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ET24 Pattern Controller

1. Density Energy 1 slug ft3 515 4 kg m3 1 ft Lb 1 356 J Specific Weight Btu 1 055kJ 1 Ib ft8 157 1 N m3 1W h 3 600kJ Power 1hp 550 ft Lb s 1 ft lb s 1 356 W 1hp 745 7 W 1 Btu h 0 293 W Viscosity 1 Ib s ft 2 089 x 10 5 centipoise Traveling 50 fom or 15 mpm is the same as 10 ips or 250 mmps To convert fom to ips multiply fom by 0 2 To convert mpm to mmps multiply mpm by 16 66 Table 1 The formula for determining the duration time for any type of event is to divide the distance to be traveled by the line speed of the product English Formula Time s Distance in Speed fpm x 2 Metric Formula Time s Distance mm Speed mpm x 16 66 Table 2 Copyright 2009 Astro Packaging ET24 Pattern Controller 19600 84 Rev D 04 07 09 39 ET24 automatically subtracts the ON DELAY TIME value from all GAP events present Formula English MinGAP ON D x MLS x 0 0002 Metric MinGap ON D x MLS x 0 0166 Where MInGAP Minimum acceptable GAP Setting in ON D ONDELAY HME ms MLS Maximum Line Speed fpm mpm 0 0002 Conversion Factor from fpm to in ms 0 0166 Conversion Factor from mpm to mm ms Example ON DELAY 10ms Maximum Speed 300 fpm 100 mpm English MinGAP ONND X MLS X 0 0002 10ms X 300fpm X 0002 06in Table 3 Metric MinGAP 10ms X 100mpm X 0166 16 6 mm A rea
2. 4 ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging 3 1 Setup Factory Configuration The ET24 can be configured to meet the user s needs These parameters are controlled by the functions explained in Section 4 2 Startup ET24 is shipped from the factory configured as follows 1 Programmable Memory is set to zero No program or test pattern is previously stored 2 Trigger Mode is set to Single Shot An input trigger voltage of 5 to 24 VDC initiates a program sequence The program sequence continues even if the trigger voltage is removed unless power is removed from ET24 3 Trigger Type is set to activate signal OFF to ON An incoming voltage transition from ground neutral or zero potential to the trigger voltage initiates a program sequence Metric English is set in inches for U S shipments Program Lock is OFF Line Speed Track Resolution is set to 0 01 inches Head ON OFF Delay Compensation is set to zero Slow line speed drop out default is set to 10 feet per minute O 0 24 9 gr d Function Lock is unlocked 3 2 Electrical Circuits and Wiring The ET24 provides 24 different patterns and can operate 4 independent heads or valve groups simultaneously The duration of these events can be defined in terms of Time or Length Time resolution is one millisecond Length resolutions are 01 in 02 in 05 in or 10 in Metric unit length resolutions are 5 mm mm 2 mm or 3 mm Leng
3. ET24 Pattern Controller Manual Number 19600 84 Revision D ET24 Pattern Controller Manual Number 19600 84 Revision D Date 04 07 09 1 800 642 7876 Copyright 2009 Astro Packaging Table of Contents 1 Safety Precautions 1 1 1 intended Use ELE 1 1 2 Personal Sale ili ek nat ice uet vd oe DO eli ne ewe aos 1 1 3 Electrical Sata aa donante fendi lapidi alano fa dre ane Beda die an Gat 1 1 4 Emergency Power Disconnect 22 2222 seen rn 1 1 5 Follow Directions scire gae ESSERE a IE PE ce Hein 1 1 6 Safety Symbols and Signal Words 2 2 Introduction 3 2 1 DESCIPLUON Scns a sun er NISUS D pad LE LE We 3 2 2 Features Maenner ee ae A neh ee en Be nt ee ee ae 3 3 Installation 4 3 1 Setup Factory Configuration 5 3 2 Electrical Circuits and Wiring 00 5 3 3 Component Installation Tachometer 1 2s ssasassaa aaa aaa aaa 7 4 Operation 8 4 1 Controls and Indicators LL 9 4 2 Power On Switch Selections Customizing T1000 1 1 1s ss sasa aaa aaa 8 Clear Memory 9 Change Temperature Scale Celsius or Fahrenheit 9 High Limit Temperature Adjustment liliis eh 9 Set Auto Standby TIME 9 Set Alarm Time to Auto Shutoff Li 9 Change All Zones Standby Temperature Setback llle 9 Change All Zones HIGH LOW Temperature Limits llli 9 Sequential System Heat Up 0 ccc tte en 10 Enable Auxiliary Features 10 I O Configura
4. ET24 Pattern Controller 19600 84 Rev D 04 07 09 9 Note Indicators displays Selector TEST and ON OFF switches are green ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging 4 2 Startup All other switches are black Self Test Before the user can program or use the system ET24 self checks the input output and memory devices During self test the Number 8 appears in every display and all LEDs illuminate Successful self test shows a normal system display looks like Unsuccessful self test shows blank display Memory Clear CAUTION This procedure removes all loaded programs Clearing memory should be the last resort if a problem has been encountered in loading or modifying a program A sequence log should be kept of timer s programs in the event of a failure All program setups are cleared to zero by holding the Test Switch to the LEFT during the configuration procedure found in Section 4 Test Pattern A factory defined test pattern can be loaded and run to determine if the ET24 is operating properly To install the test pattern hold the valve Group Selector Switch L UP while following the configuration procedure The test pattern is automatically loaded into setup number 20 Select setup number 9 and the test pattern is as follows Head Group Pattern Alternating 0 5 sec gap and stitch 25 ms cycle Copyright 2009 Astro Packaging ET24 Pattern Controller 19600 84 R
5. To reverse rotation interchange the red and black wires located under the tachometer s rubber boot system functions and programming 3 3 Component Installation Tachometer Line speed tracking is accomplished by a linear Tachometer device that must be coupled to a non slip rotating shaft of the parent Tachometer generator installation is a simple connection to any rotary shaft via a direct coupling then adjusting the calibration to display the machine line speed Once adjusted for one line speed it is correct for all line speeds The entire calibration operation is completed in seconds e The Tachometer should be mounted so that the shaft is rotating in a clockwise direction If this is not possible the tachometer leads should be reversed at Terminals 34 and 35 e The shaft must rotate at full line speeds at least 300 RPM but not greater than 3000 RPM The RPM of the tach generator must be directly proportional with the movement of the product receiving the adhesive Copyright 2009 Astro Packaging ET24 Pattern Controller 19600 84 Rev D 04 07 09 7 4 Operation 4 1 Controls and Indicators 8 ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging 1 SETUP Selector Switch Display and Indicators Switch selects TIME Mode LENGTH Mode or FROM START Mode when in DURATION Mode Displays one of 20 stored setups Simultaneously time or length values are displayed in the Duration window Indic
6. ET24 B06 On the Circuit Board is a U Shaped indicator which should be lined up with the index located on the PROM Extreme care must be taken when replacing the PROM into the socket to insure all pins have been properly aligned 7 1 ET24 PROM Replacement and Special Remote Setup 1 Disconnect incoming power 2 Disconnect incoming power and remove melt unit from service Remove ET24 from enclosure Locate existing PROM 1 on rear of ET24 Carefully remove and discard existing PROM 1 by inserting small flat blade screwdriver between PROM and socket Install new PROM 1 taking care to observe general handling limitations of static sensitive devices Ensure locator key on module is as shown and that pins are aligned and are not bent during plugging of module Reinstall ET24 in enclosure return power to melt unit and test Copyright 2009 Astro Packaging ET24 Pattern Controller 19600 84 Rev D 04 07 09 33 Remote Setup Selection Instructions 7 Determine that ET24 has proper software Revision KOO This new revision displays as in 1100 in during power on self test 8 Trigger 4 input has been reserved for remote selection of setup as follows a A series of pulses as shown must be sent to ET24 from the PLC etc Note that ET24 requires at least 130ms as a recognizable stop bit b Input signal ranges 0 VDC OFF O 5 24 VDC ONII c Start pulse of at least 200ms in Duration to begin sequence d OFF O a
7. Line speed tracking is accomplished by a linear Tachometer device Maximum flexibility is maintained by allowing the duration of each event to be separately set Duration Varying Line Speed in inches requires the use of either the tach generator to monitor the variation in line speed of the production line this option must have the jumper in Figure B as shown Duration Fixed Line Speed mode requires that the jumper in Figure A be installed as illustrated FUSE 7PIN CONNECTOR Fixed Line Speed Figure A FUSE 7PIN CONNECTOR Varying Line Speed Figure B 4 3 Adjustments Continued Once the Tach Generator is coupled to the parent machine it must be calibrated to coincide with the parent machine actual line speed This calibration is accomplished by first setting the Length Resolution and then by adjusting of the line speed Calibration Pot as described on the following page Note Prior to adjusting the tach generator always turn the line speed potentiometer to its full counter clockwise position 1 1 Length Resolution Length Resolution is a function of the number of valve groups and the systems ability to track line speed of the parent machine As the line speed of the parent machine increases the resolution decreases The Duration Type switch is held up or down during power up to display the current length resolution Copyright 2009 Astro Packaging ET24 Pattern Controller 19600 84 Rev D 04 07 09 25 The Resolution i
8. Pattern Controller 19600 84 Rev D 04 07 09 15 4 2 Startup Continued 6 10 12 Select the desired input trigger to initiate the event sequence with the Input Trigger Selector Switch M Steps 5 and 6 assign the selected valve Group Sensor combination Any sensor trigger can be assigned to any valve group Now select the Event Number J K starting with event 1 An event sequence must st always start with event and progress in sequence Select the type of event to be programmed for this event number by pushing the Event Type Selector Switch 1 The odd numbered events 1 3 5 etc are always GAP A Glue or Stitch may be selected for even events A Gap must always precede a Glue event to accommodate on delay compensation Refer to Section H Set the event Duration in seconds using the selector switches and watching the display If the Event Type is a gap or glue programming of that event is complete and is stored in memory upon selecting the next event number If the event type is a Stitch three aspects of the pattern must be defined the overall stitch Duration the stitch gap time and the stitch glue time Step 9 programs the overall Duration Toggling the Event Type Switch D UP illuminates both the stitch and gap LEDs The stitch gap time can now be entered with the Duration switches Toggling this switch UP again illuminates the stitch and glue LEDs The stitch glue Duration can now be entered Programming of
