ITW Dynatec DPC2 Manuale operativo

ITW Dynatec

An Illinois T ool Works C ompan

31 Volunteer Drive

Hendersonville, TN 37075 USA

Telephone 1.615.824.3634

FAX 615.264.5222

www.itwdynatec.com

OPERATIONS MANUAL

Manual#50-06

Rev.12.18

Adhesive A

lication Solutions ISO 9001 Certified

IMPORTANT ! - READ ALL INSTRUCTIONS BEFORE OPERATING THIS EQUIPMENT

It is the customer's responsibility to have all operators and service personnel read and understand

this information. Contact your ITW Dynatec customer service representative for additional copies.

NOTICE! Please be sure to include the serial number of your application system

each timeyou order replacement partsand/or supplies. Thiswill enableusto

send you the correct items that you need.

ITW Dynatec Service Parts Direct Dial: 1-800-538-9540

ITW Dynatec Technical Service Direct Dial: 1-800-654-6711

DPC2 DISTANCE-BASED PATTERN CONTROLLER

KIT OPERATIONS AND SERVICE MANUAL

PN 106593: 115V PN 106594: 230V

Page ii

Revised 7/99 c. 1999

DPC-2 TIMER Manual 50-06

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

ITW Dynatec c. 1999 Page iii

DPC-2 TIMER Manual #50-06 Revised 7/99

TABLE OF CONTENTS

CHAPTER 1:DESCRIPTION

General Description...................................................................................................................................... 1-1

Specifications................................................................................................................................................ 1-2

How to Use this Manual................................................................................................................................ 1-2

CHAPTER 2: INSTALLATION

Unpacking..................................................................................................................................................... 2-1

Supplied Equipment...................................................................................................................................... 2-2

Optional Accessories..................................................................................................................................... 2-3

Changing AC Input Voltage.......................................................................................................................... 2-4

Dimensions ................................................................................................................................................... 2-6

Locating the DPC-2 for Installation.............................................................................................................. 2-6

Installing the DPC-2 and Accessories........................................................................................................... 2-7

230VAC Power Cord Wiring........................................................................................................................ 2-8

Receptacle Assignments................................................................................................................................ 2-9

Important Notes ............................................................................................................................................ 2-10

Pressure Transducer Wiring Info.................................................................................................................. 2-11

CHAPTER 3: OPERATION AND PROGRAMMING

Start-Up Procedure ....................................................................................................................................... 3-1

Programming Conventions............................................................................................................................ 3-2

System Status Lights..................................................................................................................................... 3-3

Drive 1 & Drive 2 ..................................................................................................................................... 3-3

A.T.S. .................................................................................................................................................. 3-3

Trigger .................................................................................................................................................. 3-4

Speed Display............................................................................................................................................... 3-4

Programming SYSTEM Parameters ............................................................................................................. 3-4

Purge .................................................................................................................................................. 3-4

Trig Mode ................................................................................................................................................. 3-5

Lockout .................................................................................................................................................. 3-6

Pre-Delay.................................................................................................................................................. 3-7

Servo Mode............................................................................................................................................... 3-7

Constants .................................................................................................................................................. 3-8

Selecting a Program from MEMORY........................................................................................................... 3-10

Programming Glue Pattern (CHANNEL) Parameters................................................................................... 3-10

Event .................................................................................................................................................. 3-11

Delay .................................................................................................................................................. 3-11

Leading Edge Detection............................................................................................................................ 3-12

Trailing Edge Detection............................................................................................................................ 3-13

Line .................................................................................................................................................. 3-13

Gap .................................................................................................................................................. 3-13

Stitch .................................................................................................................................................. 3-14

Spike Time................................................................................................................................................. 3-15

Compensation ........................................................................................................................................... 3-16

Clearing Programmed Information ............................................................................................................... 3-18

CHAPTER 4: EXAMPLES

Purge CHANNEL 1 and CHANNEL 2......................................................................................................... 4-1

A Single EVENT Glue Pattern ..................................................................................................................... 4-2

A Multiple EVENT Glue Pattern.................................................................................................................. 4-4

Page iv ITW Dynatec c. 1999

Revised 5/09 DPC-2 TIMER Manual #50-06

CHAPTER 5: TROUBLESHOOTING

Controller Glues Every Other Sheet..............................................................................................................5-1

Glue Pattern Continually Advances or Retards.............................................................................................5-1

Glue Pattern "Jumps Around".......................................................................................................................5-2

Glue Applicators Will Not Activate..............................................................................................................5-2

DRIVE or A.T.S. Status LED is Illuminated Red.........................................................................................5-4

Program Parameters Can Not Be Modified...................................................................................................5-4

SYSTEM Parameters Can Not Be Accessed.................................................................................................5-5

Glue Pattern Repeats Itself on the Product....................................................................................................5-5

First Potion of Glue Pattern Is Cut-Off (Not Applied)..................................................................................5-5

