manual twin timer eng

TIME-BASED CONTROLLERTWIN TIMER V2

INSTRUCTIONSMANUAL

MA-5088-E 081014

GLUING SOLUTIONS

Edita:

Meler Gluing Solutions, S.A

P.I. Los Agustinos, calle G, nave D-43E - 31160 ORCOYEN Navarra (España)Tel.: + 34 948 351 110 Fax: + 34 948 351 130e-mail: [email protected]

www.meler.eu

Edición october 2014

© Copyright by Meler

Reservados todos los derechos. Prohibida su reproducción, difusión o utilización, por medios informáticos o cualquier otro medio, de todo o parte de este documento sin la autorización expresa de su propietario.

Las especificaciones e informaciones contenidas en este manual pueden ser modificadas sin previo aviso.

http://www.meler.eu

MA-5088-E MANUAL TWIN TIMER V2TABLE OF CONTENTS

TABLE OF CONTENTS

1. SAFETY GUIDELINES 1-1

General 1-1

Symbols 1-1

Electrical components 1-2

Hydraulic and pneumatic components 1-2

Thermal components 1-2

Noise 1-3

Materials 1-3

2. INTRODUCTION 2-1

Description 2-1

Intended use 2-3

Modes of operation 2-3

Controller identification 2-4

Main components 2-4

3. INSTALLATION 3-1

Preliminaries 3-1

Installation requirements 3-1

Electrical consumption 3-1

Unpacking 3-2

Content 3-2

Electrical power supply connections 3-2

External signal connections 3-3

4. USE OF UNIT 4-1

Start up and automatic process 4-1

Time regulation 4-1

MELER GLUING SOLUTIONS TABLE OF CONTENTS

Screens navigation 4-3

5. TECHICAL CHARACTERISTICS 5-1

General 5-1

Dimensions 5-2

6. ELECTRICAL DRAWINGS 6-1

7. SPARE PART LIST 7-1

MA-5088-E TWIN TIMER V2 MANUALSAFETY GUIDELINES

1-1

1. SAFETY GUIDELINES

General

The information contained in this section applies not only to everyday machine operation, but also to any procedure carried out on it, whether for preventive maintenance or in the case of repairs and the replacement of worn out parts.

It is very important to observe the safety warnings in this manual at all times. Failure to do so may result in personal injury and/or damage to the machine or the rest of the installation.

Before beginning work on the machine, read this manual carefully, and in case of any doubt, contact our Technical Service Center. We are available for any clarification that you might need.

Keep manuals in perfect condition and within reach of personnel that use the machine and perform maintenance on it.

Also provide necessary safety material: appropriate clothing, footwear, gloves and safety glasses.

In all cases, observe local regulations regarding risk prevention and safety.

Symbols

The symbols used on both the melter/applicator equipment and in this manual always represent the type of risk we are exposed to. Failure to abide by a warning signal may result in personal injury and/or damage to the machine or the rest of the installation.

WARNING: Risk of electrical shock. Carelessness may produce injury or death.

WARNING: Hot zone with high temperatures. Risk of burns. Use thermal protective equipment.

WARNING: System under pressure. Risk of burns or particle projection. Use thermal protective equipment and glasses.

WARNING: Important information for the correct use of the system. May include one or several of the previous hazards, and therefore must be kept in mind to avoid damage and injury.

MELER GLUING SOLUTIONS

1-2

SAFETY GUIDELINES

Mechanical components

The melter/applicator equipment installation uses moveable parts that may cause damage or injury. Use the equipment correctly, and do not remove the safety guards while the equipment is in operation; prevent the risk of possible entrapment due to moving mechanical parts.

Do not use the machine if the safety devices are not in place or appear to be inadequately installed.

For maintenance or repair operations, stop the movement of moveable parts by turning off the main switch.

This controller has no moving mechanical parts so in that case it presents no risk to consider.

Electrical components

The system operates with a one-phase current (230 V / 50 Hz) at a certain rated power. Never handle the equipment with the power connected, as this may result in powerful electrical shocks.

The installation must be correctly grounded.

The installation’s power cable conductors must match the required electric current and voltage.

Periodically inspect the cables to check for crushing, wear and tear, as well as to prevent tripping and falls as a result of their placement.

Hydraulic and pneumatic components

It does not include any hydraulic or pneumatic element.

