ENGLISH Prior to use of this product, please read the operating instructions carefully. If there are any further questions regarding the operation of the system, please contact LIQUIDYN under: address: LIQUIDYN GmbH Daimlerstraße 5 82054 Sauerlach GERMANY fon: +49 8104 90944-0 fax: +49 8104 90944-29 e-mail: info@liquidyn.com homepage: www.liquidyn.com Copyright LIQUIDYN GmbH 08/2013 Version 1.0-0 -
Please read before use! Before use read the complete operating instructions and all safety instructions in order to ensure safe and correct usage. The pictures and illustrations used for the present instructions might differ from the actual product. In the interest of further technical development, we reserve the right to make changes to the data and illustrations provided in these operating instructions. These operating instructions and the applicable documentation are not subject to an automatic revision service. These operating instructions describe how to operate the machine and contain important information that will assist you in using the machine for its intended purpose. No actions shall be taken that are running contrary to these instructions. The instructions must be kept in a legible state at all times. The safety instructions provided in the operating instructions must be observed. These operating instructions are intended for trained, technical personnel or correspondingly instructed persons. These operating instructions must be permanently kept at the dispensing system location and must be read, understood and applied by all persons who work on or with the dispensing system. Copyright The information contained in this documentation is part of our product know how transfer and is for the exclusive use by the machine user. It shall not be copied or otherwise duplicated or transmitted to a third party without the express written consent of the company LIQUIDYN. The user may make as many copies of this documentation as necessary for in-house purposes. Any suggestion as to how the information content of this document could be improved will be gratefully received at any time. Editorial information: Department Technical documentation Mechanical construction Electronic control system Editor Julian Hentschel Lothar Hentschel Peter Langer Date of Documentation: June/2013-1 -
Safety Symbols Safety instructions in this documentation, which should prevent personal injury, material damage or which should optimise operating procedure are given by a safety symbol and priority level. Safety instructions are used with following priority level and colour: DANGER! Ignoring this safety instruction can result in death or permanent health damage. WARNING! Ignoring this safety instruction can result in health damage. ATTENTION Material damage can be a result of ignoring this safety instruction. NOTICE Tips, information and notices. - 2 -
CE- Declaration of Incorporation The company LIQUIDYN GmbH Daimlerstr. 5 82054 Sauerlach Germany herewith confirms, that the Heater Controller T20 in the version as delivered (ex works), and to which this declaration refers, corresponds to the CE Directive 2006/42/EC dated May 17, 2006. The above described building part is a partly completed machinery according to Art. 2g of the Directive 2006/42/EC: Annex I, Articles 1.1.2, 1.1.3, 1.1.5, 1.3.2, 1.3.4 and 1.5.1. The partly completed machinery furthermore corresponds to all regulations of the Low Voltage Directive (LVD) 2006/95/EC and of the Directive 2004/108/EC relating to electromagnetic compatibility. It is the responsibility of the manufacturer of a machine to observe these directives when incorporating the building part. The documentation which is necessary according to Art.13 II of the Directive 2006/42/EC is part of the scope of delivery. Sauerlach, June 2013 Manager Peter Langer - 3 -
Table of Contents 1 INTRODUCTION... 6 1.1 Preface... 6 1.2 Scope of Delivery... 6 2 TECHNICAL DESCRIPTION... 7 2.1 Setup... 7 2.2 Technical Data... 8 2.3 Pin Assignment for the Alarm... 9 3 COMMISSIONING... 10 3.1 Prerequisites... 10 3.2 Installation... 10 4 Operation... 11 4.1 Operating Panel... 11 4.1.1 Navigation Keys... 11 4.1.2 Display... 12 4.2 Navigation Menu / Settings... 13 4.2.1 Splash Screen... 13 4.2.2 Setting Setpoint Value... 14 4.2.3 Self-Optimisation... 15 4.2.4 Setting the Alarm Signal... 16 5 SAFETY... 17 5.1 Intended Use... 17 5.1.1 Ambient Conditions... 17 5.1.2 Use Contrary to Intended Purpose... 18 5.1.3 Avoiding Material Damage... 18 5.2 Duties of Operator... 19 5.2.1 Qualified Personnel... 20 5.2.2 Alterations and Modifications... 20 5.2.3 Fundamental Safety Measures for Normal Operation... 21 5.2.4 Operator Duty of Care... 21 5.3 Employee Obligations... 22 5.4 Maintenance Work... 23-4 -
