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VC3500/VC3700 Troubleshooting Manual

Valco Cincinnati

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Schematic Description

Main Processor

A 68000 (U1) performs the following functions:

•

Control of LCD/Touchscreen module.

•

Storage of glue programs.

•

Communications with Channel Logic processors.

Reset/Watchdog Circuit

A DS1232 (U6) provides both reset and watchdog functions. "/DTACK" must occur every
150mS (typical) or a reset will occur. The reset signal is buffered by open-collector drivers
(U8) because the "/HALT" and "/RESET" signals can be both read and driven by the 68000.

Clock Circuits

An 8 MHz oscillator (U7) provides timing for the 68000. The 87C51's (U18, 19, 20) each
have a 12 MHz crystal.

Address Decode Circuit and /DTACK

74HCT138's (U10,12) provide all address decoding. These decoding signals are OR'ed
together to derive the "/DTACK" signal required by the 68000. A "/DTACK" signal
returned to the 68000 indicates that a peripheral device has read or written data to the bus,
and therefore the 68000 can continue with the next program step.

Operating System Memory

27C512 PROM's (U4,5) are used to store the operating system. Two-channel software
resides in the lower half, and four-channel software resides in the upper half. A jumper near
the center of the board should be installed (or switch set to 'ON') so the lower half of memory
is enabled (two-channel). This jumper should be cut (or switch set to 'OFF') to enable the
upper half of memory (four-channel).

Battery-Backed Program Memory

BQ4011 RAM's (U2,3) store program parameters

Touchscreen Interface

74HCT245 bi-directional buffers (U15,16) pass the data and control signals to the
LCD/Touchscreen. U15 is fixed to only send address and control signals. U16 is controlled
by "R/W" to determine the direction of data flow.

Encoder Count Circuit (Speed Calculation)

A timer within U17 (68230) outputs an active-low signal for 100mS from its port at PB6 to
U8.3. This open-collector output (U8.4), when high, allows encoder pulses to pass to the
clock input of a 74HCT393 counter (U9.1). Periodically, the 68000 will read this counter's
8-bit output through port PA of U17 (68230) and calculate the line speed. The 68000 uses
this information to size the length of the bar graph in the Minimum Speed screen to indicate
line speed.

Auxiliary Port Signals (U14-68230)

Port PC of U14 is used as the data link between the 68000 and the Channel Logic processors
(U19,20). Port PB of U14 is used to control the flow of data between these devices.

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Summary of Contents for VC3500

Page 1: ...VC3500 User s Manual Software Version 3 X Manual Number MCO35 Manual Release Date July 1999 ...

Page 2: ... this manual is furnished for educational purposes only is subject to change without notice and should not be construed as a commitment by Valco Cincinnati Inc This manual was written and designed at Valco Cincinnati Inc 411 Circle Freeway Drive Cincinnati Ohio 45246 Part Number MC035 Printed in the USA Valco Cincinnati Incorporated 411 Circle Freeway Drive Cincinnati Ohio 45246 TEL 513 874 6550 F...

Page 3: ...troller Product Model s VC3500 Year of Manufacture 1998 conforms to the following standards Safety EN 60204 1 EMC Emissions EN 50081 2 EN 55011 Class A EMC Immunity EN 50082 2 EN 61000 4 2 EN 61000 4 3 EN 61000 4 4 Degrees of Protection EN60529 1 IP54 and complies with the requirements of Low Voltage Directive 73 23 EEC EMC Directive 89 336 EEC Office of CE Conformance Cincinnati Ohio USA ...

Page 4: ...of Encoder 17 Wheel Driven Encoder 17 Gear Driven Encoder 17 Electrical Installation of Encoder 18 Scanner Installation 19 Mechanical Installation of Scanner 19 Electrical Installation of Scanner 21 Glue Valve Installation 21 Electrical Installation of Glue Valve 21 Machine Stop Relay and Beacon Interface 22 DD 1 Pump Power Supply 22 Bypass Valve Driver 23 Menus 25 Introduction 25 Primary Menus 25...

Page 5: ... Cell to Gun Dimensions 42 Specify Ratio Compensation 42 Manual Ratio Compensation 42 Automatic Ratio Compensation 43 Specify On and Off Compensation 43 Unknown Compensation Value 44 Restrict Screen Access 44 Return to the Main Screen 44 Operation 45 Introduction 45 Creating a Job 45 Saving a Job 46 Loading a Job 46 Repeating Glue Patterns 47 Clearing Data 47 Specifying the Scanner Mode 47 Specify...

Page 6: ...mple of Sending Data 81 Receiving Information from VC3500 82 Example of Receiving Data 82 Appendix C Additional Scanner Mode Configuration 83 Introduction 83 Using One Scanner to Trigger Four Independent Glue Valves 83 Applying Up To Four Patterns from a Single Glue Valve 83 Applying Up To Eight Patterns from a Single Glue Valve 84 Appendix D The VC3500J Control 87 Introduction 87 Overview 87 Inst...

Page 7: ...y The control can be designed for either two channel two valve applications or four channel four valve applications The VC3500 is used for applications where consistent glue patterns are required at high machine speeds and during speed changes The VC3500 provides complex glue patterns that can be difficult or impossible to obtain with other systems The control operator can use the control s front ...

Page 8: ... warnings WARNING Promptly repair or replace all worn or damaged electrical wiring and equipment wires to avoid danger to personnel WARNING Properly route all electrical wires to avoid danger to personnel and damage to moving parts of machine WARNING Disconnect all power before opening the control Only qualified personnel should open and service the control WARNING This symbol indicates the presen...

Page 9: ...eckout procedures stay clear of any moving mechanical parts and do not touch exposed electri cal equipment or electrical connectors WARNING Keep pump cover and electrical enclosures closed except during setup service and checkout procedures WARNING Promptly repair or replace all worn or damaged parts ...

Page 10: ...ads Trim leads to the required length Leads should be only as long as necessary for installation All wiring should be in conduits or wireways Connecting the Supply of Electrical Power Electrical connections should be made only by experienced service per sonnel The control must be connected to a clean supply of electrical power Use a dedicated circuit if possible if a dedicated circuit is not avail...

Page 11: ...Valco Cincinnati 7 Introduction This section describes the basic features of the 3500 control Basic Features Figure 1 Front Panel of VC3500 5 1 2 3a 3b 4 6a 6b 6c 6d 6e 6f 6g 6h ...

Page 12: ... the scanner detects product 5 Glue pressure adjustment You press this button to adjust glue pressure increase and decrease 6 Status indicator lights Items 6a through 6h are status indicator lights 6a Less than minimum speed X MIN illuminates when the speed of the parent machine is less than the minimum speed setting 6b Greater than minimum speed X MIN illuminates when the speed of the parent mach...

Page 13: ...horn connector See the Installation section for wiring details 5b Machine interface relay connector See the Installation section for wiring details 6 Power module This main power supply connection uses an IEC standard line cord supplied The fuse drawer in this module provides fuses for both sides of the main supply and selection of either 115 or 230VAC The on off switch for the control is also loc...

Page 14: ...ommunications interface 4 regulated air out to glue regulator Figure 3 street tee F F M 1 8 adapters F M 1 8 x 1 8 gauge 0 60 psi 7 line cord clamp screws 4 40 thread 6 power entry module During installation choose any combination of two fittings for tubing diameter male connector 3 8 x 1 8 and male elbow 1 4 x 1 8 or male connector 3 8 x 1 8 and male elbow 1 4 x 1 8 ...

Page 15: ...lco Cincinnati 11 shock arrestor T handle provides minimum pressure setting sealing nut must be tightened for proper operation to VC3500 regulated air port adhesive supply glue regulator to glue station shutoff valve Figure 3 Glue Regulator ...

Page 16: ... control should require less than 25 feet 8 m of wiring to reach the glue station sensor and shaft encoder longer wiring is available on request A 5 16 8 mm hex wrench can be used to unlock the door of the control enclosure To install the control follow these steps 1 Attach the control to a stationary vertical surface using the mounting holes located inside the control enclosure see Figure 6 Note ...

Page 17: ...Installation VC3500 User s Manual Valco Cincinnati 14 Figure 5 Mobile System Pedestal Figure 6 Mounting Hole Dimensions 66 3 1684 mm 24 3 617 mm 19 6 498 mm ...

Page 18: ...wer which allows for either 115VAC or 230VAC operation Figure 7 To replace or check mains fuses follow these steps 1 Remove all electric power from the unit 2 Remove the line cord 3 Use a small screwdriver to open the hinged door of the fuse holder 4 Remove the fuse drawer ensure that the fuses in the holder remain in place 5 The drawer is labeled 230V and 115V Rotate the drawer to the appropriate...

Page 19: ...Installation VC3500 User s Manual Valco Cincinnati 16 Figure 8 Internal Connections Diagram ...

Page 20: ...der Figure 9 a VCE 1000 encoder with a 10 inch measuring wheel is recommended To install a wheel driven encoder follow these steps 1 Mount the encoder s bracket to the frame of the parent machine 2 Ensure that the wheel of the encoder rides securely against the belt and does not slip 3 In the level 4 menu screen set ratio compensation to 100 pulses Gear Driven Encoder The following formula can be ...

Page 21: ...ired the belt should not be extremely tight Note At least 7 9 teeth should engage in the line shaft driver gear It may be necessary to fabricate an adjustable bracket to connect the encoder base to the parent machine frame Electrical Installation of Encoder A 12VDC encoder must be used with the VC3500 control The cable used to connect the encoder to the control should have a minimum of three condu...

Page 22: ... product A single scanner can be used to start the glue patterns of both channel 1 and channel 2 or the channels can have two separate scanners To install the scanner follow these steps 1 Position the scanner assembly brackets upstream from the glue station Figures 12 and 13 2 Set the scanner 1 5 to 2 0 inches 38mm to 51mm above the product Note The scanner must see through an open area on the par...

Page 23: ... 25 4 mm 500 ft min 152 4 m min 2 51 mm 1000 ft min 304 8 m min 4 102 mm 1500 ft min 457 m min 6 152 mm 2000 ft min 610 m min 8 203 mm 2 51 mm product flow minimum see chart above to VC3700 to VC3700 scanner cell to gun Figure 12 Top Down Glue Station Figure 13 Top Down Bottom Up Combination Glue Station 6 5 10 0 ...

Page 24: ...rol channel 4 If separate scanners are desired to control channel 3 and channel 4 the scanner 3 connector must be used for the scanner installed for channel 3 and the scanner 4 connector must be used for the scanner installed for channel 4 Connections are as follows Pin 1 12VDC red Pin 2 Scanner signal green Pin 3 Return black 3 Connect shield wire s to the protective earth P E terminals located n...

Page 25: ...n The front panel jam indicator also illuminates A field wireable mating connector Figure 13a is provided to wire the relay contacts to the parent machine stop circuit cable must be supplied by customer Connections are as follows Pins 1 and 2 Normally closed contact Pins 3 and 4 Normally open contact Pin 1 12VDC Pin 2 Not used Pin 3 Jam red light Pin 4 Audible alarm signal A pre wired cable is pro...

Page 26: ...A bypass valve or dump valve may be needed to divert excess glue in the glue line away from the applicator to avoid puddling during startups and quick stops A 12VDC 1A driver is available at connector J8 of the interface board Connections are as follows Pin 1 12V Pin 2 Signal ...

Page 27: ...length screen and the clear current data screen Level 2 menu screen The level 2 menu screen provides access to the scan mode screen the glue mode screen two channel model only and the repeat function Level 3 menu screen The level 3 menu screen provides access to the clear data screen the minimum speed screen and the cell to gun screen Level 4 menu screen The level 4 menu screen provides access to ...

