et4 pattern controller product manual - astro packaging

ET4 Pattern Controller

Product Manual

Manual Number: 19600-129

03/30/09

1-800-642-7876

ET4 Pattern Controller

Product Manual

Manual Number: 19600-129

Revision: D

230 VAC models are

certified for use in countries

requiring the CE mark.

Date: 03/30/09

Table of Contents

1 Safety Precautions for Hotmelt Applicator Equipment......................................................................... 1

1.1 Intended Use .................................................................................................................................... 1

1.2 Personal Safety ................................................................................................................................ 1

1.3 Electrical Safety .............................................................................................................................. 2

1.4 Emergency Power Disconnect........................................................................................................ 2

1.5 Follow Directions ............................................................................................................................ 2

1.6 Safety Symbols and Signal Words................................................................................................. 2Specific Symbols and Signal Words................................................................................................... 3Other Product Symbols ....................................................................................................................... 3

2 Introduction............................................................................................................................................. 4

2.1 Description....................................................................................................................................... 4

2.2 Features............................................................................................................................................ 5

3 Specifications .......................................................................................................................................... 6

3.1 Electrical .......................................................................................................................................... 6

3.2 Physical ............................................................................................................................................ 6

3.3 Performance .................................................................................................................................... 6

3.4 Environmental................................................................................................................................. 7

3.5 Dimensions....................................................................................................................................... 7

4 Installation .............................................................................................................................................. 8

4.1 Terminal Wiring ............................................................................................................................. 9

4.2 Terminal Functions....................................................................................................................... 104.2.1 Input Trigger ............................................................................................................................ 104.2.2 Valve Group Output Relays..................................................................................................... 114.2.3 Power Switch and Ground Termination .................................................................................. 114.2.4 Power-In Wiring ...................................................................................................................... 114.2.5 DC Power Supply .................................................................................................................... 12

4.3 Interconnect Wiring Examples.................................................................................................... 124.3.1 Example 1: AC Valve Coil Activated by 1 Trigger, No HAT Switch .................................... 124.3.2 Example 2: AC Valve Coil Activated by 1 Trigger, with HAT Switch .................................. 134.3.3 Example 3: Valve Coil Activated by Head Driver, Triggered by Photoeye............................ 144.3.4 Example 4: External DC Power Supply................................................................................... 144.3.5 Example 5: 2 Photoeyes Trigger 1 Valve Group ..................................................................... 15

5 Operation............................................................................................................................................... 16

5.1 Controls and Indicators................................................................................................................ 165.1.1 Event Type Indicators .............................................................................................................. 165.1.2 Event Selector Switch .............................................................................................................. 165.1.3 Power Switch ........................................................................................................................... 165.1.4 Set Duration/Test Switch ......................................................................................................... 16

© Copyright 2009 ET4 Pattern Controller 19600-129 Rev. D 03/30/09 i

5.1.5 Event Duration Display Window............................................................................................. 165.1.6 Valve Group 1 or 2 Indicator Lights........................................................................................ 165.1.7 Sensor Input Indicator.............................................................................................................. 16

5.2 Operating Instructions ................................................................................................................. 185.2.1 Power-Up ................................................................................................................................. 185.2.2 Factory Default Configuration Setting..................................................................................... 185.2.3 Reading Event Times............................................................................................................... 185.2.4 Setting Event Times................................................................................................................. 195.2.5 Valve Group Test Fire Function .............................................................................................. 195.2.6 Program Lock........................................................................................................................... 19

5.3 Power-On Switch Selections......................................................................................................... 205.3.1 Clear Memory .......................................................................................................................... 205.3.2 Trigger Modes.......................................................................................................................... 205.3.3 Resolution and Metric/English Units of Measure.................................................................... 205.3.4 Event Time Resolution Modes................................................................................................. 215.3.5 Stitch Mode.............................................................................................................................. 225.3.6 Pattern Skip.............................................................................................................................. 23

5.4 Sample Program............................................................................................................................ 255.4.1 Two-Valve Group System with Different Patterns on Each Valve Group.............................. 25

5.5 Summary Chart ............................................................................................................................ 26

6 Maintenance.......................................................................................................................................... 27

7 Troubleshooting .................................................................................................................................... 28

8 Repair and Replacement....................................................................................................................... 29

8.1 Replacement of Fuses and Output Relays .................................................................................. 29

8. 2 Replacement of ET4 Controller Module.................................................................................... 30

9 Parts List................................................................................................................................................ 31

Appendix A: Event Duration Log............................................................................................................ 32

ii ET4 Pattern Controller 19600-129 Rev. D 03/30/09

1 Safety Precautions for Hotmelt Applicator Equipment

This manual contains important safety information andinstructions. Failure to comply with these instructions can result indeath, injury or permanent damage to this equipment and will voidthe warranty.

1.1 Intended UseThis equipment is designed for use with standard adhesive andsealant materials with flash points above 232 °C (450 °F). Use offlammable material or material not compatible with thespecifications of this equipment can cause injury to operator anddamage to equipment.

The manufacturer has designed this equipment for safe operation.Specified models are in compliance with EN 60204-1:1997.However, heated thermoplastics and other hotmelt materials aredangerous and care must be exercised to ensure operational safety.Handling must be in accordance with hotmelt manufacturerspecifications. Never exceed the maximum application temperaturerecommended by the adhesive manufacturer.

Dispose of hotmelt properly. Refer to the Materials Safety DataSheet (MSDS) of the hotmelt for recommended disposal methods.

1.2 Personal SafetyWear the following protection when working on or around thisequipment:

Always wear heat resistant gloves rated to 205 °C (400 °F) andallow all system temperatures to stabilize below 193 °C (380 °F)before servicing. Properly ventilate equipment according to MSDSof equipment.