9. Power Supply Universal Voltage 12091 1 Enclosure ET24 11 in X9 in X 6 in 73858 Screwdriver pocket 11065 3 Kit PROM ET24 79181 02 Kit PROM ET24 Remote Settings 79181 13 Kit RAM Battery backup replacement 11081 2 7 Wire Terminal Block Connector 12299 7 8 Wire Terminal Block Connector 12299 8 12 Wire Terminal Block Connector 12299 12 Terminal Strip Labels 1 12 12298 1 Terminal Strip Labels 13 24 12298 2 Terminal Strip Labels 17 32 12298 3 Terminal Strip Labels 33 48 12298 4 Appendix A Specifications Electrical ET24 Power Requirements 100 115 V 20 W 50 60 Hz or 200 230 V 20 W 50 60 Hz Line Speed Input 1 Astro Packaging Tach Generator must generate 50 300 VDC at maximum line speed Four Triggers Inputs Voltage Type Mode 5 24 VDC 4 25 mA Astro Packaging Mini or Data Beam Photoeye Sensors recommended One Shot sequence initiates and completes with one trigger input Duration sequence initiates and continues while trigger signal is engaged Power Output Switching Relays 5 60 VDC 3 A 60 240 V 5 A Head Group Capacity 1 4 head groups Number of Head Coils in Head Group E100 Style up to 4 E900 up to 8 with 115 V power or up to 16 with 230 V power or DC power Copyright 2009 Astro Packaging ET24 Pattern Controller 19600 84 Rev D 04 07 09 35 Power Supply Output 12 VDC 200 mA or 24 VDC 200 MA Power provided for photoeye triggers a
10. TRIGGERS ET24 s power supply only supports 3 Astro Packaging photoeye sensors due to current power require ments If an additional power supply is needed contact your factory representative F attern Melt Controller Unit Astro Packaging Pattern Controllers are shipped in 1 of the following configurations 1 Controller factory wired to a melt unit no installation required Wires are terminated in both controller and melt unit with a flexible conduit connecting cable The length of the cable is selected at the time of purchase Photoeye trigger devices are also factory wired when ordered as a part of the system There is no installation required when a controller is factory wired to a melt unit 2 Controller factory wired to a flexible conduit connecting cable only some installation required Controller is wired with a connecting cable but is not connected to a melt unit A controller with wired in conduit cable is shipped either because it was ordered in that configuration or for convenience of packing and shipping Installation requires connecting numbered wires in the cable to the corresponding numbers on the melt unit terminal strip 3 Controller with no factory wiring complete installation required Installation requires making all connections within the controller as well as the melt unit Instructions in this section must be followed as well as those in the melt unit service manual and wiring schematic diagram
11. friction pins which exposes the fuses and connectors The main power fuse is a 10 amp 115 volts or 5 amp 230 volt buss type and the output fuses are 5 amp 230 volt buss type The wiring connector terminal strip is a two piece removable type to accommodate interconnect wiring Pull out the removable portion of the connector and the spring loaded wiring holes are exposed Should ET24 require service the entire unit should be returned to Astro Packaging for repair Contact the Technical Services Department for additional assistance 800 642 7876 or 714 572 1094 32 ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging PROM Replacement kkk NOTE kkk In the event of a short term power loss e g during an electrical storm or during an extreme brown out condition where line voltage drops below 70 of normal operation voltage ET24 may halt operation Should this occur reset ET24 by turning power off for 2 seconds then turn power on to restart normal operations Replacement of the PROM Programmable Read Only Memory is necessary when the software has been upgraded When replacing it is extremely important to have all power OFF from the Melt Unit and the ET24 1 2 Remove the 4 Button valve Screws from the timer Gently pull out timer module remove module from front panel by unscrewing knurled screw Locate the ET24 PROM it should be labeled with the current revision status of ET24 Bxx ex
12. important calculations and corrections are made to achieve the desired pattern lengths with correct registration at varying line speeds The purpose of this section of the manual is to provide a basic understanding of how line speed compensation is accomplished and how the delay characteristics of dispensing devices can be controlled when using the Astro Packaging ET24 Event Timer A Line Speed Compensating System dispenses the glue pattern of a specific length regardless of how fast the substrate is moving The glue bead always starts and stops at the correct locations Understanding Line Speed Compensation First imagine a simple applicator device EIOO valve with single orifice button nozzle which must apply a strip of adhesive to a series of 26 in long boards The adhesive bead length is 24 in with a space of 1 in on each end of each board As a board moves toward the applicator valve it trips a limit switch arm which activates a timer The limit switch is up stream from the applicator and hence there must be a time delay between the time that the switch is activated and the applicator device is actually turned ON The simple timer device consist of only two adjustments for two time events Event One is the delay time between activation of the limit switch and the applicator head This is called a Gap Time Setting or GAP Event two is the Glue Time Setting or simply GLUE the amount of time the applicator is ON dispensing the 24 in l
13. per minute 1 180fpm 360 900 1800 2 90 180 450 900 3 60 120 300 600 4 45 90 200 450 Head Resolution Setting Metric Group 05mm 1 0mm 20mm 3 0mm meters per minute 1 100mpm 200 400 600 2 50 100 200 300 3 35 75 150 200 4 25 50 200 150 Dimensions Appendix B Conversion Factors English gravitational unit system to International System of units S1 Quantity English Unit 1 Unit Symbol Equivalent units Length 1 foot ft 0 3048 meter m Mass 1 slug 14 59 kilogram kg Time 1 second 1 0 second S Force 1 pound Ib 4 448 newton N kg m s2 Pressure 1 Lb in2 6859 pascal Pa N m or kg m s Energy 1 ft Lb 1 356 joule J Nm or kg m s Power 1 ft Lb s 1 356 watt w J s Other convenient conversion factors Units of Measure Length ft foot ft 0 3048 m ikm 1000 m in inch 1in 25 4 mm icm 10m mm millimeters S second Area ms millisecond 1 1t2 0 0929 4m m meter 38 ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging 1in 645 2 mm fpm feet per minute mpm meters per minute VoLume ips inches per second 1f8 7 48 gal gal 0 003 79 m3 mmps millimeters per second 1ft8 1728 ins gal 3 785L 118 0 0283 m3 1m3 1000L Volume flow rate 3 785 t min 16 67 x 10 6m3 s 11t8 s 449 gal min gal min 1 ft8 s 0 0283 m3 s 1 L min 1 gal min 6 309 x 10 5m8 s Temperature T C T F 32 5 9 T SF 9 S TC G 32
14. system 4 3 Adjustments Continued An analysis of On Delay Time shows two important events 1 The bead is not deposited at the correct place 1 in 25 mm from the edge of the board It has shifted downstream 0 1 second s worth of travel At 10 ips 250 mmps the board travels 1 inch 25 mm in 0 1 second and the pattern shifts in 25 mm from the required spot on the board 2 The actual bead length is shortened by the amount of shift as well Assume that there is no OFF DELAY TIME involved in this situation The second event the GLUE time was set for 2 4 seconds After the first GAP event of 3 6 seconds occurred the second event GLUE activated as planned but nothing happened on the board for the 0 1 second of ON DELAY After the ON DELAY TIME the pattern appears and the GLUE event is completed in 2 3 seconds i e the 2 4 second GLUE time minus the 0 1 second ON DELAY TIME So the actual bead length is 23 in 575 mm at a 50 fpm 15 mpm line speed Important Technicality There is an important technicality regarding ON DELAY TIME and its effect on pattern shift which should be understood Although it was stated above that the factors contributing to the ON DELAY TIME were summed together and called ON DELAY TIME the effects of this composite delay value on pattern drift and shortening of the bead length were introduced However only those factors associated with the response time of the valving 20 ET24 Pattern Con
15. the proper time intervals Those time intervals must change linearly with the line speed changes In addition to the timing issues related to varying conveyor line speed all dispensing devices have measurable response times which must be taken into consideration There is a certain amount of delay or lag between the time that the applicator is given a signal to turn on or off and the time when the adhesive actually starts or stops on the product This aspect of applicator behavior becomes extremely critical in maintaining performance standards as line speeds increase and pattern specifications tighten With a high line speed Astro Packaging valve a 25 fpm change in line speed results in a 0 05 inch pattern shift LINE SPEED COMPENSATION is the term used to describe what a timing device must do to properly control an adhesive applicator system ina variable line speed production situation Generally variable line speed timing controls accurately account for the changes in the line speed of the parent machine However they may not automatically compensate for the electromechanical response characteristics of the hot melt applicator valve or gun Hot melt equipment users may be confused about how line speed compensation pattern timing controllers should work based on prior experience with inadequate systems In particular the user should 18 ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging understand how two
16. D 04 07 09 19 exists When the first Time Event setting the GAP is completed and the second Time Event the GLUE is activated there is a slight delay or pause before the adhesive actually appears This delay affects the location of the beginning point of the bead by moving it further back from the leading edge of the board The following example is exaggerated for illustrative purposes If the delay from signal to actual deposition was 2 seconds at 50 fpm it would take 5 6 seconds before the adhesive actually started on the board The timer GAP of 3 6 seconds calculated earlier plus the additional built in response delay of the dispensing device of 2 seconds Consequently the pattern shifts another 20 inches further from the edge of the board at 50 fpm and now starts 21 in from the edge instead of in This delay in response time present in all dispensing devices is called the ON DELAY TIME ON Delay Time is caused by many factors all of which are independent of line speed or in the example used the line speed the board is traveling Some of those factors are 1 The time from timer signal to full energizing of solenoid magnet 2 The time for energized solenoid to lift armature from valve seat 3 The time for adhesive to travel from nozzle tip to the substrate The further the nozzle is from the substrate the longer the travel time This time for adhesive travel depends on the force of gravity and the adhesive pressure in the
