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SERVICE MANUAL

1. 11 Pressurized Adhesive Hose 12 Adhesive Filter l1 13 Manual Shut off Valve 12 14 Regulator Gauge Tank Pressure ma fi 15 Relief Tank Pressure 16 Pressure Tank Assembly 59 856_0412_0_ 12 01 10 SIX CONTROL STAGES DURING APPLICATION STAGE THREE The START time delay circuit completes its timing cycle and the Air Electric Solenoid is activated The Applicator Valve opens and the adhesive passes to the finger ports of the Applica tor Head The wood finger joint has just moved into the Applicator Head and STAGE TWO The moving piece of wood now passes the sensor and the red beam The applica tor valve is still closed The time delay circuit begins timing out the interval set with the START adjustment 822 Sensor Blocked STAGE ONE A piece of wood moving on the lug chain away from the cutter head approaches the sensor 822 Sensor Unobstructed LED lighted LED off the pressurized adhesive is ace Valve Closed 268 Valve Closed forced through the finger START Timer Running ports to the wood surfaces The START adjustment synchronizes this entire operation so that the Appli cator Valve opens atthe desired START position on the wood not earlier and not later 822 Sensor Blocked LED off 268 Valve Open START Timer Complete The Air Electric Solenoid Valve shifts causing the air in
2. be approximately zero to 200 The number can e vary with wood species but a typical reading would be somewhere close to 45 2 Place a typical block or board that you will be running with a normal amount of glue for your application two inches in front of the detection lens The glued face should be parallel to the detection lens This value should be approximately 300 to 1000 The number will vary greatly with glue type and manufacture Most wood species and glue will be tested prior to system shipment to assure the system will work for your application Once you have completed this step take the average of the two numerical values determined in the steps above and set your reject threshold to this averaged value The system will now reject any board or block whose glue value drops below this determined value Your may want to get a more precise value prior to actually running the machine This may be done by taking a typical board or block and applying a full coating of glue to the 1st quarter of the board proceed to apply a 3 4 coating of glue to the 2nd quarter 1 2 coating of glue to the 3rd quarter and 1 4 coating to the 4th quarter Slowly move the piece across the face of the lens two inches in front form the 1st quarter all the way through the 4th quarter of the board by observing the numerical values you can determine the values given for the different amounts of glue that are directly in front or the lens When you ha
3. Ue os T NTER Key ri i ON 856 0412 0 12 OPERATOR INTERFACE FEATURES BASIC FUNCTIONS AND ADJUSTMENTS Service Information Press the F4 function key second row right side of the keypad to access the Service Information Screen On some screens the F4 key may be assigned to another purpose Return to the main menu as described on Main Menu in this Manual and view the F1 F4 function key assignments then press F4 This screen lists our company name address phone number and PLC software version number Please have the PLC software version readily available when calling for service help or information so that we will know the configuration of your PLC control system If for some reason your operator interface panel is inoperative you can obtain the software version number from the identification labels place on each PLC and HMI panel or on the System nameplate You can reach a service technician by phone at 831 642 6565 or by fax at 831 642 6563 In addition you may e mail us at sales apquip com F4 Key c T Ti i J w EA 856_0412 0_ 12 01 10 15 OPERATOR INTERFACE FEATURES PROGRAM MING ASSISTANCE If you have difficulties or problems with programming the settings parameters or operation of any feature of the Apquip 856 please contact Apquip Tech Help by email Sales Apquip com fax 831 642 6563 or phone 831 642 6565 If possible take a phone out to the 856 Control panel location and call u
4. 2013 SERVICE MANUAL 856 CONTROL PANEL me 7 1 e p B 28 ADHESIVE APPLICATOR SYSTEM The following Assembly Drawings are to be used in conjunction with this Manual Included DUOUOUOUOUWOUKOUVOUKUOUOWUD D DDD Drawing Number 121 221 268 268 Rebuild 375 592 582 582 07 587 600 600B 621 627 816 817 820 856FM 856FM IO 856FM 32 Description BRACKET ASSEMBLY APPLICATOR HEAD EDGE GLUE BRACKET ASSEMBLY ADHESIVE VALVE ASSEMBLY ADHESIVE VALVE REBUILD INSTRUCTIONS BRACKET ASSEMBLY SOLENOID VALVE ASSEMBLY LARGE PRESSURE TANK ASSEMBLY FLUSH TANK ASSEMBLY ADHESIVE ACCUMULATOR ADHESIVE FILTER ASSEMBLY LARGE ADHESIVE REGULATOR ASSEMBLY HIGH FLOW FINGERJOINT SYSTEM DIAGRAM NOTES EDGE GLUE SYSTEM DIAGRAM NOTES SOLENOID VALVE ASSEMBLY CONTROL PANEL ASSEMBLY INPUT OUTPUT WIRING DIAGRAM CONTROL PANELWIRING DIAGRAM APPLICATOR HEAD FINGERJOINT Additional Drawings 856_0412_0_ 12 01 10 2013 SERVICE MANUAL 856 CONTROL PANEL I x l 4 g 2 Hi ADHESIVE APPLICATOR SYSTEM CONTENTS OVERVIEW ceseeacitececa rte tideresnanpunsskudie pksamauenekeleewecmmcucesehasss AEAEE 1 ELECTRICAL INSTALLATION castes eta Se asa ahecu thea ueaininn a EA iah 2 PNEUMATIC INSTALLATION scsbesanhavaveantnentascecsuaistsutebady acl sue a a TEETE AA 3 SENSOR INSTALLATION oireeseesi aea a ARa aaa AE a a a E ERER RAE 4 CONTROL ENCLOSURE FEATURES isorinis
5. OPERATOR INTERFACE FEATURES ADDITIONAL FEATURES TIMED VALVE PURGE To access the Valve Purge parameters from the Main Menu press F4 to display the Service Screen Press the DN arrow to move down to the Chain Break Delay parameter screen the press the DN arrow to move down to the Valve Purge parameter screen Use the DN arrow to position the cursor on the parameter you wish to change then key in the new value and press enter to store the change Parameters for the Valve Purge Function Name Units Initial Value Purge Delay 1 x 1 min 1 min Purge Length 1 x 100 msec 100 msec Cycles 0 99 0 operations Purge Delay is the amount of time that will pass after the last gluing operation before the Purge Function will open the Glue Valve to purge the adhesive It is also the time betwen purge cycles Set the Purge Delay time short enough to prevent the adhesive from curing in the Adhesive Valve and Applicator Purge Length is the amount of time the Adhesive Valve will open to purge adhesive from the valve Set the Purge Length time long enough to move the adhesive through the application system Cycles is the number of purge operations ns ATE FET you wish to perform before the purge func tion should stop A setting of 0 will place the Purge Function in standby P lease contact your A pquip representative with questions regarding T imed P urge T A i 356_0412 0 12 01 10 21 OPERATOR INTERFACE FEATURES O
6. The Error Lamp will light immediately when both Frame Sensors are active and the either Luminescence Sensor reading for Glue Amount is lower than the it s respective Reject Threshold set on the Glue Detect Screen The lamp will extinguish when one of the Frame Sensors becomes inactive The comparrison between Reject Threshold and Glue Amountis only made while both Frame Sensors are active Press K2 to view the Glue Detect Screen and monitor the Glue Amount and Reject Threshold setting If the Error Lamp does not activate refer to Troubleshooting PLC Outputs in this Manual to check wiring and trace the Error Lamp voltage path CHECK PLC MARKERVALVE OUTPUT The Marker Valve is active after the Marker Delay setting has expired and for the duration of the Marker On Time setting Set a Marker Delay Time of 50 for 500 ms and a Marker On Time of 100 for 1000ms To force an error in Glue Detection set the one of the Glue Detect Reject Thresholds to 1000 or unplug one of the Luminescence Sensors Block both Frame Sensors momentarily and observe that the Error Lamp is lighted Unblock both Frame Sensors and observe the Marker Valve for activation after a 1 2 second delay Observe the Marker Valve On Time of 1 second If the Marker Valve does not activate refer to Troubleshooting PLC Outputs in this Manual to check wiring and trace the Marker Valve voltage path 92 856_0412_0_ 12 01 10 APPLICATOR VALVE ASSEM BLY See Assembly Drawing 268 T
7. i Z 4 m J 7r 2 856_0412 0 12 01 OPERATOR INTERFACE FEATURES BASIC FUNCTIONS AND ADJUSTMENTS Glue Start Delay continues This adhesive pattern setting will remain constant as long as your chain conveyor speed remains constant If the stock material size is changed and the feed speed increases or decreases you will have to adjust the settings accordingly Itis a good idea to write down the appropriate settings once they have been established so that every material size will have a predetermined setting for quick changeovers Please note that the glue spread should be adjusted so that the glue pattern is 1 16 to 3 16 away from both the leading and trailing edge to eliminate excessive squeeze out You will have to adjust this distance according to your glue type viscosity press pressure and jointtype Typically you should start with the adjustment setting so that pattern is 1 16 from the edges and adjust the pattern if necessary after viewing the finished boards from the press You should see only a small few small dots of glue squeeze out on either end The running board block count is located on the 4 line of this screen This is to let you know the exact number of boards blocks that have passed the glue applicator For directions on how to reset this counter to zero please refer to Block Counter Resetin this Manual Menu Title Numerical Value for Glue Start Board Count Title Numerical Value for B