Trained operators and service technicians should be aware ofexposed surfaces of the unit that cannot be practically safeguarded.These exposed surfaces may be hot and take time to cool after theunit has been operating.

Keep parts of the body away from rotating parts. Do not wearloose articles of clothing when operating or servicing units withrotating parts. Remove wristwatches, rings, necklaces, or otherjewelry and cover or pin up long hair before performing any workon or with the unit.

Trained operators may perform only external equipmentadjustments. Trained service technicians must perform internaladjustments and service.

Wear Safety Goggles

Wear Heat-ResistantSafety Gloves

Wear Protective Clothing

© Astro Packaging 2009 ET4 Pattern Controller 19600-129 Rev. D 03/30/09 1

1.3 Electrical SafetyDetermine voltage of this equipment before installation andconfirm compatibility with available power. Equipment must beconnected to a properly grounded circuit and installed inaccordance with all applicable electrical codes. Ground faultprotection must be provided in supply circuitry at site installation.

Models designed to EN60204-1: 1997 require power cords beapproved to a harmonized (HAR) standard and rated for 70 °C(158 °F). A HAR approved Type B plug and strain relief for powercord is required to meet standard IEC 309. Power conducting wiresmust be nominal 5.3 mm2 (10 AWG) maximum and nominal2.1 mm2 (14 AWG) minimum.

1.4 Emergency Power DisconnectIn the event of a malfunction, turn off power to the equipment atthe power off switch and remove source power to the system at thenearest main disconnect.

1.5 Follow DirectionsRead the product manual thoroughly before installation, operationor maintenance. Failure to do so can result in a serious accident orequipment malfunction. The manufacturer will not be heldliable for injuries or damage caused by misuse of thisequipment.

1.6 Safety Symbols and Signal WordsThe following safety symbols and signal words are usedthroughout the manual and on the product to alert the reader andoperator to personal safety hazards or to identify conditions thatmay result in equipment or property damage.

WARNING: Indicates a hazard, which, if notavoided, can result in serious injury, or equipmentand property damage.

CAUTION: Indicates a hazard, which, if notavoided, can result in minor injury, or equipmentand property damage.

DANGER: Indicates a hazard, which, if notavoided, will result in serious injury, includingdeath, or equipment and property damage.

!

!

!

2 ET4 Pattern Controller 19600-129 Rev. D 03/30/09 Copyright 2009

Specific Symbols and Signal Words

Other Product Symbols

The manufacturer reserves the right to make design changes forproduct improvement. This manual may not reflect all details ofthese improvements.

WARNING: High Pressure. System contentsunder pressure. Can cause serious injury and burnsor equipment and property damage. Relievepressure before servicing.

WARNING: Disconnect electrical power atexternal source. Failure to do so can causeelectrical shock.

DANGER: High Voltage. Can cause seriousinjury, including death. Disconnect electricalpower at external source before servicing

WARNING: Hot Surface. Can cause seriousinjury and burns. Wear heat resistant clothing,gloves and safety goggles.

PE

+-

On

Tank

Set Temp

Tank Heater

Off

Heated Hose

Standby Temp

Alarm

Ground

Applicator

Overtemp

Actual Temp

Protective Earth

Pump Motor

Adhesive Flow

Source Power

Valve Group Manual Task Input Output

3

2 Introduction

2.1 DescriptionThe ET4 Pattern Controller is a solid state, microprocessor-basedtimer for glue-gap or stitch patterns for one or two dispensingvalve groups. The two applicator valve groups can fire from oneinput trigger or two independent triggers. Each event pattern isdefined with easy-to-use toggle switches.

ET4 provides 9.999 seconds full scale, with 1 millisecondresolution and ± 0.5 millisecond accuracy and repeatability. It hasmemory for one set-up or pattern of events for each valve group. Adust proof, water-resistant 11" x 9" x 6" enclosure is provided.

and is recommended at line speeds above 100-150 fpm or 30-50 mpm. Mini Beam or Data Beam photoeye sensors arerecommended for head triggering input as mechanical switchesmay produce extraneous signals.

0980

398

®

2VALVE GROUP 2

EVENT

1VALVE GROUP 1

TEST

SENSOR

1

2

1

2

ET4Pattern C

ontroller

SET DURATION

The Astro Packaging head driver enhances pattern placement accuracy,

4 ET4 Pattern Controller 19600-129 Rev. D 03/30/09

2.2 FeaturesTwo timers in one: controls two independent valve groupsfrom two separate inputs

Simple toggle switch programming and operation

Accurate placement of one or two independent adhesivepatterns at fixed line speeds

Stitch patterns for adhesive cost savings

On the fly adjustment of any pattern event

Easy-to-read four digit time display

Optically isolated circuits for electrical noise immunity

Valve group test switch

Power-off memory for one pattern setup

Glue and gap events up to 9.999 seconds

Program lock security

Two event time resolution modes:

Standard mode – milliseconds

High Resolution mode – tenth milliseconds

Trigger skip feature

© Copyright 2009 ET4 Pattern Controller 19600-129 Rev. D 03/30/09 5

3 Specifications

3.1 ElectricalPower Requirements ------------ 100–115 VAC, 25 W, 50/60 Hz

------------ 200–230 VAC, 25 W, 50/60 Hz230 VAC models are certified for use in countries requiring the CE mark.

