Valco Cincinnati VC3500 User manual

VC3500 User’s Manual
Software Version: 3.X
Manual Number: MCO35
ManualReleaseDate: July 1999

© 1998 Valco Cincinnati, Inc. All Rights Reserved.
This manual is furnished with the VC3500 control and may only be used or copied in accordance with the terms of
purchase.
No part of this manual may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means,
electronic, mechanical, recording, or otherwise, without the prior written permission of Valco Cincinnati, Inc. The
information in this manual is furnished for educational purposes only, is subject to change without notice, and
should not be construed as a commitment by Valco Cincinnati, Inc.
This manual was written and designed at Valco Cincinnati, Inc., 411 Circle Freeway Drive, Cincinnati, Ohio 45246.
Part Number: MC035
Printed in the USA
Valco Cincinnati Incorporated
411 Circle Freeway Drive
Cincinnati, Ohio 45246
TEL: [phone]
FAX: [phone]
Valco Cincinnati Limited
Hortonwood 32
Telford, TF1 4 EU, England
TEL: [phone]
FAX: [phone]
Valco GmbH
Storkower Strasse 6
15749 Gallun,Germany
TEL: [phone]
FAX: [phone]

CE Declaration of Conformity
(according to EN 45014)
Manufacturer: Valco Cincinnati, Incorporated
411 Circle Freeway Drive
Cincinnati, OH 45246
USA
declares that the product:
Product Name: Glue Controller
Product Model(s): VC3500
Year of Manufacture: 1998
conforms to the following standards:
Safety: EN 60204-1
EMC Emissions: EN 50081-2
EN 55011, Class A
EMC Immunity: EN 50082-2
EN 61000-4-2
EN 61000-4-3
EN 61000-4-4
Degrees of Protection: EN60529-1, IP54
and complies with the requirements of:
Low Voltage Directive 73/23/EEC
EMC Directive 89/336/EEC
Office of CE Conformance
Cincinnati, Ohio USA

Table of Contents
Introduction ...................................................................................................................................................................... 1
About this Manual................................................................................................................................................. 1
Product Description .............................................................................................................................................. 1
Safety Information.......................................................................................................................................................... 3
General Information ............................................................................................................................................. 3
Warnings................................................................................................................................................................. 3
General Wiring Guidelines ........................................................................................................................................... 5
Routing Low-Voltage Leads ............................................................................................................................... 5
Connecting the Supply of Electrical Power...................................................................................................... 5
Basic Features .................................................................................................................................................................. 7
Introduction ............................................................................................................................................................ 7
Front Panel Features ............................................................................................................................................. 8
Bottom Panel Features .......................................................................................................................................... 9
Installation ........................................................................................................................................................................ 13
Introduction ............................................................................................................................................................ 13
Control Installation ............................................................................................................................................... 13
Mechanical Installation of Control......................................................................................................... 13
Electrical Installation of Control ............................................................................................................ 15
MainsVoltage andFuse Selection ............................................................................................. 15
Encoder Installation .............................................................................................................................................. 17
Mechanical Installation of Encoder ....................................................................................................... 17
Wheel-Driven Encoder ................................................................................................................. 17
Gear-Driven Encoder................................................................................................................... 17
Electrical Installation of Encoder........................................................................................................... 18
Scanner Installation............................................................................................................................................... 19
Mechanical Installation of Scanner........................................................................................................ 19
Electrical Installation of Scanner............................................................................................................ 21
Glue Valve Installation......................................................................................................................................... 21
Electrical Installation of Glue Valve...................................................................................................... 21
Machine-Stop Relay and Beacon Interface ...................................................................................................... 22
DD-1 Pump Power Supply ................................................................................................................................. 22
Bypass Valve Driver............................................................................................................................................. 23
Menus ................................................................................................................................................................................. 25
Introduction ............................................................................................................................................................ 25
Primary Menus ...................................................................................................................................................... 25
Main Screen ........................................................................................................................................................... 27
Glue-Pattern Edit Screen...................................................................................................................................... 28
Level-1 Menu Screen ........................................................................................................................................... 29
The Job Store Screen ................................................................................................................................ 30
The Job Title Screen ................................................................................................................................. 30
The Job-Index Screen ............................................................................................................................... 30
The Product-Length Screen..................................................................................................................... 31
The Clear-Data Screen ............................................................................................................................. 31
Level-2 Menu Screen ........................................................................................................................................... 33
The Scan-ModeScreen ............................................................................................................................. 33
The Glue-Mode Screen ........................................................................................................................... 33
The Repeat-Channel Select Screen ....................................................................................................... 33
The Repeat-Setup Screen........................................................................................................................ 33

