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

Manual #50-14 Revised 11/14 Product Description
2-3
C. 2002
Valve Mode
Standard Mode Glue pattern, with or without stitching, is initiated by a trigger
signal. Gluing at speeds between Vmin and Vmax
Standard with Dot-Mode Glue pattern, with or without stitching, is initiated by a trigger
signal. Gluing at speeds between V-min START and V-min STOP
is Dot Mode. Gluing at speeds above V-min STOP is Standard
Mode.
Dot Mode Dot- Mode between Vmin and Vmax
Random Product Length Automatic adjustment of the pattern length to different product
length. Start and Stop of the pattern is controlled with a trigger
signal. Pattern can be stitched or continuous.
Continuous Gluing with Trigger Continuous gluing controlled with a trigger signal (i.e. glue active
when trigger active). Gluing starts above 1 m/min or 1 ft/min
Continuous with Trigger and Low Speed Cut Off Continuous gluing controlled with a trigger signal (i.e. glue active
when trigger active).Gluing starts when machine speed between
Vmin and Vmax
Continuous Gluing with Low Speed Continuous gluing starts at machine speed between Vmin and
Vmax, no trigger input is required
Glue Pattern
Maximum selectable Pattern and Delay Length 0- 8000 mm in steps of 1 mm
0- 80.00 inch in steps of 0.01 inch
Stitching: Glue Bead and Break Length 1- 200 mm in steps of 1 mm
0.01- 2.00 inch in steps of 0.01 inch
Dot Mode Breaks:
1- 8000 mm in steps of 1 mm
0.01- 9.99 inch in steps of 0.01 inch
Dot Length:
0.10- 9.90 ms
Pressure Control Output
Max. Number 4
Connectors X24 to X27 4- 20 mA or 0- 20 mA and 0- 10 V scalable
Assignment Each Pressure Control Output can be assigned to any Encoder
Pressure Range min/max-Limits 0 to 100 %
Pressure Control Mode 2- or 12- Point Curve
Shutter Control
Output Connector X23 24V DC, max. 2 A
Trigger Input X20 Controlled by dedicated input or one of the Master Triggers
Machine contact, Alarm outputs and Interfaces
Machine contact X19 NPN, normally open contact required
Ready- /Alarm output connector X21 Normally open / normally closed, potential- free 24V DC, max. 500
mA or 230V AC, max. 500 mA,
RS232/485 Interface Connector X30 Option
Profibus Connector X28, X29 Option

Manual 50-14 Revised 7/03
Product Description
2-4 C. 2002
Dimensions (Basic Version, 4 or 8 Channels)
326mm (13”) 345 mm (14”)
150mm (6”)
F1 F2 F3 F4
DY 2008
Kanal 1:
Kanal 2:
Kanal 3:
Kanal 4:
Kanal 5:
Kanal 6:
Kanal 7:
Kanal 8:
MUSTER DRUCK SYSTEM KOMPENSAT.
0 m/min
Druck1: 0%
Druck2: 0% Druck3: 0% Druck4: 0% Programm.: 1
241.3mm (9.5”) 279.4mm (11”)
Operating and Connecting Elements (Basic Version)
Operating Panel
Connectors
Main Switch
Power Inlet

Manual #50-14 Revised 1/03
3--1
C. 1998
Installation
Caution!
Only authorized person should execute the following procedures. Observe
all applicable safety rules.
Danger!
Place this controller in a dry and dust-free environment and not in the
danger zone of other machines. The operating elements must be accesable
without hazards.
Connectors and Contact Definitions
6
X31
REMOTE
Connector Function Contact Definition
1234567
X1--X8 Output for Solenoids 1 to 8 +-- Shield
X9--X16 Trigger 1 to 8 GND +24 V Signal
NPN/PNP
X17 Encoder 1 and 3 GND +24 V Encoder 1 Encoder 3
X18 Encoder 2 and 4 GND +24 V Encoder 2 Encoder 4
X19 Machine contact GND Signal
NPN
X20 Trigger for Shutter Control GND +24 V Signal
NPN/PNP
X21 Alarm/ Zero Speed N.O. Common N.C.
X21 Stop/ System Ready N.O. Common N.C.
X22 Not Used
X23 Shutter Output +-- Shield
X24--X27 Pressure Control Output GND 0(4)-20mA 0-10 V +24 V
X28 Profi--Bus Connector Male Bus A Bus B Shield
X29 Profi--Bus Connector
Female 5VDC Bus A GND Bus B Shield
X30 PC--Interface RS 232
or RS 485
TXD (232)
B (485)
RXD
(232) GND A (485)
X31 Remote Control RS 485 only for ITW Dynatec Remote Control

(1)
Manual #50-14 Revised 8/2008
Installation
3--2 C. 2002
Connecting the System
Caution!
The over-excitation (spike) voltage for the outputs is shut off as a factory
default. Make sure this voltage is set appropriately for the applicator heads
being used. If necessary change the over-excitation as per instructions
provided in Chapter 4 of this manual.
Note! ITW Dynatec DynaCold and DynaCold Mini applicators always require an
over-excitation voltage of 170V.
1. Plug all connectors in the corresponding
receptacles.
2. Engage the locking ring (1) of the connector plugs
to the receptacles.
3. Connect the controller to the power supply.
Locating an Optical Trigger (Sensor)
Use the information below to assist in the proper location of an optical triggering device.
TRIGGER LOCATION GUIDELINES (All Conditions Must Be Met)
All Intermittent Modes Except RANDOM RANDOM Mode
D + L > On Compensation D + L > On Compensation
D < Repeat Length D > T + Off Compensation
D < Repeat Length
D = Distance from Optical Sensor to Glue Applicator (i.e. OFFSET)
L = Leading gap on product prior to first glue bead application.
T = Trailing gap on product after last glue bead application.
See the following diagram for additional clarification on this subject.