1 or 2 Trigger Inputs:Voltage------------------------------ 5–24 VDC, 4–25 mAType --------------------------------- Photoeye Sensor; mechanical triggers

not recommendedOutput Switching to 1 or 2 valve groups:

------------------------------ 5–60 VDC, 3 A; DC Output Relay------------------------------ 60–250 VAC, 5 A; AC Output Relay

Power Supply Output Voltage- 12 VDC, 200 mA: power for photoeyesand external triggers

Modes: One Shot: sequence initiates and completes with 1 trigger inputDuration: sequence initiates and continues while trigger signal is engaged

3.2 PhysicalEnclosure--------------------------- Protected against dust (no harmful de-

posit) and projections of water from alldirections (IP54 per EN60529); meetsNEMA specifications

CE ComplianceGeneral Requirements ---------- EN60204EMC -------------------------------- EN50081-2, EN50082-2

3.3 PerformanceStandard Mode High Resolution Mode

Event Duration Range 0.001–9.999 sec 0.1–999.9 ms

Accuracy and Repeatability ±0.5 ms ±0.05 ms

Resolution 1 ms 0.1 ms

Maximum number of valves per group:4 E100 100-230 VAC4 M100 100-230 VAC8 E900 100-115 VAC16 E900 200-230 VAC


3.4 EnvironmentalOperating temperature --------- 0–60 °C (32–140 °F)Storage temperature------------- -7–60 °C (20–140 °F)

3.5 Dimensions

28.88 cm(11.37 in.)

29.85 cm(11.75 in.)

32.03 cm(12.61 in.)

23.80 cm(9.37 in.)

16.21 cm(6.38 in.)

0980

162a

22.86 cm(9.00 in.)

0.80 cm(0.31 in.)

10.16 cm(4.00 in.)

13.97 cm(5.50 in.)


WARNING: ET4 must be connected to a properlygrounded circuit and installed in accordance withappropriate local electrical codes.

Incorrectly connected equipment can result in injury

damage, whether direct or indirect, caused by use ormisuse of this equipment.

4 Installation

following configurations:

1. Controller factory wired to a melt unit; no installationrequired. Wires are terminated in both controller and melt unitwith a flexible conduit connecting cable. The length of the cable isselected at the time of purchase. Photoeye trigger devices are alsofactory wired when ordered as a part of the system. There is noinstallation required when a controller is factory wired to a meltunit.

2. Controller factory wired to a flexible conduit connectingcable only; some installation required. Controller is wired with aconnecting cable but is not connected to a melt unit. A controllerwith wired-in conduit cable is shipped either because it wasordered in that configuration or for convenience of packing andshipping. Installation requires connecting numbered wires in thecable to the corresponding numbers on the melt unit terminal strip.

3. Controller with no factory wiring; complete installationrequired. Installation requires making all connections within thecontroller as well as the melt unit. Instructions in this section mustbe followed as well as those in the melt unit service manual andwiring schematic diagram.

!

PatternController

MeltUnit

0970

001a

®

®

®

will not be held liable for injuries or


or damage to the equipment. Astro Packaging

Astro Packaging Pattern Controllers are shipped in one of the

4.1 Terminal WiringAll wires, except the ground wire, are terminated in the orange,spring-loaded connectors attached to the circuit board. Eachconnector has 2 orange parts: a removable connector [1] and amating receptacle [2], which is permanently attached to the circuitboard. When internal wiring is required, proceed as follows:

1. Strip wires 8 mm (0.30 in.).

2. Unplug the connector from its receptacle. If removing morethan one connector, note each connector’s proper location.

3. Retract terminal spring by holding the orange connector [1] inone hand and firmly inserting a screwdriver with a 3 mm(5/32 in.) blade into terminal slot [4]. When screwdriver isfully inserted, the terminal spring is held open.

4. Insert correctly stripped wire into terminal [3]. Only two wiresof the same gauge may be inserted into the same terminal slot.

For one wire: 12 AWG maximum, 28 AWG minimum

For two wires: 16 AWG maximum, 28 AWG minimum

5. Remove screwdriver releasing spring.

6. Tug on wires to ensure the connection is secure.

7. Plug connector(s) into receptacle(s).

1

2

3

4

0980160


4.2 Terminal FunctionsAll internal terminations are made on the spring-loaded terminalstrip located on the back of the controller circuit board. Terminalnumbers and their associated functions are as follows:

4.2.1 Input TriggerNormally, 1 input trigger from the sensing device, such as aphotoeye, activates a single valve group. The ET4 accepts 2 inputtriggers for 2 independent valve groups. See illustration below. For1 photoeye to activate both valve groups, install jumpers betweenTerminals 21 and 23; and also between Terminals 22 and 24.

TRIGGER 1 TRIGGERINPUT

TRIGGERINPUTTRIGGER 2

21 (+)22 (-)

23 (+)24 (-)

0980165

21TRIGGER 1INPUT

TRIGGER 2INPUT

22

23

24

5VALVE GROUP1

VALVE GROUP2

AC

POWER

SWITCHED

POWER

6

7

8

1

2

3

4

17

16

(-)

(+)

(-)

(+)

(+)

(+)

12 VDC COMMON + 12 VDC

0980164


4.2.2 Valve Group Output RelaysThe terminals shown below illustrate the valve group output relayconnections. They are activated and deactivated by controllertiming programs. Each output relay can be either AC or DC. TheAC relay is capable of switching voltages from 24–250 VAC, 4 Amaximum. The DC relay is capable of switching voltages from 5–60 VDC, 3 A maximum. Relays are optically isolated from themicroprocessor. The outputs use a 4 A, 250 VAC fuse.

4.2.3 Power Switch and Ground TerminationA 100–115 VAC or 200–230 VAC power supply is wired toTerminals 1 and 2. Refer to controller identification label toconfirm controller voltage. Fused and switched power is availableon Terminals 3 and 4. Main power fuses are rated at 6 A for usewith 115 VAC and 3 A for use with 230 VAC controllers.