Level-3 Menu Screen ........................................................................................................................................... 34
The Clear-Data Screen ............................................................................................................................. 35
The Minimum-Speed-Setting Screen .................................................................................................... 35
The Cell-to-Gun-Setting Screen ............................................................................................................. 35
Level-4 Menu Screen ........................................................................................................................................... 36
The Product-Length Screen..................................................................................................................... 37
The Manual-Ratio-Compensation Screen............................................................................................. 37
The Automatic-Ratio-Compensation Screen........................................................................................ 37
The On/Off-Compensation-Setting Screen........................................................................................... 37
Level-5 Menu Screen ........................................................................................................................................... 38
The Inch/Metric Screen............................................................................................................................ 38
The PIN-Code Screen............................................................................................................................... 39
Level-6 Menu Screen ........................................................................................................................................... 39
Initial Setup....................................................................................................................................................................... 41
Introduction ............................................................................................................................................................ 41
Initial Setup ............................................................................................................................................................ 41
Disable Glue Valves for All Channels .................................................................................................. 41
Specify Inches or Millimeters ................................................................................................................. 41
Specify Minimum Gluing Speed ............................................................................................................ 42
Set Cell-to-Gun Dimensions ................................................................................................................... 42
Specify Ratio Compensation.................................................................................................................. 42
Manual Ratio Compensation....................................................................................................... 42
Automatic Ratio Compensation .................................................................................................. 43
Specify On and Off Compensation ....................................................................................................... 43
UnknownCompensationValue................................................................................................... 44
Restrict Screen Access ............................................................................................................................. 44
Return to the Main Screen ....................................................................................................................... 44
Operation .......................................................................................................................................................................... 45
Introduction ............................................................................................................................................................ 45
Creating a Job ........................................................................................................................................................ 45
Saving a Job ........................................................................................................................................................... 46
Loading a Job......................................................................................................................................................... 46
Repeating Glue Patterns....................................................................................................................................... 47
Clearing Data ......................................................................................................................................................... 47
Specifying the Scanner Mode ............................................................................................................................. 47
Specifying the Glue Mode ................................................................................................................................... 48
Specifying the Delay and Pattern Values .......................................................................................................... 49
Specifying the Product Length ........................................................................................................................... 49
Troubleshooting ............................................................................................................................................................... 51
Introduction ............................................................................................................................................................ 51
Internal Components ..................................................................................................................................................... 55
Introduction ............................................................................................................................................................ 55
CPU Board ............................................................................................................................................................. 56
Channel 3 and 4 Logic Board ............................................................................................................................. 57
Analog Board ......................................................................................................................................................... 57
LED Board ............................................................................................................................................................. 57
Interface Board ...................................................................................................................................................... 58
Valve Driver Board ............................................................................................................................................... 59
Power Supply Board ............................................................................................................................................. 60
RS232 Board .......................................................................................................................................................... 61
EPC Board .............................................................................................................................................................. 62
Relay Board ............................................................................................................................................................ 63

Specifications .................................................................................................................................................................... 65
Part-Number List............................................................................................................................................................ 67
How to Order Parts ............................................................................................................................................... 67
VC3500 Parts List................................................................................................................................................. 67
Optional Parts List ................................................................................................................................................ 69
Recommended Spare Parts List—Mechanical................................................................................................. 69
Recommended Spare Parts List—Electrical..................................................................................................... 70
Recommended Spare Parts List—DD-1 Pump ................................................................................................ 71
Warranty ........................................................................................................................................................................... 73
Service ................................................................................................................................................................................ 75
Appendix A —The Repeat Function .......................................................................................................................... 77
Using the Repeat Function .................................................................................................................................. 77
Appendix B —The RS232 Communications Interface ......................................................................................... 79
RS232 Communications Interface ..................................................................................................................... 79
Location Codes ...................................................................................................................................................... 79
Data Format............................................................................................................................................................ 80
Sending Information from Host to VC3500 ..................................................................................................... 81
Example of Sending Data ........................................................................................................................ 81
Receiving Information from VC3500 ............................................................................................................... 82
Example of Receiving Data..................................................................................................................... 82
Appendix C—Additional Scanner Mode Configuration ...................................................................................... 83
Introduction ............................................................................................................................................................ 83
Using One Scanner to Trigger Four Independent Glue Valves .................................................................... 83
Applying Up To Four Patterns from a Single Glue Valve............................................................................. 83
Applying Up To Eight Patterns from a Single Glue Valve............................................................................ 84
Appendix D—The VC3500J Control ......................................................................................................................... 87
Introduction ............................................................................................................................................................ 87
Overview ................................................................................................................................................................ 87
Installation of Product Scanner........................................................................................................................... 87
Electrical Installation of Remote Learn Button ............................................................................................... 87
Operation ................................................................................................................................................................ 88
MenuButtons......................................................................................................................................................... 88
Appendix E—Maintenance Procedures .................................................................................................................... E-1
Introduction ............................................................................................................................................................ E-1
Daily Maintenance ................................................................................................................................................ E-1
Weekly Maintenance ............................................................................................................................................ E-2
3-MonthMaintenance .......................................................................................................................................... E-3
6-MonthMaintenance .......................................................................................................................................... E-4
12-Month Maintenance ........................................................................................................................................ E-5