17. ELAY value from the GAP value If the shortest GAP is 1 2 seconds at maximum line speed the difference is always positive 1 1 seconds in the maximum line speed situation 22 ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging Rule 3 The minimum possible GAP length any GAP in a multiple GAP pattern can be no shorter than the distance traveled during the ON DELAY of the applicator system at the maximum line speed Reference Table 2 in Appendix Rule 4 The shortest possible bead length in a line speed compensation timer is the length of bead produced in a time equal to the OFF DELAY TIME at the fastest line speed Note it is possible to get short stripes at high line speeds using very small glue in on times in In this situation the valve is not necessarily pulled up completely to the end stop position A partially opened valve has a different off time delay than a fully opened one The ET24 is not programmed to account for this behavior To handle the full line speed range of tracking and compensation with single ON and OFF TIME DELAY values the ET24 is programmed to assume these values are fixed for the valving head Although one could adjust the off time to achieve a bead stripe shorter than the minimum OFF DELAY at maximum line speed calculation the bead length will not be correct at slower line speed conditions Rule 5 ON DELAY and OFF DELAY values are inherent behavior characteristics for a
18. ROGRAM SETUP Valve Group 3 Event Type Duration Valve Group 4 Event Type Duration 4 4 2 2 3 3 4 4 5 5 6 6 T T 8 8 9 9 10 10 42 ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging This page is left blank intentionally Astro Packaging 3845 E Miraloma Ave Unit A Anaheim CA 92806 USA call 714 572 1094 or fax 714 572 1943 44 ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging Ae A Astro Packaging warrants its products when operated and maintained in accordance with Astro Packaging recommended procedures are free of defects in material and workmanship during the periods indicated below commencing with the date the product is placed in service Warranty Product Warranty Period 1 Tank heater including entire tank when 5 years or 10 000 hours of use heater is cast into tank whichever occurs first 2 Melt unit unless specified below pattern 2 years or 2 000 hours of use controller head driver whichever occurs first 3 Stationary hose automatic electric head JR 1 year or 2 000 hours of use Series Hotmelt System or melt unit standard pail whichever occurs first unloader standard accessory purchased with a system 4 Manual hose handgun Mini Squirt III any butyl 6 months or 1 000 hours of use system any PUR system including hose gun whichever occurs first or head used with PUR any spare o
19. When the GLUE event starts no matter when it starts nothing happens for the amount of ON DELAY present in the applicator system in this case 0 1 second of glue time is lost 4 3 Adjustments Continued Thus adjustment of starting point by compensation for ON DELAY shortens the length of the glue bead by the amount of ON DELAY TIME In the example if no correction in bead length were made the bead would be shortened by in 25 mm To obtain the desired bead length the ET24 ON DELAY TIME is automatically added to the GLUE on time where multiple GAP GLUE and even STITCH GAP STITCH GLUE events are present For line speed compensation to be effective there must be a GAP Event or a space before the GLUE Event if there was no GAP event If the limit switch was positioned right underneath the valve so that as soon as the board hit the switch adhesive is expected to appear on the board As just discussed nothing happens for 0 1 second and the glue actually appears on the board 0 1 second s worth of travel later Since the limit switch is under the valve there is no GAP Event Time to move the glue event into and therefore can not provide for ON DELAY Compensation OFF Delay Time The next aspect of applicator behavior which must be taken into account in a line speed compensation situation is the time between the turn off signal to the applicator valve and the moment the adhesive flow actually stops This is called OFF DELAY and is a condi
20. ation MINUTE Hold down ones minute switch under ACTUAL Program Code window Select I O Configuration Program Code using ZONE NUMBER switch Forced Learn MODE Hold switch up or down Configuration Lock Unlock Black switches under SET VALUE HOURS window To lock configuration hold up hundreds and ones switches under SET VALUE window simultaneously To unlock configuration hold down hundreds and ones switches under SET VALUE window simultaneously 12 ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging 2 Alternating gap and glue of 0 5 sec duration 3 Alternating gap and glue of 0 5 sec duration 4 Alternating 0 5 sec gap and stitch 25 ms cycle Trigger Modes The ET24 can be configured so that the event sequence continues only as long as the photo eye trigger signal is active This Mode called Duration is selected by holding switch B DOWN during the configuration procedure To re initiate the event sequence the trigger signal must be deactivated and then activated again In Single Shot Mode the ET24 initiates a sequence once the photo eye is triggered The sequence continues to run until completion even if the trigger signal is terminated This trigger mode is selected by holding switch B UP during configuration procedure The ET24 triggers when the sensor changes state high to low or low to high Trigger Signal OFF to ON is selected by holding switch J UP during the c
21. ators illuminate according to unit of measure selected 2 3 SETUP Switches Select setup number to be run 4 DURATION Selector Switch Display and Indicators Switch selects Duration Mode Line Speed Mode or Count Mode Display shows value for Duration Mode Line Speed Mode or Count Mode Indicators illuminate when particular mode selected 5 6 7 8 DURATION Switches Toggle up to increase or down to decrease displayed event duration DURATION Mode is defined in units of TIME seconds or LENGTH inches meters In LINE SPEED Mode switches are inactive In COUNT Mode switches reset count to zero at start of production run 9 EVENT Selector Switch Display and Indicators Switch Selects STITCH GLUE or GAP event types stitch event is chosen the overall stitch time the stitch gap time and the stitch glue time must be defined Select an event number starting with Number 1 and increase sequentially to create a pattern string Display EVENT numbers Up to 24 sequential events can be programmed for each valve group setup If the duration selected is From Start trigger point the 24 events are arranged as 12 gap glue event pairs In Count Mode displays represent two most significant digits of six digit count Indicators Illuminates type of event selected 10 11 EVENT Number Switches Selects event numbers Odd numbered events are gaps no glue even numbered events are glue or stitch Also resets counter digits in Cou
22. bead length is equal to or less than the OFF DELAY TIME the calculation produces a zero or negative value and a correct compensation cannot be made For example attempting a 0 5 in bead at 50 fpm requires only 0 05 second On Time That On Time is less than the 0 1 second OFF DELAY TIME used in the example This factor defines a limit on bead length for purposes of OFF COMPENSATION for a particular OFF DELAY TIME at a given line speed which is stated in H 3 Rules for ON and OFF Delay 4 3 Adjustments Continued Rules for ON and OFF DELAY Line Speed Compensation Rule There must always be a GAP event first after the input trigger before the GLUE event ET24 does not allow Event Number to be a GLUE event the program does not permit it Rule 2 a The trigger point sensor eye placement must be physically placed up stream of the valve a sufficient distance b The minimum distance between the trigger point and the valve must be longer than the distance travelled by the product at the maximum line speed during the ON DELAY TIME In the example with 0 1 second ON DELAY and assuming a maximum line speed of 30 ips 750 mmps the trigger point must be as least 3 0 inches 75 mm upstream from the Head In fact the trigger is located 36 in 900 mm upstream so the time it takes the board to travel from the trigger point to the dispense point at 30 ips 750 mm is 1 2 seconds The compensating timer is subtracting the 0 1 second ON D
23. e Applicator Pump Motor dou Set Temp Standby Temp Overtemp Adhesive Flow ttt UN Tank Heater Alarm Actual Temp The manufacturer reserves the right to make design changes for product improvement This manual may not reflect all details of these improvements ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging 2 Introduction 2 1 Description 2 2 Features ET24 is a solid state timer tracker pattern controller that controls glue gap or stitch adhesive patterns at fixed or variable line speeds 24 sequential pattern events can be programmed in units of time time resolution is one millisecond or length length resolutions are 01 in 02 in 05 in or 10 in metric unit length resolutions are 5 mm mm 2 mm or 3 mm These events are automatically adjusted to line speed in variable line speed applications ET24 accepts 4 input triggers and provides power output simultaneously to 4 independent valve groups A valve group consists of one to four E100 style applicators or up to sixteen E900 style valve modules 20 pattern setups can be stored in memory when power is off Precise adhesive patterns are programmed in time mode for fixed line speed applications with glue and gap events up to 9 999 seconds at 1 millisecond resolution Glue events may be stitched ET24 has a built in Time to Length Converter TLC that allows programming of adhesive patterns in units of length with resolutio
24. ev D 04 07 09 11 4 2 Power On Switch Selections Customizing ET24 Powering on ET24 while holding the switches listed below for 2 seconds causes the following changes Function Switch Action Clear Memory TEST Push and hold green TEST switch to left Resolution Display SETUP Push and hold green SETUP switch up or down Current Length Trigger Mode Selection DURATION Push and hold green DURATION switch down for Duration Mode and up for Single Shot Mode Trigger Signal Black switches under Hold hundreds switch up or down during Power On SET VALUE window Continue holding this switch toggle black switches up to increase and down to decrease Auto Standby time Set Alarm Time to Auto CLOCK Hold switch up for 300 second setting or down for 90 Shut off ON OFF second setting Change All Zones STANDBY Temperature Offset Simultaneously ZONE NUMBER Black switches under SET VALUE window Hold ZONE NUMBER switch up or down during Power On Continue holding this switch while toggling black switches under SET VALUE window Change All Zones HIGH LOW Temperature Limits ZONE NUMBER Black switches under Hold ZONE NUMBER switch up or down during Power On Toggle black switches under ACTUAL Simultaneously ACTUAL window window Sequential System Heat Up TIME SET CLEAR Hold switch up for On and down for Off Enable Auxiliary Features ZONE and Hold switches up together ZONE NUMBER I O Configur