4.2.4 Power-In WiringA ground wire [2] must be connected to the grounding screw [1]located inside controller.

CR 1VALVE GROUP 1

OUTPUT RELAY

VALVE GROUP 2

OUTPUT RELAYCR 2

5+ 6

7+

8 0980166

AC

POWER

FUSED AND

SWITCHED

1 2

3

4 0980167

PE

1

2

0980168a


4.2.5 DC Power SupplyA 12 VDC supply voltage is available from the controller to powerinput trigger devices, such as limit switches, photoeyes andproximity switches.

4.3 Interconnect Wiring Examples

4.3.1 Example 1: AC Valve Coil Activated by 1Trigger, No HAT SwitchOne AC voltage valve coil or valve group is triggered from 1 inputsensor switch.

12 VDCSUPPLY200 mA

12 VDC COMMON

+ 12 VDC

17

16

0980169

21TRIGGER 1INPUT

TRIGGER 2INPUT

22

23

24

5 ACHEAD COIL(S)

TRIGGER

AC

POWER

SWITCHED

POWER

6

7

8

1

2

3

4

17

16

VALVE GROUP1

VALVE GROUP2

(-)

(-)

(+)

(+)

(+)

(+)


0980172

WARNING: Remove head-firing jumpers if a DCcontroller is to be used.

!


4.3.2 Example 2: AC Valve Coil Activated by 1Trigger, with HAT SwitchOne AC voltage valve coil or valve group is triggered through anactive HAT switch on the melt unit. Melt unit head-firing jumpersmust be installed.

21TRIGGER 1INPUT

TRIGGER 2INPUT

22

23

24

5

TRIGGER

AC

POWER

SWITCHED

POWER

6

7

8

1

2

3

4

17

16

VALVE GROUP1

VALVE GROUP2

TA 4

MELT UNITTERMINAL

TA 14A(+)

(+)

(+)

(+)

(-)

(-)


0980173


4.3.3 Example 3: Valve Coil Activated by HeadDriver, Triggered by PhotoeyeA 12 VDC sourcing photoeye triggers the controller. The 12 VDC

Group 1. For 1 photoeye to trigger both valve groups, installjumpers between Terminals 21 and 23; and also betweenTerminals 22 and 24.

4.3.4 Example 4: External DC Power SupplyAn external power supply is needed when power requirementsexceed the controller power output capacity. An example is when aprogrammable controller is used to trigger an air valve. Theexternal power supply must be added in series with the outputrelay contacts of the controller.

21TRIGGER 1INPUT

TRIGGER 2INPUT

22

23

24

5

INPUT

HEADDRIVER

DC HEADCOIL(s)+

-

PHOTOEYE TRIGGER OUTPUT(+)

PHOTOEYE COMMON (-)

PHOTOEYE 12 VDC (+)

AC

POWER

SWITCHED

POWER

6

7

8

1

2

3

4

17

16

VALVE GROUP1

VALVE GROUP2

(-)

(-)

(+)

(+)

(+)

(+)


0980174

21TRIGGER 1INPUT

TRIGGER 2INPUT

22

23

24

5

AIRVALVE

AIRHEAD

AIR OUT

AIR IN

EXTERNAL POWER SUPPLY

PROGRAMMABLE CONTROLLER

(+5 TO 24 VDC)

+

-

AC

POWER

SWITCHED

POWER

6

7

81

23

4

17

16

VALVE GROUP1

VALVE GROUP2

(+)

(+)

(+)

(+)

(-)

(-)


0980175

output signals an Astro Packaging Head Driver to activate Valve


4.3.5 Example 5: 2 Photoeyes Trigger 1 Valve GroupWhen both photoeyes see the product, a stripe of adhesive isinitiated and continues as long as both photoeyes sense theproduct. The controller triggers OFF when the leading photoeye nolonger senses the product. Set the controller for a maximum time tostop adhesive output in the event the production line stops in theON position. The pair of photoeyes can activate both valve groupsif a jumper is installed between Terminals 21 and 23, and alsobetween Terminals 22 and 24.

2000097

21TRIGGER 1INPUT

TRIGGER 2INPUT

22

23

24

5 MINI BEAM

MINI BEAM

AC

POWER

SWITCHED

POWER

6

7

8

1

2

3

4

17

16

BROWN

BLACK

BLUE

BROWN

WHITE

BLUE

VALVE GROUP1

VALVE GROUP2

(-)

(+)

(-)

(+)

(+)

(+)


21TRIGGER 1INPUT

TRIGGER 2INPUT

22

23

24

5DATABEAM

BLUE

BLACK

BROWN

BROWN

BLACK

BLUE

DATABEAMAC

POWER

SWITCHED

POWER

6

7

8

1

23

4

17

16

VALVE GROUP1

VALVE GROUP2

(+)

(-)

(+)

(-)

(+)

(+)



5 Operation

5.1 Controls and Indicators

5.1.1 Event Type Indicators[1] One of the 4 green LEDs illuminates when an event (Gap 1,Glue 1, Gap 2, Glue 2) is selected with the Event switch forprogramming or viewing.

5.1.2 Event Selector Switch[2] Selects each event being programmed or viewed. This greentoggle switch is also used to access test mode for Valve Group 1 orValve Group 2.

5.1.3 Power Switch[3] Switches main power to ET4 and valve group output relays. Ifpower for AC coils or Head Driver is provided by Terminals 3 and4, this switch enables or disables those devices.