Page 28: ... NEDERLANDS EXIT MORE PRD LENGTH COMP CHAN1 RATIO COMP COMP CHAN3 00 00 EXIT MORE EXIT MORE EXIT MORE EXIT 1 2 3 4 6 PRD LENGTH CLEAR DATA COMP CHAN2 COMP CHAN4 EXIT MORE 5 MORE EXIT 00 00 00 00 00 00 Level 1 Menu Screen Level 2 Menu Screen Level 3 Menu Screen Level 4 Menu Screen Level 5 Menu Screen Level 6 Menu Screen REPEAT If screens 3 6 have been restricted pressing MORE will display a 6 digit...

Page 29: ...re 16 Example of a Two Channel Control with Glue Mode Set to Delay Pattern Delay Pattern 1 Glue pressure bar graph This field displays the pressure supplied to the glue source The pressure is displayed in either psi or bar depending on the setup of the control 2 Glue pattern delay channel 1 This field displays the distance from the leading edge of the product to the beginning of the glue pattern 3...

Page 30: ...lays the distance from leading edge of product to beginning of first glue pattern Note A minimum of 00 01 inches 0001 mm must be entered for the delay setting to activate the channel 12 First glue pattern length This field displays the distance of the glue pattern 13 Second glue pattern delay This field displays the distance from end of first glue pattern to beginning of second glue pattern 14 Sec...

Page 31: ...automatic mode detecting a product jam condition and enabling the scanner lockout function to ignore holes in the product or dark areas such as printing CLEAR DATA Pressing this button displays the clear data screen Pressing the YES button in the clear data screen erases the current job s delay and glue pattern length settings and returns the product length setting to zero Pressing the NO button i...

Page 32: ...digit job number The function of each button is as follows EXIT Pressing this button returns you to the level 1 menu screen A This field displays the alphabet numbers and special characters DOWN This button is used to scroll down through the alphabet numbers and special characters UP This button is used to scroll up through the alphabet numbers and special characters BACK Pressing this button move...

Page 33: ... 1 menu screen Numeric Keypad The numeric keypad is used to type a product length ENTER Pressing this button enters the product length The Clear Data Screen The clear data screen Figure 17 is used to clear the current job s data The function of each button is as follows YES Pressing the YES button erases the current job s delay and glue patterns NO Pressing the NO button returns you to the level 1...

Page 34: ...AT 2 SCAN MODE REPEAT Level 2 Menu Screen CHAN 2 DEL PAT CHAN 1 DEL PAT EXIT Repeat Channel Select Screen 2 channel model This appears only on the 2 channel model Repeat Channel Select Screen 4 channel model EXIT CHANNEL 1 CHANNEL 2 Repeat Setup Screen 3 6 EXIT ENTER 00x 0 8 7 5 4 2 1 9 CHANNELS 1 4 EXIT CHANNEL 1 CHANNEL 2 EXIT SCAN 1 or 2 SCAN 1 1 2 EXIT SCAN 1 or 2 SCAN 1 1 2 Scanner Mode Scree...

Page 35: ... The Glue Mode Screen The glue mode screen Figure 18 is used to select a glue mode The function of each button is EXIT Pressing this button returns you to the level 2 menu screen CHAN 1 DEL PAT Pressing this button selects either a single delay pattern DEL PAT or a dual delay pattern DEL PAT DEL PAT for channel 1 CHAN 2 DEL PAT Pressing this button selects either a single delay pattern DEL PAT or ...

Page 36: ...t job s data or all data MIN SPEED Pressing this button displays the minimum speed setting screen which allows you to specify the minimum gluing speed CELL GUN 1 4 Pressing any of the CELL GUN buttons displays the cell to gun setting screen which allows you to specify cell to gun dimensions Figure 19 Level 3 Menu Screens and Related Screens Level 3 Menu Screen CLEAR DATA MIN SPEED CELL GUNS 1 4 EX...

Page 37: ...reen The minimum speed setting screen is used to specify the minimum gluing speed The function of each button is as follows EXIT Pressing this button returns you to the level 3 menu screen The key Pressing the key reduces the minimum speed The key Pressing the key increases the minimum speed The Cell to Gun Setting Screen EXIT Pressing this button returns you to the level 3 menu screen The numeric...

Page 38: ... displays the product length screen RATIO COMP Pressing this button displays the ratio compensation screen Either a manual or automatic ratio compensation method may be used COMP CHAN 1 4 Each channel valve has a separate compensation setting COMP CHAN1 COMP CHAN2 etc Pressing any of the COMP CHAN buttons displays the compensation setting screen for that channel Figure 20 Level 4 Menu Screen and A...

Page 39: ...tio compensation screen displays when the AUTO button on the ratio compensation screen is pressed The automatic ratio compensation screen is used to specify the number of encoder pulses per inch 25 4 mm of product line travel The function of each button is as follows EXIT Pressing this button returns you to the level 4 menu screen SAVE Pressing this button saves the new ratio compensation that is ...

Page 40: ...essure is displayed in pounds per square inch psi When the metric mode is selected all linear measurements are displayed and entered in millimeters and pressure is displayed in bar PIN Pressing the PIN button displays the PIN code screen A four digit PIN code may be entered in order to restrict access to menus 3 6 GLUE QC This button displays on two channel models but it does not have a function F...

Page 41: ...cates that this is the level 6 menu screen The function of each button is as follows Language buttons Pressing one of the language buttons causes that language to display on all of the screens EXIT Pressing the EXIT button returns you to the level 5 menu screen Figure 22 The Level 6 Menu Screen The Inch Metric Screen The inch metric screen Figure 21 is used to specify either inches or millimeters ...

Page 42: ...cify inches or millimeters follow these steps 1 Press the CONFIG button on the main screen The level 1 menu screen displays 2 Press the MORE button in the level 1 menu screen 3 Press the MORE button in menu screens 2 3 and 4 The level 5 menu screen displays 4 Press the IN METRIC button The inch metric screen displays 5 Press either the INCH MODE button or the METRIC MODE button The arrow points to...

Page 43: ...gun setting screen displays 2 Using the numeric keypad enter the distance between the channel 1 scanner and the channel 1 glue valve this value will display in either inches or millimeters depending on the setup of your control Note Each channel valve has a separate cell to gun setting CELL GUN 1 and CELL GUN 2 3 Press the ENTER button The OK DONE message displays indicating that the distance ente...

Page 44: ... to a resolution of several pulses 9 Ensure that ratio compensation is accurate by measuring the length of a glue bead dispensed at low speed 10 If necessary use the manual ratio compensation to fine tune the ratio compensation to a resolution of 0 1 pulse 11 After the ratio compensation has been established add 2 inches 50 mm to the product length setting in order to allow the jam preventer and s...

Page 45: ...g while having a number higher than 0 on the On compensation setting This will cause the training edge of the pattern to increase in length Restrict Screen Access To restrict access to screens 3 6 follow these steps 1 In the level 5 menu screen press the PIN button The PIN code screen displays 2 Press the NEW PIN button A six digit numeric keypad and a display window appear Note If a PIN code has ...

Page 46: ...tches for the desired channels in the enabled position 6 Conduct a low speed check 6a Operate the parent machine at low speed 6b Observe the glue pattern on the product Note Gluing does not begin until the parent machine is operating at the minimum threshold speed set in the control It may be necessary to adjust the minimum speed to apply glue at low speed 6c Adjust the values for delay and patter...

Page 47: ...s to select a letter 5 Press the SELECT button to enter the letter into the display The cursor will automatically move to the right 6 Select additional letters until you have entered the job name Note To erase letters you press the BACK button To add a space between letters you press the SPACE button 7 Press the EXIT button the level 1 menu screen displays 8 Press the EXIT button again the main me...

Page 48: ...oduct length setting to zero Note Once you press the YES button the data is erased and cannot be retrieved 2b Pressing the NO button returns you to either the level 1 or the level 3 menu screen without erasing any data 2c Pressing the ALL button resets the following parameters level 3 menu screen only Delay and pattern lengths in jobs 1 99 will be erased Product length 0 Scan mode 2 channel model ...

Page 49: ... bottom of the main screen DEL PAT DEL PAT In this mode a single delay or skip dimension and a single pattern dimension are displayed across the top of the main screen and a second pair of delay and pattern dimensions are displayed across the bottom of the main screen When either or both channels are in this mode multiple main screens display the delay and pattern dimensions for a single channel o...

Page 50: ...steps 1 through 6 for channel 2 Specifying the Product Length A non zero value for the product length enables the jam detection and scanner lockout functions The value entered should be approximately 2 inches 50 mm longer than the actual product To specify the product length follow these steps 1 Press the CONFIG button on the main screen The level 1 menu screen displays 2 Press the PRD LENGTH butt...

Page 51: ... 2 45 mm Delay 2 124mm Valve 1 Valve 2 Scanner Cell to gun 1 Cell to gun 2 Main screen channel 1 CHAN 2 DEL PAT BAR CONFIG CHAN 1 DEL PAT BAR 0054 0062 CONFIG 0050 0062 0040 0060 Main screen channel 2 0124 0045 2 1 Pattern 1 62 mm Pattern 2 62 mm Product flow Figure25 GluePatternExample Glue Pattern Example Scanner mode SCAN 1 1 2 Glue mode DEL PAT DEL PAT Inch metric Metric ...

Page 52: ...een 3 12V input voltage front panel indicator does not illuminate 3a Check the F1 and F2 fuses on the power supply board 3b Replace power supply board 4 5V logic voltage front panel indicator does not illuminate 4a Check the F1 fuse on the power supply board 4b Replace power supply board Scanner 1 Front panel scanner indicator does not illuminate when a product is in the scanner s detection field ...

Page 53: ...ot dispense glue 2a Check the delay DEL and pattern PAT settings A delay of at least 00 01 inches or 0001 millimeters must be entered in order to activate the channel 2b Check that the channel toggle switch on the front panel is in the enabled 1 position 2c Check that the line speed is above the minimum speed setting 2d Check for a clogged glue valve 2e Check for damage to the glue valve s cable 2...

Page 54: ...e delay value has been correctly entered 3b Ensure that the delay is correct at low speed 3c Ensure that the turn on compensation has been correctly entered 4 At high speed the pattern length is too short or too long 4a Ensure that the pattern value has been correctly entered 4b Ensure that the pattern length is correct at low speed 4c Ensure that the turn off compensation has been correctly enter...

Page 55: ...ents Figure 26 Figure 26 Internal Components of the VC3500 touchscreen EPC board power supply board connectors for optional RS232 board CPU board connectors for optional channel 3 and 4 logic board valve driver board interface board analog board LED board not shown optional relay board for jam prevention and alarm signals ...

Page 56: ...r installed dictates that two channel software is use Not installed No jumper dictates that four channel software is used Switches A pushbutton near the upper left corner provides a manual reset function Test Points TP1 CLOCK 8 MHz 5V digital clock signal from Oscillator U7 for main processor U1 TP2 CNTR CLK 5V encoder signal gated by a timer from U17 68230 PB6 These gated encoder pulses are count...

Page 57: ...a minimal length for zero speed P2 Gain Adj Not used In early models allowed adjustment to gain of frequency to voltage converter U3 Increasing the gain will increase the analog voltage at J2 pin 3 to the EPC for a given frequency of encoder pulses Connectors CO1 Connection to interface board via a 30 pin ribbon cable J2 Connection for 17VDC supply voltage from the power supply board J3 J4 Connect...

Page 58: ...oard J8 Connection for dump valve glue by pass valve Replacement Fuses 12 VDC I O Supply Label F1 Type PC Mount Value 1 5A Valco Number 085xx132 Dump Valve Active Label F2 Type PC Mount Value 1 5A Valco Number 085xx132 Indicators D1 12 V When lit this green LED indicates that the 12VDC supply for scanners encoder and by pass valve dump valve is operational D2 When lit this yellow LED indicates tha...

