ITW Dynatec DY 2008 User manual

DY 2008
Pattern Controller
CONTROLLER
Operating Manual
2008 D.BOO 11/02
ITW Dynatec
An Illinois Tool Works Company
31 Volunteer Drive
Hendersonville, TN 37075 USA
Telephone [phone]
FAX [phone]
[e-mail]
www.itwdynatec.com
ITW Dynatec K.K.
Daiwashinagawa Bldg., 7-15 Konan, 3-Chome
Minata-Ku, Tokyo 108 Japan
Telephone [phone]
FAX [phone]
[e-mail]
ITW Dynatec
Industriestraße 28
40822 Mettmann, Germany
Tel.: [phone]
FAX: [phone] / 915 111
[e-mail]
Manual #50-14
Rev.11/15
For an online copy of this manual, go to www.itwdynatec.com/manuals.htm

Manual #50-14 Revised 3/05
C. 2002 I
1: Safety Instructions 1 - 1...........................................
About this Manual 1 - 1...........................................................
Proper Use of System 1 - 1........................................................
Manual Symbols 1 - 1............................................................
Authorized Use of System 1 - 1....................................................
Installation, Maintenance, Repair or Disposal of the System 1 - 1.......................
Modification to the System 1 - 2....................................................
Working with Cover Open 1 - 2....................................................
2: Product Description 2 - 1..........................................
General 2-1....................................................................
Technical Data 2-2..............................................................
Dimensions (Basic version) 2 - 4...................................................
Operating and Connecting Elements (Basic version) 2 - 4.............................
3: Installation 3 - 1..................................................
Connectors and Pin Definitions 3 - 1................................................
Connecting the System 3 - 2......................................................
Locating an Optical Trigger (Sensor) 3 - 2...........................................
Connecting Optional Accessories 3 - 3..............................................
4: Operating 4 - 1...................................................
Operator’s Panel 4 - 1............................................................
Remote Purge Control 4 - 2.......................................................
Service Settings Menus 4 - 3......................................................
Production Setup Menu 4 - 4......................................................
Power On and Software Version 4 - 5...............................................
Service Settings 4-6.............................................................
Service Settings Menu 1 of 3 Overview 4 - 6..............................................
Service Settings Menu 2 of 3 Overview 4 - 8..............................................
Service Settings Menu 3 of 3 Overview 4 - 9..............................................
Factory Defaults 4-9..................................................................
Service Setting Programming Conventions 4 - 11.....................................
Display Contrast Adjustments 4 - 11.................................................
Service Settings Menu 1 4 - 12.....................................................
Select Language 4-12..................................................................
Load Program 4-13....................................................................
Trigger Assignment 4-14................................................................
Trigger Lock 4-15......................................................................
Encoder--Channel Assignment 4 - 15......................................................
Encoder Scaling (Encoder Type and Unit) 4 - 17............................................
Min/Max Speed Configuration 4 - 18.......................................................
Channel Mode Adjustment 4 - 19.........................................................
Change Security Lock 4 - 22.............................................................
Change Access Code 4 - 22.............................................................
Service Settings Menu 2 4 - 23.....................................................
Trigger Setup 4-23.....................................................................
Pressure Signaling 4-24................................................................
Pressure Assignment 4-25..............................................................
Pressure Curve Configuration 4 - 25.......................................................

Manual #50-14 Revised 1/09
C. 2002
II
Spike Voltage Adjustment 4 - 27..........................................................
Spike Duration Adjustment 4 - 28.........................................................
Shutter Assignment 4-29...............................................................
Shutter Dwell Timing Adjustment 4 - 30....................................................
Change Security Lock 4 - 31.............................................................
Change Access Code 4 - 31.............................................................
Service Settings Menu 3 4 - 32.....................................................
STOP Configuration 4-32...............................................................
PC--Communication (Option) 4 - 33.......................................................
Change Profibus Address (Option) 4 - 33..................................................
Shutter Trigger Setup 4-34..............................................................
Digital Configuration 4-35...............................................................
Load Factory Defaults 4 - 37.............................................................
Change Security Lock 4 - 39.............................................................
Change Access Code 4 - 39.............................................................
Production Setup 4 - 40............................................................
Stop Function 4-41....................................................................
Glue Pattern Setup 4-42................................................................
Copy/ Paste Function 4-44..............................................................
Pressure Adjustment 4 - 45.........................................................
Adjust Minimum Pressure (2--Point Curve) 4 - 45............................................
Adjust Maximum Pressure (2--Point Curve) 4 - 45...........................................
Adjust Purge Pressure (2--Point Curve) 4 - 46..............................................
Assigning the Pressure Points to the Machine Speed (12--Point Curve) 4 - 46...................
Adjust Purge Pressure (12--Point Curve) 4 - 47.............................................
System Menus: Dot Function, Stitching and Head Position 4 - 48........................
Dot Configuration 4-48.................................................................
Stitching Configuration 4 - 50.............................................................
Offset (Head Position) 4 - 52.............................................................
Speed Compensation Adjustment 4 - 54.............................................
Manual Gluing (Purge) 4 - 55......................................................
5: Troubleshooting 5 - 1.............................................
Error Messages of the DY 2008 5 - 1...............................................
Communication Error 5-1..............................................................
Over Current Failure 5-1...............................................................
Compensation Error 5-1...............................................................
Appendix A
Common Accessories App. A 1........................................................
Appendix B
Printed Circuit Boards and Wiring Information App. B 1...................................
Appendix C
Programming Log App. C 1...........................................................

