AMCOL 3500-ETC User manual

AMCOL CORPORATION
3500-ETC ELECTRONIC
TIMING CONTROLLER
Operator’s Manual

3500-ETC Operator’s Manual
Page | 1
Contents
1 Introduction ............................................................................................................... 2
2 Included Components ............................................................................................. 3
3 Assembly and Installation......................................................................................... 4
PRIOR TO GETTING STARTED ...................................................................................... 4
Installation .................................................................................................................. 4
4 Recommended Settings .......................................................................................... 6
5 Operation .................................................................................................................. 7
6 System Troubleshooting and Maintenance ........................................................... 9
7 Schematics .............................................................................................................. 10
AMCOL Corporation
21435 Dequindre, Hazel Park, MI 48030
248-414-5700
fax: [phone]
www.amcolcorp.com
File ID: 3500ETC-OM01
Approved for Use
LSB: AA-0025
LSD: 1/04/2022
FDR: PS04

3500-ETC Operator’s Manual
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1 Introduction
The AMCOL 3500E Electrostatic
Powder Application System is
designed to automatically
lubricate aluminum billets using
410 BNP EJECTEZE with press
guard and other safety
equipment actively in place.
Burns, physical demands, and
other more serious injuries can
occur with manual lubrication.
This design is universal as it can
fit most billet loading conveyors
(horizontal, vertical, and
overhead). This system is
traditionally timed and
actuated through the press PLC
and runs in harmony with the
production process.
In many situations, electronic control of the 3500 requires modifying the
programming of the press PLC and wiring in multiple connections to correctly
control the system. This can be both challenging and inefficient to do for each
system. To solve this problem, AMCOL has created a simple package to
effectively control a 3500E system with a single PLC output. If used properly, the
3500-ETC will allow for consistent, repeatable coatings with settings that can be
easily seen and changed where necessary.

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2 Included Components
Each 3500-ETC comes standard with the following components:
1. Preprogrammed Allen Bradley PLC
2. 6’ grounded power cord with plug
3. Open cable gland to insert the machine PLC control output
4. NEMA 12/13 sealed steel electrical enclosure
5. Solenoid cap prewired for quick connection to MAC 100 Series valves
6. Cable prewired for connection to EPG SPRINT Controller
7. Open cable gland for connection to VS-550 Dust Collector

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3 Assembly and Installation
PRIOR TO GETTING STARTED
•WARNING! AMCOL 3500-ETC systems are only designed to function with correctly
installed and grounded 3500E Powder Coating Systems. For installation instructions for
3500E Systems, see the AMCOL 3500E Electrostatic Powder Dispensing System Operator’s
Manual.
•WARNING! These systems operate using 110VAC and 24VDC. Do not touch any bare or
exposed wires or terminals without confirming the system is not powered.
•WARNING! Wear safety glasses at all times.
•WARNING! Unplug the system during any assembly, disassembly, and related repairs.
•WARNING! To protect the electronics from dust and other particles in the air, tighten all
cable glands, and do not leave the enclosure door open during normal operation.
Installation
1. Review the system to see that no obvious damage has occurred in
shipment.
2. See that all components are included and appropriate for your piece of
equipment.
3. Ensure the system is located near a 110VAC outlet for power.
4. Mount the system controls in a well-protected area, which can be easily
accessed by operations and maintenance personnel.
5. Attach prewired solenoid cap to existing solenoid connection.
6. Attach prewired control cable to the “remote” socket (#11) on the EPG
SPRINT controller.

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7. Optionally, replace the “on” button (PB1) of a Donaldson Torit VS-550 dust
collector with a cable connection to output 02 on the PLC.
8. Connect control signal wire from PLC or machine to ETC at input 0
through open cable gland. A terminal for a common connection is also
available if necessary. See wiring diagram for details.
9. Ensure the 3500E system is installed correctly and is ready to operate.
10. Operate the ETC manually, observing that the ETC and 3500E system
function correctly together. Note that holding the manual button will
cycle the system as long as it is held.
11. Adjust system settings where necessary.
12. Under careful observation, operate system in production environment.

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4 Recommended Settings
Item ID
Description
Recommended Setting
A
Control Input
Energize to initiate spray cycle, de-energize before
the spray cycle ends
B
Fluidizing Air
Valve
Set to at least 1 second
C
Spray Time
Set according to billet size (start at 0.5s, increase
for larger billets)
D
Collector
Set to at least 1 second
Power In
B
Fluidizing Air Valve
EPG SPRINT
Controller
A
C
D
VS-550 Dust
Collector

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5 Operation
System Spray Cycle
When the PLC or machine output is on (A), the ETC will
perform a cycle of the 3500E automatically. The Fluidizing Air
Valve will open at the start of the cycle and remain on for
the set time (B), and the spray gun will fire for the set time
(C) while the Fluidizing Air Valve is on. The dust collector will
turn on at the start of the spray cycle and continue for a
set time (D) after spraying.
While running automatically, the system should cycle as described above, and
the spray volume and pattern should be consistent. See the 3500E Operator’s
Manual for troubleshooting spray output issues.
Modifying System Cycle Settings
•Observe the current settings on the LCD screen located
inside the ETC enclosure.
•Press the right button on the PLC to move between
individual settings screens.
•Once screen with the setting that needs to be changed
is reached, press the up button to increase the time and
the down button to decrease the time.
•Minimum timings are as follows:
oFluidizing Air – 0.5s (0.1s increments)
oSpray On – 0.5s (0.1s increments)
oCollector – 1.0s (1s increments)

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Manual Actuation
To manually test the system to observe spray output,
perform the following:
•Confirm settings are correct.
•Press the left button on the PLC inside the ETC
enclosure. The system status will display manual
and perform one spray cycle. Holding the
button will perform multiple cycles until the
button is released.
Manual operation should be used to verify current settings, test spray coating,
and troubleshoot errors.

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6 System Troubleshooting and Maintenance
For troubleshooting issues related to 3500E, see the 3500E Operator’s Manual
Check in order as listed
System is not powering on
•Check if system is plugged in.
•Check if power cord wires are loose or unsecured in the terminals.
•Check if power outlet or lead is functioning correctly.
System is not activating solenoids or spray gun
•Check connections from PLC and to the terminals. See wiring diagrams for
correct connections if necessary.
•Check connections to solenoid caps or EPG SPRINT connector.
•If the lights inside the solenoid caps are functioning, check the
connection between the cap and solenoid on the 3500E.
LCD screen not displaying correct window
This error can occur from pressing the OK and ESC buttons at the same time
•Press any button on the PLC inside the ETC.
•Turn the ETC off and on.
Recommended Spares
Description
Part Number
Quantity
Lighted cap for solenoid 24VDC
110VAC
E-01013-61
1
E-01013-11
Cable gland
69915K54
1

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7 Schematics
3500-ETC-110
3500-ETC-24

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AMCOL Corporation
21435 Dequindre, Hazel Park, MI 48030
248-414-5700
fax: [phone]
www.amcolcorp.com