25. given applicator system as installed on a specific parent machine Once determined for a given installation the ON and OFF values do not change except for factors such as component wear 4 3 Adjustments Continued ON and OFF COMPENSATION as in actual production Keep in mind that ET24 is only working with the GLUE events not the GAPS It is designed to put the GLUE patterns in the correct locations not the GAPS If the GLUES are correct the GAPS are correct Calculating ON and OFF Delay Time Method a Set the ET24 ON and OFF DELAY value settings to zero b Enter the desired adhesive pattern length into the ET24 display c Runthe machine at two different line soeeds and compare the actual deposition patterns Reference Table 4 in Appendix Always measure and set the ON Delay first After setting ON Delay run the system at low and high line speeds again and check that there is no shift in the pattern start Now measure the OFF Delay shift change in length at the two line speeds and perform the calculation found in Table 5 of the Appendix Method 2 The Empirical Method using Astro Packaging high line speed valve I Input ON DELAY values keep the start of the first glue bead in correct position regardless of line speed Try 8 12 ms 2 Input OFF DELAY values until the total length of the glue bead is constant regardless of line speed Try 8 12 ms Line Speed Compensation Brief Review A line speed compensation system is re
26. he control switch associated with the function in the desired position Control Switches are defined below 3 While holding the switch in this position turn the power ON 4 Hold the control switch for at least one second and then release Programming Reference illustration on Page 1 Turn power ON to initiate a self test All LEDs illuminate and all windows display the number 8 2 Push the Program setup Switch B until the readout displays the desired program setup number The event sequence is stored in this location The unit is now ready to accept and store the program setup A full set of multi head multi event patterns can be stored in each Setup A different setup can be stored for each different package type or configuration Package types can be changed in seconds by selecting stored setup Any setup timing parameter can be modified when system active Modifications are immediate and permanently stored in memory 3 Setthe mode option to Duration using the Mode Selector Switch D 4 Setthe Duration to Time Length or Time Length From Start both LEDs on using the Duration Type Selector Switch A Selecting Length VE Length From Start requires that a TLC or Line speed Tracker Fl option is set and properly adjusted See Section l l 5 Select the appropriate valve group to be programmed by pushing the valve Group Number Select Switch L until the desired digit is displayed Copyright 2009 Astro Packaging ET24
27. he stripe shifts its starting point from the original slow line speed position to a new position and length at the highest line speed Now measure the difference using a hundredth of an inch or millimeter scale Next determine the lowest and highest line speed that the parent machine operates using the Line Speed Mode of ET24 Now determine the valve open response time using the following calculation English Head Open Pattern Shift in 001 Inch Increments Response Highest Line speed Lowest Line speed X 02 Metric Head Open Pattern Shift in Millimeters Increments Response Highest Line speed Lowest Line speed x 16 66 Example valve 400 in 0 010 sec Response 500 fpm 300 fpm x 0 2 Setting valve Compensation After the valve On Responses have been calculated they can be 28 ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging programmed into the ET24 using the following procedure First turn ET24 power OFF for 2 seconds turn power ON while hold the Mode Switch down continue holding this switch while specifying the valve compensation When the Mode Switch is held during power up the ET24 displays the valve number starting with valve number 1 the type of compensation either On indicated by the Glue LED or Off indicated by the Gap LED and the currently programmed compensation in milliseconds from 0 to 99 To modify the Duration toggle the Duration Switch under the digit yo
28. head If Driver is connected check that the trigger Light on the Driver is illuminated when the ET24 valve Group LED red illuminates 8 E 100 valve does not activate even though there is output from ET24 Check all wiring Tighten at terminal strip screws in Melt Unit Check valve coil electrical resistance with an ohm meter A 115 volt coil should read 52 55 ohms and a 230 volt coil should read 212 214 ohms Check if the valve and Hose are at application temperature 9 The output is erratic or inoperative 10 DispLay and or switches Lock up Check Line Speed indicator The dropout value is set at 10 FPM There is no output from the timer if the line speed in Length Mode drops below 10 FPM Turn the power OFF for at least five seconds Turn the power ON Clear memory 7 Repair and Replacement E 2 Servicing ET24 WARNING YOUR ET TIMER SHOULD NEVER BE POWERED WITH THE WIRING COVER REMOVED BEFORE COMMENCING WITH ANY ELECTRICAL REPAIRS DISCONNECT THE POWER FAILURE TO FOLLOW THESE INSTRUCTIONS COULD CAUSE PERSONAL INJURY OR PERMANENT DAMAGE TO THE TIMER Servicing the ET24 is accomplished via the Astro Packaging Exchange Program Contact the Technical Services Department for more details To remove the ET24 simply remove the screws that hold the unit in place and return it to Astro Packaging for repair The ET24 fuses are located behind the wiring cover The cover is removed by simply pulling it off of the two
29. hese exposed surfaces may be hot and take time to cool after the unit has been operating Keep parts of the body away from rotating parts Do not wear loose articles of clothing when operating or servicing units with rotating parts Remove wristwatches rings necklaces or other jewelry and cover or pin up long hair before performing any work on or with the unit Trained operators may perform only external equipment adjustments Internal adjustments and service must be performed by trained service technicians Determine voltage of this equipment before installation and confirm compatibility with available power Equipment must be connected to a properly grounded circuit and installed in accordance with all applicable electrical codes Ground fault protection must be provided in supply circuitry at site installation Models designed to EN60204 1 1993 require power cords be approved to a harmonized HAR standard and rated for 70 C 158 F A HAR approved Type B plug and strain relief for power cord are required to meet standard IEC 309 Power conducting wires must be nominal 4 mm 12 AWG maximum and nominal 1 3 mm 16 AWG minimum In the event of a malfunction turn off power to the equipment at the power off switch and remove source power to the system at the nearest main disconnect Read the product manual thoroughly before installation operation or maintenance Failure to do so can result in a serious accident or equipment malfuncti
30. imum line speed maintaining maximum line speed for a short period and then decelerating to a stop again This type of Movement may be too rapid to be handled by the ET24 Arranging two photo optic eye sensors so that both must see the substrate to trigger the ET24 provides accurate start stop edges control This triggering method has proven to be effective handling excessive acceleration deceleration rates 4 3 Adjustments Continued Line Speed Compensation Conclusion This presentation has discussed the basics of Line Speed Compensation for variable line speed adhesive applications ON and OFF COMPENSATION is required for accurate pattern control when line speeds vary more than 10 feet per minute and becomes more critical the higher the line speed The need for the Compensation is based on the inherent Response Time of the applicator 24 ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging Head This Response Time has been analyzed in two main components ON DELAY TIME as the valve turns on or opens and OFF DELAY TIME as the valve turns off or closes Examples have illustrated what happens to pattern location and length with each of these delays between timer signal and actual completion of the appropriate valve Response Methods for calculating the applicator response delays have been provided and are the basis for making the COMPENSATION adjustments to the original timing LINE SPEED TRACKING
31. ing the line speed Calibration Potentiometer Prior to setting the TLC the Programmable Length Resolution must be set refer to pages 1 1 and l 2 for the procedure There are two methods for setting the TLC adjustment Method One If you already know your line speed or you have an accurate tachometer available for measuring line speed simply set ET24 to this line speed This is done by selecting the Line Speed mode on the ET24 front panel and adjusting the line speed Calibration Potentiometer POT from it s full counter clockwise lowest line speed indication position so that the displayed reading is the same as the actual line speed in feet per minute Meters per minute in metric mode kkk NOTE The last digit displayed may change plus or minus one digit due to adjustment sensitivity This is normal and does not affect subsequent length settings Copyright 2009 Astro Packaging ET24 Pattern Controller 19600 84 Rev D 04 07 09 17 Method Two Eliminates the need for prior knowledge of line speed Simply set ET24 so that a one inch glue stripe would be generated by one of the heads Now run the machine with the line speed POT in the full counter clockwise position and measure the actual length of the glue stripe If it is shorter than one inch adjust the line speed POT in a clockwise direction about one quarter turn Re run the machine and measure the stripe again The stripe will be longer by an increment This helps estimate ho
32. n Line Speed mode Check original setup to insure the tachometer shaft rotates in the clockwise direction if the shaft is required to rotate in a counterclockwise direction rewire the tach generator reference C 1 4 Check to see if the Duration is set in Length or Length From Start In Time Mode the line speed will read a fixed value Check voltage from Tach Generator at Terminals 34 and 35 tach output is 45 volts 1000 r pm Terminal 34 is with respect to terminal 35 Examine the jumper under the connector to insure it is in the proper position Make sure resolution is not set too low for number of heads and line speed 4 Trigger Input LED not blinking when sensor is activated Check polarity of trigger output and determine if it is wired property 5 Trigger Input LED on continuously ET24 not being triggered Photo switch is in normally closed or ON mode Et 24 can be triggered by an ON to OFF transition by reconfiguring input trigger sense Reference D 1 3 6 D C output Modules are always ON Copyright 2009 Astro Packaging ET24 Pattern Controller 19600 84 Rev D 04 07 09 31 Trigger has no effect and no adhesive pattern is being generated DC output switches DC voltage up to 60 VDC up to 3 amps in one direction only polarized output If pattern polarity is inverted output remains on 7 The E 100 valve does not activate from the D C output of ET24 DC Driver needs to be placed between the ET DC output the