Manual #50-14 Revised 1/03
1-1
C. 1998
Safety Instructions
Authorized Use of System
Only authorized persons who have read and understood the instruction manual or who
have been trained by ITW Dynatec may install, operate or dispose off this system.
Appropriate electrical safety procedures must be observed.
A copy of this manual should be kept with the installed system as reference material.
Proper Use of the System
This controller is designed for use only with ITW Dynatec hot melt or cold glue systems.
Other applications should be attempted only after consulting with ITW Dynatec.
Manual Symbols
Caution
This symbol means that failure to observe the specific instructions could
cause damage to the equipment.
Danger! High Voltage!
This symbol means there is a danger of electrical hazard.
Note! Provides useful information regarding the use of the system.

Manual #50-14 Revised 1/03
Safety Instructions
1-2 C. 1998
Modifications to the System
No modification can be made to the system without consulting ITW Dynatec. Use only
factory--recommended parts and fittings. ITW Dynatec does not assume any resonsibility
for damage which occurs as a result of using parts that are not factory recommended.
Working with the Cover Open
Never operate this controller with open cover. There are no servicable components inside.
All settings are done via Software.
Inside the controller are electric current--carrying components. To avoid personal injury, do
not touch them while input power is ON. Disconnect and lockout main power before opening
the cover. Then wait a few seconds until all electrical components have discharged.

Manual #50-14 Revised 1/03
2-1
C. 2002
Product Description
General
The DY 2008 Pattern Controller is one component of an adhesive application system
consisting of a hot-melt unit, cold glue pressure vessel or cold glue pump, adhesive hoses
and applicator heads. The controller can be used for hot--melt or cold glue application.
The pattern controller activates solenoids for four (Basic Version) up to 128 (Option)
applicator heads in order to create individual adhesive patterns. It is possible to program
up to 16 independent glue events (16 glue + 16 delay) per channel.
Each channel can operate in one of the possible modes: glue beads, dots, continuous
gluing, random product length and stitching.
Gluing can be triggered with a photo eye, proximity switch or by exceeding a certain
machine speed.
Every channel may be assigned to its own trigger input, if desired, to increase the accuracy
of multiple parallel running products.
In order to accelerate the timing of solenoids it is possible to apply initially a higher voltage
(Over--excitation). The voltage level and the duration time of this over--excitation is
programmable via software on a channel-by-channel basis. This enables applications for
hot--melt and cold glue.
The speed of the production machine will be registered with up to four encoders and
indicated on the display. It can be used to control the speed of one or more gear pumps of
adhesive supply units or to control the glue pressure on a cold glue system via I/P or U/P
transducers. Every time the machine speed varies the glue pressure will follow.
Working with four encoders enables application on machines with different speeds e.g.
Right--Angle machine.
The pressure vs. speed ramp can be linear or for better adaptation to production conditions
a 12--point curve is programmable.
A machine contact is available to enable or disable the controller. With this contact it is
possible to start and stop the gluing together with the parent machine.
The user can select whether the gluing stops immediately or continues.
The controller can provide an output signal to close a shutter devise (automatic tip sealer)
in order to prevent clogging of cold glue applicators from drying during production breaks.
If necessary this shutter output can be activated with a dedicated trigger input.
Alternatively the programming of the glue pattern can be done on a computer and
corresponding software. An optional RS232/485 or Profibus interface can be used to
communicate with the pattern controller from an external device.
Critical conditions can be signalled by means of two alarm outputs.

Manual 50-14 Revised 11/15
Product Description
2-2 C. 2002
Technical Data
General
Operating Temperature 0°Cto+50°C(32°F to122 °F)
Storage Temperature -- 1 0 °Cto50°C(32°F to122 °F)
Power Supply 1/N/PE 230 V 50--60 Hz
1/N/PE 115 V 50--60 Hz
1/N/PE 200 V 50--60 Hz
Power Consumption 180w (8 channel version)
Operating Languages German, English, Finnish, French, Italian
Number of Programs 60 stored in permanent memory
Protection Class IP 40
(Option IP 54)
CE Approval Granted yes
Trigger
Input connectors 24 V DC, max. 100 mA, NPN, PNP, Push--Pull
Max. Number 4 Master Triggers (Triggers #1 thru 4)
1 additional per channel (Channel #5 and above)
Assignment (every channel can be assigned to a Master
Trigger or its Channel Trigger and any trigger may be “Anded”
to a Master Trigger)
Every Trigger can be assigned to each of the channel
Via AND--Function multiple Triggers can be combined.
Trigger Lock 0--8000 mm (0.01 to 80.00 in)
Encoder
Max. Number 4
Input connectors X17 and X18 24 V DC, max. 100 mA, NPN (scalable)
Assignment Any encoder can be assigned to any channel.
Configuration Metric or inch
Scaling 1--4000 pulse/m
0.01--99.99 pulse/inch
Indication of Production Machine Speed max. 1200 m/min (2000 pulses/m)
4000 ft/min (50 pulses/inch)
Speed Configuration
Start Gluing above (Vmin START)0--999 m/min
0--999 ft/min
Stop Gluing below (V min STOP)0--999 m/min
0--999 ft/min
Maximum Machine Speed (V max) 0--1200 m/min
0--4000 ft/min
Output (Valve Output)
Channel X1 to X4 (Basic Version) for Controlling of Solenoids Valves (Short circuit proof)
Max. Number 4 (Option max. 128)
Output Voltage Nominal: 24 V DC
Overexcitation:
55 V (Factory Default) or 170 V
all Channels are individually adjustable
Overexcitation Timing 0.5--2.5 ms adjustable per software in steps of 0.5 ms
Wattage Capacity per Channel max. 20 W
Total Wattage Capacity for Channels 1--8 max. 160 W
Speed Compensation 0--999 mm
9.99 inch