Thermal components

The controller works with a complete system of hotmelt application (melter, hoses and guns) that operates with temperatures reaching up to 200 °C (392 °F). The equipment must be operated using adequate protection (clothing, footwear, gloves and protective glasses) that completely cover exposed parts of the body.

Keep in mind that, due to the high temperatures reached, the heat does not dissipate immediately, even when the power (in this case, electric) source is disconnected. Therefore, use caution, even with the adhesive itself. It may remain very hot, even in a solid state.

In case of burns, immediately cool the affected area with clean, cold water. Seek medical attention as soon as possible from the company’s medical service or the nearest hospital. Do not try to remove the adhesive material from the skin.

MA-5088-E TWIN TIMER V2 MANUALSAFETY GUIDELINES

1-3

Noise

The noise level of the system is well below allowable levels, and therefore does not present a specific risk to be taken into consideration.

Materials

‘meler’ systems are designed for use with hot-melt adhesives. They should not be used with any other type of material, and especially not with solvents, which may cause personal injury or damage to internal system components.

Always use original ‘meler’ components and replacement parts, which guarantee the correct system operation and service.

When using adhesive, follow the corresponding guidelines found in the Technical and Safety Sheets provided by the manufacturer. Pay special attention to the advised work temperatures in order to prevent adhesive burning and degradation.

Ventilate the work area adequately in order to remove the vapors produced. Avoid the prolonged inhalation of these vapors.


1-4

SAFETY GUIDELINES

This page is intentionally left blank.

MA-5088-E TWIN TIMER V2 MANUAL INTRODUCTION

2-1

2. INTRODUCTION

Description

Time-based twin timer controller of Meler controls the application of adhesive on a certain substrate, being independent of its lengh. Thus it can be glued substrates with different lengths without setting new parameters for each substrate.

Two independent ‘twin’ timers allow the adjustment of the application at the begining and at the end of the substrate.

As it is a time-based controller the production speed must be constant if it is necessary to get the same accuracy at both edges of the application line.

The system starts the control by means of a photocell, as start signal, which detects the substrate when it is passing under the light detector.


2-2

INTRODUCTION

The photocell detects the product and starts a delay time in the application, not less than time for the product to reach the position of the gun.

d

t1 t2

v

Time set allows the product to reach the gun position with a certain speed ‘v’ and adjust the application to the start edge of it. The speed must be constant.

d

t1 t2

v

When time is fullfil the application of adhesive starts.

d

t1 t2

v

d

t1 t2

v

Application system with photocell detection and delay timers to apply at start and end of the product.

When the photocell doesn’t detect product the second delay timing begins It cannot be less than the value necessary to end the application.

d

t1 t2

v

The adhesive is applied while the photocell is detecting. It is not alow detecting failures, holes on the substrate or modifications in colors which corrupt the application cycle.

d

t1 t2

v

MA-5088-E TWIN TIMER V2 MANUAL INTRODUCTION

2-3

When timing is reached, the application stops till the photocell detects a new product.

d

t1 t2

v

As it is a time-based system, every photocell detection (even unintentional) starts a new cycle. A switch-off device guarantees that the unit is not active. When the main machine stops with the product in the application cycle, one stop contact of the machine (for example the product motor drive) blocks the cycle stopping the application. The system must be re-start with a reset button which also serve as inicialization signal when the system is switch-off.

Intended use

Twin timer controller should be used only for the functions described in this manual and under the limitations set forth herein.

Do not modify the installation or use items not supplied by Meler. Any modification of an element or part of the installation must be consulted to manufacturer.

Do not use to control power over than the recommended or with voltage devices other than those specified.

Modes of operation

Twin timer controller may be used in all the following modes:

Work mode_Timing device acts normally, activating application signal by two programmed timers while the amber light is off. It is an automatic process where the user must not operate with any control button.

Blocking mode_Timing device blocks the application due to stopping substrate movement with external contact opening from the main machine. Amber light remains on. When the main machine re-starts the product movement, the user must press the amber reset button.

When voltage is applied to the unit it starts in ‘blocking mode’.

Stop mode_Timing device remains switch-off without voltage, so we haven’t any control of the system.


2-4

INTRODUCTION

Controller identification

When placing orders for replacement parts or requesting help from our service center, you should know the model and reference number of your twin timer controller.

This and other technical information will be found on the identification plate located on the controller box.