33. n as low as 0 5 mm 0 01 in in both fixed line speed and line speed tracking modes With line speed input from a Tach Generator ET24 has line speed tracking capability that automatically maintains constant pattern length at varying line speeds Memory for 20 multi valve multi event programs allows quick selection of pre stored patterns Note 12 VDC 200 mA or 24 VDC 200mA power is provided for photoeye triggers and to signal head drivers Additional power source for triggering devices may be required in some applications Simple toggle switch programming 4 independent trigger inputs Independent event programming in time or length for 4 valve groups Program and configuration lock Digital readout and LED indicators Metric or English scale Displays product count and line speeds Stores 20 pattern setups Controls deposition on fixed or variable line speeds Controls parent machine time dependent functions Adjustable low line speed drop out Copyright 2009 Astro Packaging ET24 Pattern Controller 19600 84 Rev D 04 07 09 3 3 Installation A WARNING ET24 must be connected to a properly grounded circuit and installed in accordance with appropriate local electrical codes Incorrectly connected equipment can result in personal injury or damage to the equipment Astro Packaging will not be held liable for injuries or damage whether directly or indirectly caused by use or misuse of this equipment WARNING nPUT
34. nd to signal head drivers Electrical ET24 and Tachometer Supply Power 200 mA 115 V 20 50 60 Hz or 100 mA 230 V 20 50 60 Hz Input Trigger Voltage 5 24 VDC 4 25 mA Type Rise or Falling Type Signal Selectable Switch closure semi conductor switch optical detectors or proximity detectors Mode One Shot sequence initiates and completes with one trigger input Duration sequence initiates and continues while trigger signal is engaged Program Outputs 5 60 VDC 3A or Switch Capacity 60 240 V 3 A 0 crossing switch Quantity 4 Head groups of up to 4 heads each Power Supply Outputs 5 VDC 1 0A 12 VDC 0 5 A 24 VDC 0 5 Tachometer Output 33 VDC per 1000 rpm Appendix A Specifications Continued Physical Enclosure Gasket sealed water resistant metal with transparent window that meets NEMA 4 specifications Operating Temperature 0 66 C 32 150 F Storage Temperature 30 70 C 22 158 F 36 ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging Performance Copyright 2009 Astro Packaging ET24 Pattern Controller 19600 84 Rev D 04 07 09 37 Event Length Range 0 5 mm 9 999 m 0 01 999 9 in Low Rate Drop Out 2 99 mpm 5 99 fpm Head Compensation Setting Range 0 99 ms Line Speed Tracking Maximum Line Speed Head Resolution Setting English Group 0 01in 0 02in 0 05in Olin feet
35. nd ON I pulses at 100ms 10ms with the number of on pulses indicating the requested setup e The stop pulse must be greater than 130ms f This remote selection of setup overrides a portion of the Configuration Lock feature g ET24 completes any patterns in progress before triggering patterns for newly selected setup To ensure reliable performance installer must follow the wiring guidelines such as using shielded twisted pairs for signal wiring adequate separation from high current lines etc 8 Parts List 8 1 Accessories and Spares Tach Generator for Line Speed Tracking ltem Description Quantity Part Number Tach Generator with 5 ft Cable Assembly 73780 105 Tach Generator with 10 ft Cable Assembly 73780 110 Tach Generator with 15 ft Cable Assembly 73780 115 Tach Generator with 20 ft Cable Assembly 73780 120 Tach Generator with 25 ft Cable Assembly 73780 125 Mounting Kit Tach Generator 79184 1 includes pulleys gear belts and brackets Miscellaneous 34 ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging Item Description Quantity Part Number Kit ET24 Replacement Module 79195 02 includes power supply does not include output module power switch enclosure or fuses Module AC Output 24 280 V 5A 12047A 3 Module DC Output 5 60 VDC 3A 12047A 2 Fuse 4 AMP 115 230 V for Output Relays 12014 4B Fuse 5 AMP 230 V 12014 5B Fuse 10 AMP 115 V 12014 10B
36. nses have been calculated and can be programmed into the ET24 using the following procedure When the Mode Switch is held during power up the ET24 displays the valve number starting with valve 1 the type of compensation ON indicated by the Glue LED or OFF indicated by the Gap LED and the currently programmed compensation in milliseconds from 0 to 99 During the configuration procedure sect D 2 hold switch D down while specifying the valve compensation To modify the duration toggle the Duration Switch under the digit to be changed To select On or Off Compensation toggle switch I To select a different valve number toggle switch L When correcting the valve Response the ON DELAY compensation must be set first The product must run at the lowest and highest line speeds with the ON compensation adjusted to the valve Open Response Time calculated The adhesive starting point should not shift more than the resolution setting Note that the adhesive stripe is longer at the high line speed than at the lower line speed Measure the difference again and use this measurement in the valve Response calculation Using the set valve compensation procedure set the OFF DELAY Compensation This completes the valve Response Compensation procedure Configuration Procedure All configuration functions on the ET24 remain as set until changed by the following procedure To change a function 1 Turn the power off for at least two seconds Place t
37. nt Mode 12 VALVE GROUP Selector Switch Display and Indicator Selects 1 of 4 valve groups The valve group number displayed is the group being programmed or monitored Select 1 of 4 possible relay outputs normally used to control an applicator valve valve groups of up to 4 valves each This LED illuminates each time a glue or glue stitch event occurs for the valve group displayed 13 SENSOR INPUT Selector Switch Display and Indicator Assigns a selected trigger number to the valve group displayed in the valve group window The number displayed is the Input Sensor Trigger which activates any valve group once the ET24 is programmed Select 1 of 4 sensor trigger sources The selected sensor trigger input is assigned to initiate the event sequence for the displayed valve group This LED illuminates with each trigger input event 14 TEST Switch Sensor Input or Valve Group Pushing the TEST switch to the left simulates a trigger sensor input The valve timing sequence begins for the valve group displayed in the valve group window and continues as long as the switch is held in this position Pushing the TEST switch to the right activates the valve group displayed and illuminates the LED as long as the switch is held in this position Note This switch can also be used as an emergency STOP switch If it is pushed to the left and released during the running of a program setup it stops the program Copyright 2009 Astro Packaging
38. omenon with the opposite cause and effect standpoint valve Closing Response is a result of the amount of time delay after a glue event is commanded to stop by ET24 and the actual end of the adhesive stripe on the product The effect is a lengthening of the glue stripe related to increased line speed of the product With line speed changes of 10 feet per minute or less the valve Closing Lag can be ignored Correcting for valve opening and closing response is an easy procedure with ET24 First determine the valve open response time Deposit adhesive on the product at the slowest line speed Speed up the machine to its highest pace and deposit adhesive a second time The stripe will have shifted its starting point from the original slow line speed position to a new position and length at the highest line speed Now measure the difference using a hundredth of an inch or millimeter scale Next determine the lowest and highest line speed that the parent machine will operate using the Line Speed Mode of ET24 Now determine the valve open response time using the following calculation Head ON OFF Delay Compensation continued ENGLISH valve Open Pattern Shift in 001 Inch Increments Response Highest Line speed Lowest Line speed x 0 2 METRIC Head Pattern Shift in Millimeters Increments Response Highest Line speed Lowest Line speed x 16 66 14 ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging Head On Respo
39. on The manufacturer will not be held liable for injuries or damage caused by misuse of this equipment 1 6 Safety Symbols an Signal Words The following safety symbols and signal words are used throughout the manual and on the product to alert the reader and operator to personal safety hazards or to identify conditions that may result in equipment or property damage General Safety Symbols DANGER Indicates a hazard which if not avoided will result in A serious injury including death or equipment and property damage Pa WARNING Indicates a hazard which if not avoided can result in A serious injury or equipment and property damage CAUTION Indicates a hazard which if not avoided can result in A minor injury or equipment and property damage Specific Symbols and Signal Words DANGER High Voltage Can cause serious injury including death 4 Disconnect electrical power at external source before servicing WARNING Hot Surface Can cause serious injury and burns Ag Wear heat resistant clothing gloves and safety goggles WARNING Disconnect electrical power at external source Failure to do so can cause electrical shock WARNING High Pressure System contents under pressure Can cause serious injury and burns or equipment and property damage Relieve pressure before servicing Other Product Symbols O PE Ground Protective Earth H S v kel Tank Heated Hos
40. on Mode determines the units used see 16 Set the duration of the event either in seconds or inches Full scale is 9 999 seconds 99 99 inches or 999 9 inches When Line Speed Mode is selected the display shows the line speed in feet or meters per minute requires tachometer or TLC When Count Mode is selected the number of times the ET24 was triggered is displayed This count can be zeroed or preset using the toggle switches under each digit In Count Mode the event display is also used to display the 2 most significant digits of the count ET24 can maintain counts for up to four separate triggers When internal wiring is required proceed as follows a Strip wires 8 mm 0 30 in b Unplug the connector from its receptacle If removing more than one connector note each connector s proper location c Retract terminal spring by holding the orange connector 1 in one hand and firmly inserting a screwdriver with a 3 mm 5 32 in blade into terminal slot 4 When screwdriver is fully inserted the terminal spring is held open d Insert correctly stripped wire into terminal 3 Only two wires of the same gauge may be inserted into the same terminal slot For 1 wire 12 AWG maximum 28 AWG minimum For 2 wires 16 AWG maximum 28 AWG minimum e Remove screwdriver releasing spring f Tug on wires to ensure the connection is secure g Plug connector s into receptacle s 6 ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copy