Page 59: ...lit this green LED indicates that 15VDC input to regulator U3 is present D5 56 V When lit this green LED indicates that the 56VDC peak voltage is available to energize a glue valve D6 HOLD 1 When lit this yellow LED indicates that the 12VDC hold voltage is applied to glue valve 1 D7 PEAK 1 When lit this yellow LED indicates that the 56VDC peak voltage is applied to glue valve 1 D8 HOLD 2 When lit ...

Page 60: ...ltage level Pins 1 and 2 jumpered Forces a fixed hold voltage level of 12 V Pins 2 and 3 jumpered Allows adjustment of hold voltage level of 5 V to 12 V using potentiometer P3 Potentiometers P1 PTIME1 Provides adjustment between 1mS and 10mS for channel 1 Peak Voltage duration when JP2 has a jumper between pins 2 and 3 Clockwise rotation increases duration P2 PTIME2 Provides adjustment between 1mS...

Page 61: ...PU board D3 Intrfc supply When lit this green LED indicates that the 17VDC supply voltage is available to power the interface board D4 Pump supply When lit this green LED indicates that the 32VDC supply voltage is available to power the DD 1 pump RS232 Board PN 151xx375 Connectors J1 J2 Connection to the CPU board J3 Connection for serial port via ribbon cable Jumpers JP1 Hardware software handsha...

Page 62: ...Select Pins 1 and 2 jumpered Makes the E OUT signal available at J1 pin 5 allowing an external device to monitor the exhaust solenoid condition Pins 2 and 3 jumpered Makes the S OUT signal available at J1 pin 5 allowing an external device to monitor the Sensor transducer analog signal Potentiometers P1 Span Provides adjustment of transducer signal gain allowing an anticipated small transducer excu...

Page 63: ...and alarm signals from the glue inspection board 151xx410 J3 External connector used for interfacing the machine interface relay to the parent machine stop circuit J4 External connector used for interfacing a beacon alarm for jam and glue fault conditions Indicators D1 RLY When lit this yellow LED indicates that the machine interface relay is energized Replacement Fuses Beacon current limit Label ...

Page 64: ...aximum 600W instantaneous per channel not to exceed 10 duty cycle Hold voltage 5V to 12V adjustable Encoder Inputs One 40kHz maximum Type voltage VCE 1000 recommended 12VDC Miscellaneous Maximum gluing speed 2000 feet 610m per minute Maximum glue length 99 99 2539mm Flow control Internal EPC 6 Maximum glue pressure 100 psi 7 bar Job storage capacity 99 jobs Glue patterns One or two per channel Sca...

Page 65: ...lue regulator and manifold 738xx173 PC9 adhesive system pedestal 0 650 psi 1 45 8 bar glue regulator and manifold 738xx174 Machine mount 0 125 psi 1 9 6 bar glue regulator and manifold 738xx177 Machine mount 0 650 psi 1 45 8 bar glue regulator and manifold 738xx178 Beam assembly for use with 578xx032 trolley bracket 581xx298 Filter regulator manifold assembly 0 125 psi 1 9 6 bar 593xx245 Filter re...

Page 66: ...ule 115 230VAC 086xx055 Cord grip panel assembly 084xx002 Channel enable switch assembly 030xx429 Pressure adjust switch assembly 030xx430 Installation kit includes the following 781xx136 Fuse 2a 5 x 20 mm power entry module 1 Fuse 5A 5 x 20 mm valve driver board F1 2 Fuse 5A PC mount valve driver board F2 F3 4 Fuse 3 15A 5 x 20 mm power supply board F1 2 Fuse 1 6A 5 x 20 mm power supply board F2 ...

Page 67: ...ir solenoid 1 411xx057 Encoder timing belt 1 788xx300 Encoder measuring wheel 1 788xx553 Filter screen 50 mesh 1 593xx020 Filter screen 100 mesh 1 593xx087 0 ring glue filter cap 1 745xx059 Check the type of part on your system before ordering Description Part Snap track for CPU P C board 091xx382 Rivets plastic for mounting snap track 091xx374 Extraction tool for chips 781xx174 I C Chip Assembly ...

Page 68: ...ic 1 151xx363 PC board analog 1 151xx364 PC board LED 1 151xx365 PC board interface 1 151xx366 PC board 2 channel valve driver 1 151xx367 PC board power supply 1 151xx368 PC board RS232 1 151xx375 PC board assembly EPC 6 pressure control 1 151xx379 Fuse 2A power entry module 1 085xx040 Fuse 5A valve driver board F1 1 085xx206 Fuse 5A valve driver board F2 F3 1 085xx216 Fuse 3 15A power supply boar...

Page 69: ...Part Number List VC3500 User s Manual Valco Cincinnati 71 Recommended Spare Parts List DD 1 Pump Description Quantity Part Rebuild and spare parts kit 1 560xx602 ...

Page 70: ...econditioned equipment unless specified otherwise at the time of purchase will be warranted as described above for a period of ninety 90 days from the date of shipment by Valco Cincinnati Components purchased by Valco Cincinnati Inc from others for inclusion in its products are warranted only to the extent of the original manufacturer s warranty In no event shall Valco Cincinnati Inc be liable for...

Page 71: ... quoted at that time Any part that fails during the warranty period shall be returned prepaid to Valco Cincinnati by the customer for disposition Note Upon request Valco Cincinnati personnel are available to repair or replace such parts at the customer s facility Charges for this service include travel time and expenses If an equipment problem is the result of customer abuse improper installation ...

Page 72: ...annel 1 follow these steps 1 At the level 2 menu press the GLUE MODE button The glue mode screen displays Figure 27 2 Set the glue mode for channel 1 to DEL PAT DEL PAT press the CHAN 1 button to toggle between the two selections 3 Press EXIT to return to main screen Figure 27 The Glue Mode Screen Figure 28 Glue Pattern Edit Screen 4 At the main screen touch one of the four digit numbers on the to...

Page 73: ...ain screen 12 Press the CONFIG button 13 Press the MORE button in the level 1 menu screen The level 2 menu screen displays 14 Press the REPEAT button The repeat function screen displays 15 Press channel 1 The repeat setup screen for channel 1 displays 16 To program 18 additional inches of delay pattern press 1 and then press 8 17 Press the ENTER button The OK DONE message displays in the edit box ...

Page 74: ...not respond to data shown in location codes pertaining to channels 3 and 4 It will also not respond to data shown in location codes 3 4 and 7 8 unless the respective glue modes are set 1 Channel 1 Delay length 2 Channel 1 Pattern length 3 Channel 1 2nd Delay length 4 Channel 1 2nd Pattern length 5 Channel 2 Delay length 6 Channel 2 Pattern length 7 Channel 2 2nd Delay length 8 Channel 2 2nd Patter...

Page 75: ...5 Speed in feet per minute receive only Bytes 4 1 are hexadecimal digits 36 Repeat factor for channel 1 0 no repeat 37 Repeat factor for channel 2 0 no repeat 38 Repeat factor for channel 3 0 no repeat 39 Repeat factor for channel 4 0 no repeat 40 Marker station distance from glue station 41 Marker skip distance from leading edge of product 42 Marker mark distance 43 Tolerance codes for glue inspe...

Page 76: ...data bits and 1 stop bit 1 Send send request byte from host Send request byte 254dec 2 Receive ACK acknowledge byte from VC3500 This indicates that the control will start looking for the data After the request byte is received the control returns ACK 255dec If this byte is not returned after 500ms the host must terminate the send 3 Send byte 4 byte 3 byte 2 byte 1 location code from host Byte 4 Ms...

Page 77: ...a parent machine control The data is requested by the host computer using the following format 1 Send receive request byte from host Receive request byte 253dec 2 Receive ACK byte from VC3500 3 Send location code from host 4 Receive Byte 4 Byte 3 Byte 2 Byte 1 from VC3500 Example of Receiving Data To display the first glue pattern length follow these steps 1 Send 253 2 Wait for ACK 3 Send 2 4 Rece...

Page 78: ... 3 In the level 2 menu screen press the SCAN MODE button 4 Press the SCAN 1 1 2 button 5 Press the SCAN 3 3 4 button Applying Up To Four Patterns from a Single Glue Valve In order to apply up to four glue patterns from a single glue valve follow these steps Electrical Connections 1 The scanner 1 connector J1 of the interface board must be used as the interface point for the single scanner used in ...

Page 79: ...J1 on the interface board as follows Pin 1 12VDC Pin 2 Scanner signal Pin 3 Return 2 Install a wire jumper from J1 pin 2 to J3 pin 2 on the interface board 3 Install a wire jumper from J3 pin 3 to J4 pin 3 on bottom valve driver board in order to parallel the outputs of channels 1 and 2 4 Install a wire jumper from J3 pin 3 to J4 pin 3 on top valve driver board in order to parallel the outputs of ...

Page 80: ...ns for channel 2 enter delay and pattern information for patterns 3 and 4 12 In the glue pattern edit screens for channel 3 enter dealy and pattern information for patterns 5 and 6 13 In the glue pattern edit screens for channel 4 enter delay and pattern informatin for patterns 7 and 8 ...

Page 81: ...l the product scanner follow these steps 1 Locate the product scanner 1 2 inches above the product 2 Apply power to the glue control 3 Place product 0 75 to 1 00 inches below normal product travel 4 Turn the adjustment screw counterclockwise until the LED is not illuminated 5 Adjust the product scanner sensitivity by turning the adjustment screw clockwise just until the LED illuminates Electrical ...

Page 82: ...duct scanner The control measures the product length subtracts the delay dimension on both the leading and the trailing edges and enters the remaining length into the pattern dimension Normal gluing will begin with the next product Note Either the delay or pattern dimensions may be altered to affect changes in the glue pattern placement Menu Buttons Since the VC3500 is a single channel control the...

Page 83: ...ems only OTHERWISE DAMAGE TO EQUIPMENT COULD OCCUR Action Date Shift Initials 1 Clean the exterior portion of the glue valves nozzle tips glue heads etc 2 Purge the glue valves if necessary and ensure proper glue flow 3 Ensure that air and glue pressure settings are correct 4 If using glue inspection Ensure that sensor is clean Lens must be clean and clear with no scratches Check sensor for proper...

Page 84: ...t 5 Reassemble the fluid section 6 Using the 3 way purge valve on the output of the glue filter purge all air from the system 7 Purge each valve in the system Approximately 1 2 ounces of glue should be purged for proper glue flow 8 Check for any glue leakage on the needle seat Replace the needle plunger assembly and seat if leaks or dripping occurs 9 For non contact valves only Apply a small amoun...

Page 85: ...Initials 1 Encoder mounting a Check timing belt gear and pulley teeth and proper timing belt tension b If using measuring wheel check for wear and proper wheel tension on machine belt c If using direct drive encoder check coupling and rotation of shaft for proper alignment 2 Perform the Weekly Maintenance procedure ...

Page 86: ...l Valco Cincinnati E 4 6 Month Maintenance Actions Date Shift Initials 1 Flush entire glue system except for the central pumping system with a vinegar and water solution 1 gallon of vinegar to 10 gallons of water 2 Perform the Weekly Maintenance procedure ...

Page 87: ...tions Date Shift Initials 1 Flush the entire glue system including the central pumping system with a vinegar and water solution 1 gallon of vinegar to 10 gallons of water 2 Disassemble thoroughly clean and rebuild each fluid regulator assembly and glue valve 3 Perform the Weekly Maintenance procedure ...

Page 88: ...VC3700 User s Manual Software Version 3 X Manual Number MCO34 Manual Release Date July 1999 ...

Page 89: ...is manual is furnished for educational purposes only is subject to change without notice and should not be construed as a commitment by Valco Cincinnati Inc This manual written and designed at Valco Cincinnati Inc 411 Circle Freeway Drive Cincinnati Ohio 45246 Part Number MC034 Printed in the USA Valco Cincinnati Incorporated 411 Circle Freeway Drive Cincinnati Ohio 45246 TEL 513 874 6550 FAX 513 ...