8. Enter 2 for the board Program for board 4 on the Enter Sides to Glue Screen Glue will be on the Right Side Board 4 of 6 is displayed on the Enter Sides to Glue screen The cursor will blink at the Side to Glue value The screen may display 0 or or any previously programmed value Press numeral 2 and then press enter to store the new value for Sides to Glue for board 4 Press F4 lt NEXT gt to move to the next board in the series NOTE It is very important that you press enter after every pattern value change in order for the PLC to accept the new value If you do not press enter your change will not be stored and the pattern will remain at the previously programmed value If you make a mistake press the correct numeral key and press enter again Press F3 lt PREV gt to move to the previous board in the series Key in the correct option 0 1 2 or 3 press enter to store the correction Press F3 or F4 to move in the series to make corrections Glue Right Side of Board 4 iii Menu Title a F4Key F unction K eys F 3Key ESC Key yr A a a SCROLL DN Key Numeral K eys 3 gt ii ys NTER Keys g f 33 856 0412 O_ 12 01 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS SERIESPROGRAM EXAMPLE Enter Sides to Glue continues 7 Enter 2 for the board Program for board 5 on the Enter Sides to Glue Screen Glue will be on the Right Side Board
9. In addition there are cases such as the dye valve where you may want to leave the valve on slightly longer to make either a larger mark or even stripe the entire length of the board An initial numerical setting of 10 will usually be a good starting point You can change this setting while in operation when adjustment is needed Typically this setting should always be less than the Marker Start Delay Time as the duration of this output should not be longer than the time it takes for the two boards to move by the Detection point If longer the Marker would affect the next board on the lug chain Menu Title Marker Start Delay Marker On Time K 3 Key F4 Key F unction kos is Y ESC Key 7 F A ee SCROLL DN Key Numeral K eys r RE Y7 NTER Key oo pal Me 856 0412 0_ 12 SYSTEM COMPONENT IDENTIFICATION 1 Control Enclosure 4 On Air Control Line 2 Coalescer Filter Regulator 5 Framing Sensors Assembly 6 Adhesive Sensor 3 Off Air Control Line 7 Applicator Head weed a 8 Wood Sensor z H zl irr 9 Adhesive Valve Assembly Hoo le 10 Bracket X Y Adjustment Adhesive T Valve Mount
10. Verify your board series program using the F3 and F4 buttons before exiting this screen Press F1 to move up lt UP gt one menu level to the Program Series Data Screen NOTE It is very important that you press enter after every pattern value change in order for the PLC to accept the new value If you do not press enter your change will not be stored and the pattern will remain at the previously programmed value r n STAT a e e Menu Title FlKey F3Key FA Key ESC Key a fa A ee a a SCROLL DN Key Numeral K eys al wf NTER Key T 856 0412 0O_ 12 01 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS SERIES PROGRAM EXAMPLE Program Series Data Let s program a series of 6 boards gluing the right side with board 1 dry 1 Proceed to the Series Status Screen Press K4 to move to the Series Status screen The screen will display the series program that was last used Press F4 to move down lt DOW N gt to the Program Series Data screen The cursor will blink on the current Total Pierces value Press numeral 6 and then press enter to store the new value for Total Pieces 2 Enter 6 as the Total Pieces value on the Program Series Data Screen Press F4 to move down lt DOW N gt to the Enter Sides to Glue Screen NOTE Itis very important that you press enter after every pattern value change in order for the PLC to accept the new value If you do not press enter your change w
11. 1 Gry Wht wire 86 856_0412_0_ 12 01 10 TROUBLESHOOTING TROUBLESHOOTING BOARD SKIP SERIES FUNCTION PLACE DOOR SAFETY SWITCH TO OVERRIDE POWER SWITCH TO ON With Line Voltage at terminals 1 and 2 pull the Door Safety Switch plunger to the override Pull the plunger button with insulated pliers or pull the 6 screw attached to the plunger outward about 1 4 The override position closes the Door Safety Switch and allows the Enclosure to operate with the Door open Move the ON OFF Switch to ON The Power Indicator Lamp will light REFER TO DRAWING 856 AND 856 32 FOR COMPONENT AND TERMINAL IDENTIFICATION CHECK SERIES STATUS Review the Optional Program Functions Section of this Manual with regards to Series Operation Using the Series Status Screen note the side of the board which is to have the adhe sive application Run the boards through the System slow enough to check that the adhesive is properly applied with regards to the Series Status Screen If the adhesive is applied properly then reprogram the Series if necessary to achieve the desired lay up pattern If the adhesive is not applied with regards to the Series Status Screen then check the PLC Outputs per Troubleshooting PLC Outputs in this Manual to verify Air Valve connections and voltage paths 856_0412_0_ 12 01 10 87 TROUBLESHOOTING TROUBLESHOOTING GLUE DETECT FUNCTION PLACE DOOR SAFETY SWITCH TO OVERRIDE POWER SWITCH TO ON With Line Volta
12. Confirmation Screen This screen gives you a chance to change your mind after you have pressed Reset on the Glue Metering Per Piece Screen F2 Press F2 to reset the accumulated glue metering Data and usage history F4 Press F4 to return to the Glue Metering Per Piece Screen without resetting the usage history OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS GLUE METERING Calibration Screen This screen is divided into two sections old on the left and new on the right The current KFT and meter Glue Volume in ml are shown to the left half of the screen The proposed KFT based on the new Glue Volume entered by the operator is shown to the right KFT K Factor ml Glue Volume F1 F2 F3 F4 This is the multiplication factor that is determined by the last calibration of the meter It is found on the meter calibration document Meter Press F1 to move to the MainMenu and end the Calibration process Press F2 to enter the Calibration mode Test blinks in calibrate mode This is the volume of Adhesive as measured by the Glue Press F3 to move up to the Glue Metering Input screen and end the Cali bration process Press F4 to accept the proposed change to the KFT and end the Calibra tion process Calibration Procedure Material Required A Graduated Beaker of sufficient vol ume to accurately measure a dis pensed glue sample Press F2 to start the Calibration pr
13. FUNCTIONS SERIESPROGRAM EXAMPLE Enter Sides to Glue continues 13 Observe the program as boards are sent through the system The screen below shows that the next board to pass through is board 5 in a series of 6 boards and glue will be applied to the right side of the board As the fourth piece passes the board sensor is activated and glue is applied to the right side of the board The board count will increment Glue Right Side of Board 4 of 6 i 7 J a M enu ____ Title F2 Key F4 Key Function K eys ESC Key a fa A a a SCROLL DN Key N umeral K eys 4 a wf NTER Key lt a 856_0412 _0_ 12 01 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS SERIESPROGRAM EXAMPLE Enter Sides to Glue continues 14 Observe the program as boards are sent through the system The screen below shows that the next board to pass through is board 5 in a series of 6 boards and glue will be applied to the right side of the board As the fifth piece passes the board sensor is activated and glue is applied to the right side of the board The board count will increment Menu Title F2Key Te Glue Right Side of 3 i Li Board 5 of 6 ec EEE gt B SCROLL DN Key Numeral K eys ae oe he Y7 l NTER Key lt 856 0412 0 12 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS SERIESPROGRAM EXAMPLE Enter Sides to Glue continues 15 Observe the program as b
14. TO SENSOR Connect a positive meter lead to lower I O Terminal 10 and the negative lead to lower I O Terminal 2 where the Sensor wires are connected About 24VDC should appear across the terminals If the proper power supply voltage does not appear then check the upper I O Terminals for 24VDC and the DC Power Supply output terminals as well Check wiring of the following points DC Power Supply V Wht Blu wire DC DC Power Supply V Red Blu wire DC 24 Upper I O Terminal 3 No wire DC Jumpered to Terminal 4 Wht Grn wire Upper I O Terminal 10 Red Blu wire DC 24 Lower I O Terminal 2 Blu wire DC Lower I O Terminal 10 Brn wire DC 24 CHECK OUTPUT SIGNAL FROM SENSOR Connect the negative meter lead to Upper I O Terminal 3 and the positive meter lead to Lower I O Terminal 2 Have an assistant activate the sensor by placing Glue in front of the Sensor When the Sensor is blocked the voltage will be about OVDC When the Sensor is unblocked the voltage will be VDC or 20VDC to 24VDC If not check wiring of the following points When the Sensor is blocked if Input 10 5 indicator on the PLC does not go ON check wiring of the following points Lower I O Terminal 2 Blk Upper I O Terminal 2 Bik Yel PLC Terminal 10 5 BIk Yel NOTE The detection depth of the Level Sensor is adjusted to detect the Glue beyond the inner surface of the Intermediate Tank The signals work as follows The Black Output wire will be atOVDC when the S