2008 D 12/98 Installation
3--3
C. 1998
Manual #50-14 Revised 3/2005
Connecting Optional Accessories
The DY2008 may be supplied with optional accessories as follows:
1. Remote Front Panel (28.11101.601): this allows the DY2008 operator interface to be
installed up to 10 meters (33 feet) away from the main control box. This is provided as an
option for the four and eight channel units and is standard for 12 or more channel units.
2. Remote Purge Control (28.11101.602): this allows one-person operation of the manual
gluing (purge) function at distances up to 10 meters (33 feet) from the Main Control Unit or
Remote Front Panel (if installed).
3. Data Interface Option (28.00005.107): this provides the ability to control the
programming of the DY2008 from another CPU via a RS232 or RS485 data interface.
Use the diagrams that follow as a guide in connecting the above accessories to the DY2008
Control Unit.

Manual #50-14 Revised 8/2008
Installation
3--4 C. 2002
PC
DY 2008
Purge Control
Magnet mount
Connectin
g
O
p
tions Directl
y
to Control Unit

2008 D 12/98 Installation
3--5
C. 1998
Manual #50-14 Revised 3/2005
Remote Panel
PC
DY 2008
Purge Control
Attach terminal
to ground wire
Turn mounting
clip clockwise in
slot.
Magnet mount
Ground Wire
Mounting Clip (used
for panel mounting)
Connecting Options Through Remote Front Panel
Remove screw
to attach Mounting
Bracket.
Remote Panel
Mounting Bracket.
Data Cable

Manual #50-14 Revised 8/2008
Installation
3--6 C. 2002
ITW Dynatec
An Illinois Tool Works Company
Adhesive
Application
Solutions

Manual #50-14 Revised 8/08 Page 4-- 1
C. 1998
Operation
Operator’s Panel
DY2008
C1:S
C2:S
C3:D
C4:S
C5:S
C7:C
C8:R
STOP
PATTERN SYSTEM COMP.
1: 0 m/min
PRESS1: 0%
PRESS2: 0%
PRESS3: 0%
PRESS4: 0%
PROGRAM:
Machine Speed
All Channels stopped via serial interface
All Channels stopped via Purge Control
All Channels stopped via Profi--Bus
All Channels manually stopped
Stop cause by external contact
EXTER.STOP
STOP
Manual Gluing (Purge)
Service Menu
Manual Stop
Enter Button
Clear Button Numeric Keys
Function Keys
Glue Pattern:
Channel 1: 3 Glue Events
Channel 2: 1 Glue Event
Channel 3: Dot Mode, 1 Event
Channel 4: 4 Glue Events
Channel 5: 5 Glue Events
Channel 6: Turned Off
Channel 7: Continuous Gluing
Channel 8: Random Length Gluing
Pressure Indication
Program Number
1
2: 0 m/min
3: 0 m/min
EXTER.STOP
Encoder 2 Encoder 1 BUS-STOP
COM 2-STOP
4: 0 m/min
LEDs Signal
Activation of the
Valve Outputs
PRESSURE
S: Trigger Indication for Standard Mode Gluing
C: Trigger Indication for Continuous Mode Gluing
D: Trigger Indicator for Dot Mode Gluing
R: Trigger Indication for Random Mode Gluing
Encoder 3
Encoder 4
COM-STOP
Function Keys F1, F2, F3, F4
These keys can have changing functions. The lower line of the display above
the keys will indicate the current function.
Manual Gluing (Purge) Button
This button is used to activate the valve outputs manually. It is possible to select individual
channels. The button operates only when manual stop (see below) mode is activated.
Service Button
Use this button to open the configuration menu. The button operates only when manual stop (see
below) mode is activated.
Stop Button
Pressing this button will stop gluing. “STOP” will flash at the top, center of the display when this
mode is active.
Numeric Keys
Use these keys to enter parameter values.
Clear Button
Pressing this button will reset a parameter to the previously programmed value or to “0” (zero),
depending upon the specific parameter.
Enter Button
This button is used to confirm a new entry.

Page 4-- 2 Manual #50-14 Revised 8/08 C. 1998
Remote Purge Control
Purge Control
Channel
Indicator
Channel
Select
Stop Button
Manual Gluing
Button
}
Channel Indicator
Displays the current channel selected from the Remote Purge Control Unit.
Channel Select Buttons
Use the “increment” or “decrement” button to change the current channel displayed in the
Channel Indicator.
Stop Button
Used to place the control into a STOP condition for manual gluing activation. Also causes the
pressure output circuitry (X24 through X27) to output programmed PURGE PRESSURE when
STOP is activated. STOP activation is indicated by an amber LED that is continuously
illuminated. See the section of this chapter on Stop Conditions for more detail. Deactivating
STOP will also automatically cease manual gluing operations on any channels that are still
active.
Manual Gluing (Purge) Button
Used to activate (amber LED on continuously) or deactivate (amber LED is either OFF or
flashing) the current channel displayed in the Channel Indicator LED’s.
Mounting Note
A magnet is attached to the back side of the Remote Purge Control unit for convenient mounting to any ferrous
metal object.