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ITW Dynatec
An Illinois T ool Works C ompan y
31 Vo lu nteer Drive
Henderson ville, TN 37075 USA
Teleph one 1.615.824.3634
FAX 615.264.5222
www.itwdynatec.com
Adhesive Application Solutio ns ISO 9001 Certified
DPC2 DISTANCE-BASED PATTERN CONTROLLER
KIT OPERATIONS AND SERVICE MANUAL
PN 106593: 115V
IMPORTANT ! - READ ALL INSTRUCTIONS BEFORE OPERATING THIS EQUIPMENT
It is the custome r's responsibility to have all operators and service personnel read and understand
this information. Contact your ITW Dynatec c ustomer servic e representative for additional copies.
NOTICE! Please be sure to include the serial number of your application system
each time you order replacement parts and/or supplies. This will enable us to
send you the correc t items that you need.
ITW Dynatec Technical Service Direct Dia l: 1-800-654-6711
PN 106594: 230V
ITW Dynatec Service Parts Direct Dial: 1-800-538-9540
OPERATIONS MANUAL
Manual #50-06
Re v.12.18
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Related Manuals for ITW Dynatec DPC2
Summary of Contents for ITW Dynatec DPC2
- Page 1 It is the custome r's responsibility to have all operators and service personnel read and understand this information. Contact your ITW Dynatec c ustomer servic e representative for additional copies. NOTICE! Please be sure to include the serial number of your application system each time you order replacement parts and/or supplies.
- Page 2 1999 Page ii DPC-2 TIMER Manual 50-06 Revised 7/99 ITW Dynatec An Illinois Tool Works Company Adhesive Application Solutions...
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Page 3: Table Of Contents
ITW Dynatec c. 1999 Page iii DPC-2 TIMER Manual #50-06 Revised 7/99 TABLE OF CONTENTS CHAPTER 1:DESCRIPTION General Description ............................1-1 Specifications..............................1-2 How to Use this Manual..........................1-2 CHAPTER 2: INSTALLATION Unpacking ..............................2-1 Supplied Equipment............................2-2 Optional Accessories............................. 2-3 Changing AC Input Voltage.......................... - Page 4 Page iv ITW Dynatec c. 1999 Revised 5/09 DPC-2 TIMER Manual #50-06 CHAPTER 5: TROUBLESHOOTING Controller Glues Every Other Sheet ......................5-1 Glue Pattern Continually Advances or Retards ..................... 5-1 Glue Pattern "Jumps Around" ........................5-2 Glue Applicators Will Not Activate ......................5-2 DRIVE or A.T.S.
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Page 5: Chapter 1:Description
DESCRIPTION Description The ITW Dynatec DPC-2 Distance-based Pattern Control unit is a microprocessor-based electronic control system. It may be used in any process that requires the actuation of electrical output devices based upon distance traveled. It is specifically designed to control glue application valves used in adhesive systems. -
Page 6: Specifications
Page 1 - 2 ITW Dynatec c. 1999 Revised 8/04 DPC-2 CONTROL KIT Manual #50-06 The DPC-2 requires an encoder (speed) and sensor (trigger) input to function properly. The trigger input senses the product to be glued and initiates a countdown within the Control Unit based upon the programmed pattern. -
Page 7: Chapter 2: Installation
Chapter 2 INSTALLATION The ITW Dynatec DPC-2 Control Unit is very easy to install and operate. It is highly recommended, however, that the entire contents of this manual be read before installation to become familiar with the many features of this equipment and to avoid potential safety hazards. -
Page 8: Supplied Equipment
Page 2 - 2 ITW Dynatec c. 1999 Revised 4/10 DPC-2 CONTROL KIT Manual #50-06 Supplied Equipment The DPC-2 Control Kit is supplied with the following equipment. Please inventory these parts immediately upon unpacking the Control Kit to assure all items are present. -
Page 9: Optional Accessories
Page 2 - 3 DPC-2 CONTROL KIT Manual #50-06 Revised 5/09 Optional Accessories The following accessories are available from ITW Dynatec for use with the DPC-2 Control Kit: Description Part Number Mini Reflective Photo Sensor Assembly, 2ms Response (6’ cord) L21746 Reflective Photo Sensor Assembly, 1ms Response (6’... -
Page 10: Changing Ac Input Voltage
Page 2 - 4 ITW Dynatec c. 1999 Revised 8/04 DPC-2 CONTROL KIT Manual #50-06 Changing AC Input Voltage WARNING: Changing the operating voltage requires access to the DPC-2 Control Unit’s internal power supply. Only qualified maintenance technicians should attempt this procedure. - Page 11 ITW Dynatec c. 1999 Page 2 - 5 DPC-2 CONTROL KIT Manual #50-06 Revised 4/10 1. Remove the 6 screws that secure the upper and lower portions of the Control Unit display panel using a cross-point screwdriver. 2. Remove the lower panel (the portion housing the...