Page 90: ...troller Product Model s VC3700 Year of Manufacture 1998 conforms to the following standards Safety EN 60204 1 EMC Emissions EN 50081 2 EN 55011 Class A EMC Immunity EN 50082 2 EN 61000 4 2 EN 61000 4 3 EN 61000 4 4 Degrees of Protection EN 60529 1 IP54 and complies with the requirements of Low Voltage Directive 73 23 EEC EMC Directive 89 336 EEC Office of CE Conformance Cincinnati Ohio USA ...

Page 91: ... of Encoder 18 Scanner Installation 19 Mechanical Installation of Scanner 19 Electrical Installation of Scanner 21 Glue Valve Installation 21 Electrical Installation of Glue Valve 21 Machine Stop Relay and Beacon Interface 22 DD 1 Pump Power Supply 22 Bypass Valve Driver 22 Continuous Gluing 23 Glue Sensor Installation 23 Capacitive Glue Sensor 23 MechanicalInstallation 23 ElectricalInstallation 2...

Page 92: ...n 40 The On Off Compensation Setting Screen 40 Level 5 Menu Screen 42 The Inch Metric Screen 42 The PIN Code Screen 42 The Glue Inspection Setup Screen 42 The Cell Marker Edit Screen 43 The Marker Skip Marker Mark Select Screen 43 The Marker Pattern Edit Screen 43 Level 6 Menu Screen 43 Initial Setup 45 Introduction 45 Disable Glue Valves for All Channels 45 Specify Inches or Millimeters 45 Specif...

Page 93: ...Recommended Spare Parts List DD 1 Pump 79 Warranty 81 Cold Glue Equipment and Electronic Controls 81 Hot Melt Units Hoses Valves and Related Equipment 81 Service 83 Service Needs 83 Appendix A The Repeat Function 85 Using the Repeat Function 85 Appendix B The RS232 Communications Interface 87 RS232 Communications Interface 87 Location Codes 87 Data Format 88 Sending Information from Host to VC3700...

Page 94: ...r use with up to two glue detection sensors It will also operate up to four jam prevention sensors The VC3700 is used for applications where consistent glue patterns are required at high machine speeds and during speed changes The VC3700 provides complex glue patterns that can be difficult or impossible to obtain with other systems The control operator can use the control s front panel touch scree...

Page 95: ... warnings WARNING Promptly repair or replace all worn or damaged electrical wiring and equipment wires to avoid danger to personnel WARNING Properly route all electrical wires to avoid danger to personnel and damage to moving parts of machine WARNING Disconnect all power before opening the control Only qualified personnel should open and service the control WARNING This symbol indicates the presen...

Page 96: ...g checkout procedures stay clear of any moving mechanical parts and do not touch exposed electri cal equipment or electrical connectors WARNING Keep pump cover and electrical enclosures closed except during setup service and checkout procedures WARNING Promptly repair or replace all worn or damaged parts ...

Page 97: ...ads Trim leads to the required length Leads should be only as long as necessary for installation All wiring should be in conduits or wireways Connecting the Supply of Electrical Power Electrical connections should be made only by experienced service per sonnel The control must be connected to a clean supply of electrical power Use a dedicated circuit if possible if a dedicated circuit is not avail...

Page 98: ...Valco Cincinnati 7 Introduction This section describes the basic features of the 3700 control Basic Features Figure 1 Front Panel of VC3700 ...

Page 99: ...minates when the scanner detects product 5 Glue pressure adjustment You press this button to adjust glue pressure increase and decrease 6 Status indicator lights items 6a through 6h are status indicator lights 6a Less than minimum speed X MIN illuminates when the speed of the parent machine is less than the minimum speed setting 6b Greater than minimum speed X MIN illuminates when the speed of the...

Page 100: ...for air to exhaust to atmosphere It is not normally connected 2 Air input Input for regulated air 80 100 psi 6 5 8 bar 3 Computer interface DB 9 socket for optional RS232 communications standard DTE 4 Air output This output is connected to the glue regulator to provide speed dependent glue pressure 5 Optional machine interface items 5a and 5b are machine interface connectors 5a Beacon horn connect...

Page 101: ...ommunications interface 4 regulated air out to glue regulator Figure 3 street tee F F M 1 8 adapters F M 1 8 x 1 8 gauge 0 60 psi 7 line cord clamp screws 4 40 thread 6 power entry module During installation choose any combination of two fittings for tubing diameter male connector 3 8 x 1 8 and male elbow 1 4 x 1 8 or male connector 3 8 x 1 8 and male elbow 1 4 x 1 8 ...

Page 102: ...lco Cincinnati 11 shock arrestor T handle provides minimum pressure setting sealing nut must be tightened for proper operation to VC3700 regulated air port adhesive supply glue regulator to glue station shutoff valve Figure 3 Glue Regulator ...

Page 103: ...The control should require less than 25 feet 8 m of wiring to reach the glue station sensor and shaft encoder longer wiring is available on request A 5 16 8 mm hex wrench can be used to unlock the door of the control enclosure To install the control follow these steps 1 Attach the control to a stationary vertical surface using the mounting holes located inside the control enclosure see Figure 6 No...

Page 104: ...Installation VC3700 User s Manual Valco Cincinnati 14 Figure 5 Mobile System Pedestal Figure 6 Mounting Hole Dimensions 66 3 1684 mm 24 3 617 mm 19 6 498 mm ...

Page 105: ...wer which allows for either 115VAC or 230VAC operation Figure 7 To replace or check mains fuses follow these steps 1 Remove all electric power from the unit 2 Remove the line cord 3 Use a small screwdriver to open the hinged door of the fuse holder 4 Remove the fuse drawer ensure that the fuses in the holder remain in place 5 The drawer is labeled 230V and 115V Rotate the drawer to the appropriate...

Page 106: ... INPUT BLACK RETURN BLUE 12 V BROWN INPUT BLACK RETURN BLUE 12 V BROWN INPUT BLACK RETURN BLUE 12 V RED INPUT ORANGE RETURN BLACK Purge input blau Purge return blk Valve output brn Valve return white Purge input blau Purge return blk Valve output brn Valve return white 12 V BROWN INPUT BLACK RETURN BLUE 12 V BROWN INPUT BLACK RETURN BLUE ...

Page 107: ...ravel should be supplied to the VC3700 If less than 100 pulses per inch 25 4 mm are supplied poor resolution may result in pattern placement errors If more than 100 pulses per inch 25 4 mm are supplied the maximum specified speed of 2000 feet min 610 m min must be reduced There are two primary types of encoders Wheel driven encoder Gear driven encoder Wheel Driven Encoder If using a wheel driven e...

Page 108: ...equired the belt should not be extremely tight Note At least 7 9 teeth should engage in the line shaft driver gear It may be necessary to fabricate an adjustable bracket to connect the encoder base to the parent machine frame Figure 10 Typical Installation of a Gear Driven Encoder drive gear minimum 7 9 teeth line shaft drive driven gear machine base machine base Adjustable mounting supplied by cu...

Page 109: ...t A single scanner can be used to start the glue patterns of both channel 1 and channel 2 or the channels can have two separate scanners To install the scanner follow these steps 1 Position the scanner assembly brackets upstream from the glue station Figures 12 and 13 2 Set the scanner 1 5 to 2 0 inches 38 to 51mm above the product Note The scanner must see through an open area on the parent machi...

Page 110: ... 25 4 mm 500 ft min 152 4 m min 2 51 mm 1000 ft min 304 8 m min 4 102 mm 1500 ft min 457 m min 6 152 mm 2000 ft min 610 m min 8 203 mm 2 51 mm product flow minimum see chart above to VC3700 to VC3700 scanner cell to gun Figure 12 Top Down Glue Station Figure 13 Top Down Bottom Up Combination Glue Station 6 5 10 0 ...

Page 111: ...in 2 Scanner signal Pin 3 Return 3 Connect shield wire s to the protective earth P E terminals located near cord grip base plate 4 Tighten the cord grip used by the scanner cable s Glue Valve Installation Electrical Installation of Glue Valve The glue valve cable should have a minimum of two conductors 18 20 AWG and a shield four conductors and a shield if a remote purge is required To connect the...

Page 112: ... Pump Power Supply A source is available to supply power for a DD 1 pump at connector J6 of the power supply board 151xx368 This supply is 32VDC fused at 1 6A with connections as follows Pin 1 0V Pin 2 32VDC Since the DD 1 pump is configured to accept an AC source and then rectify it to DC polarity of a DC source is not relevant Bypass Valve Driver A bypass valve or dump valve may be needed to div...

Page 113: ...o that there is approximately 1 16 1 5 mm clearance between the product and the upper and lower guide bars Figures 14 and 15 2 Position the sensor so that there is a 1 4 6 mm maximum between the detecting surface of the sensor and the product Note Glue should be on the opposite side of the product from the sensor 3 Tighten the screw on the housing to secure the sensor Electrical Installation The c...

Page 114: ...per guide bar sensor plastic 1 16 1 5 mm glue on this side lower guide bar product maximum 1 4 Figure 15 Typical Installation Capacitive Sensor Only upper guide bar glue on this side product sensor plastic housing maximum 1 4 6 mm 1 16 1 5 mm lower guide bar Figure 16 Capacitive Glue Sensor LED adjustment screw ...

Page 115: ... steps 1 Mount the sensor onto the guide bracket so that its sensing surface is approximately 1 inch 25mm above the glue line being sensed 2 Adjust the guiding bars so that the product has the least horizontal and vertical movement Pay attention to the scanning range when adjusting the bars 3 Connect the cable to the plug receptacle on the glue sensor Electrical Installation The cables used to con...

Page 116: ...e two positions The UV signal can be viewed using a piece of UV sensitive copy paper The UV signal emits several dot signals in a line These dots should be slightly out of focus and perpendicular to the glue line A right angle lens is available to rotate the UV signal so it is perpendicular to the glue line Lens Replacement The lens is screwed in and can be replaced by another lens Scanning distan...

Page 117: ...late 4 Tighten the cord grips used by the product scanner cables Marker Valve or Kicker Diverter Installation Mechanical Installation The unit must be less than 255 inches 6477 mm from the product scanner used for glue inspection It must also be less than 7 products from the scanner Electrical Installation The cable used to connect the marker valve or kicker diverter to the control should have a m...

Page 118: ... the product length screen and the clear current data screen Level 2 menu screen The level 2 menu screen provides access to the scan mode screen the glue mode screen two channel model only and the repeat function Level 3 menu screen The level 3 menu screen provides access to the clear data screen current job or all the minimum speed screen and the cell to gun screen Level 4 menu screen The level 4...

Page 119: ...ISH FRANÇAIS DEUTSCH EXIT MORE JOB STORE ITALIANO ESPAÑOL NEDERLANDS EXIT MORE PRD LENGTH COMP CHAN1 RATIO COMP 00 00 EXIT EXIT MORE EXIT MORE EXIT 1 2 3 4 6 PRD LENGTH CLEAR DATA COMP CHAN2 EXIT MORE 5 IN METRIC MORE EXIT 00 00 00 00 00 00 REPEAT GLUE QC PIN MORE If screens 3 6 have been restricted pressing MORE will display a 6 digit numerickeypad REPEAT GLUE MODE SCAN MODE EXIT MORE 2 5 6 3 4 1...

Page 120: ... the leading edge of the product to the beginning of the glue pattern 3 Channel 1 glue pattern edit This field displays the channel assignment for the delay and pattern length settings seen on the left and right of this display 4 Software version This field displays the software version used by the control PSI CHAN 1 DEL PAT 03 00 CONFIG CHAN 2 DEL PAT 2 3 4 5 6 1 7 8 9 10 00 00 00 00 00 00 00 00 ...