41. onfiguration procedure A rise type trigger is activated when the incoming signal goes from OFF to ON By holding switch J DOWN during the configuration procedure the ET24 input trigger can be configured to activate when the incoming signal is falling This trigger signal is known as ON to OFF This trigger type is inactive when voltage is applied and is activated by opening or grounding the incoming signal Metric or English Function English or Metric display is for Length or Resolution values Metric is selected by holding the Sensor Input switch M in the DOWN position during the configuration procedure English is selected by holding switch M in the UP position during the configuration procedure Program Lock Program Lock is used to protect stored values To toggle between locked and unlocked mode hold switch L DOWN while pushing Trigger Test switch N to the right This is not a power on procedure Configuration Lock Unlock Configuration lock is used to prevent access into any unused valve Groups and to protect programmed configurations from being changed To toggle between lock and unlock modes hold switches E and H UP to lock and DOWN to unlock while powering up timer Line Speed Tracking Resolution The Length Resolution function is the number of valve groups and the systems ability to track line speed of the parent machine As the line speed of the parent machine increases the resolution decreases Switch A is held up or do
42. ong bead of glue 4 3 Adjustments Continued Next assume that the applicator system is perfect there is no delay between the instant the timer sends the signal for the applicator to turn ON and when the adhesive actually hits the board to start the pattern Also there is no delay between the timer signal and applicator shut OFF the adhesive bead stops on the board at the same instant as OFF The line speed of the traveling board must be known before the time settings for the two events can be calculated If the board is traveling at 50 fpm or 15 mpm GAP time setting is as follows at a line speed of 10 ips we must wait for the 36 in of board travel to occur before we fire the applicator Divide 36 in by the line speed of 10 ips and the answer is 3 6 seconds for the GAP setting Reference Table in Appendix The 24 in glue application should stay ON 2 4 seconds at 50 fpm if an ideal situation existed where o there are no time delays between the time the valve is turned ON and the time the adhesive appears on the substrate and or o no delays between the time the valve is turned OFF and the time the adhesive stops then these timer settings would place the adhesive bead exactly where it needs to be on the boards for the two different line speeds ON and OFF DELAY TIMES ON Delay Time With an actual applicator system the ideal situation presented above never Copyright 2009 Astro Packaging ET24 Pattern Controller 19600 84 Rev
43. quired to make accurate calculation of ON DELAY TIME and OFF DELAY TIME values These two values are the key operating elements to the system Without them accurate line speed compensation cannot be accomplished and patterns are out of registration and the glue lengths are not correct Remember ON DELAY and OFF DELAY are totally independent of each other Both values must be set for accurate adhesive deposition It is important to note that the ET24 line speed compensation device is Copyright 2009 Astro Packaging ET24 Pattern Controller 19600 84 Rev D 04 07 09 23 designed to correctly apply adhesive to a given substrate when the substrate is moving at varying line speeds within a given range of acceleration and deceleration If the acceleration or deceleration is excessive an improper pattern may result There are two types of production situations where a changing velocity is encountered I The machine line speed gradually accelerates and slows down with the line production Here the pattern may shift slightly because the ET24 computer is working with old line speed input data The ET24 recalculates ON and OFF compensation every 0 1 seconds If the line speed changed dramatically during this 1 10 of a second the deposited pattern would be incorrect reference Table 3 in Appendix 2 The product moves in an intermittent motion under the glue head Each product piece moves in a cyclic pattern from stop accelerating to max
44. r replacement component pneumatic head industrial heated hose T100 Temperature Controller nozzle nozzle bar 5 Rebuilt equipment 90 days or 500 hours of use whichever occurs first B The sole liability of Astro Packaging and exclusive remedy extended to any Astro Packaging customer shall be limited to replacing or repairing at the option of Astro Packaging any product returned under the terms of this warranty Labor and related expenses incurred to install replacement or repaired parts are not covered by this warranty C Astro Packaging is not responsible for repair or replacement of any product that has been subject to abuse misuse alteration accident or negligent use nor for repairs made by an unauthorized person or with parts other than those provided by Astro Packaging D Astro Packaging assumes no responsibility for the performance of adhesives or other materials used with its products E The warranty for a product repaired or replaced under this warranty shall continue in effect for the remainder of the original warranty period or for ninety 90 days following the day of shipment by Astro Packaging of the repaired or replaced product whichever period is longer F No warranty is made with respect to custom products or products developed designed and manufactured to customer specifications except as specifically stated in writing by Astro Packaging G Astro Packaging is responsible only for payment of shipping charge
45. readout may be encountered Changes of 1 or 2 digits is normal and do not effect performance If the readout is fluctuating greater than 1 or 2 digits check the Tach Generator coupling for excessive physical bounce or misalignment Align the tach generator so that it is as close to the axis of the rotating coupling shaft as possible When using a gear belt and pulley set it tight and as near perpendicular to the moving surface 26 ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging as possible It is recommended an idler gear be used to prevent exceeding the one pound over hung load rating of the Tach Generator EXAMPLE OF SHAFT COUPLING EXAMPLE OF FRICTION WHEEL EXAMPLE OF GEAR BELT AND PULLEY Once ET24 is adjusted to the proper line speed no further adjustment is required it tracks line speed changes accurately Method Two This method is used when there is no way of pre determining the line speed of product movement setup ET24 so that one valve group can be triggered Select the glue event and length mode and length mode of operation Set the four length digits to a predetermined number such as 1 000 inch the longer the better Once set run the line at the slowest line speed With the product in place deposit adhesive on the product Next remove the product from the machine and measure the actual length of the adhesive stripe If length is incorrect adjust the POT from its full counter clockwi
46. right 2009 Astro Packaging Power for the ET24 internal functions is 200 mA at 115 VAC or 230 VAC 50 60 Hz The diagram below is a guide to the electrical connections within the ET24 Following are examples of different types of trigger configurations Program Lock with power on Configuration Lock Head Group Hold down Hold switches H and E UP during power up to toggle between lock and unlock mode Trigger common terminals 20 22 24 and 26 are connected together internally The ET24 accommodates only one sinking type trigger Sourcing triggers are required when multiple triggers are needed Interconnect Wiring Example TA Designates terminal point found within the melt unit Interconnect Wiring Example 2 The ET24 is configured for line speed tracking using the tachometer generator A 24 VDC Photoeye powered by the ET24 senses a carton and triggers the ET24 with a 24 VDC signal The 24 VDC output of the ET24 sequences an Astro Packaging DC Driver for valve 1 TA Designates terminal point found within the melt unit Interconnect Wiring Example 3 The ET24 is configured for line speed tracking using the tachometer generator A 12 VDC signal from a Programmable Controller triggers the ET24 The ET24 activates an output signal to the valve group relays which in turn activates the DC Driver to fire a valve solenoid Wiring Diagram ET24 to Tachometer Note When viewing face of tachometer rotation should be clockwise
47. rnal Time to Length Converter TLC The ET24 is triggered by a case sensor switch The valve group outputs are wired directly to the melt unit 115 V valve coil circuit The melt unit is configured for an internal wired HAT Head Activated Test switch Any output can be used to control other equipment such as electric motors or air solenoids The outputs are optically isolated from the timer to prevent electrical noise problems AC or DC output relays are available Trigger source can be a simple switch closure sensor or semiconductor switch as used in optical or proximity detectors Any trigger source can be program assigned to initiate an event sequence for any valve group The assignment is made using the front panel switch No rewiring is required to change the trigger source for a valve group The term valve group is used because each output provides a sufficient voltage and current capacity to activate 4 heads from the same program control relay These four heads are activated in parallel running the same program event setup The valve group output can be operated with any mix of AC or DC program output relays specified at the time of the order Each valve group event sequence is programmed independently and the program is permanently stored in memory Up to four valve groups can be programmed each with its own 24 event sequence When the input is triggered all valve group program setups are initiated simultaneously Selecting Durati
48. s The matrix below shows Switch and Display actions Rate Mode Switch and Display Copyright 2009 Astro Packaging ET24 Pattern Controller 19600 84 Rev D 04 07 09 29 Switch Display Sensor Inactive Inactive Head Group Inactive Inactive Event Number Inactive Inactive 30 ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging Event Type Inactive Inactive Last 3 digits of Duration Inactive Duration Display Rate Duration Type Inactive Inactive Set Up Inactive Inactive Count Mode Switch and Display Switch Display Function Indicate Sensor Sensor Active Active Associated with count Head Group _ Inactive Inactive Most significant Event Number Active Active digits of Count Switch used to reset Event Type Inactive Inactive Most significant Duration Active Active digits of Count Switch used to reset Duration Type Inactive Inactive Indicates setup Set Up Active Active associated with count 5 Maintenance No maintenance required on ET4 6 Troubleshooting 1 Setup display flashing The Duration type Time From Start or Length From Start has been improperly programmed Check data entry for over Lapping errors 2 Glue or Gap suddenly doubles in Length while parent machine is accelerating The resolution is set at a tolerance that is too fine for the line speed of the tracker Adjust ET24 resolution to a Lower tolerance Ref D 1 8 3 No line speed reading i