CHAPTER 6: INSTALLATION & MAINTENANCE

Replacement Parts.........................................................................................................................................6-1

Typical System Diagrams..............................................................................................................................6-1

Electrical Schematics.....................................................................................................................................6-3

Component Illustration: Hot Melt Gear Pump System..................................................................................6-4

Bill of Materials: Hot MeltGear Pump System .............................................................................................6-5

Component Illustration: Hot Melt Piston Pump Overview ...........................................................................6-6

Bill of Materials: Hot Melt Piston Pump Overview......................................................................................6-7

ITW Dynatec c. 1999 Page 1 - 1

DPC-2 CONTROL KIT Manual #50-06 Revised 8/04

Chapter 1

DESCRIPTION

Description

The ITW Dynatec DPC-2 Distance-based Pattern Control unit is a microprocessor-based

electronic control system. It may be used in any process that requires the actuation of

electrical output devices based upon distance traveled. It is specifically designed to

control glue application valves used in adhesive systems. Examples of applications where

the DPC-2 may be used include, but are not limited to, case sealing, labeling, and bag

making.

The DPC-2 can be operated on either 120v or 240v AC, single-phase power. A set of

contacts is provided to allow a signal to be sent to an external controller (such as a PLC)

when the DPC-2 is switched on.

All controls and displays are mounted inside a rugged enclosure with a protective door.

The enclosure meets environmental ratings of IP54, protecting against water and solid

object infiltration when the door is latched and all output/input receptacles at the bottom

of the DPC-2 Control Unit are either connected to cables or capped. The display is a

bright, seven-segment LED device that affords easy viewing at any angle and in any

lighting environment. All connectors are standardized to simplify installation.

The DPC-2 Control Unit has non-volatile memory for up to four programs. Each program

has two CHANNEL outputs. Each CHANNEL is independent of the other and has four

programmable EVENTS. An EVENT is defined as a DELAY (no glue) and a LINE

(glue). Each LINE may be programmed to apply continuous glue or apply in a STITCH

(series of dashes) or SPOT (series of dots) pattern.

Programming is accomplished by depressing the appropriate CHANNEL or SYSTEM

button until the desired parameter LED is illuminated on the left side of the display panel.

Depressing the DIGIT button causes the values on the display to flash. Rotating the

VALUE knob modifies the displayed value. Depressing the RUN/STOP button so the

LED is illuminated signifies the glue system is active and will respond to trigger inputs.

Activity of the DRIVE 1, DRIVE 2 and A.T.S. (Automatic Tip Sealer) outputs and the

TRIGGER input is indicated in the top right corner of the display via illumination of the

respective LED’s.

Facilities for a remote PURGE device (supplied standard with the system) and Automatic

Tip Sealers (optional equipment used in cold glue systems) offer the operator ease of glue

system maintenance during times of system inactivity. The Automatic Tip Sealer (A.T.S.)

Drive output is provided for use with cold glue systems that may employ tip sealing

devices to prevent the glue from drying in the applicator nozzle during periods of glue

system inactivity.

Pattern initiation may be set for either of two trigger modes: Single or Repeat. See

Chapter 2 (Operation and Programming) for further information concerning TRIGGER

MODE.

Page 1 - 2 ITW Dynatec c. 1999

Revised 8/04 DPC-2 CONTROL KIT Manual #50-06

The DPC-2 requires an encoder (speed) and sensor (trigger) input to function properly.

The trigger input senses the product to be glued and initiates a countdown within the

Control Unit based upon the programmed pattern. The encoder tracks the machine speed

assuring consistent glue pattern length as machine speed varies. A Servo output is also

available that provides the necessary signals to automatically adjust adhesive output

pressure as speed varies. This helps to ensure consistent glue volume as machine speed is

modified.

A key-actuated system lock is provided on the Controller’s front panel. This lock prevents

any unauthorized change to the programming when activated.

Specifications

Operating Temperature: 32 to 113 degrees F (0 to 45 degrees C), 0 to 90% RH, non-condensing

Storage Temperature: -14 to 140 degrees F (-10 to 60 degees C), 0 to 90% RH, non-condensing

Maximum Switching Rate: 500 cycles per second

Number Channels (Drives): 2 independently controlled

Program Storage Capacity: 4

Number Events per Program 4 (4 delays and 4 glues)

Maximum Power Output: 26 Watts, current limited at 1.25 amps per channel

Applicator Overload Protection: Electronic Sensing

Maximum Speed: 1,500 fpm

Number Encoder Inputs: 1

Encoder Scaling: 100 pulses per inch

Number Trigger Inputs: 1

Minimum Trigger Duration: 1ms

Servo Output: 0 to 10 VDC, 0 to 20 mA, or 4 to 20 mA (operator selectable)