5.4.1 Secure Main Switch Against Getting Switched On... 24 5.4.2 Measurements on Energized Components... 24 5.4.3 Safety Rules for Working on Electrical Systems... 25 5.5 Residual Risk... 26 5.5.1 Pneumatic... 26 5.5.2 Electrical Current... 26 6 APPENDIX... 27 6.1 Service... 27-5 -
1 INTRODUCTION 1.1 Preface The Heater Controller T20 serves to control the nozzle heater hotmelt(hm) (Part No. DH9230 / DH9240) of P-Dot and P-Jet micro dispensing valves by LIQUIDYN. These instructions help you to promptly commission the heater controller, thus only the basic features are explained in detail. For more complex settings, please refer to the enclosed operating instructions by the manufacturer Panasonic. 1.2 Scope of Delivery The Part-Number TR1230 contains the following: Figure Description - Heater Controller T20 - IEC power connector - 6 -
2 TECHNICAL DESCRIPTION 2.1 Setup Front side: Rear side: Alarm (see Chapter 2.3) Power 230 V AC IEC power connector Operating Panel (see Chapter 4) Cable Connection for the nozzle heater cable Fuse 1 A/T - 7 -
2.2 Technical Data Designation Gehäuse Dimensions housing Weight Power supply Maximum power consumption Input Output Electrical connection Interface Maximum heating temperature (nozzle heater) Operation Description Aluminium 105 x 65 x 205 mm 0.9 kg 230 V AC 0.5 A 230 V 230 V IEC connector cable 5-pin socket (nozzle heater) 2-pin socket (alarm output) 180 C Operating panel (Panasonic) ATTENTION Failure to observe the technical data means that a problem free process cannot be guaranteed and damage to the device cannot be ruled out. - 8 -
2.3 Pin Assignment for the Alarm Alarm output 7-pin socket, external view Pin Assignment 1 Alarm output 1 2 nc (not connected) 3 nc (not connected) 4 nc (not connected) 5 nc (not connected) 6 Alarm output 2 7 nc (not connected) NOTICE Furthermore the heater controller is equipped with an alarm output which switches (opens) a potential free contact upon a pre-set control deviation and thus transmits an alarm signal to a higher-level controller. - 9 -
3 COMMISSIONING 3.1 Prerequisites For operation of the heater controller the following infrastructure is necessary: Power Supply: Use the enclosed IEC power supply cable with 230V AC. Heater Element: The Heater Controller T20 is compatible with the following heaters: - LIQUIDYN Nozzle Heater Hotmelt(HM) for tube connection; Part-No. DH9230 - LIQUIDYN Nozzle Heater Hotmelt(HM) with 10ccm reservoir; Part-No. DH9240 ATTENTION Upon failure to observe these instructions, a flawless operation of the micro dispensing valve cannot be guaranteed. ATTENTION Only use the above mentioned LIQUIDYN heaters. Upon use of different heaters a flawless operation cannot be guaranteed and the warranty is voided. 3.2 Installation How to proceed: 1. Connect the heater controller with the enclosed IEC power supply cable. (230 V AC / 0.5 A) 2. Connect the heater with the heater controller (5-pin Tuchel connector). 3. After connection to the power supply the controller conducts a self-test which takes approximately 3 seconds. The actual value display indicates the sensor identifications and temperature unit. The set point display shows the upper limit of the measuring range. During the self-test all outputs and control displays are switched off. The controlling process starts only after the test is finished. The actual value and the set point value are indicated. - 10 -
4 Operation Introduction (Basic Features) The T20 is equipped with a temperature display for actual values and set point values. The set point value can be pre-set within a range from 0 C to +180 C max. Furthermore the heater controller is equipped with an alarm output which switches (opens) a potential free contact upon a pre-set control deviation and thus transmits an alarm signal to a higher-level controller. The controller offers an automated self-optimisation which enables adaptation of the step response to the corresponding external conditions. The control behaviour corresponds to that of a PID Controller. 4.1 Operating Panel 4.1.1 Navigation Keys Display (see Chapter 3.1.2) up arrow-key: down arrow-key: MODE key: OUT/OFF key: Increases the numerical value. Decreases the numerical value. Switches between the features and saves the set point value. Switches the temperature controller on/off. (press and hold for 3 seconds) - 11 -
4.1.2 Display Set point value display (PV): Actual value display (SV): Control display SV1: Control display SV2: Control display Tx/Rx: Control display AT: Control display OUT1: Control display OUT2: Control display A1: Control display EVT: The actual value is shown in Red. (PV = process value) The set point value is shown in Green. (SV = set value). The display lights up Green when the actual value (SV) is indicated. Not connected. With controller types that include a communication feature the display lights up Yellow during data transmission. This display lights up Yellow during selfoptimisation or during auto-reset (AT = autotuning). This display lights up Green when the control output OUT1 or the heater power output is activated. (With a DC output this display lights up in an interval of 0.25 s.) When the output OUT2 is activated, this display lights up Yellow. When the alarm output A1 is activated this display lights up Red. When the Transmission Output (Output A2 or heater power alarm output) is activated this display lights up Red (EVT = event). - 12 -