Page 121: ...lue mode 11 First glue pattern delay This field displays the distance from leading edge of product to beginning of first glue pattern 12 First glue pattern length This field displays the distance of the glue pattern 13 Second glue pattern delay This field displays the distance from end of first glue pattern to beginning of second glue pattern 14 Second glue pattern length This field displays the d...

Page 122: ...the automatic mode detecting a product jam condition and enabling the scanner lockout function to ignore holes in the product or dark areas such as printing CLEAR DATA Pressing this button displays the clear data screen Pressing the YES button in the clear data screen erases the current job s delay and glue pattern length settings and returns the product length setting to zero Pressing the NO butt...

Page 123: ... as follows EXIT Pressing this button returns you to the level 1 menu screen A This field displays the alphabet numbers and special characters DOWN This button is used to scroll down through the alphabet numbers and special characters UP This button is used to scroll up through the alphabet numbers and special characters BACK Pressing this button moves the cursor backward in the job name field era...

Page 124: ...ure 20 is used to clear the current job s data The function of each button is as follows YES Pressing the YES button erases the current job s delay and glue patterns NO Pressing the NO button returns you to the level 1 menu screen without erasing any data Figure 21 Level 2 Menu Screen and Associated Screens Scanner Mode Screen Glue Mode Screen Repeat Channel Select Screen GLUE MODE SCAN MODE EXIT ...

Page 125: ...elects use of a common scanner scanner 1 for channels 1 and 2 The Glue Mode Screen The glue mode screen Figure 21 is used to select a glue mode The function of each button is EXIT Pressing this button returns you to the level 2 menu screen CHAN 1 DEL PAT Pressing this button selects either a single delay pattern DEL PAT or a dual delay pattern DEL PAT DEL PAT for channel 1 CHAN 2 DEL PAT Pressing ...

Page 126: ...ob s data or all data MIN SPEED Pressing this button displays the minimum speed setting screen which allows you to specify the minimum gluing speed CELL GUN 1 2 Pressing either of the CELL GUN buttons displays the cell to gun setting screen which allows you to specify cell to gun dimensions Level 3 Menu Screen CLEAR DATA MIN SPEED CELL GUNS 1 2 EXIT MORE CLEAR DATA CELL GUN 1 CELL GUN 2 MIN SPEED ...

Page 127: ...een The minimum speed setting screen is used to specify the minimum gluing speed The function of each button is as follows EXIT Pressing this button returns you to the level 3 menu screen The key Pressing the key reduces the minimum speed The key Pressing the key increases the minimum speed The Cell to Gun Settting Screen EXIT Pressing this button returns you to the level 3 menu screen The numeric...

Page 128: ... in the product or dark areas such as printing RATIO COMP Pressing this button displays the ratio compensation screen Either a manual or automatic ratio compensation method may be used COMP CHAN 1 2 Each channel valve has a separate compensation setting Pressing either of the COMP CHAN buttons displays the compensation setting screen for that channel Figure 23 Level 4 Menu Screen and Associated Sc...

Page 129: ...tion screen displays when the AUTO button on the ratio compensation screen is pressed The automatic ratio compensation screen is used to specify the number of encoder pulses per inch 25 4 mm of product line travel The function of each button is as follows EXIT Pressing this button returns you to the level 4 menu screen SAVE Pressing this button saves the new ratio compensation that is displayed at...

Page 130: ... METRIC MODE PIN Code Screen Glue Inspection Setup Screen GLUE QC MARKER Cell Marker Edit Screen IN METRIC PIN Level 5 Menu Screen Marker Skip Marker Mark Select Screen EXIT MARKER MARK MARKER SKIP EXIT NEW PIN EXIT NEW PIN NEW PIN New PIN Entry Screen 5 6 3 4 1 2 MARKER SKIP or MARKER MARK EXIT 3 6 ENTER 0000mm 0 8 7 5 4 2 1 9 MARKER PATTERN EXIT 3 6 ENTER 0000mm 0 8 7 5 4 2 1 9 VALVE Marker Patt...

Page 131: ...his button returns you to the level 5 menu screen INCH MODE Pressing this button sets the control to imperial inch and psi measurements METRIC MODE Pressing this button sets the control to metric mm and bar measurements The PIN Code Screen The PIN code screen Figure 24 is used to specify a PIN code in order to restrict screens 3 6 The function of each button is as follows EXIT Pressing this button...

Page 132: ...stance MARKER MARK Pressing this button displays the marker pattern edit screen for the marker mark distance The Marker Pattern Edit Screen The marker pattern edit screen Figure 24 is used to specify the pattern skip and mark distance on a faulty product The function of each button is as follows EXIT Pressing this button returns you to the marker skip marker mark select screen Numeric keyboard The...

Page 133: ...g setup procedure Specify Inches or Millimeters 1 Press the CONFIG button on the main screen The level 1 menu screen displays 2 Press the MORE button in the level 1 menu screen 3 Press the MORE button in menu screens 2 3 and 4 The level 5 menu screen displays 4 Press the IN METRIC button The inch metric screen displays 5 Press either the INCH MODE button or the METRIC MODE button The arrow points ...

Page 134: ...ng screen displays 2 Using the numeric keypad enter the distance between the channel 1 scanner and the channel 1 glue valve this value will display in either inches or millimeters depending on the setup of your control Note Each channel valve has a separate cell to gun setting CELL GUN 1 and CELL GUN 2 3 Press the ENTER button The OK DONE message displays indicating that the distance entered has b...

Page 135: ...n to accept the new ratio compensation setting Note Automatic ratio compensation is used to determine a general ratio compensation to a resolution of several pulses 9 Ensure that ratio compensation is accurate by measuring the length of a glue bead dispensed at low speed 10 If necessary use the manual ratio compensation to fine tune the ratio compensation to a resolution of 0 1 pulse 11 After the ...

Page 136: ...n forward at high speeds Enable Glue QC 1 At the level 5 menu screen press the GLUE QC button The glue inspection setup screen displays 2 Press the MARKER button The cell marker edit screen displays 3 Using the numeric keypad enter the distance from the first product scanner used for glue inspection to the marker valve or kicker diverter 4 Press the ENTER button The OK DONE message displays 5 Pres...

Page 137: ...ld be used for capacitive sensors The low range can be used for most other sensors The tolerances available in each range are Tolerance Button Low Range High Range GREEN 5 mm 25 mm AMBER 10 mm 40 mm RED 20 mm 50 mm Restrict Screen Access To restrict access to screens 3 6 follow these steps 1 In the level 5 menu screen press the PIN button The PIN code screen displays 2 Press the NEW PIN button A s...

Page 138: ...age 55 5 Enable the glue valves 5a Place the toggle switches for the desired channels in the enabled position 6 Conduct a low speed check 6a Operate the parent machine at low speed 6b Observe the glue pattern on the product Note Gluing does not begin until the parent machine is operating at the minimum threshold speed set in the control It may be necessary to adjust the minimum speed to apply glue...

Page 139: ...s to select a letter 5 Press the SELECT button to enter the letter into the display The cursor will automatically move to the right 6 Select additional letters until you have entered the job name Note To erase letters you press the BACK button To add a space between letters you press the SPACE button 7 Press the EXIT button the level 1 menu screen displays 8 Press the EXIT button again the main me...

Page 140: ...oduct length setting to zero Note Once you press the YES button the data is erased and cannot be retrieved 2b Pressing the NO button returns you to either the level 1 or the level 3 menu screen without erasing any data 2c Pressing the ALL button resets the following parameters level 3 menu screen only Delay and pattern lengths in jobs 1 99 will be erased Product length 0 Scan mode 2 channel model ...

Page 141: ... top of the main screen and a second pair of delay and pattern dimensions are displayed across the bottom of the main screen When either or both channels are in this mode multiple main screens display the delay and pattern dimensions for a single channel only To select the glue mode follow these steps 1 Press the CONFIG button on the main screen The level 1 menu screen displays 2 Press the MORE bu...

Page 142: ...e first glue pattern to the beginning of the second glue pattern 5 At the second glue pattern length field enter the length of the second glue pattern 6 Press the PAGE DOWN button to see pattern information for the next channel 7 Repeat steps 1 through 6 for channel 2 Specifying the Product Length A non zero value for the product length enables the jam detection and scanner lockout functions The v...

Page 143: ...2 45 mm Delay 2 124mm Valve 1 Valve 2 Scanner Cell to gun 1 Cell to gun 2 Main screen channel 1 CHAN 2 DEL PAT BAR CONFIG CHAN 1 DEL PAT BAR 0054 0062 CONFIG 0050 0062 0040 0060 Main screen channel 2 0124 0045 2 1 Pattern 1 62 mm Pattern 2 62 mm Product flow Figure 25 Glue Pattern Example Glue Pattern Example Scanner mode SCAN 1 1 2 Glue mode DEL PAT DEL PAT Inch metric Metric ...

Page 144: ...uses on the power supply board 3b Replace power supply board 4 5V logic voltage front panel indicator does not illuminate 4a Check the F1 fuse on the power supply board 4b Replace power supply board Scanner 1 Front panel scanner indicator does not illuminate when a product is in the scanner s detection field 1a Check the distance between the scanner and the product see the Installation section of ...

Page 145: ...ot dispense glue 2a Check the delay DEL and pattern PAT settings A delay of at least 00 01 inches or 0001 millimeters must be entered in order to activate the channel 2b Check that the channel toggle switch on the front panel is in the enabled 1 position 2c Check that the line speed is above the minimum speed setting 2d Check for a clogged glue valve 2e Check for damage to the glue valve s cable 2...

Page 146: ...nsation has been correctly entered 4 At high speed the pattern length is too short or too long 4a Ensure that the pattern value has been correctly entered 4b Ensure that the pattern length is correct at low speed 4c Ensure that the turn off compensation has been correctly entered Glue Inspection 1 Intermittent rapid flahing of the PASS light 1 Ensure that the glue QC tolerance doubled is not great...

Page 147: ...s s internal components Figure 26 touchscreen EPC board power supply board connectors for optional RS232 CPU board valve driver board and or glue logic inspection board interface board analog board LED board connectors for optional channel 3 and 4 logic board Figure 26 Internal Components of the VC3700 ...

Page 148: ...alled dictates that two channel software is use Not installed No jumper dictates that four channel software is used Switches A pushbutton near the upper left corner provides a manual reset function Test Points TP1 CLOCK 8 MHz 5V digital clock signal from Oscillator U7 for main processor U1 TP2 CNTR CLK 5V encoder signal gated by a timer from U17 68230 PB6 These gated encoder pulses are counted by ...

Page 149: ...length for zero speed P2 Gain Adj Not used In early models allowed adjustment to gain of frequency to voltage converter U3 Increasing the gain will increase the analog voltage at J2 pin 3 to the EPC for a given frequency of encoder pulses Connectors CO1 Connection to interface board and glue inspection board via a 40 pin ribbon cable This cable is split with the first ten conductors going to the g...

Page 150: ...upply voltage from power supply board J8 Connection for dump valve glue by pass valve Replacement Fuses 12 VDC I O Supply Label F1 Type PC Mount Value 1 5A Valco Number 085xx132 Dump Valve Active Label F2 Type PC Mount Value 1 5A Valco Number 085xx132 Indicators D1 12 V When lit this green LED indicates that the 12VDC supply for scanners encoder and by pass valve dump valve is operational D2 When ...

Page 151: ...lit this green LED indicates that 15VDC input to regulator U3 is present D5 56 V When lit this green LED indicates that the 56VDC peak voltage is available to energize a glue valve D6 HOLD 1 When lit this yellow LED indicates that the 12VDC hold voltage is applied to glue valve 1 D7 PEAK 1 When lit this yellow LED indicates that the 56VDC peak voltage is applied to glue valve 1 D8 HOLD 2 When lit ...