ValcoCincinnati 1
Introduction
About this Manual
Valco Cincinnati has prepared this manual as an aid for installing, operating, and servicing the VC3500 control.
This manual provides specific information about the unit, and general guidelines and references when discussing
other equipment such as glue systems, scanners, encoders, and dispensing valves.
If you need more information, please contact your Valco Cincinnati representative.
Product Description
Valco’s VC3500 is a sophisticated microprocessor control that provides precise adhesive delivery. The control can
be designed for either two-channel, two-valve applications or four-channel, four-valve applications.
The VC3500 is used for applications where consistent glue patterns are required at high machine speeds and during
speed changes. The VC3500 provides complex glue patterns that can be difficult or impossible to obtain with other
systems. The control operator can use the control’s front-panel touch-screen to edit glue patterns while the parent
machine is operating.
The VC3500 features a user-friendly, multi-language display; multiple pattern placement; speeds of up to 2000 feet
(610 m) per minute; internal flow control; and optional RS-232 communications with external devices. The VC3500
control can store up to 99 fully programmed jobs.

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General Information
It is the purchaser’s responsibility to ensure that all local, county, state, and national codes, regulations, rules, and
laws relating to safety and safe operating conditions are met and followed.
The best safeguard is trained personnel. The purchaser is responsible for providing personnel who are adequately
trained to install, operate, and maintain Valco components and systems.
This section contains information that is essential to the safety of personnel. Safety information is included through-
out the rest of the manual as well. The following safety conventions are used to indicate potential safety hazards:
Warnings
All personnel involved with the installation, operation, and maintenance of the equipment must read and thoroughly
understand the following warnings:
WARNING! Promptly repair or replace all worn or damaged electrical wiring
and equipment wires to avoid danger to personnel.
WARNING! Properly route all electrical wires to avoid danger to personnel
and damage to moving parts of machine.
WARNING! Disconnect all power before opening the control. Only qualified
personnel should open and service the control.
WARNING! This symbol indicates the presence of un-insulated dangerous
voltage within the product’s enclosure. This voltage may cause electrical
shock or fire. Failure to observe precaution may result in death, personal
injury, and/or equipment damage.
WARNING! This convention is used to alert the user to important installation,
operation, and/or maintenance information. Failure to observe precaution
may result in personal injury or death.
CAUTION! This convention is used to alert the user to important installation,
operation, and/or maintenance information. Failure to observe precaution
may result in damage to equipment.
Safety Information

SafetyInstructions ManualName
ValcoCincinnati4
WARNING! When making adjustments or performing checkout procedures,
stay clear of any moving mechanical parts and do not touch exposed electri-
cal equipment or electrical connectors.
WARNING! Keep pump cover and electrical enclosures closed except during
setup,service, andcheckout procedures.
WARNING! Promptly repair or replace all worn or damaged parts.

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Routing Low-Voltage Leads
When routing low-voltage leads, follow these guidelines:
•Do not route low-voltage leads in the same conduit as wires carrying a high-current load.
•Do not route low-voltage leads adjacent to, or across wires carrying a high-current load. If low-voltage
leads must cross or run parallel to wires carrying high current, keep the leads at least 6" (152 mm) from
high-current wires.
•Do not splice or solder leads.
•Trim leads to the required length. Leads should be only as long as necessary for installation.
•All wiring should be in conduits or wireways.
Connecting the Supply of Electrical Power
Electrical connections should be made only by experienced service per-
sonnel!
The control must be connected to a “clean” supply of electrical power. Use a dedicated circuit if possible—if a
dedicated circuit is not available, donot connect the control to a circuit that supplies high-amperage equipment. Use
another circuit such as a lighting circuit.
General Wiring Guidelines
Electrical installation should be accomplished only by experienced service
personnel!