4.2 Navigation Menu / Settings The temperature controller is factory pre-set. You merely have to pre-set the set point value. Furthermore these operating instructions describe the self-optimisation and the alarm setting. For further settings refer to the enclosed instructions by Panasonic. 4.2.1 Splash Screen To switch off the temperature controller proceed as follows below: Flow Chart Note Off Status Press the OUT/OFF-key longer (1-2 Sec.) to switch the temperature controller on or off. Splash screen (Actual/set point value display) - 13 -
4.2.2 Setting Setpoint Value With the set point value the temperature to which the nozzle heater should be warmed is set. Flow Chart Note Splash Screen (Actual/setpoint value display) Press the MODE key once. Menue item Setpoint value temperature and Set the desired value using the up arrow and down arrow keys and confirm with MODE. Splash Screen (Actual/setpoint value display) - 14 -
4.2.3 Self-Optimisation During self-optimisation (Auto-Tuning) or Offset-correction (Auto-Reset) the P-, I- and D-values are automatically re-set and adapted to the corresponding external conditions (e.g. room and outside temperature). Flow Chart Note Splash Screen (Actual/set point value display) + Simultaneously press the Up arrow and MODE-keys. Main menue Select self-optimisation with the Up arrow-key. Menue item Auto tuning Confirm with MODE. Now self-optimisation starts, during the process the AT control display flashes. - 15 -
4.2.4 Setting the Alarm Signal The temperature value which triggers the alarm signal is a relative value in relation to the set point value (the control display A1 flashed Red). The following Section describes how to set the regulation deviation value starting from the set point value. Flow Chart Note Splash screen (Actual/set point value) + Simultaneously press the Up arrow- and MODE-keys. Main menue Keep on pressing the MODEkey until A1 appears on the display. Menue item Alarm value and Pressing the up arrow or down arrow-key longer activates the fast-forward mode. Confirm with MODE. Splash screen (Actual/set point value) - 16 -
5 SAFETY 5.1 Intended Use Intended Use General Regulations The controller is for indoor use only. Do not use micro dispensing systen in explosive atmosphere or with explosive materials. 5.1.1 Ambient Conditions Observe the following ambient conditions: Environment Operating Temperature Humidity Ambient Conditions 0 C to 40 C. Do not expose controller to direct heat sources! 10 % to 80 %. Keep dry! Storage Temperature -25 C to 60 C IP-Protection Class IP40-17 -
5.1.2 Use Contrary to Intended Purpose The manufacturer shall accept no claims whatsoever if the device is used for any other than the intended purpose. Use contrary to intended purpose includes: Operation in an environment which does not comply with the specified protection class and/or with the hygiene regulations defined by the customer product. Operation in explosive atmosphere The protection offered by the device can be impaired by the use of spare parts not manufactured or authorised by LIQUIDYN. Use of explosive substances for dispensing and cleaning. Dispensing materials that do not meet the requirements specified in this documentation and that were defined during the acceptance prodedure. Non-compliance with the information provided in Chapter 5.1.3 Avoiding Material Damage. 5.1.3 Avoiding Material Damage To avoid damage to the controller: Operate heaters (optional) within the approved temperature range only. (max. appoved temperature is 90 C). Only use heaters that are distributed by LIQUIDYN specifically for this micro dispensing valve. Adhere to the specific maintenance intervals. Do not subject valve needle to force, knocks or impact. Avoiding long standstill periods with the system switched on. Do not operate controller in dry condition (i.e. without dispensing material) - 18 -