49. s displayed in the Durations three least significant digits The possible resolutions are 0 01 in 0 02 in 0 05 in and 0 1 in 1 2 3 mm To modify the current resolution toggle the least significant Duration Switch while the Duration Type switch is being held up for a larger resolution or down for a smaller resolution The resolution must be set for the number of heads on the system and the maximum system line speed If the resolution is set too fine for the maximum line speed the ET24 may misread the tach and generate a glue stripe that is twice as long as called for at high line speed Number of Heads Resolution Setting 1 Head 2 Head 3 Heads 4 Head 0 01 inch 180 ft min 90 ft min 60 ft min 4 5 ft min 0 02 inch 260 ft min 180 ft min 120 ft min 9 0 ft min 0 05 inch 900 ft min 450 ft min 300 ft min 225 ft min 0 10 inch 1800 ft min 900 ft min 600 ft min 450 ft min mm 110 m min 55 m min 37 5 m min 27 5 m min 1mm 220 m min 110 m min 75 m min 55 m min 2mm 440 m min 220 m min 150 m min 110 m min 3 mm 660 m min 330 m min 225 m min 165 m min 4 3 Adjustments Continued Line Speed Calibration There are two methods of line speed calibration Method One After measuring the line speed of product movement place the ET24 into line speed mode and adjust the Line Speed Rate POT fully counter clockwise and then clockwise until the line speed reading on the ET24 is the same as the line speed being measured Slight changes in the ET24
50. s for delivery of a repaired or replaced product via the least expensive means of transport to customer or an authorized Sales and Service Center in the Continental United States only Payment for shipment to Astro Packaging or an authorized Sales and Service Center for evaluation repair or replacement is the responsibility of the customer H For service under this warranty contact the factory authorized representative from which the product was purchased THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY EXPRESSED OR IMPLIED INCLUDING THE WARRANTY OF MERCHANTABILITY AND FITNESS FOR THE PARTICULAR PURPOSE Equipment Record Record the information below on all equipment received and retain for your record Systems melt units hoses guns heads pattern controllers drivers etc Products were purchased from Astro Packaging Product Model Description Serial No Product Part Number Order No Date Received Start Up Date Invoice No Product Model Description Serial No Product Part Number Order No Date Received Start Up Date Invoice No Product Model Description Serial No Product Part Number Order No Date Received Start Up Date Invoice No Product Model Description Serial No Product Part Number Order No Date Received Start Up Date Invoice No Product Model Description Serial No Product Part Number Order No Date Received Start Up Date Invoice No Product Model Description Serial No Product Part Number Order No Date Recei
51. se position This operation may have to be repeated three or four times to dial in the exact length desired Once accurately adjusted the Tach Generator tracks varying line speeds 4 3 Adjustments Continued Head open and Closing Responses Head Open Response Head Open Response is an electromechanical delay time phenomenon The delay is the amount of time that transpires after the ET24 commands the valve to open and the adhesive actually reaches the product At relatively slow production line speeds or production line speeds that do not vary more than 10 feet per minute valve On Response Compensation is not necessary However where line speeds are varying over more than 10 feet per minute valve Response Compensation must be adjusted for accurate adhesive placement See Section H Line Speed Compensation kkk NOTE kkk The minimum possible GAP length any GAP in a multiple GAP pattern can Copyright 2009 Astro Packaging ET24 Pattern Controller 19600 84 Rev D 04 07 09 27 be no shorter than the amount of inherent ON DELAY found in the applicator system at the maximum line speed ET24 automatically subtracts the ON DELAY TIME value from all GAP Events present Failure to allow for this results in undesirable outputs or adhesive patterns Example A machine using ET24 varies in production line speed from 100 feet per minute up to 500 feet per minute At 100 feet per minute the adhesive stripe is positioned exactly as desired Ho
52. sonable approximation of acceleration related pattern shift can be calculated using the following formula Highest Speed fpm Lowest Speed fpm 40 ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging Pattern Shift in X 0 00033 Time Required To Change Speed Min Highest Speed mpm ibowest Speed mpm Pattern Shift mm X 0 0277 Time Required To Change Seed Min Appendix B Conversion Factors Continued Table 4 English D x D in ON DELAY ms X 1000 ipso psi Metric Do D mm ON DELAY ms X 1000 mmps mmps Table 5 English D Da in OFF DELAY ms X 1000 ipso pS2 Metric D D mm OFF DELAY ms X 1000 mmps mmps PROGRAMMING SEQUENCE LOG PROGRAM SETUP Valve Group 1 Event Type Duration Valve Group 2 Event Type Duration 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 Copyright 2009 Astro Packaging ET24 Pattern Controller 19600 84 Rev D 04 07 09 41 10 10 H H 12 12 13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24 24 PROGRAMMING SEQUENCE LOG P
53. t Change Actual Operation Mode een 18 PROGRAM Indicator Flashes and All Other Displays are Blank 18 SET VALUE LED Flashes sche res ea ne ie RISE 18 T1000 Changes to STANDBY Mode on Its Own o 18 Celsius RUN Temperature Exceeds Maximum 245 C and Goes Into Alarm State 18 RUN Indicator Flashes rn 18 SET VALUE Switches do not Change Display lle 19 DAY HOURS and MINUTES Switches Do Not Change Display nern 19 T1000 Does Not Enter Desired MODE Automatically When CLOCK Feature is Used 19 7 Repair and Replacement 20 7 1 T1000 Prom Replacement s evri eor rsr en 20 8 Parts List 22 8 1 Kits and Spares co ever RE EUREN es ERR aoe ey r EE QURE EE 22 Appendix A Specifications 23 Electrical doe p VERONA E E ends ev e ex des p ERES 23 POYSICA HE 23 Performance se er des eios Vb ius oe pean denied dee Rud wa n e e 23 Appendix B Programming Sequence Log 24 Appendix C T1000 with Special C00 PROM 25 Appendix D Pump Motor Standby B26 or CO0 PROM 29 Warranty 31 ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging 1 Safety Precautions for Hotmelt Applicator Equipment 1 1 Intended Use 1 2 Personal Safety Wear Safety Goggles Wear Heat Resistant Safety Gloves Wear Protective Clothing 1 3 Electrical Safety 1 4 Emergency Power Disconnect 1 5 Follow Directions This manual contains important safet
54. t without effecting adjacent event positions KKK NOTE kkk ANY EVENT CAN BE REPROGRAMMED OR MODIFIED DURING OPERATION HOWEVER THE PROGRAM CHANGES DO NOT TAKE EFFECT UNTIL THE NEXT TRIGGER SEQUENCE Sample Program Two valve system with different patterns 1 Assume the ET24 is being used with a KB 20 on a top and bottom case sealer The top and bottom glue stripes are different The top has a 100 ms gap 300 ms of glue a 500 ms gap and a second glue stripe 300 ms long The bottom valve has a 50 ms gap 400 ms of glue a 400 ms gap and a second 400 ms glue stripe The sensor input is on input Val Sample Program A stitch pattern 2 Assume that valve group 2 event number 4 is a stitch pattern The total stitch Duration is 500 ms with a stitch gap of 25 ms and a stitch glue of 75 ms Event is a 250 ms gap The sequence is initiated from trigger 1 Applicator valve response time creates problems with adhesive placement during varying line speeds The ET24 can be adjusted to compensate for the response time so that the adhesive is deposited at the same place on the product regardless of the line speed Time to Length Converter TLC The Time to Length Converter TLC is an integral feature of the ET24 The TLC generates an adjustable digital signal that makes the ET24 believe it is looking at a constant line speed tracking device The TLC allows programming of the ET24 in length increments rather than time The adjustment is made us
55. th measurements are accomplished by the integrated on board Time to Length Converter TLC in both fixed line speed and line speed tracking modes There are 2 types of event sequences Typical or From Start Typical prior event end defines following event start point or From Start each event referenced to start trigger user can change any event without affecting adjacent pattern placement The string of event sequences can be initiated by a single input trigger The trigger can be generated by a contact closure or an optional photo switch The 4 valve groups are preselected as either AC or DC outputs Any one of 4 input sensors can be assigned to trigger a program sequence for any combination of the 4 outputs Each of the 4 outputs provides the ability to switch up to 4 Astro Packaging valves a Valve Group providing control for a total of 16 valves Sensor input can be triggered from a wide variety of sources switch closure semi conductor switches optical detectors or proximity detectors With the installation of one jumper wire on the terminal strip the ET24 can provide an internal trigger voltage of 5 12 or 24 VDC to an external switch If the external sensor generates its own voltage the ET24 can accept trigger voltages of 5 to 24 VDC Copyright 2009 Astro Packaging ET24 Pattern Controller 19600 84 Rev D 04 07 09 5 3 2 Electrical Circuits and Wiring Continued The ET24 is configured for length mode using the inte
56. the stitch event is complete when the next event number is selected An event gap glue or stitch can be defined in terms of TIME seconds LENGTH inches meters or FROM START duration of events from point trigger first activated Note Do not toggle the Event Type Switch until the Event Number is toggled or timer will revert to a glue event Repeat Steps 5 thru 10 until the desired event sequence is completed An event sequence can be terminated by either programming all 24 events or programming an event with a Duration of 0 000 In the normal event sequence whenever the ET24 see an event with the Duration set at 0 000 the timer assumes this to be the last event in the sequence Repeat steps 3 thru 11 for each valve group Once all valve groups have been programmed the programming for the setup selected in step 2 is 16 ET24 Pattern Controller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging 4 3 Adjustments complete Repeat steps 2 thru 13 for each additional setup 14 The From Start Duration display continues to add each new event to previous gap glue event pairs It also displays the accumulated time or distance for all previous gap glue event pairs To stop the From Start the glue portion of the event pair is set to 0000 The gap event must not be set to 0 or a failure indication blinking digits occurs An event sequence can be programmed in normal sequential mode and switched to From Start to allow moving an even
