication

The following steps provide procedures for configuring the robot
communication DeviceNet.
1. Click/touch the Program Screen and then click/touch the Pro−Meter S

Setup button.
2. Set up the Pro−Meter S PLC specifications.
Configure the Robot Controller Analog Signal

See Figure 48.
Configure the robot controller to vary the analog (or tool speed) signal from
0 to 10 Vdc over the full range of robot speed.
1. Determine the highest and lowest robot speeds to be used in

production.
2. Configure the robot controller to produce an analog signal of + 10 Vdc
when the robot is moving at or slightly above maximum speed.
3. Configure the robot controller to produce the analog signal of 0 Vdc
when the robot is stationary.
NOTE: A robot speed of 80% corresponds to 8 Vdc. A robot speed of
40% corresponds to 4 Vdc. This percentage (1) is shown in the lower,
right corner of the Inputs From Robot screen. To access this screen,
click/touch the Test Points button (2) then click the Inputs from Robot
button (3).

1
2
Figure 48 Inputs From Robot Screen
Robot Interface/Communication Ethernet

Refer to the documentation provided with the system to information on the
robot interface and communication Ethernet.

Repair
Repairs consist of replacing the operator interface panel and the PLC parts.

documentation.
Disconnect equipment from line voltage. Failure to observe this warning

may result in equipment damage, personal injury, or death.

Troubleshooting
Problem Possible Cause Corrective Action
1. Meter does not Major fault. Access the View Faults screen to
dispense determine the cause of the fault
condition.
Controller in Manual Mode. Set PS PLC controller to the Auto
mode.
No air to meter solenoids . Check supply air to the gun and refill
meter solenoids. Make sure the
regulator is set to at least 70 psi.
Robot signals not in the proper See the I/O timing chart for proper
sequence. robot I/O sequence.
2. Meter does not refill Low unloader pressure. Confirm that pump has been
pressurized. Check the air pressure
to the bulk unloaders. Make sure
there is enough air pressure to refill
the meter cylinders.
No air to meter solenoids. Check supply air to the gun and refill
meter solenoids. Make sure the
regulator is set to at least 70 psi.
Clogged refill valve(s). Remove the refill valve and either
clean or replace the refill valve
cartridge.
3. Bead deposition Nozzle too high above work piece. Modify robot path to lower the nozzle.
inconsistent
Material speed through nozzle too Increase the bead size setting or
low. robot analog voltage. Refer to
Startup in the Operation section.
Nozzle not large enough. Install a larger nozzle. Contact a
Nordson representative for part
numbers.
4. Unexpected bead size Nozzle partially blocked. Remove nozzle; clean or replace.
change
Material exceeded shelf life. Use fresh material.

Parts
PS PLC Controllers
PS PLC’s without Vision
Part Voltage Pro−Meter Type Temperature Control Notes
1615341 120 Single Electric A, B
1615349 120 Double Electric A, B
1615339 480 Single Ambient
1615343 480 Single Electric A, C
1615345 480 Single TCU
1615347 480 Double Ambient
1615351 480 Double Electric A, C
1615353 480 Triple Ambient
PS PLC’s with Vision
1615340 480 Single Ambient
1615342 120 Single Electric A, B
1615344 480 Single Electric A, C
1615346 480 Single TCU D
1615348 480 Double Ambient
1615350 120 Double Electric A, B
1615352 480 Double Electric A, C
NOTE A: Partial Heat
B: 4 Heat Zones
C: 6 Heat Zones
D: Heat only

See Figure 49 and refer to the following table for available parts and part
numbers.
Figure 49 PS PLC Parts
Item Part Description

1 1614202 INTERFACE, operator, 10-in. color, touch screen, standard
1 1614203 INTERFACE, operator, 10-in. color, brandless, enhanced
1 1614207 INTERFACE, operator, 15-in. color, brandless, enhanced
2 1614198 SWITCH, ethernet, 16-port, unmanaged
2 1514505 SWITCH, ethernet, 8-port, unmanaged
3 1614191 POWER SUPPLY, 90−264 Vac, 24 Vdc out, 240 W
4 1614210 MODULE, CPU, ethernet, 2-port, 600 Kb
4 1614211 MODULE, CPU, ethernet, 2-port, 1 Mb
4 1614212 MODULE, CPU, ethernet, 2-port, 2 Mb
5 1614208 MODULE, input, digital, 16-channel, sink
5 1614213 MODULE, output, digital, 16-channel, source
5 1614215 MODULE, spring−terminal, 18 pin
6 1614217 MODULE, spring-terminal, 4/6−pin
Ordering Parts
Additional parts are application-specific, refer to the system documentation
that shipped with the controller to order additional parts.


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Process Sentryt PLC Controller

Customer Product Manual

For parts and technical support, call the Industrial Coating

NORDSON CORPORATION • AMHERST, OHIO • USA

Part 1615366-01 E 2018 Nordson Corporation

E 2018 Nordson Corporation Part 1615366-01

Part 1615366-01 E 2018 Nordson Corporation

Process Sentryt PLC Controller

Make sure all equipment documentation, including these instructions, is

Some examples of unintended use of equipment include

S using incompatible materials

Regulations and Approvals

E 2018 Nordson Corporation Part 1615366-01

S Do not operate or service equipment unless you are qualified.

If you suffer a fluid injection injury, seek medical care immediately. If

The National Spray Equipment Manufacturers Association has created a

Part 1615366-01 E 2018 Nordson Corporation

WARNING: Any injury caused by high pressure liquid can be serious. If

S Go to an emergency room immediately.

Injection in the skin is a serious traumatic injury. It is important to treat the

Consultation with a plastic surgeon or a reconstructive hand surgeon may

E 2018 Nordson Corporation Part 1615366-01

Fire Safety (contd)

Halogenated Hydrocarbon Solvent Hazards

Part 1615366-01 E 2018 Nordson Corporation

Action in the Event of a Malfunction

E 2018 Nordson Corporation Part 1615366-01

S displays recover procedures if faults are detected,

Table 1 Major Components

Part 1615366-01 E 2018 Nordson Corporation

PS PLC with TCU

PS PLC without TCU

Figure 1 Process Sentry PLC Controller

E 2018 Nordson Corporation Part 1615366-01

Part 1615366-01 E 2018 Nordson Corporation

WARNING: The PS PLC contains electrical connections that can be fatal.

NOTE: Refer to the Optional Controller Configurations section for

1. Unpack the PS PLC controller and inspect it for dents, scratches,

S Hard wire the controller to a dedicated power supply to provide safe

E 2018 Nordson Corporation Part 1615366-01

Operator Interface, Screens and Setup

See Figure 2 and refer to Table 2.

NOTE: Refer to the Optional Controller Configurations section for

Select the screen to choose one of the main menus.

Table 2 System Status Screen

Part 1615366-01 E 2018 Nordson Corporation

Figure 2 System Status Screen

E 2018 Nordson Corporation Part 1615366-01

Use the User Login to:

Figure 3 User Login Screen

Part 1615366-01 E 2018 Nordson Corporation

Table 3 Test Points Screen

Figure 4 Test Point Screens (1 of 6)

E 2018 Nordson Corporation Part 1615366-01

Figure 5 Test Point Screen (2 of 6)

Figure 6 Test Point Screen (3 of 6)

Part 1615366-01 E 2018 Nordson Corporation

Figure 7 Test Point Screen (4 of 6)

Figure 8 Test Point Screen (5 of 6)