15. aroe aea aa eaaa a A ATE 5 OPERATORINTERFACE FEATURES sia stcjssccsa sewers carapericanidwor a aain iaa E R E 7 Main MENU sissen a a EE aa aaa aaa A 7 BASIC FUNCTIONS AND ADJUSTMENTS orsiriiisinsiiiisiekiiin enana aa aaeoa i aiana 8 Glue Start Delay sieri oneee iinan TAARE ANEA E EKA EAEAN R EEO EERENS 8 Glue Length Delay areeni ninni aiiai iia ENAERE AEEA ARNESEN 10 Bl ck Counter ROSCOE savska nipa a a E A EERE 12 Flush SOWIE hierin a a an aaa N deh E a A a aE ia 13 Service Infor MMM ODD sssusa E a a a e es 15 PROGRAMMING ASSISTAING Eo icusiec sour sencelareratascuannadvareteuniiaaNlas inai ae aA 16 ADDITIONAL PROG RAM FEAT Re Scien cpcnvuratunspsantaananvasdatvadsuneasvenlanauddanalinacbdcecaians 17 REMOTE FLUSH OP PURGE easevacsirhaasepuresancitcseervacsanixheiieicbualusalicbodtiehes a seas 17 OID LE VE MONITOR vcastenscensntenserumsvau ceeds sauleduesuaeaseddentugan aa a i 18 CHAIN BREAK DELAY cisarina a iad Ai a E EE ERRA 19 RESUME RAMP UP DELAY sseseicisiernes i i a e 20 TIMED VALVE PURGE a i at a aia ate eiei sil eee hai laden hse ATE REAR 21 OPTIONAL PROGRAM FUNCTIONS sys euscstaidenianenseddaprenodanarndacsuniiuaasabadeldendaanesuns 22 SERIES BOARD SKIP OPERATION sccusssecerescndccntcudiccaaacnr audneleadaindaaBavecanssnns 22 Setup and Installa ON act cntecetecersiscis caida iaaceine Seaidyahcwetley cakes dead sed KENETET E 23 Series Status nersini ekani oia e yea E E Ea copa slo ned aAa pcan a E E A a aa ea 24 Program Series Data srsiisse
16. at the previously programmed value r r SIRAT 1 Total Pieces in Series Menu Title PERE F4 Key Function K eys ESC Key 7 A ee a 2 SCROLL DN Key Numeral K eys al H d NTER Key T 856 0412 0O_ 12 01 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS SERIES OPERATION Enter Sides to Glue The Enter Sides to Glue screen is used to enter or change the Side to Glue value for each board in th eseries The screen will prompt you to enter the desired board program The cursor will be flashing a zero if the unit has never been programmed before for the first board of your series The number zero signifies that you don t want glue on either edge This number can be replaced with either 1 2 or 3 by keying in the appropriate number using the numeral keys and pressing enter The four choices available are 0 1 2 and 3 The numbers signify the following 0 no glue on either side 1 glue on the left side only 2 glue on the right side only 3 glue on both sides Menu _____ Title Side to Glue Value for Board 1of4 T das g gt P SCROLL DN Key Numeral K eys _ CU E NTER Key lt a 856_0412 0 12 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS SERIESOPERATION Enter Sides to Glue continues Press F3 to move to the previous lt PREV gt board in the series Press F4 to move to the next lt NEXT gt board in the series
17. blocked the voltage will be VDC If this is not so check wiring at the following points Repeat this test with PLC Output Terminals Q0 0 if applicable to your 856 System OVDC wiring Upper I O Terminal 6 Wht Grn wire x2 Upper I O Terminal 4 Wht Grn wire x2 Upper I O Terminal 13 Wht Grn wire Wht Blu wire Upper I O Terminal 18 Wht Grn wire x2 Upper I O Terminal 22 Wht Grn wire Upper I O Terminal 12 Wht Blu wire x2 Upper I O Terminal 20 Wht Blu wire x2 Upper I O Terminal 28 Wht Blu wire Air Electric Solenoid lead May be more than one depending on your 856 System 84 856_0412_0_ 12 01 10 TROUBLESHOOTING TROUBLESHOOTING PLC OUTPUTS CONTINUES PLACE DOOR SAFETY SWITCH TO OVERRIDE POWER SWITCH TO ON With Line Voltage at terminals 1 and 2 pull the Door Safety Switch plunger to the override Pull the plunger button with insulated pliers or pull the 6 screw attached to the plunger outward about 1 4 The override position closes the Door Safety Switch and allows the Enclosure to operate with the Door open Move the ON OFF Switch to ON The Power Indicator Lamp will light REFER TO DRAWING 856 AND 856 32 FOR COMPONENT AND TERMINAL IDENTIFICATION CHECK PLC VDC OUTPUT SIGNAL S continues Outputs used are determined by your system configuration Valve Left Output PLC Terminal Q0 0 Upper I O Terminal 25 Lower I O Terminal 25 Valve Right Output PLC Terminal Q0 1 Upper I O Terminal 26 Lower I O
18. cursor will be located on the numerical value for the Marker Start Delay This value will set the time delay between the fault detection and the Marker output activation Set the value from 0 instantaneous to 999 The value has an increment of 10 milliseconds Therefore a value of one represents 10 milliseconds and a value of 999 represents 9 990 milliseconds which is almost ten seconds 1 ms equals 1 1000 of asecond i SATI iii Menu Marker Start Title Delay K3Key Marker On Time F4 Key F unction Kes ir ESC Key 7 a g A j 50 a gt B SCROLL DN Key Numeral K eys e E NTER Key 856_0412 0 12 OPTIONAL FUNCTIONS GLUE METERING Board Marker continues The duration that the Board Marker is energized can be programmed by moving the flashing cursor to the On Time field Press the DN arrow key to scroll to the second line item On Time in the Board Marker Screen Set the value from 0 instantaneous to 999 The value has an increment of 10 milliseconds Therefore a value of one represents 10 milliseconds and a value of 999 represents 9 990 milliseconds which is almost ten seconds 1 ms equals 1 1000 of asecond The minute increments allow the outputs on time to be precisely controlled It may seem logical that as short an on time as possible would be most desirable but often times an output device will require different on time depending on how fast it responds to a signal
19. it takes for the conveyor to coast down to a stop when the power is removed This will ensure that there is glue on the board up to the time the chain has stopped Scns e j 1 Should the Chain break after a board has activated the sensor but before the glue has started Gluing will begin at the completion of the Start Time and gluing will end at the completition of the Chain Break Delay Time as the conveyor is stopped Fia 2 Should the Chain break while gluing is in progress Gluing will continue until the end of the Chain Break Delay Time as the con veyor is stopped gt a 3 Should the Chain break while the run Length is in progress Gluing will continue until the end of the Length Time or Chain Break Delay Time whichever occurs first 5 q a i E 856_0412 O_ 12 01 10 19 OPERATOR INTERFACE FEATURES ADDITIONAL FEATURES RESUME RAM P UP DELAY The Resume Ramp Up Delay is used to continue applying glue as the chain signal is activated and the conveyor begins to move Without the Resume Ramp Up Delay the board may be partially glued and unusable The Resume Ramp Up Delay allows the board to be completely glued when the Chain is started This all depends on how far the chain moves when power is removed Parameters for the Resume Ramp Up Delay Function Name Units Initial Value Chain Break Delay 10 x 10 msec 100 msec Resume Length 1 x 1 msec 1 msec Resume Length is the maximum length o
20. joint The Applicator Assembly must be repositioned slightly lower to give equal clearance above and below steel Applicator Fingers The 375 Bracket Assembly has a vertical adjustor to position the Applicator Head In this example turn the vertical adjustor knob to move the Applicator Head downward See Applicator Head Alignment Figure A in this manual for the desired alignment of the Applicator and joint JOINT E Figure 7 by a 6 ADHESIVE ON LOW ER SUR FACE AND NONE ON UPPER SUR FACES The Applicator Head is incorrectly aligned vertically to the wood finger joint The Applicator Assembly must be repositioned slightly higher to give equal clearance above and below steel Applicator Fingers Turn the Vertical Adjustor Knob to move the Applicator Head upward 7 GLUE BUILDUP ON APPLICATOR HEAD If glue appears on the side surfaces of the Applicator Head check to see thatthe Applicator Head is at 90 with respect to the wood joint 856_0412_0_ 12 01 10 AIR CONTROLS Pressurized air lines are normally used at just two points in the Apquip System 1 Air supply to pressurize the tank 2 Air supply to the Control Enclosure to operate the applicator valve This system requires a maximum of 60 PSIG of clean dry air Moisture and compres sor blowby will affect the performance of the system s spool sleeve assembly The Apquip system includes Coalescer Filter to remove normal levels of impurities Do not lubricat
21. operator interface panel has four lines of text the operator can quickly learn to operate the 856 even with limited computer knowledge The interface unit also has eight function keys enabling the operator to quickly access and change critical values using the 10 digitkeypad and scrolling arrows Asis the case with any piece of machinery it is still important that the operator take the time to thoroughly read the manual for a clear understanding of principles 856 Ver x xA The basic 856 control unitis designed to start and stop the adhesive pattern The basic 856 Version A will also provide you with a board count feature and a flush switch In addition with optional PLC programming and DIN rail mountable hardware you can easily upgrade features for your glue application needs 856 Ver x xB Programable Board Skip The 856 board skip unit was designed for edge and face lamination lines that need to control one or two gluing operations simultaneously The 856 Version B can be easily programmed through the operator interface panel so that each individual board in a series can have either both sides glued the left top side face only glued the right bottom side face only glued or neither side face glued It should be clear that this program is designed for use with only one sensor controlling the start and stop of the adhesive pattern so the pattern cannot be staggered from one side face to another 856 Ver x xC Glue Detection T
