Operating Manual Bedienungsanleitung Universal-Steuergerät Dual Channel Controller 97152
Contents 1 Please observe the following ..............................................................52 1.1 1.2 1.3 1.4 Emphasized sections.......................................................................................................52 Items supplied.................................................................................................................52 Safety instructions ..........................................................................................................
Contents 50 5 Operation ............................................................................................ 70 5.1 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.4 5.5 5.6 5.7 5.7.1 5.7.2 5.8 5.8.1 5.8.2 5.9 5.10 5.11 5.11.1 5.11.2 5.11.3 Lock/unlock controller ................................................................................................... 70 Programming procedure...................................................................................
Contents 7.2.2 7.2.2.1 7.2.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.2.6.1 7.2.6.2 7.2.7 7.2.8 7.2.9 7.2.10 7.3 XS 2 Product reservoir ...................................................................................................88 XS 2 product reservoir with digital level sensor (e.g. model 97125).............................88 XS 2 Analog product reservoir (e. g. models 97106/97108)..........................................88 XS 3 Flow monitor ....................................................................
1 Please observe the following Before installing the system: For safe and successful operation of the unit, read these instructions completely. If instructions are not observed, the manufacturer can assume no liability. Be sure to keep the manual close at hand for further reference. 1.1 Emphasized sections Danger! Danger is the signal word used to indicate an imminently hazardous situation that, if not avoided, will result in death or severe injury.
1 Please observe the following While under warranty, the unit may be repaired by an authorized Henkel service representative only. Danger! The manufacturer cannot be held responsible for damage or injury of any kind because of misuse or improper application or because of failure to observe safety instructions or warnings. It is the responsibility of the user to ensure that all devices actuated by the controller are positioned in a safe manner.
2 2.1 Description Theory of operation The Loctite® Dual Channel Controller 97152 utilizes the latest microprocessor technology to create a user-friendly control system for workstations in manufacturing environments. The controller is made up of a micro-controller core, a user interface keypad and graphic LCD display. A solenoid valve module and a precision pressure regulator are integrated into the unit; an external solenoid valve module may be connected as an additional option.
2 2.2 Description Displays, operating elements and connections 1 2 3 1 2 3 Display Displays all information required for setup, status, etc., see section 2.3 Precision pressure regulator Precision pressure regulator to regulate reservoir pressure. Turn the regulator knob to adjust the dispense pressure within a range from 0.00 bar to 700 bar (0 to 100 PSI). If error message “12 Supply? “ is displayed with a beep, the reservoir is either empty or has been switched off.
2 Description 4 5 7 6 97152 A A B B ESC ESC 4 5 6 7 56 Start Start Key: Channel A Key: Channel B – To select the channel for further adjustments. – In the setup menus, these keys are used to switch the relevant options on or off. Key: Monitoring Without preselection of a channel, the online monitoring On/Off menu is displayed. With preselected channel, the online monitoring Setup menu is displayed.
2 Description 97152 A 9 A 8 B B 10 ESC 11 ESC 8 9 10 11 Start Start Key: Preselection of stored dispense programs For manual selection of stored dispense applications. The display shows the selected application in the 3rd line, indicated as letters (a-d) in square brackets. Key: Time With preselected channel, the value setup menu is displayed. – For adjusting dispense, pre-delay and post-delay times.
2 Description 97152 A A B B ESC ESC Start Start 12 13 14 15 12 Key: Setup and Manual mode Without preselected channel, for the following settings: – Language setting, – Channel setting, – Factory settings, – Setup of dispense program change, and – Checking of input and output signals. With preselected channel, the adjustments for setup mode can be made, such as dispensing valve On or Off.
2 Description P in 6-8 bar I/0 P in 6-8 bar I P out 0.1-7 ba r 0 I I 0 P out 0.1-7 ba r 0 I/0 I 0 A B A B XS16 16 16 17, 18 19 20, 21 22 XS5 RS 232 17 18 19 20 21 22 Pneumatic Connection Reservoir Regulated air pressure supply (0 - 7 bar, 0 – 100 PSI) to the reservoir, for + 0.05 air hose OD Ø 6 mm –0.10 , ID Ø 4 mm. Pneumatic Connection A to a dispense valve I = Dispense valve open. O = Dispense valve closed.
2 Description 24 25 XS16 XS5 RS XS3 Flow 26 27 232 Monitor ervoir 26 27 60 XS17 XS10 PLC Interface XS12 Va XS18 XS1 Sta rt Made in 25 Port lves Place for 24 XS8 I/O XS2 Res Henkel AG Standort & Co. KGaA M Gutenber ünchen gs D-85748 tr. 3 Garching 23 23 XS11 DC Drive 100-240 VAC, 50 /60 Hz Fuse Power Co : 2A T (time-lag ) nsumption : 100 W Serial No . Sticker German y Connection XS 8 I/O Port Connection option for additional peripheral units.