Holding Voltage: 16 VDC

Over-Voltage: 48 VDC

Over-Voltage Duration: 0 to 25.5ms, operator selectable

Input Voltage: 115 or 230 VAC ±10%, single phase

Input Power: 60 Watts

Power-on Contact Rating: 10A resistive, 7.5A inductive @ 250 VAC

How to Use this Manual

The following typographic conventions are used throughout this manual:

ALL CAPITALS: Parameter, Button and Knob titles displayed on the DPC-2 Control

Unit Display Panel

Bold: Information found on the DPC-2 Control Unit’s LED Display

ITW Dynatec c. 1999 Page 2 - 1

DPC-2 CONTROL KIT Manual #50-06 Revised 1/02

Chapter 2

INSTALLATION

The ITW Dynatec DPC-2 Control Unit is very easy to install and operate. It is highly

recommended, however, that the entire contents of this manual be read before installation

to become familiar with the many features of this equipment and to avoid potential safety

hazards.

WARNING: Line voltage is present at several places inside this Control Unit

when it is connected to an AC power source. Electrical shock will result if

contact is made with line voltage. This shock may be extremely hazardous. Do

not disassemble or assemble this unit or make electrical connections unless

all line voltage sources are removed.

Unpacking

Carefully unpack and inspect the DPC-2 enclosure for external damage. The Control Unit

is shipped completely assembled. There should be no rattles or loose pieces inside the

unit

Page 2 - 2 ITW Dynatec c. 1999

Revised 4/10 DPC-2 CONTROL KIT Manual #50-06

Supplied Equipment

The DPC-2 Control Kit is supplied with the following equipment. Please inventory these

parts immediately upon unpacking the Control Kit to assure all items are present.

Qty Description Part Number

1 Control Unit, DPC-2 106591

1 Purge Control 106078

1 Output Kit (contains two 10 foot drive output cables,

one end with connector, the other end unterminated) L21754

1 set Security Lock Switch with 2 keys 107189

3 Sealing Cap, 9-pin Receptacle (attached to ATS,

SERVO and DRIVE 2 output connectors) 106023

1 Manual, DPC-2 (the manual you are currently

reading) 50-06

Security Lock Keys

Output

Cables

Purge Control

DPC-2 Control Unit

ITW Dynatec c. 1999 Page 2 - 3

DPC-2 CONTROL KIT Manual #50-06 Revised 5/09

Optional Accessories

The following accessories are available from ITW Dynatec for use with the DPC-2

Control Kit:

Description Part Number

Mini Reflective Photo Sensor Assembly, 2ms Response (6’ cord) L21746

Reflective Photo Sensor Assembly, 1ms Response (6’ cord) L21701

Fiber Optic Photo Sensor Assembly (6’ cord) L21745

Foot Switch Assembly (10’ cord) 106114

Trigger/Encoder Extension Cable, 10’ (may be used with any of the above

photo sensors, foot switch or encoder assembly) L21747

Encoder Assembly, 1200 PPR 109076

Encoder/ Wheel/ Bracket Assembly, includes 15’ cable 112433

Encoder/ Wheel/ Bracket Assembly with machine mount bracketry 112435

Adhesive Supply Control Cable (used with “S” and “M” series ASU’s or

other melt units that have built in isolation of the 0 to 10 VDC signal and

with Pressure Transducer Assembly, 105754).

106609

0 to 10 Volt Adhesive Supply Control Kit (includes a signal isolator board

and 10’ cable). Used with hot melt units that do not possess an isolated 0 to

10 volt control circuit (Dynatec ASU’s that pre-date the “S” and “M” series).

L21749

Pressure Transducer Assembly, used for control of fluid regulator in cold

glue systems or as input to hot melt piston-pump systems. PN 106609 must

also be ordered.

105754

Sealing Cap, 4-Pin Receptacle (seals unused 4-pin connectors for IP54

integrity) 106116

Sealing Cap, 9-Pin Receptacle (seals unused 9-pin connectors for IP54

integrity) 106023

Single Head Cord, 10’ (allows connection of a single applicator to a drive

output, used primarily with cold glue applicators) 106006

Solenoid Cord, RCA(M)/Unterminated, 10’ (used with 106006) 340-010-XA

Solenoid Cord, RCA(M)/RCA(F), 10’ (used with 106006) 340-010-AA

Page 2 - 4 ITW Dynatec c. 1999

Revised 8/04 DPC-2 CONTROL KIT Manual #50-06

Changing AC Input Voltage

WARNING: Changing the operating voltage requires access to the DPC-2

Control Unit’s internal power supply. Only qualified maintenance technicians

should attempt this procedure.

The DPC-2 Control Unit is capable of operating from 115VAC or 230VAC input

voltage. Your unit has been factory pre-set to one of these voltages. There should be a

sticker attached to the lower left corner of Control’s front panel, just above the power

switch, identifying the factory-set voltage.

WARNING: Disconnect the DPC-2 from its power source before attempting this

procedure.

The steps itemized on the next page should be followed to change the Control Unit’s

operating voltage from the factory pre-set value.

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