57. tion like ON DELAY caused by factors in the applicator itself and is unrelated to the line speed of the substrate or line speed In the case of the Astro Packaging electric heads the OFF DELAY is related to the movement of the armature in the guide tube the collapse of the magnetic field spring force in the valving assembly and so forth To simplify the concept one single time value OFF DELAY TIME is used to represent the total effect of all Copyright 2009 Astro Packaging ET24 Pattern Controller 19600 84 Rev D 04 07 09 21 contributing factors To understand OFF DELAY we return to the same example used before and assume that there is a 0 1 second OFF DELAY TIME Also for simplicity at this point assume that there is no ON DELAY TIME Only one dimension changes with OFF DELAY TIME the length of the glue bead increases At 50 fpm 15 mpm the glue Timer setting was 2 4 seconds and switched off at that time setting The actual valve valve did not stop precisely at that point but continued for another 0 1 second At this line speed the glue bead is extended 0 1 seconds x 10 ips 250 mmps inch 25 mm Thus it can be seen that the presence of OFF DELAY causes a longer glue pattern This extended length can be corrected with OFF Compensation OFF COMPENSATION only works with GLUE Events if shortening the glue bead length by the OFF DELAY TIME If at a given line speed the amount of time needed to produce the required glue
58. tion Program Codes 11 Forced Learni a ELI lg pl ATA dira Sl Nok hee 11 4 3 Startup uice I LEA a a ee ERI a 12 SN ERO IR DEE fut REI Ta 12 Setting Zone Temperature Tank Hose or Head 12 Duplicating Temperature Settings iliis tenes 12 Setting Alternate Temperature Limits 13 Change Standby Temperature Setback 111ssass kanan saka saa asas aaa 14 Change HIGH LOW Temperature Limits 1 1s ss sasa aaa sasa skaran a 14 Scanning Temperatures s sasasa saak aaa sasa aaa aka aaa 14 Glock Control ota a Aa aar ita 15 Duplicating DAY Settings i ssssaasasasaaaaaa kakak aaa saak aaa aaa 15 4 4 System Management Lock Procedures s ssasasa aaa aaa sasa kaa 16 Configuration Lock Unlock s sasa sasa saa sasa aaa aa aaa aaa aaa aaa 16 Program Lock Unlock LL 16 5 Maintenance 16 Copyright 2009 Astro Packaging ET24 Pattern Controller 19600 84 Rev D 04 07 2009 Table of Contents Continued 6 Troubleshooting 17 ALARM Indicator is Illuminated 17 Hoses and Heads do not Heat but Tank Does 17 T1000 Controller does not Function and Only Displays Zeros 1 1 sasa saka na 17 HOLD SCAN Switch when Keyed to Right does not Start Scanning Zones 17 Unit Overheats and Shows Alarm Indicators Shuts Down eee eee eee 17 MODE Selector Does Not Change DISPLAY Mode 0c cece eee eee 18 MODE Selector Does No
59. troller 19600 84 Rev D 04 07 09 Copyright 2009 Astro Packaging device itself affect the total glue pattern length by shortening it The distance of the nozzle from the substrate has no effect on the actual length of the glue bead Compensating for the time it takes the adhesive to travel from the nozzle to the substrate by adding this amount of time to the GLUE in on time in produces a longer pattern length than desired This in delivery time in factor is not covered in this presentation Timing adjustments do have to be made where high line speed or distance to substrate make it a significant factor in pattern accuracy To correct for the ON DELAY factor the timer can be equipped with On Delay Compensation or ON COMPENSATION To move the adhesive forward to the correct starting point the ON DELAY TIME should be subtracted from the GAP time This places the start of the adhesive bead exactly where it should be In other words the GAP must be shortened and the valve fired sooner to hit the proper registration mark on the substrate On Compensation shows the effect of subtracting the ON DELAY value from the GAP preceding the GLUE setting The bead is adjusted by anticipating the ON DELAY and starting the GLUE sooner It is important to note however that although the start point has now been corrected the actual length of the bead pattern is still shorter than desired because the total GLUE time was fixed for a specific amount 2 4 seconds
60. u wish to change Always measure and set ON DELAY compensation first When the pattern start point is not shifting with changing line speed measure the change in patter length caused by the OFF DELAY Determine and set the OFF DELAY using the same procedure and formula used for ON Delay To select ON or OFF Compensation toggle the Event Type Switch To select a different valve number toggle the valve Group Switch Note Make certain the ON OFF compensation does not interfere with the glue pattern at high line speeds Example At 250 feet per minute a 0 5 inch glue stripe is laid down in 10 milliseconds If the off compensation is 15 milliseconds there is virtually no time for the valve to open Head Response Compensation Procedure ON DELAY Compensation Must be set first and the product run at the lowest and highest line speed with the on compensation adjusted to the valve Open Response Time calculated above The adhesive starting point should not shift more than the resolution setting Note that the adhesive stripe is longer at the high line speed than at the lower line speed Measure the difference again and use this measurement in the in Head Response in calculation Using the set valve compensation procedure set the OFF DELAY Compensation This completes the valve Response Compensation procedure Rate or Count Mode Switch amp Display Interaction Inline line speed and Count Modes the display and switches take on new function
61. ved Start Up Date Invoice No Product Model Description Serial No Product Part Number Order No Date Received Start Up Date Invoice No Astro Packaging 3845 E Miraloma Ave Unit H Anaheim CA 92806 714 572 1094
62. w many more quarter turns of the potentiometer that must be made to lengthen the stripe to one inch Example e If on the first run the stripe was one half inch and a one quarter turn lengthened the stripe by one eighth inch it takes three more quarter turns to get the stripe to be one inch long Fine tuning can be accomplished with on or two more runs Once the stripe length is displayed on ET24 no further adjusting is necessary Now programming in length is possible eliminating the problem of converting line speed to time of event Note always turn the POT to it s full counter clockwise lowest reading position before calibration After adjusting the TLC for a given glue event the adjacent gap event is inaccurate This is due to valve open and close response An explanation of this response is found in Section H Correcting for valve response is simple with ET24 the procedure is found on page 1 4 and 5 Adjust ON compensation and check the pattern for glue gap accuracy The event will be shorter now adjust the OFF compensation and check pattern for accuracy 4 3 Adjustments Continued Line Speed Compensation In adhesive applications there are many situations where the production line speed varies from time to time and yet the length of the adhesive bead pattern must remain the same To accomplish this constant pattern length with varying line speeds the amount of time the adhesive valve is dispensing must be continuously adjusted to
63. wever it takes 10 msec for the adhesive to reach the product surface after triggering If machine line speed is increased to 500 feet per minute the product is moving 400 feet per minute faster In the 10 msec it takes to deposit the adhesive to the product the product has moved 8 inches further than at 100 feet per minute and the adhesive is deposited 8 inches from the desired position Head Closing Response This phenomenon is similar to valve Open Response with the opposite cause and effect standpoint valve Closing Response is a result of the amount of time delay after a glue event is commanded to stop by ET24 and the actual end of the adhesive stripe on the product The effect is a lengthening of the glue stripe related to increased line speed o f the product With line speed changes of 10 feet per minute or less the valve Closing lag can be ignored Example Using the previous example with line speed changes 100 500 ft min assume the closing lag to be 15 ms the adhesive stripe grows 1 2 inches in length This is a very serious problem if the desired stripe is 1 25 inches it ends up being almost twice as long at 500 ft min 4 3 Adjustments Continued Correcting valve Opening and Closing Response To correct valve opening and closing responses first determine the valve open response time Deposit adhesive on the product at the slowest line speed Speed up the machine to its highest line speed and deposit adhesive a second time T
64. wn during power up to display the current length resolution The Resolution is displayed in the Duration Display window The possible resolutions are 0 01 inches I mm 0 02 inches 2mm 0 05 inches 3mm or 0 10 inches To modify the current resolution hold switch A UP and toggle switch E UP for larger resolution or DOWN for smaller resolution Copyright 2009 Astro Packaging ET24 Pattern Controller 19600 84 Rev D 04 07 09 13 4 2 Startup Continued The resolution must be set for the number of heads on the system and the maximum system line speed If the resolution is set too fine for the maximum line speed the ET24 may misread the tach generator and generate a glue stripe that is twice as long as called for at high line speed For more information on Line Speed Tracking reference Section in this manual Head ON OFF Delay Compensation Head Open Response is an electromechanical delay time phenomenon The delay is the amount of time that transpires after the ET24 commands the valve to open and the adhesive actually reaches the product At relatively slow production line speeds or production line speeds that do not vary more than 10 feet per minute valve On Response Compensation is not necessary However where line speeds are varying over more than 10 feet per minute valve Response Compensation must be adjusted for accurate adhesive placement See Section H Line Speed Compensation Head Closing Response is a similar phen
65. y information and instructions Failure to comply with these instructions can result in death injury or permanent damage to this equipment and will void the warranty This equipment is designed for use with standard adhesive and sealant materials with flash points above 232 C 450 F Use of flammable material or material not compatible with the specifications of this equipment can cause injury to operator and damage to equipment The manufacturer has designed this equipment for safe operation Specified models are in compliance with EN 60204 1 1993 However heated thermoplastics and other hotmelt materials are dangerous and care must be exercised to ensure operational safety Handling must be in accordance with hotmelt manufacturer specifications Never exceed the maximum application temperature recommended by the adhesive manufacturer Dispose of hotmelt properly Refer to the Materials Safety Data Sheet MSDS of the hotmelt for recommended disposal methods Wear the following protection when working on or around this equipment Always wear heat resistant gloves rated to 205 C 400 F and allow all system temperatures to stabilize below 193 C 380 F before servicing Properly ventilate equipment according to MSDS of the material used Do not store combustible materials in vicinity of equipment Trained operators and service technicians should be aware of exposed surfaces of the unit which cannot be practically safeguarded T

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