2 Description XS16 XS5 RS XS3 Flow 232 Monitor XS8 I/O 34 Port XS17 XS10 PL C Interfa ce XS2 Res ervoir XS12 Va lves XS18 33 XS1 Star t 28 29 30 Henkel AG Standort & Co. KGaA Münche n Gutenbe rg D-85748 str. 3 Garching Place for Se XS11 DC 32 Drive 100-240 VAC, 50 /60 Hz Fuse Power Co : 2A T (time-lag ) nsumption : 100 W rial No.
2 2.3 2.3.1 Description Start display - Overview Display overview This display is an overview of the most important parameters of all active channels. The factory default setting for Channel A is always in active mode. The display also shows the status of product supply if a reservoir has been connected. 2 lines of information about the channels (channel status) are displayed. – The capital letter in the frame indicates the dispense channel, – Program step of the channel as a figure.
2 2.4 Description Controller access function This function is a safety feature to safeguard the system against unauthorized manipulation. Enter a PIN as desired to prevent unauthorized users from configuring the controller, changing dispense applications, etc. Enter number "2000" to unlock. In locked condition, only the following functions can be accessed: – On/off switching of product reservoir, i.e. reservoir pressurization/depressurization for replacing the bottle of product..
2 2.6 Description Menu types Push the relevant keys to open a menu. While the red ring on the Selector / Confirm button is illuminated, the button can be turned or pressed to – change settings such as dispense time, – scroll within a menu, but also to – store the selected value. Within the On/Off menu, the channel keys for dispense channels A and B are defined as switches.
2 2.7.1 Description Integrated pneumatic solenoid valve module: 1 dispense channel All components are connected to the connectors of dispense channel A and actuated in the dispense channel A system menu. The Flow Monitor is connected to connection XS 3, the product reservoir is connected to connection XS 2. Connectable components LOCTITE designations 1 dispense valve with double acting actuator (for dispense valves with single acting actuator, close port 0 with blind plug).
2 2.7.3 Description External pneumatic/electric solenoid valve module: 2 dispense channels All components must be connected to the external solenoid valve module. Connecting components to a mixed configuration of internal and external valve modules is not possible. Flow monitors are connected to connection XS 3. Use splitter cable 97529 for connecting two pressure based on-line preamplifiers. The product reservoir is connected to connection XS 2.
2 2.8 Description Factory settings Factory settings for both dispense channels Advancing slide........................................................................... Off Rotor............................................................................................ Off Flow monitor ............................................................................... Off DC motor..................................................................................... Off Continuous mode.........................
3 3.1 3.2 3.3 68 Technical Data Electrics Power supply 100-240 VAC; 50/60 Hz Power consumption approx. 60 W Power fuse Glass tube miniature fuse, 2A semi time-lag Internal control voltages 5 VDC; 24 VDC Protection IP 33 acc. to VDE 0470, Part 1 / EN 60529-1991 Pneumatics Pneumatic supply min. 2 bar; max. 10 bar Observe technical data specified for the dispense valve! Quality If the required quality is not achieved, install a Loctite® 97120 filter regulator.
4 4.1 Installation Environmental and operating conditions – Keep product feed lines as short as possible. The shorter the feed line, the smaller the specific resistance and the lower the required dispense pressure. – Avoid kinking of feed lines. – Typically, the feed line should be no longer than 2 m. – Carefully tighten all fittings. – Avoid exposure to direct sunlight and UV radiation! – Avoid condensing humidity. – Avoid splash water. – For indoor use only.
5 5.1 Operation Lock/unlock controller This function is a safety feature to safeguard the system against unauthorized manipulation, refer also to section 2.4. Lock • Keep ESC/Lock key 11 depressed for more than 3 s. • Turn the button to select a number which is not the number "2000". • To store the setting, press key 10 Enter or push the button. The controller is locked. Unlock • Keep ESC/Lock key 11 depressed for more than 3 s. • Turn the button to select the number "2000".
5 5.2.2 Operation Dispense channel configuration The key for Channel A is quoted only as an example. Push the key of the channel for which you have to make the adjustments. • First press key 4 Channel A, then key 7 Setup. –For adjustments in menu option Advancing Slide, proceed as described in section 5.4 –For adjustments in menu option Rotospray, proceed as described in section 5.4 –For adjustments in menu option Flow monitor, proceed as described in sections 5.4 and 5.7.