5.2 Duties of Operator PLEASE NOTE The operating company must ensure compliance with the following requirements. The manufacturer will accept no claims whatsoever if these requirements are not complied with. Operation of the Controller: The controller must only be operated when in good working order. The controller may only be operated under the specific operating conditions (see Chapter 5.1). The controller must may only be operated when all safety devices and safety components are installed correctly and fully functional. Controller Faults: In the event of fault in the power supply and/or damage to the electrical equipment, the controller must be switched off immediately and secured to prevent it being switched on again. Disconnect the controller from the pneumatic supply. All faults and damages indicated by the system or determined in any other way must be rectified immediately. Persons and Personnel: Unchecked access of unauthorised persons to the safety area of the controller (even when the machine is stationary) is prohibited. Persons who are under the influence of alcohol, other drugs or medication, which impair their reactions, must not operate or maintain the controller. All persons entrusted with the installation, maintenance and operation of this controller must have read and understood the operating instructions beforehand and must be aware of the potential risks associated with the use of the controller. - 19 -
5.2.1 Qualified Personnel Qualified personnel are persons who, on account of their training experience instruction as well as their knowledge of applicable standards stipulations accident prevention regulations operating conditions have been authorised by the person responsible for the safety of the controller to execute the required tasks and who are able to identify and avoid possible hazzards. PLEASE NOTE For the definition of technical personnel, see VDE 0 105 or IEC 364 which also governs the prohibited use of unqualified persons. Knowledge of first aid measures as well as of the local rescue services is additionally required. 5.2.2 Alterations and Modifications ATTENTION Unauthorized alterations and modifications to the controller are prohibited for safety reasons. The manufacturer excludes any liability for damages resulting therefrom. Unauthorized alterations and modifications will furthermore lead to a complete loss of any warranty claims. - 20 -
5.2.3 Fundamental Safety Measures for Normal Operation The controller may only be operated by authorised persons who are specially trained for this purpose. They must be familiar with and able to work in accordance with the operating instructions! Before switching on the controller check and make sure that there are only authorised persons in the working area of the controller. Before starting production, check the controller for visible damage and make sure that it is operated only when in perfect working order! Any defects found must be reported immediately! Rectify any defects immediately! Before starting production, remove all material/objects that are not required for production from the working area of the controller! Before starting production, check and make sure that all safety devices are fully functional! 5.2.4 Operator Duty of Care In particular, the operator must ensure that: the provisions specified under Chapter 5.1 Intended Use are adhered to. all safety labels remain attached to the controller and in a legible state. This version of the controller is only used for the intended application. - 21 -
5.3 Employee Obligations This section is only valid for Germany. For completeness, it is also in the translation. The obligations of the employees are as stated in regulation 15 section 2 of the labour protection laws, which covers employee obligations in protection law, and subsequently formulated in section 1: Within the framework of paragraph 1, the employees must use the following as designated in particular machines, equipment, tools, working materials, transportation equipment supplies, safety installations and provided personal protective devices intended. FIRE HAZARD Upon entering and leaving your working area watch out for burnt smell or smoke development. In case of burnt smell or smoke development report fire immediately and get help! - The material to be processed can cause fire. Follow the manufacturer s Material Safety Data Sheets and the instructions contained therein. - Switchgear cabinet - although the risk of fire is very low for the switchgear cabinet it cannot be excluced even with the best maintenance. - 22 -
5.4 Maintenance Work DANGER ELECTRIC SHOCK! - Disconnect the controller from the power supply before beginning work on electrical or electronic system components or opening the switchgear cabinet. - Disconnect mains power plug. System is safely isolated from the power supply. Check safe isolation from the power supply with suitable measuring instruments. Only perform maintenance work on the controller that is safely isolated from the power supply! - Wear safety footwaer! DANGER THROUGH PNEUMATIC PRESSURE Before beginning maintenance work switch off pneumatic compressed air supply before disconnecting the controller from the pneumatic connections. Technical Qualifications and Requirements Maintenance work requires that the personnel carrying out the work has a high level of