5.1.4 Set Duration/Test Switch[4] Toggle this switch up to increase the event duration or toggledown to decrease the event duration. Toggling adjusts the eventduration by 1 millisecond or 1 tenth of a millisecond. Holding it inthe up or down position causes the number display to scrollrapidly. The Set Duration switch is also used as the valve grouptest firing switch.

5.1.5 Event Duration Display Window[5] Four numeric LED displays show the time period selected for aspecific valve group and event. Time is displayed in seconds,0.001 through 9.999 or 0.0001 through 0.9999 seconds.

5.1.6 Valve Group 1 or 2 Indicator Lights[6] A green LED displays the valve group presently accessed forprogramming, program viewing, or testing.

5.1.7 Sensor Input Indicator[7] A green LED illuminates with each trigger input for the valvegroup shown by the Valve Group LED.


2 VALVE GROUP 2

EVENT

1 VALVE GROUP 1

TEST

SET DURATION

SENSOR

1 2

1 2

0980

178

15

6

7

2

3

4


5.2 Operating Instructions

5.2.1 Power-Up1. Turn power on.

2. Watch for all LEDs to illuminate and all display windows toread 8. This indicates ET4 is in self-test, checking inputs,outputs, and memory.

3. If self-test detects a problem, display goes blank (seeSection 8: Troubleshooting).

4. Upon successful completion of self-test and brief display ofthe software revision number and the event time resolutionmode, the time previously set for first event, Gap 1 and ValveGroup 1 is displayed. Refer to Section 5.3.4: Event TimeResolution Modes, for illustration of power-on displayinformation.

5.2.2 Factory Default Configuration SettingUnless otherwise specified, the ET4 is configured as follows whenshipped from the factory:

1. Programmable memory is set to zero (all event times are set tozero).

2. Trigger mode is set to One-Shot. An input trigger voltage of±5 to 24 VDC will initiate and complete a program sequenceof Gap, Glue, Gap, Glue.

3. Stitch Mode is not activated.

4. Event time resolution is in Standard Mode (Duration Range:0.001–9.999 sec).

5. Trigger polarity is positive.

5.2.3 Reading Event TimesProgrammed times may be observed for all Event and Valve Groupcombinations.

1. Toggle Event Selector switch until the combination of LEDsdisplays the event and valve group needed. Event time isdisplayed in event duration window. Only 2 LEDs areilluminated at any one time except in the Valve Group/Testmode. Test mode activates after cycling through both valvegroups and all events one time.


5.2.4 Setting Event Times1. To set or change duration of a given event, use Event Selector

switch to select event (Gap 1, Glue 1, Gap 2, or Glue 2) and toselect Valve Group 1 or 2.

2. Use Set Duration switch to set desired time for each event.Toggle Set Duration switch up or down to change event time.Holding the switch causes time to scroll rapidly.

3. Determine time for the initial Gap 1 by measuring amount oftime it takes for the substrate to travel from trigger to nozzlelocation or start of first glue pattern. Enter this value for Gap 1by toggling Set Duration switch up.

4. Set Glue 1, Gap 2, and Glue 2 event times according todesired pattern using Set Duration switch.

5. Record all set values in Event Duration Log in Appendix A forreference should “Clear Memory” be needed.

5.2.5 Valve Group Test Fire Function1. To test fire a valve group, toggle Event Selector switch until

only Valve Group 1 or 2 illuminates and duration display isblank.

2. To fire selected valve group continuously, hold Set Durationswitch up.

3. To fire selected valve group in programmed sequence, holdSet Duration switch down.

5.2.6 Program LockTo prevent event time settings from being altered, place controllerinto Program Lock mode.

1. With power on, hold Event Selector switch to left and key SetDuration switch down momentarily.

2. Release Event Selector switch. Each time this sequence isperformed, controller toggles between locked and unlockedfunction.


5.3 Power-On Switch Selections

5.3.1 Clear MemoryClear memory if a problem is encountered in loading or modifyinga program. All program set-ups clear to zero by holding the EventSelector switch to the left during power-up configuration changeprocedure.

5.3.2 Trigger ModesOne-Shot Mode – ET4 initiates a sequence once photoeye istriggered. The sequence continues to run until completion even ifthe trigger signal is terminated. This is the default setting.

1. To set trigger to One-Shot mode, power-on ET4 while holdingthe Set Duration switch up.

2. To re-initiate event sequence, deactivate signal and activateagain.

Duration Mode –The ET4 can be configured so the event sequencecontinues only as long as the photoeye trigger signal is active. Theevent sequence terminates immediately upon loss of trigger signal.

1. To set trigger to Duration mode, power-on ET4 while holdingthe Set Duration switch down.

5.3.3 Resolution and Metric/English Units of Measure1. Power-up ET4-T while holding Length/Line Speed Display

switch down. Use Set Length switch to select resolution 0.5,1.0, 2.0, or 3.0 mm (0.01, 0.02, 0.05 or 0.1 in.). See SpeedTracking, Section 5.4 for details on selecting resolution.

2. After 2 seconds, release the Length/Line Speed Displayswitch. Selecting appropriate resolution also selects metric orEnglish tracking.

3. Recalibrate Line Speed after changing resolution.

CAUTION: This procedure removes all loadedprograms. A log of all programmed settings isrecommended.

!


5.3.4 Event Time Resolution ModesET4 has 2 time resolution modes. The Standard Mode allows eventtime settings in millisecond increments for Glue or Gap lengthsfrom 0.001 to 9.999 seconds. The High Resolution Mode allowsevent time settings in tenths of milliseconds increments for eventsfrom 0.1 to 999.9 millisecond.