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Introduction
This section describes the basic features of the 3500 control.
Basic Features
Figure 1. Front Panel of VC3500
5
1
2
3a
3b
4
6a
6b
6c
6d
6e
6f
6g
6h

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ValcoCincinnati8
Front-Panel Features
The following are descriptions of the features on the front panel (see Figure 1).
1Touch-screen display
All glue pattern parameters are entered and displayed using the touch-screen.
2Valve enable switches
“|”—Valve is enabled and ready to dispense glue under program control.
“0”—Valve is disabled and will not dispense glue.
PURGE—Valve will dispense glue as long as the switch is manually held in this position.
3Valve indicator lights (items 3a and 3b are valve indiator lights)
3a Valve enable indicator lights
This light illuminates when the valve enable switch is placed in the “|” (enabled) position (see
item 2). This light will not illuminate when the valve enable switch is placed in the “0” (disabled)
position.
3b Valve dispensing indicator lights
This light illuminates when the valve is dispensing glue (purge function or a programmed command).
4Scanner indicator lights
This light illuminates when the scanner detects product.
5Glue pressure adjustment
You press this button to adjust glue pressure (“+” = increase and “ -” = decrease)
6Status indicator lights
Items 6a through 6h are status indicator lights.
6a Less than minimum speed
“<X/MIN” illuminates when the speed of the parent machine is less than the minimum speed setting .
6b Greater than minimum speed
“>X/MIN” illuminates when the speed of the parent machine is greater than the minimum speed setting.
6c Jam
This light illuminates when a scanner detects a product that is longer than the product length value entered
in the control.
6d Encoder
This light illuminates when encoder pulses are received by the control.
6e 56V
“56V” illuminates when the 56-volt valve peak voltage is supplied.
6f 12V coil hold voltage
“12V” illuminates when the 12-volt valve hold voltage is supplied.
6g 12V input supply voltage
This light illuminates when the 12-volt supply for scanners and the encoder is operational. This light will
be illuminated under normal operating conditions.
6h 5V logic supply voltage
This light illuminates when the 5-volt logic supply is operational. This light will be illuminated under
normal operating conditions.

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Bottom Panel Features
The following are descriptions of the features on the bottom panel (Figure 2).
1Air exhaust output
This output is for air to exhaust to the atmosphere. It is not normally connected.
2Air input
Input for regulated air, 80-100 psi (6.5–8 bar).
3Computer interface
DB-9 socket for optional RS232 communications (standard DTE)
4Air output
This output is connected to the glue source to provide speed-dependent glue pressure.
5Optional machine interface (items 5a and 5b are machine interface connectors)
5a Beacon/horn connector
See the “Installation” section for wiring details.
5b Machine interface relay connector
See the “Installation” section for wiring details.
6Power module
This main power supply connection uses an IEC standard line cord (supplied). The fuse drawer in this
module provides fuses for both sides of the main supply and selection of either 115 or 230VAC. The on/
off switch for the control is also located on this module.
Note! Ensure that the proper fuse configuration is installed to suit the power source. (See the “Installation”
section for details.)
7Line cord clamp
Two clamps are included in the installation kit. One clamp fits the included European line cord and the
other clamp fits the included North American line cord. You use two 4-40x 3/8² screws to attach clamp to
enclosure.

BasicFeatures VC3500 User’s Manual
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Figure 2. Bottom Panel of VC3700
5a. beacon/horn connector
5b. relay connector
1. air exhaust
2. air input
3. RS232 communications interface
4. regulated air (out) to glue regulator (Figure 3)
street tee, F-F-M, 1/8
adapters, F-M, 1/8 x 1/8
gauge, 0-60 psi
7. line-cord clamp
screws, 4-40 thread
6. power entry module
During installation, choose any
combination of two fittings for
tubing diameter:
male connector, 3/8 x 1/8 and male elbow, 1/4 x 1/8 or
male connector, 3/8 x 1/8 and male elbow, 1/4 x 1/8

BasicFeaturesVC3500 User’s Manual
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shock arrestor
T-handle (provides
minimum pressure setting)
sealing nut
(must be tightened
for proper operation)
to VC3500 regulated air port
adhesivesupply
glue regulator
to glue station
shutoff valve
Figure 3. Glue Regulator