Main components

1. Screen and keyboard for programming

2. Reset button

3. Working amber light

4. Input photocell connection

5. Output solenoid valve connection

6. Cycle blocking signal connection

7. Electrical main switch

8. Solenoid valve number selector

9. Electrical connection socket

10. DC power supply

11. Siemens Logo

9

10

1

11

4

8

67 5231

MA-5088-E TWIN TIMER V2 MANUALINSTALLATION

3-1

3. INSTALLATION Warning: The time-based controllers are installed in equipment with updated technology with foreseeable risks. Therefore, you should allow only the access to skilled people, with sufficient training and experience in handling, installation or repair of such equipment.

Preliminaries

The controller is normally supplied with the elements necessary for installation and use. However, some components must be supplied by the user depending on the location and connections of each facility including:

• Power cable for power supply.

• Cycle blocking signal connecting cable.

• Controller eventual support for its fixation to the machine.

Installation requirements

Before installing or using a time-based controller we must ensure that the space for it allows the location, connection and use of the entire system. We must also ensure that the electrical supplies meet the requirements demanded by the used device.

Electrical consumption

Before connecting the twin timer controller we must take into account the total consumption of the system and provide an appropriate power supply.

Check nameplate of the controller before the connection, in order to connect device to the appropriate voltage.

Connect and ensure a correct grounding of the device.

Warning: Risk of electrocution. Even when the equipment is turned off, voltage remains in the intake terminals, which may be dangerous during internal equipment manipulations.

It is recommendable for the electrical connection to incorporate a circuit breaker against overloads and a residual current switch against possible residual currents.

The power associated with this protection is indicated on the nameplate of the feeder.

MELER GLUING SOLUTIONS INSTALLATION

3-2

Unpacking

Before proceeding with the installation of the controller, it should be removed from its location in a carton box and examined in order to detect any possible breakage or deterioration.

Communicate any defect, even to the outer packing materials, to your ‘meler’ Representative or to the Main Office.

Content

A complete system of time-based controller should include the following accesories (on customer demand):

• Photoelectric sensor to start the cycle

• Solenoid valve connecting cable

• Power supply connecting cable

• Cycle blocking signal connecting cable

• Instructions manual

Electrical power supply connections

The controller is supplied to be connected to the power supply of single phase 230 VAC with netral, depending on their power consumption.

It is always imperative to install a good ground connection.

The maximum and minimum values are listed on the nameplate of the system.

Warning: Risk of electrical shock. Carelessness may produce injury or death.

The electrical wire is connected to the contoller. When you receive the item, it is only necessary to connect to the electrical grid.

If for any reason it is necessary to disconnect the supply wires of the controller, make sure that the twin timer is disconnected of the electrical grid and remove the cables later.

1x 230 + NNT L

MA-5088-E TWIN TIMER V2 MANUALINSTALLATION

3-3

External signal connections

1. Start cycle signal connection

Connect the photocell sensor cable in the appropiate connector in the rear side of the controller. The connector must be plugged matching the little rib in its perimeter with the corresponding in the socket.

Fix the connector by the threaded nut.

2. Solenoid valve output connection

Connect the solenoid valve cable in the appropiate connector in the rear side of the controller. The connector must be plugged matching the little rib in its perimeter with the corresponding in the socket.

Fix the connector by the threaded nut.

3. Cycle blocking external contact connection

Connect the cycle blocking external contact cable in the appropiate connector in the rear side of the controller. The connector must be plugged matching the little rib in its perimeter with the corresponding in the socket.

Fix the connector by the anchor clip.

The end of this cable could be connected to a non-voltage contact for this purpose: manual switch, auxiliary normally open contact of the line motor power switch, relé output of PLC, etc.

MELER GLUING SOLUTIONS INSTALLATION

3-4


MA-5088-E TWIN TIMER V2 MANUAL USE OF UNIT

4-1

4. USE OF UNIT This section presents how to use the time-based controller. Even if its operation is very simple, it should not be used by non-trained personnel.

Warning: An improper use can cause damage to the equipment itself or to the operator.

Start up and automatic process

The operation of the controller is absolutely automatic and only needs to switch it on to begin the automatic process.

Connect the controller to the electrical grid and turns on the time based controller with the main swich. The yellow led of the pushbutton will blink if the cycle blocking external contact is closed whereas if this contact is opened, the yellow led will remain on.