Page 152: ...mpered Allows adjustment of hold voltage level of 5V to 12V using potentiometer P3 Potentiometers P1 PTIME1 Provides adjustment between 1mS and 12mS for channel 1 peak voltage duration when JP2 has a jumper between pins 2 and 3 Clockwise rotation increases duration P2 PTIME2 Provides adjustment between 1mS and 12mS for channel 2 peak voltage duration when JP3 has a jumper between pins 2 and 3 Cloc...

Page 153: ...PU board D3 Intrfc supply When lit this green LED indicates that the 17VDC supply voltage is available to power the interface board D4 Pump supply When lit this green LED indicates that the 32VDC supply voltage is available to power the DD 1 pump RS232 Board PN 151xx375 Connectors J1 J2 Connection to the CPU board J3 Connection for serial port via ribbon cable Jumpers JP1 Hardware software handsha...

Page 154: ...Select Pins 1 and 2 jumpered Makes the E OUT signal available at J1 pin 5 allowing an external device to monitor the exhaust solenoid condition Pins 2 and 3 jumpered Makes the S OUT signal available at J1 pin 5 allowing an external device to monitor the Sensor transducer analog signal Potentiometers P1 Span Provides adjustment of transducer signal gain allowing an anticipated small transducer excu...

Page 155: ... limit Label F1 Type PC Mount Value 3A Valco Number 085xx207 Glue Inspection Board PN 151xx410 Connectors J1 MSTOP Connection to drive machine interface relay on relay board J2 INDICTRS Connection to supply beacon and alarm signals to Relay board J3 KCK VLV Connection to drive a spray marker kicker or diverter for rejected products J4 MARK SCAN Not used J5 Scanner 1 Connection for product scanner ...

Page 156: ...driver is active SCN1 When lit this segment indicates that the scanner for glue inspection channel 1 senses product SCN2 When lit this segment indicates that the scanner for glue inspection channel 2 senses product GLU1 When lit this segment indicates that the glue sensor for glue inspection channel 1 senses glue GLU2 When lit this segment indicates that the glue sensor for glue inspection channel...

Page 157: ...seconds JP2B 0 3 seconds JP2C 0 5 seconds None 1 0 seconds JP4 Irton Data Engineering use only JP5 Serial Comm Engineering use only When jumper is installed diagnostic data is available at JP4 JP6 Future JP7 Channel 1 rear flap check Pins 1 and 2 jumpered enabled Pins 2 and 3 jumpered disabled JP8 Channel 2 rear flap check Pins 1 and 2 jumpered enabled Pins 2 and 3 jumpered disabled JP9 Test Engin...

Page 158: ...0 duty cycle Hold voltage 5V to 12V adjustable Encoder Inputs One 40kHz maximum Type voltage VCE 1000 recommended 12VDC Miscellaneous Maximum gluing speed 2000 feet 610m per minute Maximum glue length 99 99 2539mm Flow control Internal EPC 6 Maximum glue pressure 100 psi 7 bar Job storage capacity 99 jobs Glue patterns One or two per channel Scanner lockout function Internal Jam preventer function...

Page 159: ...l Valco Cincinnati 74 Glue Inspection Channels Two Glue sensor type voltage NPN sinking 12VDC Product sensor type voltage NPN sinking 12VDC Spray marker driver Sinking 12VDC 1A Pass Fail tolerance bands 0 2 inches 0 4 inches 0 8 inches ...

Page 160: ...stal 0 650 psi 1 45 8 bar glue regulator and manifold 738xx174 Machine mount 0 125 psi 1 9 6 bar glue regulator and manifold 738xx177 Machine mount 0 650 psi 1 45 8 bar glue regulator and manifold 738xx178 Beam assembly for use with 578xx032 trolley bracket 581xx298 Filter regulator manifold assembly 0 125 psi 1 9 6 bar 593xx245 Filter regulator manifold assembly 0 650 psi 1 45 8 bar 593xx246 PC b...

Page 161: ...assembly 084xx002 Channel enable switch assembly 030xx429 Pressure adjust switch assembly 030xx430 Installation kit includes the following 781xx136 Fuse 2a 5 x 20 mm power entry module 1 Fuse 5A 5 x 20 mm valve driver board F1 2 Fuse 5A PC mount valve driver board F2 F3 4 Fuse 3 15A 5 x 20 mm power supply board F1 2 Fuse 1 6A 5 x 20 mm power supply board F2 2 Fitting male connector 1 4 x 1 8 1 Fit...

Page 162: ...r 832 fluid pressure regulator 1 593xx038 Repair kit for DD 1 pump 1 560xx560 12 VDC 3 way air solenoid 1 411xx057 Encoder timing belt 1 788xx300 Encoder measuring wheel 1 788xx553 Filter screen 50 mesh 1 593xx020 Filter screen 100 mesh 1 593xx087 0 ring glue filter cap 1 745xx059 Check the type of part on your system before ordering Description Part Beacon with audible alert 481xx033 Beacon cable...

Page 163: ... 1 151xx367 PC board power supply 1 151xx368 PC board RS232 1 151xx375 PC board assembly EPC 6 pressure control 1 151xx379 PC board assembly glue inspection 1 151xx410 PC board assembly machine stop beacon interface 1 151xx404 Fuse 2A power entry module 1 085xx040 Fuse 5A valve driver board F1 1 085xx206 Fuse 5A valve driver board F2 F3 1 085xx216 Fuse 3 15A power supply board F1 1 085xx208 Fuse 1...

Page 164: ...Part Number List VC3700 User s Manual Valco Cincinnati 79 Recommended Spare Parts List DD 1 Pump Description Quantity Part Rebuild and spare parts kit 1 560xx602 ...

Page 165: ...econditioned equipment unless specified otherwise at the time of purchase will be warranted as described above for a period of ninety 90 days from the date of shipment by Valco Cincinnati Components purchased by Valco Cincinnati Inc from others for inclusion in its products are warranted only to the extent of the original manufacturer s warranty In no event shall Valco Cincinnati Inc be liable for...

Page 166: ... quoted at that time Any part that fails during the warranty period shall be returned prepaid to Valco Cincinnati by the customer for disposition Note Upon request Valco Cincinnati personnel are available to repair or replace such parts at the customer s facility Charges for this service include travel time and expenses If an equipment problem is the result of customer abuse improper installation ...

Page 167: ...annel 1 follow these steps 1 At the level 2 menu press the GLUE MODE button The glue mode screen displays Figure 27 2 Set the glue mode for channel 1 to DEL PAT DEL PAT press the CHAN 1 button to toggle between the two selections 3 Press EXIT to return to main screen Figure 27 The Glue Mode Screen Figure 28 Glue Pattern Edit Screen 4 At the main screen touch one of the four digit numbers on the to...

Page 168: ...ain screen 12 Press the CONFIG button 13 Press the MORE button in the level 1 menu screen The level 2 menu screen displays 14 Press the REPEAT button The repeat function screen displays 15 Press channel 1 The repeat setup screen for channel 1 displays 16 To program 18 additional inches of delay pattern press 1 and then press 8 17 Press the ENTER button The OK DONE message displays in the edit box ...

Page 169: ...tion codes pertaining to channels 3 and 4 It will also not respond to data shown in location codes 3 4 and 7 8 unless the respective glue modes are set 1 Channel 1 Delay length 2 Channel 1 Pattern length 3 Channel 1 2nd Delay length 4 Channel 1 2nd Pattern length 5 Channel 2 Delay length 6 Channel 2 Pattern length 7 Channel 2 2nd Delay length 8 Channel 2 2nd Pattern length 9 Channel 3 Delay length...

Page 170: ...5 Speed in feet per minute receive only Bytes 4 1 are hexadecimal digits 36 Repeat factor for channel 1 0 no repeat 37 Repeat factor for channel 2 0 no repeat 38 Repeat factor for channel 3 0 no repeat 39 Repeat factor for channel 4 0 no repeat 40 Marker station distance from glue station 41 Marker skip distance from leading edge of product 42 Marker mark distance 43 Tolerance codes for glue inspe...

Page 171: ...ta bits and 1 stop bit 1 Send send request byte from host Send request byte 254dec 2 Receive ACK acknowledge byte from VC3500 3700 This indicates that the control will start looking for the data After the request byte is received the control returns ACK 255dec If this byte is not returned after 500ms the host must terminate the send 3 Send byte 4 byte 3 byte 2 byte 1 location code from host Byte 4...

Page 172: ...h as that found on a parent machine control The data is requested by the host computer using the following format 1 Send receive request byte from host Receive request byte 253dec 2 Receive ACK byte from VC3700 3 Send location code from host 4 Receive Byte 4 Byte 3 Byte 2 Byte 1 from VC3700 Example of Receiving Data To display the first glue pattern length follow these steps 1 Send 253 2 Wait for ...

Page 173: ... on the valve driver board in order to parallel the outputs of Channels 1 and 2 3 Connect the glue valve cable to J3 on the valve driver board as follows Pin 1 Purge input Pin 2 Purge return Pin 3 Valve output Pin 4 Valve return Menu Setup and Pattern Entry 4 In the level 2 menu screen press the GLUE MODE button 5 Select DEL PAT DEL PAT for both channels 1 and 2 The CHAN 1 and CHAN 2 buttons toggl...

Page 174: ...l the product scanner follow these steps 1 Locate the product scanner 1 2 inches above the product 2 Apply power to the glue control 3 Place product 0 75 to 1 00 inches below normal product travel 4 Turn the adjustment screw counterclockwise until the LED is not illuminated 5 Adjust the product scanner sensitivity by turning the adjustment screw clockwise just until the LED illuminates Electrical ...

Page 175: ...duct scanner The control measures the product length subtracts the delay dimension on both the leading and the trailing edges and enters the remaining length into the pattern dimension Normal gluing will begin with the next product Note Either the delay or pattern dimensions may be altered to affect changes in the glue pattern placement Menu Buttons Since the VC3700 is a single channel control the...

Page 176: ...ems only OTHERWISE DAMAGE TO EQUIPMENT COULD OCCUR Action Date Shift Initials 1 Clean the exterior portion of the glue valves nozzle tips glue heads etc 2 Purge the glue valves if necessary and ensure proper glue flow 3 Ensure that air and glue pressure settings are correct 4 If using glue inspection Ensure that sensor is clean Lens must be clean and clear with no scratches Check sensor for proper...

Page 177: ...t 5 Reassemble the fluid section 6 Using the 3 way purge valve on the output of the glue filter purge all air from the system 7 Purge each valve in the system Approximately 1 2 ounces of glue should be purged for proper glue flow 8 Check for any glue leakage on the needle seat Replace the needle plunger assembly and seat if leaks or dripping occurs 9 For non contact valves only Apply a small amoun...

Page 178: ...Initials 1 Encoder mounting a Check timing belt gear and pulley teeth and proper timing belt tension b If using measuring wheel check for wear and proper wheel tension on machine belt c If using direct drive encoder check coupling and rotation of shaft for proper alignment 2 Perform the Weekly Maintenance procedure ...

Page 179: ...l Valco Cincinnati E 4 6 Month Maintenance Actions Date Shift Initials 1 Flush entire glue system except for the central pumping system with a vinegar and water solution 1 gallon of vinegar to 10 gallons of water 2 Perform the Weekly Maintenance procedure ...

Page 180: ...tions Date Shift Initials 1 Flush the entire glue system including the central pumping system with a vinegar and water solution 1 gallon of vinegar to 10 gallons of water 2 Disassemble thoroughly clean and rebuild each fluid regulator assembly and glue valve 3 Perform the Weekly Maintenance procedure ...

Page 181: ...VC3500 VC3700 Troubleshooting Manual Manual Number MC048 Release Date May 1999 ...