At power-on, ET4 displays 3 brief sequences for 3 seconds eachbefore resting on the First Event Time as follows:

To change time resolution modes:

1. Power down. Wait 3 seconds. Turn on power.

2. Watch display move from Self Test (8888) to SoftwareRevision (e.g., 20X) to Time Resolution Mode (1 or 100).

3. During the 3-second period that the Time Resolution Mode isdisplayed, hold the Event switch to the right and key the SetDuration switch up for the High Resolution Mode or down forthe Standard Mode.

NOTE: In High Resolution Mode, the minimum time for Gap 1 is000.1 ms.

NOTE: The High Resolution Mode and display is present inSoftware Revision B05 (displayed as 205) and later.

1 0 0 0 0 0 . 1

Standard Mode

High Resolution Mode

(0.001–9.999 sec)

(0.1–9.999 ms)

Self Test

8 8 8 8

Software Revision

2 0 X

Time Resolution

1

First Event Time

0 . 0 0 0

Self Test

8 8 8 8

Software Revision

2 0 X

Time Resolution

First Event Time

0980179


5.3.5 Stitch ModeET4 supports stitching of patterns within glue events in one or bothvalve groups. The stitch values are selected for each valve groupand will be the same for both glue events within a valve group.

See illustration on opposite page for the following instructions:

1. Set all initial glue and gap settings for Valve Group 1 andValve Group 2 before going into the Stitch Mode to set stitchpatterns. See Section 5.2.4: Setting Event Times, for exactprocedure.

2. After setting the basic Glue 1 and Glue 2 values for one orboth valve groups, go into Stitch Mode to set the values for thestitch patterns. Stitch Mode may be activated for one or bothvalve groups.

3. To enter a Stitch Mode, power-up ET4 while holding SetDuration switch [2] down and Event Selector switch [1] to theright.

4. To set the stitch values for both glue events on Valve Group 1,the Valve Group 1 LED will be illuminated, Gap 1 LED willnot be lit. Use the selector Set Duration switch to enter theOFF stitch value.

5. Toggle the Event Selector switch to the next position to theright. Gap 1 illuminates and Glue 1 is not lit. Use Set Durationswitch to enter the ON stitch value.

6. To set stitch values for Valve Group 2, toggle Event Selectorswitch to the right. Valve Group 2 LED is lit and Gap 2 is notlit. Enter stitch value for OFF time for both glue events usingSet Duration switch.

7. To set the ON time for stitch pattern for Valve Group 2, toggleEvent Selector switch to next position. Glue 2 LED is off.Enter desired ON value for stitch using Set Duration switch.

8. When Stitch Function is activated for a valve group all gluefunctions for that valve group are in Stitch Mode. The stitchpattern is the same for Glue 1 and Glue 2 for a single valvegroup.

9. Exit Stitch Mode by holding Event Selector switch to rightand momentarily keying Set Duration switch down.


5.3.6 Pattern SkipThe ET4 Pattern Controller can skip a user-selected number oftriggers, then glue a selected number of products.

• Skip Count is the number of triggers the ET4 will skip.

• Trigger Count is the number of triggers the ET4 will process(glue).

Access Pattern Skip as follows:

1. Power-up the ET4 while holding the Event switch right andthe Duration switch up, then release the switches. The ET4displays the current trigger polarity for Valve 1.

2. Toggling the Event switch steps the display through:

• Valve Group 1 Polarity (Valve Group 1 LED lit)

• Valve Group 2 Polarity (Valve Group 2 LED lit)

• Valve Group 1 Trigger Count (Valve Group 1, Sensor LEDslit, display shows current count - 99 max)

• Valve Group 1 Skip Count (Valve Group 1 LED lit, displayshows current count - 99 max)

• Valve Group 2 Trigger Count (Valve Group 2, Sensor LEDslit, display shows current count - 99 max)

• Valve Group 2 Skip Count (Valve Group 2 LED lit, displayshows current count - 99 max)

2 VALVE GROUP 2

EVENT

1 VALVE GROUP 1

TEST

SET DURATION

SENSOR

1 2

1 2

0980

163

1

2


DISPLAY/LED Guide:

LEDs Lit Indicates

Valve 1, Glue 1 Valve 1 = positive polarity

Valve 1, Gap 1 Valve 1 = negative polarity

Valve 2, Glue 2 Valve 2 = positive polarity

Valve 2, Gap 2 Valve 2 = negative polarity

Valve 1 Sensor Valve 1 Trigger Count is displayed

Valve 1 (only) Valve 1 Skip Count is displayed

Valve 2 Sensor Valve 2 Trigger Count is displayed

Valve 2 (only) Valve 2 Skip Count is displayed

If either trigger or skip count is zero, the skip feature is disabledfor that valve, and the valve glues on every trigger.


5.4 Sample Program

5.4.1 Two-Valve Group System with DifferentPatterns on Each Valve Group

and bottom case sealer. Top and bottom adhesive stripes aredifferent. The top has a 100 ms gap, 300 ms stripe, a 500 ms gapand a second stripe 300 ms long. The bottom valve will have a50 ms gap, 400 ms stripe, a 400 ms gap and a second 400 msstripe.

Program:

Step 1. Power On, Self-Test.

Step 2. Place Set Duration switch to unlocked condition.

Step 3. Key in times as follows:

Toggle Event Selector switch to indicate event and valve groupand use Set Duration switch to enter and display the followingvalues:

GAP 1 GLUE 1 GAP 2 GLUE 2

Valve Group 1 0.100 0.300 0.500 0.300

Valve Group 2 0.050 0.400 0.400 0.400

Step 4. All times are now stored in memory and the ET4 is readyto run. Set the Set Duration switch to locked mode toprevent times from being changed.

Formula for determining time needed for a specific event length:

Metric: Time (seconds) = Distance (mm)

Speed (m/m) X 16.66

English: Time (seconds) = Distance (in.)