22. take 100 rotaion of the potentiometer 89 856_0412_0_ 12 01 10 TROUBLESHOOTING TROUBLESHOOTING GLUE DETECT FUNCTION CONTINUES CHECK THE FRAME SENSORS The Frame Sensors define the window of operation for the Luminescence Sensor If the Frame Sensors are adjusted improperly the joints may not be checked atall by the Luminescence Sensor The initial setup of the Frame Sensors is vertical along the centerline of the Lumines cence Sensor looking perpendicular down onto the lumber on the fingerjointer The Red beams of the Frame Sensors should be about 75 1 apart on the lumber Set the Frame Sensors then check the sensitivity of the Glue Detect Reject Threshold The Frame Sensors may be angled toward or away from each other changing the operation window of the luminescence detection A gap of 50 between the Red Beams of the Frame Sensors would give the Detection System a wider window of operation where you may receive more errors at the leading and trailing edges of the joint A gap of 2 0 would give the Detection System a smaller window where you may miss glue voids on the joint Once the Frame Sensors are set begin with a lower Glue Detect Reject Threshold where there are no detection errors Slowly increase the Reject Threshold by incre ments of 10 to the point where the system detects non existent errors Lower the RejectThreshold setting by 15 20 to eliminate the detection of non existent errors Example Start
23. the value from 0 instantaneous to 999 The value has an increment of 10 milliseconds Therefore a value of one represents 10 milliseconds and a value of 999 represents 9 990 milliseconds which is almost ten seconds 1 ms equals 1 1000 of asecond Menu Marker Start Title Delay K3Key Marker On Time F4 Key F unction Kes ir ESC Key ESC P E E gt B SCROLL DN Key Numeral K eys m4 Y7 NTER Key 856 0412 0 12 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS GLUE DETECTION Board Marker continues The Start Time and Duration that the Board Marker is energized can be programmed by moving the flashing cursor to the On Time field Press the DN arrow key to scroll to the second line item On Time in the Bad Glue Marker Screen Set the value from 0 instantaneous to 999 The value has an increment of 10 milliseconds Therefore a value of one represents 10 milliseconds and a value of 999 represents 9 990 milliseconds which is almost ten seconds 1 ms equals 1 1000 of asecond The minute increments allow the outputs on time to be precisely controlled It may seem logical that as short an on time as possible would be most desirable but often times an output device will require different on time depending on how fast it responds to a signal In addition there are cases such as the dye valve where you may want to leave the valve on slightly longer to make either a larger mark or even stripe the
24. 412_0_ 12 01 10 TROUBLESHOOTING TROUBLESHOOTING SENSING ELECTRONICS CONTINUES 2 MANUAL VALVE OPERATOR On the Enclosure Door locate the FLUSH Switch This Switch is used to place the System into Flush Operation The System is placed into Flush Operation when the FLUSH Switch is pressed and will remain in Flush Operation until the FLUSH Switch is released During the Flush Op eration the Air Electric Solenoid is activated causing the Adhesive Valve to open allowing adheisve flow through the Applicator Head Release the FLUSH Switch to terminate the Flush Operation When the Flush Opera tion is terminated the Air Electric Valve is deenergized causing the Adhesive Valve to close and shut off the adhesive flow through the Applicator Head Apquip LLC Ver x x Service 831 642 6565 5 Harris Court Bldg Q Monterey CA 93940 FT Fr F Fa KZ KF 1 2 3 A 4 2 6 lt q gt ACK 7 8 9 V 0 sHiet INS JHevp ENTER 79 856_0412_0_ 12 01 10 TROUBLESHOOTING TROUBLESHOOTING WOOD SENSOR FUNCTION PLACE DOOR SAFETY SWITCH TO OVERRIDE POWER SWITCH TO ON With Line Voltage at AC Input Terminals 2 and 3 pull the Door Safety Switch plunge
25. 5 of 6 is displayed on the Enter Sides to Glue screen The cursor will blink at the Side to Glue value The screen may display 0 or or any previously programmed value Press numeral 2 and then press enter to store the new value for Sides to Glue for board 5 Press F4 lt NEXT gt to move to the next board in the series NOTE Itis very important that you press enter after every pattern value change in order for the PLC to accept the new value If you do not press enter your change will not be stored and the pattern will remain at the previously programmed value If you make a mistake press the correct numeral key and press enter again Press F3 lt PREV gt to move to the previous board in the series Key in the correct option 0 1 2 or 3 press enter to store the correction Press F3 or F4 to move in the series to make corrections z EAT T d l Glue R ight Side of Menu FH j Board 5 Title F1Key F4Key 1 A i F 3 Key i ESC Key T g o SCROLL DN Key i l Numeral K eys 7 NTER Key g f 34 856 0412 0 12 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS SERIESPROGRAM EXAMPLE Enter Sides to Glue continues 8 Enter 2 for the board Program for board 6 on the Enter Sides to Glue Screen Glue will be on the Right Side Board 6 of 6 is displayed on the Enter Sides to Glue screen The cursor will blink at the Side to Glue value The sc
26. 50 and press ENTER This can be continued until pattern is set exactly where you want the glue to stop Menu Title Board Count Title Numerical Value for Board Count Numerical Value for Glue Start Function K eys F2 Key ESC Key SCROLL DN amp 6 gt E K Numeral K eys Fs X e i a i eye oo og E E 856 0412 0_ 12 OPERATOR INTERFACE FEATURES BASIC FUNCTIONS AND ADJUSTMENTS Glue Length Delay continues This adhesive pattern setting will remain constant as long as your chain conveyor speed remains constant If the stock material size is changed and the feed speed increases or decreases you will have to adjust the settings accordingly Itis a good idea to write down the appropriate settings once they have been established so that every material size will have a predetermined setting for quick changeovers Please note that the glue spread should be adjusted so that the glue pattern is 1 16 to 3 16 away from both the leading and trailing edge to eliminate excessive squeeze out You will have to adjust this distance according to your glue type viscosity press pressure and jointtype Typically you should start with the adjustment setting so that pattern is 1 16 from the edges and adjust the pattern if necessary after viewing the finished boards from the press You should see only a small few small dots of glue squeeze out on either end The running board block count is located on th
27. ATORVALVE OPENS LATE Decrease the numerical value of the GLUE START DELAY setting to open Applicator Valve earlier and bring the adhesive closer to the leading edge of the block 3 APPLICATOR VALVE CLOSES EARLY Increase the numerical value of the GLUE LENGTH DELAY set ting to close Applicator Valve later and extend the adhesive pattern toward the trailing edge of the block F igure 3 856_0412 _0_ 12 01 10 AD USTMENT TROUBLESHOOTING 4a Applicator Valve either 1 Opens too early or 2 Closes too late or 3 Opens early AND closes late In all three cases there is adhe sive on the Applicator Fingers before the wood reaches the Head Figure 4a WS IF 4a ISTHE CASE THEN 4b Increase the numerical value of GLUE START DELAY setting and decrease the nu merical value of GLUE LENGTH DELAY setting to re center the adhesive pattern so there are spared areas as shown in Figure 4b Then decrease the numerical value of GLUE START DELAY setting to advance the adhesive up to the leading edge of the block Figure 4b Now increase the numerical value of GLUE LENGTH DELAY setting to extend the adhesive pattern to the trailing edge of the block 856_0412_0_ 12 01 10 71 AD USTMENT TROUBLESHOOTING ea Figure 5 gt Ee s 5 ADHESIVE ON UPPER SUR FACE AND NONE ON LOWER SUR FACES Applicator head is incorrectly aligned vertically to the wood finger
28. Adhesive Valve Reapply air to the Control Enclosure and Pressure Tank at 60 psig Now press the FLUSH Switch to perform the FLUSH operation The Applicator Valve should now open and adhesive should flow from the finger ports of the Applicator Head If no adhesive appears at the Applicator Head then the APPLICATORVALVE must be taken apart and serviced PEEP E ooa i i Tr P Start the lug chain drive and run a few wood joints OE i The Applicator Valve should open each time a wood te joint passes through the sensor s beam If the Applicator Valve doesn t open as the wood Paa B joints pass then proceed with Manual Section EE ES OFF TROUBLESHOOTING ELECTRICAL CONTROLS U O L Ss S Wood lo g ON Sensor Frame Sensors Glue Sensor 856_0412_0_ 12 01 10 TROUBLESHOOTING INTERNAL ELECTRICAL COMPONENT IDENTIFICATION THE SMALL RED INDICATOR VISIBLE IN THE SENSOR HOUSING NEAR THE CABLE GLOWSWHEN THE CONTROL ENCLOSURE IS ENERGIZED IT GOES OUT WHEN THE SENSOR DETECTSAN OBJECT UPTO 1 1 2 FROM THE EDGE OF THE ALUMINUM SENSOR HOUSING Examine the
29. Electrical Diagram Drawing 856 32 and 856 10 See Drawing 856 x xY Control Panel Assembly of your System Version to locate the electrical components inside the Control Enclosure a Electrical Wiring Harness l Cord Grip b PLC m Base Chain Relay c Analog Input Module n Chain Relay d Power Supply 24VDC o AC InputTerminals e Door Safety Switch p Fuseholder Terminal f Jumper Terminal q Terminal Ground g 1 O Terminals r On Off Switch h End Block Terminal S Connectors HMI DC amp PLC i Lamp 24VDC t Door Latch j Solenoid Cable u E200 Interface k Solenoid Valve 24VDC v Enclosure Door PROCEED WITH CAUTION SOME TESTS ARE PERFORMED WITH THE CONTROL ENCLOSURE ENERGIZED SOME COMPONENTS WILL BE AT LINE VOLTAGE 856 0412 0O_ 12 01 10 TROUBLESHOOTING TROUBLESHOOTING ELECTRICAL CONTROLS PLACE POWER TO OFF OPEN ENCLOSURE DOOR CHECK SUPPLY VOLTAGE Using a voltmeter check the AC voltage between ter