technical knowledge and reliability. The person entrusted with the maintenance work must have the appropriate technical knowledge. The basic qualifications must at least correspond to those of a skilled worker in a technical profession. Steps must be taken to ensure that the authorised person can safely and reliably carry out maintenance work on devices and equipment used in automation engineering. The maintenance work must be carried out such that the system or machine is restored to its original operating condition. Safety Devices Safety devices may only be disabled by technical personnel if absolutely necessary as part of the maintenance work. The safety devices must be placed into operation again on completion of the maintenance work. Check the safety devices to ensure they are fully functional. Safety Components Safety components such as limit switches and other control components must not be disabled. If, however, it is necessary to disable such safety components for maintenance purposes, they must be reliably placed into operation again on completion of the maintenance work. Check the safety components to ensure they are fully functional. Cleanliness When maintaining the controller mind a clean and tidy workplace. - 23 -
5.4.1 Secure Main Switch Against Getting Switched On Introduction Secure main switch against getting switched on with a lock. Thus, Restart of machine by unauthorized persons is prevented. When main switch has to be switched on When main switch has to be switched on for maintenance work, then make sure, that in this time nobody can be harmed. After completion of maintenance work, secure main switch against getting switched on! 5.4.2 Measurements on Energized Components Introduction If measurements on energized components have to be done, then work with another person. In emergency situation this person can switch off the machine and pull the plug. If necessary this person can call for help and can help you. Requirements on tool Only use voltage isolated tools. Tool must be regularly checked. - 24 -
5.4.3 Safety Rules for Working on Electrical Systems Safety Rule Rule 1 Rule 2 Rule 3 Rule 4 Rule 5 Procedure Before starting work: Shut down power supply. Secure to prevent switch-on. Prevent the system from being unintentionally switched on again by: Switching off the fuse and carrying it with you until maintenance work is finished. Securing the master switch with a padlock. If the power plug was disconnected, do not leave the plug lying next to the socket. Place the plug within eyeshot. Check safe isolation from power supply. Before starting work: Check safe isolation from the power supply with a two-pole voltage tester. Important note: Single-pole voltage testers do not provide the same level of safety. Earthing and short-circuiting. Necessary only for voltages of more than 1000 volt. Earthing must be carried out first. EARTH must then be connected to the active short-circuiting components. Cover or screen off adjacent live components. Voltage below 1000 V: Cover with insulated cloths, tubing, moulded parts. Voltage above 1000 V: Cordon off live components with warning signs and ropes. Wear protective equipment such as safety helmet with face visor and high-insulation gloves. - 25 -
5.5 Residual Risk 5.5.1 Pneumatic CAUTION! Spiraling pressure hoses can cause injury. Pneumatic tubes are in operation under high pressure. Measures for Maintenance Work: Pressurized modules and pressure tubes have to be made pressure-less before you start with maintenance or repair. After end of work on pneumatic open pressure-supply slowly and pay attention to sound of exhausting pressure air. Demands on Staff Only personnel with appropriate expertise may work on pneumatic devices. 5.5.2 Electrical Current DANGER ELECTRIC SHOCK Defective electrical components may be live (under voltage). Danger to life on contact with these components. Measures for Defective Electronical Equipment: Defects found on electrical components and operating equipment must be rectified immediately. The system must be taken out of operation and secured to prevent it being switched on again for as long as defects have not been rectified. The system must not be placed in operation before defects have been reliably rectified. Check that all electrical connections are made and secure before starting up the machine. Corresponding to their design, the electrical connections may have to be screwed down or locked. - 26 -
6 APPENDIX 6.1 Service If you cannot correct the problem yourself then please contact our technical support. Please have the following information ready: Controller Serial-Number Description of the problem Previous instances and process specific information The service department can be reached under the following number: +49 8104 90944-0 Monday to Friday from 9:00 12:00 and 14:00 17:00-27 -