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Page 12: Dimensions
Page 2 - 6 ITW Dynatec c. 1999 Revised 8/04 DPC-2 CONTROL KIT Manual #50-06 Dimensions 1.19" 3.5" 3.5" 1.19" 5.25” 30mm 89mm 89mm 30mm 133.4mm 0.27" 11.56" 11.56" 294mm 294mm 10.81" 275mm 9.75" .5" .375" 248mm 13mm 10mm Locating the DPC-2 for Installation Mount the DPC-2 in a cool, dry, clean and well-ventilated area. -
Page 13: Installing The Dpc-2 And Accessories
ITW Dynatec c. 1999 Page 2 - 7 DPC-2 CONTROL KIT Manual #50-06 Revised 11/05 Installing the DPC-2 and Accessories Mount the DPC-2 Control Unit as close to the Trigger Input Device, Encoder and the Glue Applicators as is possible. -
Page 14: 230Vac Power Cord Wiring
Page 2 - 8 ITW Dynatec c. 1999 Revised 8/04 DPC-2 CONTROL KIT Manual #50-06 230VAC Power Cord Wiring WIRE COLOR DESIGNATION Brown or Black Power (+) Blue or White Neutral (-) Green Ground CAUTION: Avoid the installation of input or output cords near or parallel to power lines from other machinery. -
Page 15: Receptacle Assignments
ITW Dynatec c. 1999 Page 2 - 9 DPC-2 CONTROL KIT Manual #50-06 Revised 4/11 Receptacle Assignments Below are the pin assignments for the input/output receptacles located at the bottom of the DPC-2 Control Unit. Drive 1 Drive 2 Trigger... -
Page 16: Important Notes
Output Kit cables are connected. Polarity Sensitive solenoids, such as ITW Dynatec P/N 030A057 require attention to the manner in which the Output Kit wires are connected. It is imperative that the White Wire be connected to the solenoid’s “positive”... -
Page 17: Pressure Transducer Wiring Info
ITW Dynatec c. 1999 Page 2 - 11 DPC-2 CONTROL KIT Manual #50-06 Revised 11/05 PRESSURE TRANSDUCER WIRING INFO BLACK CABLE TO PATTERN CONTROLLER... - Page 18 Page 2 - 12 ITW Dynatec c. 1999 Revised 8/04 DPC-2 CONTROL KIT Manual #50-06 c. 1999 ITW Dynatec...