5 5.3 Operation Menu "System setup" The first step is to preconfigure the controller. For this purpose, the controller must be unlocked. This menu is activated by pressing the key This is the menu for general setup of the dispensing system. Turn the button to select the desired entry which will be displayed in large letters, and confirm by pressing key 10 Enter. Confirm any adjustments to settings by pressing key 10 Enter. Press key 11 ESC/Lock to leave the menu. 5.3.
5 5.3.4 Operation Stored dispense program changeover types: This is the option for selecting the type of changeover for the stored dispense programs. – No changeover, as these programs will not be used. – Manual changeover by pressing key 8 Preselection of stored dispense programs – Changeover using external control signal via interface XS 8. 5.3.5 I/O signal status This is an overview of all digital and analogue inputs and outputs with their current switch statuses.
5 5.4 Operation Menu "Dispense channel setup" This menu is activated by pressing the keys A or B and . If the menu is activated without preselecting a channel, Channel A will be automatically switched to active mode. Setup options are the same for both channels. This is the menu where dispense channels A and B can be configured. The channel keys for dispense channels A and B are defined as switches. The relevant keys are used to switch the peripherals and functions On ( ) or Off (X).
5 5.5 Operation Menu "Setup mode" This menu is activated by pressing the keys A or B and . Caution! In this mode, all units connected to the controller or to the external valve module will be actuated. For example, a connected advancing slide will move to its dispense position when the channel is switched on ( ). There must be no obstacles within this range. Any unit switched on in this mode, although not activated in the channel system menu, will be actuated.
5 5.6 Operation Menu "Dispense, pre-delay and post-delay times, DC motor speed" This menu is activated by pressing the keys A or B This is the option for selecting – Dispense time, – Pre-delay time, – Postdelay time and – Percentage speed of a connected DC motor Use keys 4 Channel A or 5 Channel B to scroll through the menu. Adjustments are made by turning the button. Pre-delay time: This is the time that elapses until the rotor or the dispense step starts.
5 5.7 5.7.1 Operation Menu "Online Flow Monitor" Value setup This menu is activated by pressing the keys A or B and . Pressing the key 6 Monitoring without preselecting a channel will automatically switch Channel A to active mode. Preselection of the dispense channel is required to call up the setup menu for Channel B. This is the option for selecting – tolerance, 10% - 400%, – evaluation start point, – evaluation stop point, and – measuring time factor value, 1- 10.
5 5.8 5.8.1 Operation Setup of reservoir pressure, empty and refill signals Reservoir pressure setup • Turn the regulator knob 2 to adjust the dispense pressure within a range from 0.00 bar to 7.00 bar (0 to 100 PSI). If error message “12 Supply?“ is displayed with a beep, the dispense pressure setting was changed by more than ± 10 %. Press key 10 Enter to store the indicated dispense pressure as new comparison value for automatic pressure monitoring.
5 5.10 Operation Setup of dispense time This menu is activated by pressing the keys A or B and . • Turn the button to select the desired dispense time and press key 10 Enter to store. This section explains the necessary steps for adjusting the required amount of product to be dispensed. It contains all the information required for easy and fast setup. In addition, the "Start settings" table is explained. The operating manuals of the relevant system components must be available for reference.
- 5 Operation Outgassing of products To avoid problems due to outgassing of products, use low dispense pressure and longer dispense timing for your process whenever possible. In addition, it is helpful to depressurize the dispense valve at regular intervals. If possible, reduce the valve closing speed (refer to operating manual of relevant dispense valve). High viscosity products Use a feed line with larger internal diameter for dispensing high viscosity products.
5 5.11 Operation Programming of Online Flow Monitor The integrated flow monitoring function of controller 97152 is used for monitoring the quality of adhesive applied to the parts. This means that the flow monitor detects and evaluates the following dispensing malfunctions: – Air bubbles in the dispensing system – Pressure changes in the dispensing system – Lost or clogged dispense needle – Touch-down of dispense needle on the part.
5 5.11.1 Operation Actuate flow monitoring • Push the key for the channel for which the monitoring function is to be activated. Screens displayed are different for each operating mode. Screen display in time-controlled mode Measurement curve Boundary line Measurement Start of Evaluation Boundary line Measurement End of Evaluation X-Axis Dispense, Lenght 120 pts. Status line – Status line – see section 2.6.2.
5 5.11.2 Operation Setup of parameters for monitoring • Push the key for the channel for which the monitoring function has been activated. • Push key 6 Monitoring to go to the setup menu. If no graph is indicated, this means that no dispense monitoring function has been activated for this channel. To activate the monitoring function, see section 5.8.1.