30. G COMPONENTS CHECK sissseiiemi isiin a 66 DYNAMIC ADJUSTMENT secacixceunshesteyeelasenvanait ac tapsuises i aa aaa a TA 67 SQUEEZE OUT zoroaren ara e E EEA E TE N NNE EE EA AEAEE A ENEAS EASE ETRS AEE 69 ADJUSTMENT TROUBLESHOOTING scrierii sieri iiiaiA 70 Applicator valve correct application scscitasiioscmdisikontiemimemnaieaenoseets 70 Applicator valve opens late sassisnssineraruainsaraihescmaah ai aaia 70 Applicator valve closes early ch nmsmranuccnmammednsmamiermuateereaadaneas 71 Applicator valve opens early and or closes late ceeceeeeeeeseeeeeeeeeeeeeeneneaeaes 71 Adhesive on upper surface and none on lower surfaces eeeserrrererrrerrrrree 72 Adhesive on lower surface and none on upper surfaces ccceceeeseseseeeeeeeeees 72 Glue Buildup OmApplicat r Head serere nispera aaa aE 72 AIR CONTROLS ussavsercinicntainesrmrnnnteassensnntcteneuaiateauen dean dar E a A a a TEA 73 TROUBLESHOOTING ormus a ae aa EE E E E einem 74 Troubleshooting Fluid SUP PIY miersii iiini aa aea Ra EEA EKARA RAA 74 Troubleshooting Applicator Valve Assembly ssssssssssssssssrrrereersrrrrrrrerrrrrrrreerrsen 75 Internal Electrical Component Identification essssssssssssssssrrrrrerersrrrrrreersrrrrrree 76 Troubleshooting Electrical Controls sisccnisds consis scvisensduscenndesseddanideunsenedeaserdseusansabudes 77 Troubleshooting Sensing ElectroniCS essssssssesssssrrrrressssrrrrressssrrrrrersrrrrrrrereesrs 78 Troubleshooting WOOD Sensor Functio
31. Main Menu i The Block Count can also be seen on the i amp amp A z F1 Glue Start time screen the F2 Glue ESC Length time screen and the F3 Block 4 5 g Counter Reset screen oe eee f SCROLL DN Key E ag E Fi F4 is the Service Screen which shows the Apquip shipping address and 856 Program Version W hen on the Main Menu press F4 to get to the Service Screen If you are the F1 F4 screens press F4 to activate the Flush Screen and allow the flush operation as with previous program versions A Remote Flush Switch is installed on the Enclosure to re xk i Smancorsy duce wear on the HMI keypad When onthe Main MenuF Function screen press the DN arrow to move to the Main Menu K Function screen On the Main Menu K Function Screen K4 Glue Rate Info has replaced the K4 Service Menu selection SCROLL UP Key I I M I Returing to the Main Menu can be w n complished by pressing ESC twice from oo g A any screen If on any F1 F4 Screen press FRC K1 to return to the MainMenu Ifonany K1 4 5 a e K4 Screen press F1 to return to the Main oe Menuunlessthe key is assigned to another E JE Y function oo E on HEF bn 856_0412 O_ 12 01 10 OPERATOR INTERFACE FEATURES BASIC FUNCTIONS AND ADJUSTMENTS Glue Start Delay Press the F1 function key at the top left corner of the keypad to access the Glue Start Delay Screen On some screens the F1 key may be assigned to another purp
32. Marker components should be installed above the lumber and downstream of the Glue Sensor The maximum distance from the Glue sensor should be no more than the conveyor lug spacing Please contact your Apquip representative with questions regarding Glue Detection setup 856_0412_0_ 12 01 10 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS GLUE DETECTION FUNCTION Glue Detect Status From the Main Menu press the K2 function key second row second from the left to to to the Glue Detection Status Screen The first column ACTUAL value is a display only field to show the current Luminescence Sensor reading for each Sensor and cannot be changed As the return signal from the Glue Detect Sensors change due to variations in luminescence in the amount of glue on the joint this display value will change The display range is from 0 to 1000 The second column THRESHOLD value is an editable field to set the minimum reading which is allowed to pass during the inspection If the Glue amount is lower than the Reject Threshold for either Sensor then an error condition is set and the Error Lamp is momentarily lighted and the error is added to the Glue Detect Marker queue Both Readings must be above the Reject Threshold for a good board Actual Glue reading from Luminescence Menu Sensors Title i Sensor 1 SIATT H Sensor 2 4 Previously set E Reject Threshold K2Key F4 Key Function K eys ESC Key a P A aw ceo a
33. NTER Key 856_0412 _0_ 12 01 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS SERIESOPERATION Series Status continues The below screen shows board 1 as the next board to go through the system of a series of 4 boards and the glue will be applied on the right side of the board Press F2 to reset lt RST gt the Series to the first board in that series This is useful if you want to start the series over at the beginning after processing a gew boards Press F4 to move down lt DOWN gt one menu level to the Program Series Data screen e e i pee Menu ____ Title Side to Glue Function K eys a 2 SCROLL DN Key Numeral K eys _ E NTER Key 856_0412 _0_ 12 01 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS SERIES OPERATION Program Series Data The Program Series Data Screen is used to enter or change the value for Total Pieces in the Series The Screen will prompt you to input the total number of pieces in your series Key in the number of pieces in your series using the numeral keys then press enter Press F4 to move down lt DOWN gt one menu level to the Enter Sides to Glue screen Press F1 to move up lt UP gt one menu level to the Series Status screen NOTE It is very important that you press enter after every pattern value change in order for the PLC to accept the new value If you do not press enter your change will not be stored and the pattren will remain
34. PTIONAL FUNCTIONS SERIES BOARD SKIP OPERATION Series Operation allows the operator to quickly program the sequence for gluing a panel or particular lay up This feature is used when edge gluing or face laminating surfaces that need an occasional dry board To access the Series Status Screen press the K1 Function Key second row on the left On some screens the K1 key may be assigned to another purpose Press the ESC key to return to the main menu and view the F1 F4 function key assignments then press K1 The Series function can be used when gluing a single face or edge or dual faces or edges The dual face or edge systems will need two valves two applicator heads and two mounting positioning brackets However both gluing operations must directly oppose each other as the timimg of both gluing operations will notbe differentiated from one side to the other NOTE Ona single edge or face gluing system you will only utilize part of the program You will only program for the right side board and disregard the left side You will utilize the glue on right side only or no glue on either side Menu E _ Title F unction kys m 4 4 4 le l ESC Key K1 Key 7 g q A a cc ia E a i SCROLL DN Key Numeral K eys _ ue aa NTER Key3 mA 856 0412 0_ 12 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS SERIESOPERATION Setup and Installation Setup for Series Operation is the same as
35. R INTERFACE FEATURES BASIC FUNCTIONS AND ADJUSTMENTS Flush Switch continues The flush switch should be used to flush adhesive from the system with water or cleaning fluid When using this switch for this purpose please remove the applicator head insert the flush hose and have a bucket to catch wash fluid coming out of the flush hose Remember that cleaning fluid is generally much less viscous than the adhesive and will consequently shoot out of the flush hose under considerable pressure Please wear appropriate eye protection while completing this task The flush switch may also be used to prime the adhesive in the system This is often useful when starting the system up for the shift or after a break By depressing and quickly releasing the Flush Switch you can assure there is glue in the applicator head If this is not done it may resultin an inadequate glue spread on the first few boards The Manual Valve Operator installed on the Door is the preferred method to perform a flush operation This will reduce excess wear on the soft membrane switch of the HMI and save costly repairs The Manual Valve Operator can be pressed at any time to perform Flush operations The HMI will not display the Flush Screen when performing Flush operations using the Manual Valve Operator Saat Pe Menu Title i F4 Key Function K eys 4 4 4 J ESC Key 7 5 F A aw 50 a gt B SCROLL DN Key Numeral K eys
36. R INTERFACE FEATURES OPTIONAL FUNCTIONS SERIESPROGRAM EXAMPLE Enter Sides to Glue continues 5 Enter 2 for the board Program for board 3 on the Enter Sides to Glue Screen Glue will be on the right side Board 3 of 6is displayed on the Enter Sides to Glue screen The cursor will blink at the Side to Glue value The screen may display 0 or or any previously programmed value Press numeral 2 and then press enter to store the new value for Sides to Glue for board 3 Press F4 lt NEXT gt to move to the next board in the series NOTE It is very important that you press enter after every pattern value change in order for the PLC to accept the new value If you do not press enter your change will not be stored and the pattern will remain at the previously programmed value If you make a mistake press the correct numeral key and press enter again Press F3 lt PREV gt to move to the previous board in the series Key in the correct option 0 1 2 or 3 press enter to store the correction Press F3 or F4 to move in the series to make corrections SMA OP pe a Glue Right Side of Board 3 M enu ____ Title FA Key Se ee F1lKey Function K eys a ESC Key 7 g o SCROLL DN Key F3Key Numeral K eys 7 NTER Key g f 32 856 0412 0 12 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS SERIESPROGRAM EXAMPLE Enter Sides to Glue continues 6