When the block external contact changes state (open to close) or the unit swiches on and the block external contact is closed, the yellow pushbuttom will blink.

To press the reset button and the yellow led will turn off and the controller will be able to start to work.

Enough that the photocell sensor detects a substrate to glue the cycle starts applying a line of adhesive along the substrate.

To understand the automatic cycle process see chapter ‘2. Introduction’ of this manual.

Time regulation

Time regulation for adjusting the distance not applied from the start and end edges of the substrate can be done through the small keyboard with the help of the screen placed in the front panel.

Start delay time (T ON) is the time passed between the detection of the photoelectric sensor and the starting moment of applying the glue. The value cannot be less than 10 ms, so we recommend that distance between photoelectric sensor and gun should be 20 to 50 mm minimum.


4-2

USE OF UNIT

The end delay time (T OFF) is the time between photoelectric sensor stop its detection and the end of the application line. This value cannot be less than 10 ms, so we recommend that distance between photoelectric sensor and gun should be 20 to 50 mm minimum.

v

v

T ON

d

T ON

v

v

T OFF

d

T OFF

Warning: The minimum distance (gap) between two substrates must be geater than the distance selected between photosensor and gun. If not application failures can be gotten, or continuous application along several substrates or simple no application at all

MA-5088-E TWIN TIMER V2 MANUAL USE OF UNIT

4-3

Screens navigation

When the programmer switches on, appears the photocell 1. Previously, explained that the start delay time of the solenoid valve is ON and the end delay time of solenoid valve is OFF.

To select the photocell 2 press F2. To come back to photocell 1 press F1.

The number 1 refers to the photocell 1 (Trigger 1) whereas the number 2 concerns to photocell 2 (Trigger 2). T1 represents the photocell 1 detecting and T2 represents the photocell 2 detecting. There are 4 possibilities of detection:

- Photocells 1 and 2 are detecting substrate (figure 1).

- Photocell 1 is detecting but the photocell 2 no (figure 2).

- Photocell is detecting substrate but the photocell 1 no (figure 3).

- Neither photocell 1 nor photocell 2 is detecting substrate (figure 4).

Figura 3

Figura 1

Figura 4

Figura 2


4-4

USE OF UNIT

To change the delay time of the solenoid valves, following the instructions below:

Turn on the unit and when appears one of the screen described previously. push during 3 or 4 seconds the ESC key. It will show up a segment underneath the start delay time of the 1 photocell by default.

To manipulate this time, push the OK key and the number where it was the segment will change to a bold number.

Push up or down arrow to manipulate this number (bold number) and left and right arrows to move for the different time units on this delay time.

To manage another delay time, push the OK key and the segment will appear again.

Push the right arrow to change to the menu below and push the left arrow to change to the menu above.

To modify a delay time you must have the bold number, unless you will only be able to move for the different menus. To change state (segment-bold number or conversely) always push OK key.

If the substrate stops, the application cycle goes on because the photosensor is detecting continuously, so it gets a non-stop application of glue until the system is switch off. That’s why it is necessary to connect a blocking external contact that shuts of the application if the main machine stops.

Just re-start the main machine movement and press to reset the pushbutton to activate the cycle again. Yellow led will stay off, showing the allowing signal to apply.

It is very important to understand that the controller never work if the blocking contact is not connected. The contact block can be closed (the controller can work) or opened (the driver can not work), but if it is not connected to the main machine, the controller will never work.

MA-5088-E TWIN TIMER V2 MANUAL TECHNICAL CHARACTERISTICS

5-1

5. TECHICAL CHARACTERISTICS

General

Power supply voltage

Maximum power consumption

Minimum programmable time

Resolution

Photocell

Solenoid valve

Internal timers

Dimensions (LxWxH)

230V 1~ 50/60 Hz + N + PE

15W

10ms (0001)

10ms

1 o 2 (24VDC NPN)

1 o 2 (24VDC 5.4W)

2 o 4 (T ON inicio / T OFF final)

