ITW Dynatec DPC2 Operation manual

ITW Dynatec
An Illinois T ool Works C ompan
y
31 Volunteer Drive
Hendersonville, TN 37075 USA
Telephone [phone]
FAX [phone]
www.itwdynatec.com
OPERATIONS MANUAL
Manual#50-06
Rev.12.18
Adhesive A
pp
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.