37. SC Key F F A t oo g P E E gt B SCROLL DN Key Numeral K eys _3 e E Y NTER Key E i q BEE g OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS SERIESPROGRAM EXAMPLE Enter Sides to Glue continues 4 Enter 2 for the board Program for board 2 on the Enter Sides to glue Screen Glue will be on the Right side Board 2 of 6 is displayed on the Enter Sides to Glue screen The cursor will blink at the Side to Glue value The screen may display 0 or or any previously programmed value Press numeral 2 and then press enter to store the new value for Sides to Glue for board 2 Press F4 lt NEXT gt to move to the next board in the series NOTE Itis very important that you press enter after every pattern value change in order for the PLC to accept the new value If you do not press enter your change will not be stored and the pattern will remain at the previously programmed value If you make a mistake press the correct numeral key and press enter again Press F3 lt PREV gt to move to the previous board in the series Key in the correct option 0 1 2 or 3 press enter to store the correction Press F3 or F4 to move in the series to make corrections Satie OP Pd i Glue R ight side of man Fs Board 2 Title FlKey F4 Key F3 Key ESC Key ESC das g gt D SCROLL DN Key Numeral K eys _3 e E Y NTER Key an 856_0412 0 12 OPERATO
38. Setup for Edge Gluing or Face Gluing Operations The Series function can be used when gluing a single face or edge or dual faces or edges The dual face or edge systems will need two valves two applicator heads and two mounting positioning brackets However both gluing operations must directly oppose each other as the timimg of both gluing operations will notbe differentiated from one side to the other Please contact your Apquip representative with questions regarding Series Board Skip setup 856_0412_0_ 12 01 10 23 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS SERIESOPERATION Series Status The Series program can be set up for patterns involving up to 99 boards The pattern can be set up so that each individual board can have glue on both sides glue on either the left or right side or no glue on either side If you are gluing the faces itis the same setup but you will have to regard the left side as the bottom face and the right side as the top face or visa versa The Series Status Screen displays the count of the next Board to be glued the total number of boards in the Series and the side to glue value for that board The screen will display the board number and the side to glue value for each board in the series as it passes through the system ext Board wan mee Menu z i Title Total Boards Side to Glue Function K eys a 2 SCROLL DN Key Numeral K eys E 3
39. T SENSOR Connect the negative meter lead to Upper I O Terminal 23 and the positive meter lead to Lower I O Terminal 22 When the Sensor is unblocked the voltage will be about OVDC Have an assistant block the sensor When the Sensor is blocked the voltage will be VDC or 20VDC to 24V DC If not check wiring of the following points When the Sensor is blocked if Input 0 3 indicator on the PLC does not go ON check wiring of the following points Lower I O Terminal 23 Wht Upper I O Terminal 23 Grn PLC Terminal 10 3 Grn NOTE The Frame Sensor is adjusted for Light detection the signals work as follows The White Output wire will be atOVDC when the Sensor is unblocked and VDC when the Sensor is blocked Reference is DC Common on the Sensor s Black wire 91 856_0412_0_ 12 01 10 TROUBLESHOOTING TROUBLESHOOTING GLUE DETECT MARKER FUNCTION CONTINUES PLACE DOOR SAFETY SWITCH TO OVERRIDE POWER SWITCH TO ON With Line Voltage at terminals 1 and 2 pull the Door Safety Switch plunger to the override Pull the plunger button with insulated pliers or pull the 6 screw attached to the plunger outward about 1 4 The override position closes the Door Safety Switch and allows the Enclosure to operate with the Door open Move the ON OFF Switch to ON The Power Indicator Lamp will light REFER TO DRAWING 856 AND 856 32 FOR COMPONENT AND TERMINAL IDENTIFICATION CHECK ERROR LAMP AND MARKER OUTPUT CHECK ERRORLAMP OUTPUT
40. Terminal 26 Metering Marker Valve Output PLC Terminal Q0 3 Upper I O Terminal 16 Lower I O Terminal 16 Error Lamp Output PLC Terminal Q0 4 Upper I O Terminal 21 Lower I O Terminal 21 Vio wire Vio wire BIk wire Air Electric Solenoid lead Brn wire Brn wire BIk wire Air Electric Solenoid lead Grn wire Grn wire BIk wire Air Electric Solenoid lead Gry wire Gry wire Vio wire Error Lamp lead Glue Detect Marker Valve Output PLC Terminal Q0 5 Upper I O Terminal 27 Lower I O Terminal 27 85 Yel wire Yel wire BIk wire Air Electric Solenoid lead 856_0412_0_ 12 01 10 TROUBLESHOOTING TROUBLESHOOTING CHAIN RELAY PLACE DOOR SAFETY SWITCH TO OVERRIDE POWER SWITCH TO ON With AC Line Voltage at terminals 1 and 2 pull the Door Safety Switch plunger to the override Pull the plunger button with insulated pliers or pull the 6 screw at tached to the plunger outward about 1 4 The override position closes the Door Safety Switch and allows the Enclosure to operate with the Door open Move the ON OFF Switch to ON The Power Indicator Lamp will light REFER TO DRAWING 856 AND 856 32 FOR COMPONENT AND TERMINAL IDENTIFICATION CHECK CHAIN RELAY The Chain Relay is used as an additional condition for allowing gluing operations by the 856 Control Enclosure The Chain Inputis connected to the Fingerjointer con veyor power so the Chain Input should be active whenever the conveyor is operating The m
41. ads in series with the Bottom Sensor output using 0 200 ma scale Remove the Yellow wire from Upper I O Terminal 16 Connect the Black Probe to Upper I O Terminal 16 and the Red Probe to the Yellow wire Perform the tests below to evaluate the Sensor output CHECK OUTPUT SIGNAL FROM THE SENSORS Place a block of wood with no luminescent glue within 2 of the Luminescence Sen sors the Glue Amount displayed on the Glue Detect Screen should be at or near zero The Ammeter will display at or near zero ma The Sensitivity adjustment on the sen sor may be adjusted to obtain the proper zero reading for Glue Amount when there is no glue on the board Some varieties of lumber have natural luminescence which will be detected by the Sensor 88 jo ad 856 0412 0_ 12 0 TROUBLESHOOTING TROUBLESHOOTING GLUE DETECT FUNCTION CONTINUES PLACE DOOR SAFETY SWITCH TO OVERRIDE POWER SWITCH TO ON With Line Voltage at terminals 1 and 2 pull the Door Safety Switch plunger to the override Pull the plunger button with insulated pliers or pull the 6 screw attached to the plunger outward about 1 4 The override position closes the Door Safety Switch and allows the Enclosure to operate with the Door open Move the ON OFF Switch to ON The Power Indicator Lamp will light REFER TO DRAWING 856 AND 856 32 FOR COMPONENT AND TERMINAL IDENTIFICATION CHECK OUTPUT SIGNAL FROM THE SENSORS CONTINUES Place a block of wood with the proper glue a
42. age 80 856_0412_0_ 12 01 10 TROUBLESHOOTING TROUBLESHOOTING WOOD SENSOR OUTPUT SIGNALS PLACE DOOR SAFETY SWITCH TO OVERRIDE POWER SWITCH TO ON With Line Voltage at terminals 1 and 2 pull the Door Safety Switch plunger to the override Pull the plunger button with insulated pliers or pull the 6 screw attached to the plunger outward about 1 4 The override position closes the Door Safety Switch and allows the Enclosure to operate with the Door open Rotate the ON OFF Switch to ON The Operator Interface display will light REFER TO DRAWINGS 856 AND 856 32 FOR COMPONENT AND TERMINAL IDENTIFICATION CHECK DC SUPPLY VOLTAGE TO SENSOR Connect a positive meter lead to lower I O Terminal 8 and the negative lead to lower I O Terminal 6 where the Sensor wires are connected About 24VDC should appear across the terminals If the proper power supply voltage does not appear then check the upper I O Terminals for 24VDC and the DC Power Supply output terminals as well Check wiring of the following points DC Power Supply V Wht Blu wire DC DC Power Supply V Red Blu wire DC 24 Upper I O Terminal 6 Wht Grn wire DC Upper I O Terminal 8 Red Blu wire DC 24 Lower I O Terminal 6 Blk wire DC Lower I O Terminal 8 Red wire DC 24 CHECK OUTPUT SIGNAL FROM SENSOR Connect the negative meter lead to Upper I O Terminal 6 and the positive meter lead to Lower I O Terminal 5 Have an assistant block the sensor When the Sens
43. ain purpose for the Chain Inputis to prevent gluing operations when boards are not moving on the fingerjointer PLC Outputs Q0 0 and Q0 1 will not activate when the Chain Input is inactive Some test operations should be performed with the Chain Input inactive Verify the proper operation of PLC Inputs while preventing activation of the PLC Glue Valve outputs while the Chain Relay is inactive Error and Marker Outputs will continue to function when the Chain Input is inactive The Chain Relay can be checked by measuring line voltage between Chain Relay Base Terminals A1 and A2 Line voltage will be 24VDC or 1 110 120VAC or 220 240VAC depending on the supply power from your plant Set the meter to read AC Voltage and connect the meter leads across the Chain Relay Base Terminals A1 and A2 Have an assistant supply and disconnect the chain signal Look for audible and visual indicators of the Chain Relay shifting If it does not shift when the proper voltage is present replace the Chain Relay CHECK CHAIN RELAY SIGNAL TO PLC Input 10 1 on the PLC will indicate ON when the Chain Relay signal is properly con nected to the PLC If this is not so check wiring at the following points PLC Terminal L Red Blu wire 4 places Upper I O Terminal 9 Red wire Red Blu wire Chain Relay Base Terminal 21 Red wire Chain Relay Terminal 21 connects to Terminal 24 when the Chain Relay is activated Chain Relay Base Terminal 24 Gry Whtwire PLC Terminal 10