Page 182: ...l purposes only is subject to change without notice and should not be construed as a commitment by Valco Cincinnati Inc This manual was written and designed at Valco Cincinnati Inc 411 Circle Freeway Drive Cincinnati Ohio 45246 Part Number MC048 Printed in the USA Valco Cincinnati Incorporated 411 Circle Freeway Drive Cincinnati Ohio 45246 TEL 513 874 6550 FAX 513 874 3612 Valco Cincinnati Limited...

Page 183: ...ES 8 CPU CENTRAL PROCESSING UNIT BOARD 151XX362 9 SERVICE ACCESS POINTS 9 SCHEMATIC DESCRIPTION 10 CHANNEL 3 4 LOGIC BOARD 151XX363 12 SERVICE ACCESS POINTS 12 SCHEMATIC DESCRIPTION 12 ANALOG BOARD 151XX364 12 SERVICE ACCESS POINTS 12 SCHEMATIC DESCRIPTION 12 LED BOARD 151XX365 VC3500 OR 151XX406 VC3700 14 SERVICE ACCESS POINTS 14 SCHEMATIC DESCRIPTION 14 INTERFACE BOARD 151XX366 15 SERVICE ACCESS...

Page 184: ...RVICE ACCESS POINTS 21 SCHEMATIC DESCRIPTION 21 EPC BOARD 151XX379 22 SERVICE ACCESS POINTS 22 SCHEMATIC DESCRIPTION 22 RELAY BOARD 151XX404 24 SERVICE ACCESS POINTS 24 SCHEMATIC DESCRIPTION 24 GLUE INSPECTION BOARD 151XX410 VC3700 ONLY 25 SERVICE ACCESS POINTS 25 SCHEMATIC DESCRIPTION 26 OPERATION NOTES 28 PIN ACCESS 28 TROUBLESHOOTING FLOW CHART 29 CE CONFORMANCE 30 ...

Page 185: ...VC3500 VC3700 Troubleshooting Manual Valco Cincinnati Page 1 System Level Documents ...

Page 186: ...ntral Processor Unit board EPC Electro Pneumatic Control module LCD Liquid Crystal Display and Touchscreen module LED Light Emitting Diode board PEM Power Entry Module RS232 RS232 communications board XF1 Transformer 1 24 VAC 175 VA XF2 Transformer 2 36 VAC 80 VA XF3 Transformer 3 28 VAC 80 VA ...

Page 187: ...g board 151xx365 LED board VC3500 only 151xx366 Interface board 151xx367 Valve Driver board 151xx368 Power Supply board 151xx375 RS232 communications board 151xx379 EPC board 151xx404 Machine Interface Relay board 151xx406 LED board VC3700 only 151xx407 Grounding Board 151xx410 Glue Inspection board Schematics 999xD151 198 CPU board 999xB151 199 Channel 3 4 Logic board 999xC151 200 Analog board 99...

Page 188: ...S011 CPU Board 151xx362 ETS012 Analog board 151xx364 ETS013 LED board 151xx365 ETS014 Power Supply board 151xx368 ETS015 Interface board 151xx366 ETS016 Valve Driver board 151xx367 ETS017 Base Unit 084xx003 Not a complete control ETS021 EPC board 151xx379 ETS030 RS232 board 151xx375 ETS032 VC3500J with Learn Mode ...

Page 189: ...rom a three phase power main dual fuses should be installed The PEM provides on off control through a double pole switch Finally a filter is utilized to prevent line noise from interfering with the operation of the VC3500 and to prevent high frequency signals generated within the VC3500 from appearing on the power lines XF1 Transformer 1 A41 175 24 The primary winding of Transformer 1 is connected...

Page 190: ...or 99 glue programs Reset Watchdog circuitry ensures the main processor does not get caught in a non recoverable program loop Channel Logic processors for channels 1 2 Scanner Lockout processor for channels 1 2 Channel Logic 3 4 board The Channel Logic board for channels 3 4 is an optional daughter board that attaches directly to the CPU board using connectors J5 and J6 It includes the following C...

Page 191: ...u 2 This code is in addition to a customer defined 4 digit PIN and should not be revealed to customers LED board The LED board displays on off status of glue valves scanners encoder and system power supplies It also displays whether the line is below or above minimum speed and the jam condition Glue valves can be individually Enabled for gluing programs disabled 0 or turned on for purging 1 using ...

Page 192: ...urfaces are bonded to a single point referred to as protective earth and denoted by a lined ground symbol within a circle This point is located towards the bottom of the main panel On later models a terminal board 151xx407 is provided to allow multiple connections to this point Input Ground Lined ground symbol In order to provide noise isolation for the logic circuits a separate power supply circu...

Page 193: ...tware is utilized Installed A jumper installed dictates that two channel software is used Not Installed No jumper dictates that four channel software is used Switches A pushbutton near the upper left corner provides a manual reset function Test Points TP1 CLOCK 8 MHz 5 V digital clock signal from Oscillator U7 for Main Processor U1 TP2 CNTR CLK 5 V Encoder signal gated by a timer from U17 68230 PB...

Page 194: ...the lower half and four channel software resides in the upper half A jumper near the center of the board should be installed or switch set to ON so the lower half of memory is enabled two channel This jumper should be cut or switch set to OFF to enable the upper half of memory four channel Battery Backed Program Memory BQ4011 RAM s U2 3 store program parameters Touchscreen Interface 74HCT245 bi di...

Page 195: ...for Channel 1 U19 87C51 provides the Channel Logic function for Channel 2 Analog Pressure Circuit A buffered representation of the sensed air pressure ANALOG BAR GRAPH from U4 7 of the Analog board is presented to the positive input of an A D converter U21 LTC1096 The serial output of this device is read by the 68000 through port PB0 of U17 The 68000 uses this information to size the length of the...

Page 196: ... JP1 Low Pressure Limit Select A low air pressure limit may be selected for delivery to glue source Normally this is set to 0 Other possible selections are 10 25 and 50 of full pressure Potentiometers P1 Bar 0 Adj Allows adjustment of the pressure bar graph on the LCD Touchscreen to a minimal length for zero speed P2 Gain Adj Not used In early models allowed adjustment to gain of frequency to volt...

Page 197: ...verter U3 at pin 6 Op amp output U4 pin 14 allows this voltage and the glue pressure to be varied by adjusting Digital Pot U1 Op amp output U4 pin 1 acts as an adder to add an offset determined from setting of Jumper JP1 to be added to the previous op amp stage This provides a low limit to the drive signal for the EPC 6 therefore a low limit to air pressure that supplied to the glue source Pressur...

Page 198: ...re Adjust switch Schematic Description 5v Logic Supply A 7805 U6 provides a regulated 5v supply for logic on this board Resistor R2 is in series with the regulator to provide some voltage drop to decrease the power dissipation across the regulator 12v EPC 6 Supply A 7812 U7 provides the supply voltage for the EPC 6 Valve Enable Switch Inputs Valve enable and purge signals for four channels are con...

Page 199: ...unction Label Type Value Valco Number 12vdc I O Supply F1 PC Mount 1 5A 085xx132 Dump Valve Active F2 PC Mount 1 5A 085xx132 Indicators D1 12V When lit this green LED indicates that the 12vdc supply for scanners encoder and by pass valve dump valve is operational D2 When lit this yellow LED indicates that the by pass valve is activated and that the parent machine is above minimum speed Jumpers JP1...

Page 200: ... to energize the coil of a 12 vdc relay when a jam condition occurs This signal is turned off goes to 12 vdc when the parent machine speed drops below minimum speed This circuit can drive a maximum load of 500mA This output signal is normally connected to J1 of the Machine Interface Relay board 151xx404 to drive relay RL1 This relay provides an immediate machine stop A delayed stop for special mac...

Page 201: ...is available to energize a glue valve D4 15V When lit this green LED indicates that 15 vdc input to regulator U3 is present D5 56V When lit this green LED indicates that the 56 vdc peak voltage is available to energize a glue valve D6 HOLD 1 When lit this yellow LED indicates that the 12 vdc hold voltage is applied to glue valve 1 D7 PEAK 1 When lit this yellow LED indicates that the 56 vdc peak v...

Page 202: ...xed Variable Hold Voltage level Pins 1 2 jumpered Forces a fixed Hold Voltage level of 12v Pins 2 3 jumpered Allows adjustment of Hold Voltage level of 5v to 12v using potentiometer P3 Potentiometers P1 PTIME1 Provides adjustment between 1mS and 12mS for Channel 1 Peak Voltage duration when JP2 has a jumper between pins 2 3 Clockwise rotation increases duration P2 PTIME2 Provides adjustment betwee...

Page 203: ...R5 and capacitor C17 isolate the current demands of this channel from the other channel Resistor R17 provides a bleed off path for the charge on capacitor C17 when the VC3500 is turned off At the same time that the 556 timer is triggered to begin its timing npn transistor Q1 is turned on which in turn drives the high current IGFET Q5 to pass the Hold Voltage to the Valve output at connector J3 Dio...

Page 204: ...is green LED indicates that the 17 vdc supply voltage is available to power the Interface board D4 Pump Supply When lit this green LED indicates that the 32 vdc supply voltage is available to power the DD 1 Pump Schematic Description Two isolated DC supplies are provided Bridge rectifier BR1 rectifies 14VAC to an unregulated 17VDC Capacitor C1 provides filtering Fuse F1 limits the combined current...

Page 205: ... Pins 1 2 jumpered Normal configuration DB9 to DB9 Null Modem Cable Pins 2 3 jumpered DB9 to DB25 and special cables Note JP2 and JP3 must be jumpered in the same manner Schematic Description U1 PAL20V8 contains all address decoding and miscellaneous logic The PAL equations are included on drawing 999XB151 208 U3 NS16C552 is an industry standard Dual UART U2 MAX232A is a single chip RS232 level co...

Page 206: ... excursion to effect a full scale 0 to 12v change at TP2 P2 Zero Provides adjustment for nulling the pressure transducer signal at zero pressure P4 Gain Not installed on later models Provides adjustment of feedback loop gain and affects the hysteresis and frequency for switching the Intake and Exhaust solenoids Schematic Description Diode D1 protects the circuit from applying the 12 to 24vdc suppl...

Page 207: ...input command signal with the buffered transducer signal The GAIN pot P4 provides adjustment of feedback loop gain and affects the hysteresis and frequency for switching the Intake and Exhaust solenoids Op Amp U5 output pin 1 controls the Intake solenoid Op Amp U5 output pin 14 controls the Exhaust solenoid ...

Page 208: ...d 151xx410 J3 External connector used for interfacing the Machine Interface relay to the parent machine stop circuit J4 External connector used for interfacing a Beacon Alarm for Jam and Glue Fault conditions Indicators D1 RLY When lit this yellow LED indicates that the Machine Interface relay is energized Replacement Fuses Function Label Type Value Valco Number Beacon current limit F1 PC Mount 3A...

Page 209: ...d via a 20 pin ribbon cable J11 Connection for 17 VDC supply voltage from the Power Supply board Indicators D1 Multi segment LED indicator MSTOP When lit this segment indicates that the Machine Stop signal relay is active HORN When lit this segment indicates that the alarm horn signal is active JAM When lit this segment indicates a Jam condition exists G FLT When lit this segment indicates the pre...

Page 210: ...ar Flap Check Pins 1 2 jumpered Enabled normal configuration Pins 1 3 jumpered Disabled useful if a capacitive sensor is used with a large sensing area JP9 Test Engineering Use Only When jumper installed diagnostic data is available at JP7 JP8 Schematic Description Ground Reference The ground reference used on this board for scanner and glue sensor inputs is isolated from other grounds used in the...