Speed (f/m) X 0.2


Assume ET4 is used with an Astro Packaging melt unit on a top

5.5 Summary Chart

Mode

Self Test

One ShotTrigger

Duration

Normal

Set StitchMode

Lock

N = Normal (Center Position)

Power ON

Clear Memory

Power = ONEvent = Left

Power = ONDuration = Up

Power = ONDuration = Down

Power = ON

N

N

Left

Right

Up

Down

N

N

Left

Right

N

N

N

N

Up

Down

Left Down

Power = ONEvent = Right

Duration = Down

Test LED displays and shows REV no.

Clears Memory

Display = 8888 All LEDs on.

Display off. LEDs off.

Puts system in one shot mode

Puts system in duration mode

Adjusts gap and glue lengths

Selects head andstitch to be modified

Adjusts stitch times

Program Lock

Duration

Event

Event

Length

Locks adjustmentcapabilities (toggle)

Rotates system through

adjustable events



No effect on current displays or LEDs.

Tests displays, shows REV no. and

Event Time Resolution, enters into normal

operation mode.

Entry Key Selection

EventSelectorSwitch

SetDurationSwitch

Operation DescriptionPage

ReferenceDisplays

18

20

20

20

19

22

19

21

EventTime

Resolu-tion

Power ON.Wait until 8888and Rev. no.

have displayed.Select resolution

in next 3 sec.

RightTime

Resolution

Puts unit in High Resolution Mode

Puts unit in Standard Mode

"1" after 8888and PROM number

"100" after 8888and PROM number

Power-On Configurations

Event Time Resolution

Program Lock

Trigger Polarity andSkip Count

Power=ON/IEvent=RightDuration=Up

Right Up

Sets TriggerPolarity and

Trigger Count,Trigger Skip

23

Notes:1. See Power-On Switch Selections, Section 5.3, for a complete explanation of all power-on configurations.

2. All switches listed in Entry Key Selection must be activated simultaneously for at least 1 second.

3. When 2 switches are used to select mode after power is on, as in Program Lock and Event Time Resolution,

hold the first switch and toggle the second switch for at least 1 second.

(ON and OFF values)

At each head group setting,appropriate Gap or Glue LEDs illuminate to allow setting OFF and ON values.

2000105


6 Maintenance

The ET4 enclosure should be kept free of dust. Clean at least onceyearly. Frequency of cleaning is dependent on the ET4 operatingenvironment.


7 Troubleshooting

Problem Solutions

Trigger Input LED not blinkingwhen sensor is activated.

1. Check trigger signal polarity.

2. Check trigger signal type (source or sink).

3. Check trigger signal strength (5–24 VDC).

4. Check trigger signal duration (> 1 ms).

5. Is trigger wired to proper terminals? (See TerminalWiring, Section 4.1.)

Trigger Input LED is oncontinuously. ET4 not beingtriggered.

1. Check wiring at terminal strip. (See Terminal Wiring,Section 4.1.)

2. Photoeye is blocked or gain is too high.

DC output modules installed inET4 always on.

1. Do you have a DC module instead of an AC module?

2. DC output switches DC voltages up to 60 VDC and3 A in one direction only (polarized output). If polarityis inverted, the output remains on continuously.

Applicator does not activate fromthe DC output of ET4.

1. Applicator requires a DC head driver be placedbetween the ET4 DC output and the applicator.

2. If a DC head driver is connected, check input andoutput lights on the driver to ensure they illuminatewhen green ET4 valve group LED illuminates.

Cannot alter event duration. 1. Is program lock set?

2. Program lock must be off to allow program change.

ET4 triggers one time but doesnot repeat an event sequence.

1. Deactivate trigger and reactivate to start a sequence.

ET4 blanks all displays after self-test.

1. Self-test detects an internal problem. Consult factoryrepresentative.

ET4 has locked up. Nothing ishappening.

1. Turn power off for 2 seconds and then turn power on toreset ET4.

Tried power off/on procedure,ET4 still locked up.

1. Clear memory and reprogram event sequence. If thisdoes not resolve problem, contact factoryrepresentative.

ET4 triggers with no triggersignal present.

1. Use grounded shield wire on power and input leads.

Event time limited to less than 1second (999.9 ms)

1. Change event time resolution mode from HighResolution to Standard Resolution.


8 Repair and Replacement

See Parts List, in Section 9, for all replacement parts listed in thissection.

Should the controller require service, return entire control panelassembly to factory for repair. The only serviceable parts are thevalve group output relays, output relay fuses, and main powerfuses.

8.1 Replacement of Fuses and Output Relays1. Disconnect power.

2. Remove control panel from enclosure by removing 4 screwsholding the control panel.

3. Locate the fuses [3,4] and output relays [5] on the back oftimer board, and remove defective fuse or relay with ascrewdriver. Main power fuses (F1 and F2) [4] are rated for 6A for 100–115 VAC controller and 3 A for 200–230 VACcontroller. Output relays [5] require 4 A fuses (F3 and F4) [3].

4. Insert output relay [5] making certain pins are properlyoriented.

5. Secure hold-screw located in center of output relay [5].

WARNING: Never power pattern controller withthe control panel removed. Before starting anyelectrical repair, disconnect power. Failure tofollow instructions could cause injury orpermanent damage to controller.

!