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Page 19: Start-Up Procedure
ITW Dynatec c. 1999 Page 3 - 1 DPC-2 CONTROL KIT Manual #50-06 Revised 7/99 Chapter 3 OPERATION & PROGRAMMING Start-Up Procedure 1. Open the latch on the right side of the DPC-2 Control Unit and swing open the lid. -
Page 20: Programming Conventions
Page 3 - 2 ITW Dynatec c. 1999 Revised 7/99 DPC-2 CONTROL KIT Manual #50-06 Programming Conventions The DPC-2 employs the following programming conventions: 1. All CHANNEL modifications are performed on the Program displayed (Pr-1, -2, -3 or -4) when the MEMORY LED is illuminated. -
Page 21: System Status Lights
ITW Dynatec c. 1999 Page 3 - 3 DPC-2 CONTROL KIT Manual #50-06 Revised 7/99 System Status Lights There are four LED’s in the top right corner of the Display Panel that provide an indication of the current system status. These lights are described in further detail below: Drive 1 &... -
Page 22: Trigger
Page 3 - 4 ITW Dynatec c. 1999 Revised 7/99 DPC-2 CONTROL KIT Manual #50-06 caters for this by allowing a 35ms dwell time from Trigger Input until the gluing program will function. This means that if the first delay length is programmed to be less than the equivalent of 35ms the first glue line will start late then revert to the normal pattern in successive cycles. -
Page 23: Trig Mode
ITW Dynatec c. 1999 Page 3 - 5 DPC-2 CONTROL KIT Manual #50-06 Revised 7/99 2. Depress the DIGIT button until the desired granularity is obtained. 3. Rotate the VALUE knob to the desired value (0 to 100%). 4. Depress the SYSTEM button again and the display will show = = = 0. The red LED next to PURGE will be flashing. -
Page 24: Lockout
Page 3 - 6 ITW Dynatec c. 1999 Revised 7/99 DPC-2 CONTROL KIT Manual #50-06 TRIG MODE Display Settings DISPLAY MEANING SInG Single Mode – a single glue pattern cycle is performed upon trigger initiation. The glue pattern will continue to its conclusion regardless of whether the trigger signal remains present. -
Page 25: Pre-Delay
The 0 to 20 mA and 4 to 20 mA are most commonly used with Pressure Transducer devices. The ITW Dynatec Pressure Transducer Assembly (105754) uses the 4 to 20 mA SERVO output for its control. Refer to Chapter 2 of this manual for further information... -
Page 26: Constants
Page 3 - 8 ITW Dynatec c. 1999 Revised 7/99 DPC-2 CONTROL KIT Manual #50-06 CHANGING SERVO MODE The SERVO MODE setting is modified as follows: 1. Power down the DPC-2 with the main switch on the front panel. 2. Press and hold the SYSTEM button while powering ON the DPC-2 Control Unit. - Page 27 ITW Dynatec c. 1999 Page 3 - 9 DPC-2 CONTROL KIT Manual #50-06 Revised 7/99 SLOPE PRESSURE NOTE: Threshold ZERO PRESSURE AT ZERO SPEED LSTO SPEED SETTING THRESHOLD PRESSURE 1. Depress the SYSTEM button until the yellow LED to the left of CONSTANTS is illuminated.
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Page 28: Selecting A Program From Memory
Page 3 - 10 ITW Dynatec c. 1999 Revised 7/99 DPC-2 CONTROL KIT Manual #50-06 The glue pressure will now be automatically adjusted by the DPC-2 Control Unit (via the SERVO output) as machine speed is varied between Low Speed Turn On and maximum machine speed without any operator intervention. -
Page 29: Event
ITW Dynatec c. 1999 Page 3 - 11 DPC-2 CONTROL KIT Manual #50-06 Revised 7/99 b. All CHANNEL parameters are stored in “non-volatile” memory, the settings are retained even when DPC-2 Control Unit input power is lost or the power switch is turned off. -
Page 30: Leading Edge Detection