44. as 4 gt SB SCROLL DN Key Numeral K eys E E NTER Key E i q g yfe DEL HELP OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS GLUE DETECTION FUNCTION Set Reject Threshold When moving to the Glue Detect Status Screen the flashing cursor will be located at the numerical value field for the Reject Threshold on Sensor 1 Change this setting by keying in a numerical value from zero to 1000 then press enter to store the new value Use the DN Key to move the cursor to the Reject Threshold on Sensor 2 and change the setting to the same value as Sensor 1 The program will not accept any value higher than 1000 This will set the threshold at your determined value Actual Glue reading from Luminescence Menu Sensors Title Sensor 1 Sensor 2 R eject Threshold 14 Previously set K2Key FA Key ESC Key F A ee a a SCROLL DN Key Numeral K eys _ al wf NTER Key T 856 0412 0O_ 12 01 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS GLUE DETECTION FUNCTION Set Reject Threshold continues This value will need to be fine tuned once in production but to get a rough setting you will need to take the following steps 1 Place a typical block or board that you will be running without any glue two inches in front of the detection lens The surface that is supposed to haver glue applied to itshould be n parallel to the detection lens This value should
45. ay extend the working life of your valve between rebuilds Please consult with an Apquip representative if you feel you have to rebuild your valve too frequently The standard U Cup Seal Part 258 24 is a soft Black rubber with no O Ring and the optional U Cup Seal Part 268 37 is Orange in color with an O Ring The Orange U Cup Seal has less reactivity with petroleum products such as oil This seal is pre ferred when applying urethane adhesives where an oil reservoir is in use 856_0412_0_ 12 01 10 94 ADHESIVE FILTER See Assembly Drawing 600 The Adhesive Filter accepts replaceable screen elements in three different wire mesh sizes Screen sizes are 16 30 and 50 mesh Refer to drawing 600 for part num bers For single component adhesives use the 30 or 50 mesh element For two component adhesives with powder catalyst the 16 mesh element provides less restriction For low viscosity unfilled adhesives use the 50 mesh element Some powdered catalysts contain large particles that are not removed during the manufacturing process Use of these catalysts will require pre filtering after mixing in your mill This pre filtering can be done by pouring the mixed adhesive through an ordinary window screen into a plastic bucket Apquip also provides a large capacity Adhesive Filter Part 600B that can be used when there is a large volume of adhesive being applied 600B Filters also accept screen elements in three different wire mesh s
46. d not pressurize the Adhesive Tank until this test is complete 1 POWER SWITCH The Main Switch is on the face of the Control Enclosure Door Locate the switch labelled OFF ON and rotate the Switch to the ON position The Operator Interface will light and display text to indicate the Control Enclosure has been powered up Locate the Sensor in its mounting and check the back end of the aluminum Sensor block The Sensor LED will be lighted when power is applied to the enclosure Place an object or your hand in front of the Sensor between 0 and 1 5 away from the eye opening The LED will extinguish when the object blocks the Sensor and relight when the object is moved away MANUALVALVE OPERATE The Manual Valve Operator is on the Control Enclosure Door locate the switch labelled FLUSH and press The FLUSH switch bypasses the sensing circuit and will activate the Air Electric Solenoid Valve while the FLUSH button is pressed You will hear the Air Electric Solenoid activate when the FLUSH Switch is pressed and deactivate when the FLUSH Switch is released The Adhesive Valve will open when the Air Electric Valve is energized and close when the Air Electric Valve is deenergized The Chain Voltage supply to the Control Enclosure is not required when per forming the Flush operation GLUE CYCLE TEST With the Chain Voltage ON place an object or your hand in front of the Sen sor between 0 and 1 5 away from
47. d that gets glued It will display the amount of glue dispensed for the previous board There isa slight delay as the display does not update immediately Purge and Flush operations are not monitored or included in glue usage data a at Pe a mC Ri T T La tes px renee 856_0412 O_ 12 01 10 52 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS GLUE METERING Input Screen KFT K Factor GWT Gallon Weight LGW Low Glue Weight This is the multiplication factor that is determined by the last calibration of the meter Itis found on the meter calibration document This is the weight of one gallon of Adhesive per the Adhe sive Manufacturer It can be found on the specification sheet of the adhesive This setting is the lowest allowable glue weight for the joint or board Any time the glue dispensed is less than this set ting the Error Lamp will light momemtarily This also sets up the use of the Marker Output to either mark or kick off the board with below adequate glue Use the DN arrow to position the cursor on the parameter you wish to change then key in the new value and press enter to store the change F3 Press F3 to move up to the Glue Metering Per Piece screen F4 Press F4 to move down to the Glue Metering Calibration screen ik 856_0412 O_ 12 01 10 53 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS GLUE METERING Reset
48. e 4 line of this screen This is to let you know the exact number of boards blocks that have been run past the glue applicator For directions on how to reset this counter to zero please refer to Block Counter Resetin this Manual Menu Title Numerical Value for Glue Length oard Count Title Numerical Value for Board Count ESCKe 7 a 9 A y ype lt gt A SCROLL n Numeral Keys a ey E JE Y ENTER Key oo 4f cial HELP 856 0412 0_ 12 OPERATOR INTERFACE FEATURES BASIC FUNCTIONS AND ADJUSTMENTS Block Counter Reset To access the Block Counter Reset Screen press the F3 function key top row third from the left On some screens the F3 key may be assigned to another purpose Return to the main menu as described on Main Menu in this Manual and view the F1 F4 function key assignments then press F3 To reset the block count press 1 on the numerical keypad and press ENTER If you press 3 on the numerical keypad and press ENTER the counter will remain at the present count The Block Count on the 4 line will indicate that you have reset the Block Counter Menu Title a a ja Selection Options l l Selection Variable Numerical Value for Board Count ro l i g gt P SCROLL DN Key Numeral K eys Re ae Y7 NTER Key lt a 856_0412 0 12 OPERATOR INTERFACE FEATURES BASIC FUNCTIONS AND ADJUSTMENTS Flush Switch Apquip 856 Control Enclosu
49. e back end of the Sensor Housing is lighted It will light when there is Glue within range of the Sensor This is the normal blocked condition for the Sensor The Output will be ON when there is Glue detected by the Sensor Move the Sensor so that it does not detect the Glue in the Tank or tilt the Tank so that the Glue is not directly in front of the Sensor When the Glue is not detected the LED at the back end of Sensor will extinguish This is the normal unblocked condition for the Sensor The Output will be OFF when there is no Glue detected by the Sen sor The 856FM will respond when there is no Glue detected by the Sensor by light ing the Error Lamp until Glue is detected again The LED will be litonly when Glue is detected If this is not the case replace the Sensor assembly 82 856_0412_0_ 12 01 10 TROUBLESHOOTING TROUBLESHOOTING LIQUID LEVEL SENSOR OUTPUT PLACE DOOR SAFETY SWITCH TO OVERRIDE POWER SWITCH TO ON With Line Voltage at terminals 1 and 2 pull the Door Safety Switch plunger to the override Pull the plunger button with insulated pliers or pull the 6 screw attached to the plunger outward about 1 4 The override position closes the Door Safety Switch and allows the Enclosure to operate with the Door open Rotate the ON OFF Switch to ON The Operator Interface display will light REFER TO DRAWINGS 856 AND 856 32 FOR COMPONENT AND TERMINAL IDENTIFICATION CHECK DC SUPPLY VOLTAGE
50. e the air supply All control lines are 1 4 plastic tubing The air fittings are the quick release type To attach an air line push the plastic tubing firmly into the fitting See A To remove the air line depressurize the line push the tubing firmly into the fitting then using your fingers push the locking ring in on the fitting While holding the lock ring in pull the tubing out See B A TO CONNECT B TO DISCONNECT Replace the Coalescer Filter Element whenever itis no longer white in color Contin ued use of a contaminated Element will permit impurities to cause inconsistent op eration of the Air Electric Valve A combination of cold air in the mill and oil in the air supply can also cause intermittent or sluggish Air Electric Valve operation 73 856_0412_0_ 12 01 10 TROUBLESHOOTING If your Adhesive Applicator System does not function then proceed with trouble shooting to isolate the problem to one of three subsystems fluid supply applicator valve assembly or electrical controls TROUBLESHOOTING FLUID SUPPLY Shut off the air supply to the pressure tank Disconnect the pressurized adhesive supply hose at the applicator valve assembly This hose may be under pressure so loosen the fitting slowly Place the end of the hose over a small container Turn the air pressure regulator at the top of the tank slowly CLOCKWISE until A The gage indicates 20 PSI and there is no flow from the hose or B adhesive flows f