F4

F1

F3

F2

2

3

1

4

5

0980182


8. 2 Replacement of ET4 Controller Module

1. See Voltage Selector [1] above for correct positioning ofvoltage selector of new controller module.

2. Remove controller module from enclosure by removing 4screws from the corners of the face plate.

3. Unplug removable, orange connectors [2] from receptacles onthe old circuit board, leaving all wires in place.

4. Remove ON/OFF switch cover from front of faceplate.

5. Remove 4 screws holding circuit board to faceplate.

6. Replace old circuit board and secure to faceplate with 4screws. Replace ON/OFF switch.

7. Insert the new controller module by reconnecting orangeconnectors [2] into the receptacles on the new controllermodule and reconnecting the ground wire to the enclosure.See Section 4.2.3: Power Switch and Ground Termination, forproper grounding.

8. Replace the 4 screws in the 4 corners of the face plate.

9. Follow instructions for controller start-up in Section 5.2:Operating Instructions.

F4

F1

F3

F2

2

3

1

4

5

0980182


9 Parts List

Item Description Single OutputQuantity

Dual OutputQuantity

Part Number

Spares

ET4 Pattern Controller, 100–115 VAC, 2inputs

1 1 77129

ET4 Pattern Controller, 200–230 VAC, 2inputs

1 1 77130

Miscellaneous Spares

Kit, ET4 Replacement Module (includespower supply and switch; does not includefaceplate, output module, enclosure orfuses)

1 1 79195-04

Fuse, 3 A 230 VAC, main power 2 2 12014-3B

Fuse, 4 A for output relay 2 2 12014-4B

Fuse, 6 A 115 VAC, main power 2 2 12014-6B

DC Output Relay 5–60 VDC, 3 A 1 2 12047A-2

AC Output Relay 24–280 VAC, 5 A 1 2 12047A-3

Pocket screwdriver 1 1 11065-3

Universal Enclosure, Assy 1 1 73858


Appendix A: Event Duration Log

After clearing memory, the Trigger Type defaults to One-Shot, the Resolution defaults to 0.5 mm(0.01 in.), the Line Speed Drop Out defaults to 3 m/min (10 ft/min), and all duration values go to zero.

Record selected values programmed into the ET4 Pattern Controller for later reference.

Valve Group 1

Event # Type Length ValveCompensation

Values

1 Gap 1 OFF ms

2 Glue 1 o Stitch Option* ON ms

Stitch Gap

Stitch Glue

3 Gap 2

4 Glue 2

Valve Group 2

Event # Type Length ValveCompensationValues

1 Gap 1 OFF ms

2 Glue 1 o Stitch Option* ON ms

Stitch Gap

Stitch Glue

3 Gap 2

4 Glue 2

General

Type/Duration

Trigger Type (circle 1) One-Shot** or Duration

Length Resolution (circle 1) 0.5 mm**, 1.0 mm, 2.0 mm, 3.0 mm, 0.01 in**., 0.02 in., 0.05 in., or0.10 in.,

Line Speed Drop Out m/min or ft/min (default is 3 m/min or 10 ft/min)

NOTE:

* The stitch values are selected for each valve group and are the same for both Glue Events within avalve group.

** This value or type is the default.


Warranty

1 of 2

indicated below commencing with the date the product is placed in service.

Product Warranty Period1. Tank heater (including entire tank when 5 years or 10,000 hours of use, heater is cast into tank) whichever occurs first

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 un-loader; standard accessory purchased with a system

system; any PUR system (including hose, gun whichever occurs first or head used with PUR); any spare or 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

Labor and related expenses incurred to install replacement or repaired parts are not covered by this warranty.

misuse, alteration, accident, or negligent use, nor for repairs made by an unauthorized person or with parts

products.

E. The warranty for a product repaired or replaced under this warranty shall continue in effect for the remainder of

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

via the least expensive means of transport, to customer or an authorized Sales and Service Center in the

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 waspurchased.

THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY EXPRESSED OR IMPLIED, INCLUDING THEWARRANTY OF MERCHANTABILITY AND FITNESS FOR THE PARTICULAR PURPOSE.

Complete Reverse Side and Retain for Your Records

A. Astro Packaging warrents its products, when operated and maintained in accordance withrecommended procedures, are free of defects in material and workmanship during the periods

B. The sole liability of Astro Packaging and exclusive remedy extended to any customer shall be limited

C. Astro Packaging is not responsible for repair or replacement of any product that has been subject to abuse,

the original warranty period, or for ninety (90) days following the day of shipment by Astro Packaging of the

customer specifications, except as specifically stated in writing by Astro Packaging.

G. Astro Packaging is responsible only for payment of shipping charges for delivery of a repaired or replaced product,

2. Melt unit (unless specified below); pattern 1 year or 2000 hours of use,

to replacing or repairing, at the option of Astro Packaging, any product returned under the terms of this warranty.

other than those provided by Astro Packaging.

D. Astro Packaging assumes no responsibility for the performance of adhesives or other materials used with its

Continental United States only. Payment for shipment to Astro Packaging or an authorized Sales and Service

Astro Packaging 3845 E. Miraloma Ave, Suite A, Anaheim, CA 92806 1-800-642-7876 phone 714-572-1943 fax

4. Manual hose; handgun; Astromini; any butyl 6 months or 1,000 hours of use,

2 of 2

Equipment RecordRecord the information below on all equipment received and retain for your records.

(Systems, melt units, hoses, guns, heads, pattern controllers, drivers, etc)

Products were purchased from:___________________________________________

Product Model/Description__________________________ Serial No._____________

Product Part Number______________________________ Order No._____________

Date Received____________ Start-Up Date____________ Invoice No.____________


















Date Received_____________ Start-Up Date___________ Invoice No.____________

Astro Packaging 3845 E. Miraloma Ave, Suite A, Anaheim, CA 92806 1-800-642-7876 phone 714-572-1943 fax

Astro Packaging

et4 pattern controller product manual - astro packaging

Documents