197 x 241 x 81 mm


5-2

TECHNICAL CHARACTERISTICS

Dimensions

197

241

81

MA-5088-E TWIN TIMER V2 MANUAL ELECTRICAL DRAWINGS

6-1

6. ELECTRICAL DRAWINGS

A

B

C

D

E

F

A

B

C

D

E

F

1 2 3 4 5 6 7 8

DIBUJADO/DRAWN

MODIFICADO/MODIFIED

CLIENTE/CUSTOMER

FECHA/DATE NOMBRE/NAME DENOMINACIÓN/NAME EQUIPO/EQUIPMENTREFERENCIA/REFERENCE

HOJA/SHEET: HOJAS/SHEETS

DISP.: SITC.:J.Z.R.06/11/2013

25/03/2014 JESUSZCONNECTION

1 4

E00900330TWIN TIMER 2 PHOTOCELLS

L N PE

+

G1

S1

1

2

1X1 1X2 1X3

1/3CN5

2/3PE/3

A1

L+ M

+24V

0V

/4.D1#30A2:SERIAL

L

L

N

N

1.1

1.1

L1

L1

L1L

N

N

N

1.2

1.2

1.2

+24V

+24V

+24V

+24V

+24V

+24V

0V

0V

0V

0V

0V

0V

TWIN TIMER

A

B

C

D

E

F

A

B

C

D

E

F

1 2 3 4 5 6 7 8

DIBUJADO/DRAWN

MODIFICADO/MODIFIED

CLIENTE/CUSTOMER



DISP.: SITC.:15/11/2013

25/03/2014 JESUSZINPUTS

2 4


I1 I2 I3 I4 I5

INPUTS

I6 I7 I8

LOGO RCA1

I1 I2 I3 I4 I5 I6 I7 I8

1/4CN6

2/43/44/4

3

4

S2

1/5CN7

2/53/54/55/5

+24V

0V

+24V

0V

1R1

2 I1

1/4CN10

2/43/44/4

1R2

2 I2

3

4

S3

+24V+24V +24V

+24V

+24V +24V

+24V

+24V

+24V

I1I1

I1

I1

I3

I5I5

I2

I2I2

I2

+24V

+24V

+24V

0V0V 0V

0V

0V0V

0V

PHOTOCELL 1

INHIBITIONRESET

PHOTOCELL 2

A

B

C

D

E

F

A

B

C

D

E

F

1 2 3 4 5 6 7 8

DIBUJADO/DRAWN

MODIFICADO/MODIFIED

CLIENTE/CUSTOMER



DISP.: SITC.:15/11/2013

25/03/2014 JESUSZOUTPUS

3 4


OUTPUTS

Q1 Q2 Q3 Q4

LOGO RCA1

Ref:

Q1A Q1B Q2A Q2B Q3A Q3B Q4A Q4B

1/4CN8

2/43/44/4

1/4CN9

2/43/44/4

X1

X2

P1

+24V

0V

+24V

0V

+24V+24V

+24V

+24V

+24V

+24V

+24V

+24V

+24V

Q1B

Q1B

Q2B

Q2B

0V0V 0V

0V

0V

0V

0V

0V

0V

Q4B

OUTPUT 1 OUTPUT 2 RESET LIGHT

A

B

C

D

E

F

A

B

C

D

E

F

1 2 3 4 5 6 7 8

DIBUJADO/DRAWN

MODIFICADO/MODIFIED

CLIENTE/CUSTOMER



DISP.: SITC.:15/11/2013

25/03/2014 JESUSZSCREEN

4 4


1

5

6

9

A2

SERIAL

+

+24V

0V

/1.F8 #30


6-2

ELECTRICAL DRAWINGS


MA-5088-E TWIN TIMER V2 MANUALSPARE PART LIST

7-1

7. SPARE PART LISTThe list of the most common spare parts of the twin timer controller appears in this chapter in order to provide you with quick and safe information.

The spare parts are naturally assembled in several groups, located in the equipment.

As a visual aid it includes general images of the pieces, numbered to facilitate location within the drawing.

The lists provide the name of the reference and parts.


7-2

SPARE PART LIST

Nº Ref. Denomination

1 115000960 Siemens Logo TD screen

2 150022480 Led pushbutton (yellow)

3 150022530 Contact N/O

4 150022490 Led yellow

5 16010004 Female socket connector 4 pole

6 16010010 Female socket connector 5 pole

7 16010012 Male plug 90ºconnector 5 pole

8 150021600 Main switch

9 115000950 Programmable relay Logo Siemens

10 10110070 Power supply 230VAC/24VDC

11 16000004 Male socket connector 4 pole

12 27000001 Complete photocell with wire

10 9

11

12

8 65

74

231

manual twin timer eng

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