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Introduction
This section contains both mechanical and electrical installation instructions. Read the “Safety” section in this
manual before attempting these procedures.
Electrical installation should be accomplished only
by experienced service personnel!
Refer to Figure 8 for detailed layout of internal connections.
Control Installation
Mechanical Installation of Control
The control should be installed on the operator’s side of the parent machine, in a location where vibrations will not
occur. The control should require less than 25 feet (8 m) of wiring to reach the glue station, sensor,and shaft encoder
(longer wiring is available on request). A 5/16" (8 mm) hex wrench can be used to unlock the door of the control
enclosure.
To install the control, follow these steps:
1. Attach the control to a stationary, vertical surface, using the mounting holes located inside the control enclosure
(see Figure 6).
Note! The control may also be mounted either to Valco’s machine-mount pedestal or mobile-system pedestal
(see Figures 4 and 5).
Installation
Figure 4. Machine-Mount System Pedestal
Manifold with (4)
3/8" NPT
ports
25.75"
(654 mm)
9.33"
(237 mm)
13"
(330 mm)
0-125psi
regulator/filter
assemblyshown
1.25"
(31.8 mm)
3" (76 mm)
.406" (10.3m) diameter

Installation VC3500 User’s Manual
ValcoCincinnati14
Figure 5. Mobile System Pedestal
Figure 6. Mounting Hole Dimensions
)
66.3"
(1684 mm)
24.3" (617 mm) 19.6" (498 mm)

InstallationVC3500 User’s Manual
ValcoCincinnati 15
Electrical Installation of Control
The main’s supply must be 115/230 VAC, 50/60 Hz, 2/1 A. The 115/230 power requirement is field-switchable.
The power module accepts a standard IEC line cord (supplied).
To connect the line cord, follow these steps:
1. Attach the line cord clamp to the bottom surface of the VC3500, using the two screws on either side of the power
module.
2. Insert the line cord into the power module
3. Tighten the line cord clamp to prevent inadvertent loss of power.
Note! The line cord supplied can either be directly wired to a branch circuit or (with the proper plug type)
plugged into a 115 or 230 VAC outlet socket. The wire colors of the supplied line cord are as follows:
Mains Voltage and Fuse Selection
The fuse holder on the bottom panel of the power module contains the fuse drawer, which allows for either 115VAC
or 230VAC operation (Figure 7).
To replace or check mains fuses, follow these steps:
1. Remove all electric power from the unit.
2. Remove the line cord.
3. Use a small screwdriver to open the hinged door of
the fuse holder.
4. Remove the fuse drawer (ensure that the fuses in
the holder remain in place).
5. The drawer is labeled “230V” and “115V.” Rotate the
drawer to the appropriate voltage.
6. For line-to-neutral operation, use the shorting clip
(jumper) and one fuse. Shorting clip must be on left
side (when rotated to read the correct voltage). For
line-to-line operation, use two fuses.
7. Replace the drawer in the fuse holder and close the
door of the fuse holder.
8. The operating voltage shows through the window in
the fuse holder door. Ensure that voltage is correct.
9. Replace the line cord.
Wire Type International Line Cord Color North American Line Cord Color
Line Brown Black
Neutral Blue White
Ground Green/Yellow Green
Figure 7. Fuse Drawer
230V (USA)
line-to-line
230V (Europe) or
115VAC (USA)
line-to-neutral
shorting clip
115V/230V

Installation VC3500 User’s Manual
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Figure 8. Internal Connections Diagram

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Encoder Installation
Mechanical Installation of Encoder
An encoder must be installed in order for the control to determine the speed of the parent machine. For best results,
100 pulses per inch (25.4 mm) of product travel should be supplied to the VC3500. If less than 100 pulses per inch
(25.4 mm) are supplied, poor resolution may result in pattern placement errors. If more than 100 pulses per inch
(25.4 mm) are supplied, the maximum specified speed of 2000 feet/min (610 m/min) must be reduced.
There are two primary types of encoders:
•Wheel-driven encoder
•Gear-driven encoder
Wheel-Driven Encoder
If using a wheel-driven encoder (Figure 9), a VCE-1000 encoder with a 10-inch measuring wheel is recommended.
To install a wheel-driven encoder, follow these steps:
1. Mount the encoder’s bracket to the frame of the parent machine.
2. Ensure that the wheel of the encoder rides securely against the belt and does not slip.
3. In the level-4 menu screen, set ratio compensation to 100 pulses.
Gear-Driven Encoder
The following formula can be used to determine the correct combination of gear teeth and encoder for approxi-
mately 100 pulse per inch (25.4 mm):
Teeth-S xCounts =Pulses per inch (25.4 mm) of travel
Teeth-E Travel
Teeth-S=Number of teeth on the line-shaft driver gear
Teeth-E=Number of teeth on the encoder driven gear
Counts=Number of encoder pulses per revolution
Travel=Product travel in inches (or millimeters divided by 25.4) per revolution of the drive shaft
Figure 9. Example of a Wheel-Driven Encoder