Page 3 - 12 ITW Dynatec c. 1999 Revised 7/99 DPC-2 CONTROL KIT Manual #50-06 1. Depress the desired CHANNEL button until the LED to the left of DELAY is illuminated. 2. Depress the DIGIT button until the desired programming granularity is selected. -
Page 31: Trailing Edge Detection
ITW Dynatec c. 1999 Page 3 - 13 DPC-2 CONTROL KIT Manual #50-06 Revised 7/99 Trailing Edge Detection DELAY equals the distance from the Glue Valve to the start of the LINE (glue). LINE DELAY TRIGGER DEVICE GLUE VALVE DIRECTION OF TRAVEL Line The LINE parameter is the “glue”... -
Page 32: Stitch
Page 3 - 14 ITW Dynatec c. 1999 Revised 7/99 DPC-2 CONTROL KIT Manual #50-06 LINE with GAP = 00.00 48 VDC X = SPIKE TIME DURATION 16 VDC 0 VDC LINE DURATION LINE with GAP = “Z” & STITCH = 0 NOTE SHORT SPIKE TIME DUE TO END OF “LINE”... -
Page 33: Spike Time
ITW Dynatec c. 1999 Page 3 - 15 DPC-2 CONTROL KIT Manual #50-06 Revised 7/99 1. Depress the desired CHANNEL button until the LED to the left of STITCH is illuminated. 2. Depress the DIGIT button until the desired programming granularity is selected. -
Page 34: Compensation
Page 3 - 16 ITW Dynatec c. 1999 Revised 7/99 DPC-2 CONTROL KIT Manual #50-06 Displayed values range from 000.1 to 025.5 These numbers are expressed in milliseconds. NOTES: 1. Air-operated 24 VDC valves will require a 1.5 to 2 ms SPIKE TIME to properly activate. - Page 35 ITW Dynatec c. 1999 Page 3 - 17 DPC-2 CONTROL KIT Manual #50-06 Revised 7/99 5. Run product at a very slow speed (30 to 50 feet per minute) and assure the glue pattern is being applied in the desired position on the substrate. The PRE-DELAY value may need to be modified if the glue pattern is starting too soon or too late from the leading edge of the substrate.
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Page 36: Clearing Programmed Information
Page 3 - 18 ITW Dynatec c. 1999 Revised 7/99 DPC-2 CONTROL KIT Manual #50-06 resolving compensation errors: PROBLEM SOLUTION Leading Edge Increase distance from Trigger to Glue Actuator (PRE-DELAY Compensation distance). Be certain to re-program the new PRE-DELAY value. -
Page 37: Purge Channel 1 And Channel 2
ITW Dynatec c. 1999 Page 4 - 1 DPC-2 CONTROL KIT Manual #50-06 Revised 7/99 Chapter 4 PROGRAMMING EXAMPLES The following examples are provided to assist in better understanding the programming of the DPC-2 Control Unit. They assume that all components of the glue system (i.e. -
Page 38: A Single Event Glue Pattern
Page 4 - 2 ITW Dynatec c. 1999 Revised 7/99 DPC-2 CONTROL KIT Manual #50-06 11. Rotate the VALUE knob until = = = 2 is displayed on the front panel of the DPC-2. 12. Repeat Steps #9 and #10 above. This time the DRIVE 2 LED will illuminate. - Page 39 ITW Dynatec c. 1999 Page 4 - 3 DPC-2 CONTROL KIT Manual #50-06 Revised 7/99 7. Depress the CHANNEL 1 button until the LED to the left of LINE is illuminated. Select the value 04.00 by depressing the DIGIT button and rotating the VALUE knob.
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Page 40: A Multiple Event Glue Pattern
Page 4 - 4 ITW Dynatec c. 1999 Revised 7/99 DPC-2 CONTROL KIT Manual #50-06 A Multiple EVENT Glue Pattern The following example places a series of dots, dashes and a solid line on a substrate using two glue applicators. The two glue applicators are offset by one inch to illustrate a method of “cheating”... - Page 41 ITW Dynatec c. 1999 Page 4 - 5 DPC-2 CONTROL KIT Manual #50-06 Revised 7/99 5. Depress the CHANNEL 1 button. The LED above this button will illuminate and the LED to the left of EVENT will also illuminate. Rotate the VALUE knob until 1 is displayed.