5 Operation Setup of measuring time factor • Press key 4 Channel A, or key 5 Channel B. Adjustable factor: 1-10. • For adjustments of values see section 5.1. • Press key 10 Enter to store the settings and return to the Monitoring screen 5.11.3 Setup of reference dispensing • Press key 6 Monitoring. The overview of flow monitoring modules is displayed. • To run one or several reference dispensing cycles, monitoring of the dispense channel must first be activated as described in section 5.11.1.
5 Operation Monitoring status screen This overview shows the current status of connected flow monitors. • Without channel preselection, press key 6 Monitoring twice.
0 6 Troubleshooting Malfunction Digital display does not light up. Possible Cause – No power supply. – Power switch 22 in position O (Off). – Power fuse 31 defective. – Power cord defective. – Controller defective. Corrective Action • Check supply voltage. • Set power switch 22 to position I (On). • Check/replace 31 mains fuse. • Replace power cord. • Henkel Service. – No compressed air. – Product reservoir not actuated or defective. • Check compressed air supply.
7 7.1 Annex Spare parts and accessories Item no. Description Type no. – I/O Multiplex Box XS 8........................................................... 97522 7.2 Order no. 840911 – I/O Multiplex Box XS 12......................................................... 97521 840910 – Splitter cable XS 3/XS 4 .......................................................... 97529 945063 – Start splitter cable..................................................................... 97203 142638 – Foot switch....
7 Annex 7.2.2 XS 2 Product reservoir 7.2.2.1 XS 2 product reservoir with digital level sensor (e.g. model 97125) Reservoir digital Levelsensor Controller 4 1 Tank Refill 1 1 blue 2 4 0VDC/GND 3 1 Tank Empty 2 2 3 3 black 2 3 brown + 24V 0VDC GND GND 4 5 5 6 6 7 7 8 8 9 9 0VDC 4 1 2 3 Identification Signal + 24V Output 7.2.2.2 4 + 24V XS 2 Analog product reservoir (e. g.
7 7.2.3 Annex XS 3 Flow monitor Controller Pre-Amplifier 1 Analogue/IN 2 3 Analogue/IN 4 5 1 Sensor Signal A 0-10VDC 2 Sensor Signal B 0-10VDC GND 4 3 5 6 7 6 Identification Signal 7 8 8 9 9 + 24VDC All other pins may never be connected! 7.2.4 XS 5 Serial interface RS232 To be connected via serial cable, pins 7 and 8 must not be assigned. Observe the serial interface protocol. 9600 baud/1stop bit/no parity/8 data bits.
7 7.2.5 Annex XS 8 I/O Port Controller 1 2 3 4 5 6 I/O Output A I/O Output B Hi-Speed Output A Hi-Speed Output B I/O Inputg A I/O Input B GND Output 11 12 12 13 13 GND Input +24 VDC XS 10 PLC internal power supply Controller 6 9 10 11 15 Ready Channel A Ready Channel B Error Channel A Error Channel B Start Channel A Start Channel B 1 2 3 4 5 1 6 1 2 2 7 +0VDC 8 Pot. 24V 9 Reset Channel A 10 Reset Channel B 11 Tank Refill 13 Tank Emtpy 13 15 +24VDC 1 2 12 Pot.
7 7.2.6.2 Annex XS 10 PLC external power supply Controller 1 2 3 4 5 6 PLC 1 Ready Channel A 2 Ready Channel B 3 Error Channel A 4 Error Channel B 5 Start Channel A 2 6 Start Channel B 7 8 8 10 11 9 Pot. 24V Reset Channel A 10 1 11 1 2 12 Tank Refill 12 13 Tank Emtpy 13 14 Pot. 0V 15 7.2.
7 7.2.8 Annex XS 12 External solenoid valve module Controller Solenoid Modul 1 1 2 2 Start Rotor C 3 Dispense Valve C 4 4 Adv. Slide C in front Analogue/IN Adv. Slide C in front Analogue/IN Adv. Slide C back 5 6 Dispensing Valve C 3 5 6 7 Advancing Slide C 7 8 8 +0VDC 9 9 10 10 Start Rotor D 11 Dispense Valve D 11 12 Adv. Slide D in front 12 13 Analogue/IN Adv. Slide D in front Analogue/IN Adv.
7 7.3 Annex EC Declaration of Conformity Declaration of Conformity The Manufacturer according to EC regulations Henkel AG & Co. KGaA Standort München Gutenbergstr. 3 D-85748 Garching b. München declares that the unit designated in the following is, as a result of its design and construction, in accordance with the European regulations, harmonized standards, national standards and technical specifications listed below. Designation of the unit Dual Channel Controller 97152 Equipment item no.
Henkel AG & Co. KGaA Standort München Gutenbergstraße 3 D-85748 Garching b. München C Henkel AG & Co.