Page 211: ...SL2 JP SL3 JP SL4 Other signals used by this I C from the CPU board are MIN_SPD and ENCODER Glue Inspection Channel Logic U10 87C51 provides the Glue Inspection Channel Logic function for Channel 1 U11 87C51 provides the Glue Inspection Channel Logic function for Channel 2 Product Sensor and Glue Sensors are inputs to these devices Pass and Fail LED s located on the front panel for each channel ar...

Page 212: ... Manual Valco Cincinnati Page 28 Operation Notes PIN Access The customer may select one 4 digit PIN to restrict access to menu levels 3 and higher The proprietary PIN available for Valco personnel use only is a 6 digit code 362436 ...

Page 213: ...ting Flow Chart Malfunction Description See Section Absence of Glue A Bypass Valve B DD 1 Pump D Encoder Light E Front Panel F Glue Volume G Glue Inspection I Jam J Machine Stop M Pattern Placement P Scanner Light S Warning Beacon W EPC Adjustment X Analog Board Adjustment Y ...

Page 214: ...t be in the 1 position Is Channel Toggle Switch enabled Run Machine without product Enable Channel E1 help Starting point of troubleshooting process Required manual operation Decision block no yes Corrective action Help and additional information Offpage reference Symbol Key ...

Page 215: ... yes no yes Run Machine without product Run machine above minimum speed Enable Channel Is Encoder light on front panel on no yes E1 Go to Encoder Light Malfunction page E1 to make further checks on Encoder Absence of Glue help help A2 Go to Absence of Glue page A2 to make further checks help A1 help Stop Machine Is Control s exhaust port on continuously yes 1 Air input and output lines may not be ...

Page 216: ...t on front panel flash no yes S1 Go to Scanner Light Malfunction page S1 to make further checks on Scanner help A2 Run Machine with product Absence of Glue cont A3 Go to Glue Absence page A3 to make further checks help ...

Page 217: ...e cont Does Valve light on front panel flash no V1 Go to Valve Light Malfunction page V1 to make further checks on Valve help yes 1 Check that ribbon cable between 151xx366 Interface board and 151xx362 CPU board is secure 2 Check that ribbon cable between 151xx366 Interface board and 151xx365 LED board is secure 3 Replace 151xx366 Interface board 4 Replace 151xx362 CPU board 5 Replace 151xx365 LED...

Page 218: ... 151xx362 1 Check that regulated shop air going into VC3500 is 80 to 100 psi 2 Adjust T handle glue regulator so that output glue pressure is about 20 psi 3 Check for a clogged glue valve Is 12v coil LED on front panel on yes Is 15v LED on Valve Driver board on no no 1 Check that connector J2 on 151xx367 Valve Driver board is secure 2 CheckFuse F1 on 151xx367 Valve Driver Board 3 Replace 151xx367 ...

Page 219: ...4 of 151xx367 Valve Driver Board to position 1 2 4 Change jumpers JP2 and JP3 of 151xx367 Valve Driver Board to position 1 2 5 Check for damage to glue valve s cable 6 Replace glue valve cable and or glue valve no 1 Replace 151xx367 Valve Driver board yes no 1 Check that ribbon cable between 151xx366 Interface board and 151xx367 Valve Driver board is secure 2 Replace 151xx366 Interface board A1 Ab...

Page 220: ...pass valve should be heard clicking or vibration felt help Control iand bypass valve are functioning properly Check air lines and glue source 1 Check wiring at connector J8 on 151xx366 Interface board 2 Check for correct wiring at bypass valve 3 Check for damaged cable connecting dump valve to control Is this measurement approximately 0vdc At below minimum speed measure dc volts on Interface board...

Page 221: ...68 Power Supply board 1 Check wiring at connector J7 on 151xx368 Power Supply board 2 Check for correct wiring at Pump controller 3 Check for damaged cable connecting Pump controller to control Do LED s D6 D7 in DD 1 alternately turn on off Replace Pump control no yes Control and Pump control are functioning properly Check air lines and glue lines D1 Is 151xx368 Power Supply LED D4 lit no yes Do L...

Page 222: ...eed screen function 1 Check that ribbon cable between 151xx366 Interface board and 151xx365 406 LED board is secure 2 Replace 151xx365 406 LED board yes no yes no no no yes yes In Minimum Speed Screen accessed from Menu Level 3 the lower bar indicates actual machine speed This bar should vary as the machine speed varies The upper bar is adjustable and indicates the minimum speed setting help E2 Go...

Page 223: ...ections at J5 of 151xx368 Power Supply board The symbol for this light is an arrow entering a box help no no yes yes Is DMM available for measuring voltages E3 Is LED D3 of 151xx368 Power Supply board on 1 Check fuse F2 on 151xx368 Power Supply board 2 Check connectiions at J1 of 151xx368 Power Supply board 3 Replace 151xx368 Power Supply board yes no Go to Encoder Light Malfunction page E3 to mak...

Page 224: ...ts on Power Supply board 151xx368 from J5 pin 1 to J5 pin 2 Is this measurement approximately 17vdc 1 Check connections at J5 of 151xx368 Power Supply board 2 Check connections at J7 of 151xx366 Interface board yes no yes no Measure ac volts on Power Supply board 151xx368 from J1 pin 1 to J1 pin 2 Is this measurement approximately 14vac 1 Check replace fuse F2 on 151xx368 Power Supply Board 2 Repl...

Page 225: ...ld be lit 56v 12v coil symbols 12v arrow box symbol 5v logic symbol and either X MIN or X MIN Stop Machine Does touchscreen illuminate Have fuses been checked in Power Entry Module 1 Check fuses in Power Entry Module 2 Check that mains power is on The fuses in Power Entry Module are accessible from exterior bottom surface of cabinet The line cord must be removed in order to open fuse door help 1 C...

Page 226: ... on Power Supply board 151xx368 from J1 pin 3 to J1 pin 4 cont F2 Is this measurement approximately 14vac Replace 151xx368 Power Supply board yes F1 Go to Front Panel Malfunction page F1 to repeat checks help Replace transformer A41 80 28 no ...

Page 227: ...vdc Replace 151xx365 406 LED board yes F1 Go to Front Panel Malfunction page F1 to repeat checks help 1 Check connections at J3 on 151xx368 Power Supply board 2 Check connections at J2 on 151xx365 406 LED board no Measure dc volts on 151xx368 Power Supply board from J3 pin 1 to J3 pin 2 Is this measurement approximately 17vdc yes no ...

Page 228: ...n page F1 to repeat checks help no Is yellow backlight visible from rear of Touchscreen no yes 1 Check red and black wire connections on rear of Touchscreen module 2 Check connections at J2 of 151xx368 Power Supply board 3 Replace 151xx368 Power Supply board 4 Replace Touchscreen module Is DMM available for measureing voltages no 1 Check that ribbon cable at J3 of 151xx362 CPU board is secure 2 Ch...

Page 229: ...rear of Touchscreen module 2 Check connections at J2 of 151xx368 Power Supply board Measure dc volts on 151xx368 Power Supply board from J2 pin 1 to J2 pin 2 Is this measurement approximately 12vdc yes no Measure dc volts on Touchscreen module from black wire to red wire Is this measurement approximately 12vdc yes no 1 Check replace fuse F1 on 151xx368 Power Supply board 2 Replace 151xx368 Power S...

Page 230: ...d from the glue valve glue should exit hose smoothly at 1 to 2 cups per minute help X1 Go to EPC Adjustment page X1 to adjust the Electronic Pressure Control board help yes no G1 1 Check for a clogged glue valve 2 Replace air assist MAC valve 3 Replace glue valve Use Glue Pressure toggle switch to determine limits of pressure adjustment Is air guage attached to output air port yes no Y1 Go to Anal...

Page 231: ...rker Skip in Glue QC screen is not zero 5 Check that MarkerMark in Glue QC screen is not zero 6 Check that product sensor for Glue Inspection channel is functioning 7 Check that Glue Sensor is functioning 8 Check ribbon cable from 151xx362 CPU board J4 to 151xx410 Glue Inspection board J10 Glue Inspection Malfunction Glue Inspection does not function I1 ...

Page 232: ...nd glue source 1 Check wiring at connector J6 on 151xx366 Interface board 2 Check for correct wiring at Jam interface relay 3 Check for damaged cable connecting Jam interface relay to control Is this measurement approximately 12vdc Without Jam condition measure dc volts on Interface board 151xx366 from J6 pin 3 to J6 pin 2 Is this measurement approximately 0vdc Replace 151xx366 Interface board no ...

Page 233: ...0 no yes 1 Check cable wiring from 151xx410 Glue Inspection board J1 to 151xx404 Machine Interface board J1 2 Replace 151xx410 Glue Inspection board Is MSTOP Indicator lit on 151xx410 no yes For VC3700 1 Check minimum speed setting 2 Check ribbon cable from 151xx362 CPU board J4 to 151xx410 Glue Inspection board J10 3 Check seating of U9 U10 U11 on 151xx410 Glue Inspection board 4 Replace 151xx410...

Page 234: ...o Compensation value has been entered correctly 3 Check that the Cell to Gun value has been entered correctly 1 Check that the Pattern value has been entered correctly 2 Check that the Ratio Compensation value has been entered correctly Glue several products with machine at high speed At high speed Is delay before gluing correct no yes At high speed Is the pattern length correct no yes 1 Adjust th...

Page 235: ... to indicate activation help S2 Is Scanner cable correctly terminated inside control Correct terminations yes no See Manual for correct terminations help 1 Check that ribbon cable between 151xx366 Interface board and 151xx365 406 LED board is secure 2 Replace 151xx366 Interface board 3 Replace 151xx365 406 LED board Scanner sensitivity should be adjusted so that it senses objects only 1 5 inches 4...

Page 236: ...nections at J5 of 151xx368 Power Supply board The symbol for this light is an arrow enteing a box help no no yes yes Is DMM available for measuring voltages S3 Is LED D3 of 151xx368 Power Supply board on 1 Check fuse F2 on 151xx368 Power Supply board 2 Check connectiions at J1 of 151xx368 Power Supply board 3 Replace 151xx368 Power Supply board yes no Go to Scanner Light Malfunction page S3 to mak...

Page 237: ...ts on Power Supply board 151xx368 from J5 pin 1 to J5 pin 2 Is this measurement approximately 17vdc 1 Check connections at J5 of 151xx368 Power Supply board 2 Check connections at J7 of 151xx366 Interface board yes no yes no Measure ac volts on Power Supply board 151xx368 from J1 pin 1 to J1 pin 2 Is this measurement approximately 14vac 1 Check replace fuse F2 on 151xx368 Power Supply Board 2 Repl...

Page 238: ...e F1 on 151xx404 Machine Interface board 4 Check wiring from 151xx404 Machine Interface board connector to beacon 5 Check bulbs in beacon 6 Check horn enable switch on beacon Warning Beacon Malfunction Beacon Lights or Horn do not function W1 ...

Page 239: ...yes no 1 Rotate P1 SPAN one half turn at a time clockwise until the DEC LED is not illuminated 3 turns maximum 2 Then rotate P1 one more half turn clockwise 1 Rotate P1 SPAN one half turn at a time counter clockwise until the INC LED is not illuminated 3 turns maximum 2 Then rotate P1 one more half turn counter clockwise EPC is adjusted properly The EPC 151xx379 is factory set No further adjustmen...

Page 240: ... LCD display should be very short about 1 16 inch If bar is not visible rotate P1 clockwise If bar is too long rotate P1 counter clockwise help Adjust Glue Pressure to Maximum Hold the Glue Pressure toggle on VC3500 front panel for 10 seconds to ensure maximum pressure help Adjust P2 GAIN counter clockwise for full bar graph If P2 is installed maximize the pressure bar graph on the LCD display by ...

Page 241: ...shooting Manual Valco Cincinnati Page 30 CE Conformance Testing for CE conformance was performed at Laboratory Test Services Incorporated in Massachusetts and Valco Cincinnati Incorporated during the month of December 1995 ...

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