- Page 42 Page 4 - 6 ITW Dynatec c. 1999 Revised 7/99 DPC-2 CONTROL KIT Manual #50-06 16. Depress the CHANNEL 1 button until the LED to the left of EVENT is once again illuminated. Rotate the VALUE knob until 3 is displayed. This indicates the programming of EVENT 3 of the selected Program.
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Page 43: Chapter 5: Troubleshooting
1. The DPC-2 requires a 100 Pulse Per Inch encoder input to properly calculate speed and distance. The ITW Dynatec Encoder Kit (L21702) is designed to supply 100 PPI provided the supplied wheel is being driven in a 1:1 ratio to machine production speed. The encoder will require re-installation at another position on the machine if this ratio does not exist. -
Page 44: Glue Pattern "Jumps Around
Page 5 - 2 ITW Dynatec c. 1999 Revised 7/99 DPC-2 CONTROL KIT Manual #50-06 Ø G “J ” ATTERN UMPS ROUND The pattern is sometimes in the correct position, but at other times it starts early or is applied late. The problem could be in the trigger, encoder or pattern control unit. - Page 45 ITW Dynatec c. 1999 Page 5 - 3 DPC-2 CONTROL KIT Manual #50-06 Revised 7/99 3. Are DELAY and LINE values programmed? A program may have been inadvertently selected from MEMORY that has no DELAY or LINE information entered. 4. Is the Trigger Device activated for at least 1 millisecond? The DPC-2 avoids “false triggers”...
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Page 46: Drive Or A.t.s. Status Led Is Illuminated Red
The DPC-2 Control Unit is defective if the DRIVE fault is again indicated by the red Status LED. It should be sent to ITW Dynatec for repairs. 4. The problem is in either the Output Cable or Output Device (Glue Applicator or Automatic Tip Sealer) if the Status LED is green when the Trigger Device is activated with the Output Cable disconnected. - Page 47 ITW Dynatec c. 1999 Page 5 - 5 DPC-2 CONTROL KIT Manual #50-06 Revised 7/99 Ø SYSTEM P ARAMETERS ANNOT CCESSED The RUN/STOP button must be depressed until the LED above this button is dimmed in order to access all SYSTEM parameters with the exception of LOCKOUT, PRE-DELAY and CONSTANTS..
- Page 48 Page 5 - 6 ITW Dynatec c. 1999 Revised 7/99 DPC-2 CONTROL KIT Manual #50-06 c. 1999 ITW Dynatec...
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Page 49: Chapter 6: Installation & Maintenance
(see Installation Drawings at end of chapter) Diagrams of typical system configurations are provided to assist in the integration of the DPC-2 Controller with your glue system. Contact ITW Dynatec Technical Service at 800- 654-6711 for additional assistance, if necessary. - Page 50 Page 6 - 2 ITW Dynatec c. 1999 Revised 4/10 DPC-2 CONTROL KIT Manual #50-06 Item Description Part Number Electrical Fuse, 630mA 106084 Upper Display Panel, Complete, DPC-2 116196 Lower Display Panel, Complete, DPC-2 116197 Filter Printed Circuit Board 109247...
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Page 51: Electrical Schematics
Page 6 - 3 Rev.12.18 Electrical Schematics... -
Page 52: Component Illustration: Hot Melt Gear Pump System
Page 6 - 4 Revised 7/99 Component Illustration: Hot Melt Gear Pump System... -
Page 53: Bill Of Materials: Hot Meltgear Pump System
Page 6 - 5 Revised 7/99 Bill of Material: Hot Melt Gear Pump System... -
Page 54: Component Illustration: Hot Melt Piston Pump Overview
Page 6 - 6 Revised 7/99 Component Illustration: Hot Melt Piston Pump Overview... -
Page 55: Bill Of Materials: Hot Melt Piston Pump Overview
Page 6 - 7 Revised 7/99 Bill of Material: Hot Melt Piston Pump Overview... - Page 56 Page 6 - 8 ITW Dynatec c. 1999 Revised 5/09 DPC-2 CONTROL KIT Manual #50-06 c. 1999 ITW Dynatec...
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