51. eam from the glue detection lens The actual marking or removal equipment will vary according to different customer requirements The glue detection unit will only be looking for a defective adhesive application when a board or block is directly in front of the lens so the blank areas between lugs or boards will not be seen as defects 856F M Control im Enclosure fo nee E Et le a Al i Q sy jj o e SS Wood D Frame Sensor ne Sensors TA 856 0412 0 12 01 10 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS GLUE DETECTION Setup and Installation Glue Detection and Framing Sensors are typically installed within 12 downstream of the Adhesive Applicator and should be located where the block is still on the Lug riding on the Bed Rail and optimally under the Air Bag The Frame Sensors are to be mounted above the lumber similar to the drawing below The Glue Detection Sensor is to be mounted approximately 2 away from the face of the glued fingers at the centerline of the Frame Sensors When the lumber is below the Frame Sensors and they are both active the Glue Sensor reading is monitored to determine if the glue level is above the minimum setting and the apropriate is action taken when the reading is low
52. ensor detects Glue and VDC when the Sensor detects NO Glue Reference is DC Common on the Sensor s Blue wire 856_0412_0_ 12 01 10 83 TROUBLESHOOTING TROUBLESHOOTING PLC OUTPUTS PLACE DOOR SAFETY SWITCH TO OVERRIDE POWER SWITCH TO ON With Line Voltage at terminals 1 and 2 pull the Door Safety Switch plunger to the override Pull the plunger button with insulated pliers or pull the 6 screw attached to the plunger outward about 1 4 The override position closes the Door Safety Switch and allows the Enclosure to operate with the Door open Move the ON OFF Switch to ON The Power Indicator Lamp will light REFER TO DRAWING 856 AND 856 32 FOR COMPONENT AND TERMINAL IDENTIFICATION CHECK PLC OUTPUT SIGNAL S Have an assistant block the sensor Observe the Output Indicators on the PLC De pending on your 856 System setup indicators for PLC Outputs Q0 0 or Q0 1 or both will light light when the Sensor is blocked and extinguish when the Sensor is un blocked PLC Output Q0 1 is for single Adhesive Valve Systems and will activate when the Sensor is Blocked PLC Outputs Q0 0 and Q0 1 are the Left and Right Adhesive Valves respectively which will activate according to your Series Program for 856 System Revision B or Revision D Connect the negative meter lead to I O Terminal 13 DC and the positive meter lead to PLC Output Terminal Q0 1 When the Sensor is unblocked the voltage will be about OVDC When the Sensor is
53. entire length of the board An initial numerical setting of 10 will usually be a good starting point You can change this setting while in operation when adjustment is needed Typically this setting should always be less than the Marker Start Delay Time as the duration of this output should not be longer than the time it takes for the two boards to move by the Detection point If longer the Marker would affect the next board on the lug chain Swan ey f Menu Marker Start Title Delay K 3 Key Marker On Time FA Key F unction Kos ir ESC Key 7 a g A j 50 a gt B SCROLL DN Key Numeral K eys m4 Y7 NTER Key 856 0412 0 12 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS GLUE METERING The Glue Metering functions of this unit will allow the operator to determine if the proper amount of glue has been applied to a given work piece either a finger jointed block or an edged glued strip Once a proper GM Pc volume has been determined for a given species of wood and glue type the operator can seta minimum numeric value for an acceptable applicaton If the adhesive measurement for a given work piece drops below the set level the board will be rejected If the work piece is rejected the board will either be marked or physically removed from the manufacturing process The marking or removal output from the PLC can be delayed so that the dye nozzle or removal equipment can be located downstrea
54. eririris ien innii EEEa EEREN OERE AEE 26 Enter Sides to a si So eas icinctansied nena acpielanaynic i a TE Eaa 27 S ries Pattern EXAMP lE coca ree wecerereeseeavccncdeie baer ice Siwena EEEE TERE Aa 29 GLUE DETECTION cerris eiiiai e e aaa aAa A E 43 Setup and Installation epics cere ran cx nels vanish tnnh chad edvned aves doen EERE 44 VE DESC TON Stas rossis rset iiaia aiana aik iA a Ea A ENRERE 45 Set Reject TAresShOld asic tha este reece iiae EEEIEE TE AEE EEEREN 46 Glue Detection Board Mark r sssini nane aikanaa 48 GLUE METERING srsrrkersrnti e e ir alte EE E anal EEA 50 Setup and Installa tOM eisirean ii iiia Eiaa Ea EEEE EE OERA 51 Glu Metering Status sruse ineine aE AAKER EE AT Eiaa 52 Glue Metering Input Data sisisi in Na EREE AENA ERER 53 ResetContirmMmat ON ossessi aa EEA a E ESEE a 54 Meter Cali bDratiO eoseid a A a a E AA TE AA 55 Glue Metering Board Marker sssssssssssrnesrrrrnrrrrrnrrrrrrrrrrrnrrrrrrrrrrnnrrrrrerrrrrna 57 8 Cl CONTENTS SY STEM COMPONENT IDENTIFICATION sine lecssessnevdncaxavcnsvavcedncs cdbeulennrantanedeslorutedeers 59 SIX CONTROL STAGES DURING APPLICATION sexiierteurevaivavaucse ccaxscaiestanutatataatedeseas 60 ADHESIVE APPLICATOR HEAD siccstsicinpsiastedscnva darlin r veda a a ilaa 62 APPHUCATOR HEADALIGNMENT siisincsshotssdlenciarsaaeid sasiictabisjsnuaswautuin a a E a 62 APPUCATORHEAD CLEAN UP scrocco a aeia a a E E EENS 64 WOOD SENSOR MOUNTING siosioina iiaia aaeain AA aA E 65 SENSIN
55. f time the glue valve will be when the Chain is restored after the board has passed the view of the sensor This is longer than Run Length F2 setting as the conveyor is ramping up to speed after the Chain has been restored Set the Chain Break Delay equal to the time ittakes the conveyor to stop when the chain is removed Set the Resume Length to 20 greater than the Run Length 1 If the Chain is restored while a board is in view of the sensor Gluing will begin immediately and end at the completion of the Run Length Timer 2 If the Chain is restored from a Chain break while gluing is in the Run Length Gluing will startimmediately and continue until the end of the adjusted Resume Length calcu lated as follows Adj Resume Length Resume Length Run Length used Chain Break Delay Ex Run Length 200msec Resume Length 240msec Chain Break Delay 100msec Gluing occurred 50msec into the Run Length therefore 50msec used Adj Resume Length 240msec 50msec 100msec 90msec When the Chain is restored Gluing will begin immediately and gluing will stop after the end of the Adjusted Resume Length or 90msec 3 If the Chain is restored and gluing has restarted but a new board enters the view of the Sensor Gluing is stopped and Start Time begins for the new board entering the gluing station P lease contact your A pquip representative with questions regarding Chain B reak Resume R amp U p Dday 856_0412_0_ 12 01 10 20
56. ge NOTE A small gap or spared area 1 16 1 8 should be left on both ends of the adhesive pattern to allow for a little squeeze forward rearward of the adhesive dur ing assembly Refer to the Manual Section on SQUEEZE OUT for more adjustment modifications for Squeeze Out 856_0412_0_ 12 01 10 68 SQUEEZE OUT Fine Droplets Fine Droplets To double check your adhesive pattern settings examine an assembled wood joint farther down the line A very thin bead of adhesive or fine droplets squeezed out on tip of the joint indicate a sufficient quantity of adhesive applied to the joint i e cor rect adhesive pressure Squeeze out on the edge surface of the joint should be minimal To remove the leading edge squeeze out increase the numerical value of the GLUE START DELAY setting To remove the trailing edge squeeze out decrease the numerical value of the GLUE LENGTH DELAY setting When these Delay values are correctly set the adhesive pattern will be slightly less than the width of the joint thereby allowing for a little squeeze forward rearward of adhesive and preventing excessive side squeeze out SMALL GAP FOR SQUEEZE FORWARD SMALL GAP FOR SQUEEZE REARWARD 69 856_0412_0_ 12 01 10 AD USTMENT TROUBLESHOOTING 1 CORRECT APPLICATION An even film of adhesive on upper and lower face of wood fingers No drips No dry areas Figure 1 Correct Adhesive Application 2 APPLIC
57. ge at terminals 1 and 2 pull the Door Safety Switch plunger to the override Pull the plunger button with insulated pliers or pull the 6 screw attached to the plunger outward about 1 4 The override position closes the Door Safety Switch and allows the Enclosure to operate with the Door open Move the ON OFF Switch to ON The Power Indicator Lamp will light REFER TO DRAWING 856 AND 856 32 FOR COMPONENT AND TERMINAL IDENTIFICATION CHECK LUMINESCENCE SENSORS The two Luminescence Sensors are analog sensors requiring a 24VDC supply voltage and and havning an output range from 5 10ma When power is applied an orange LED on the top of the Sensor is lighted and the Sensor emits a three low level purple LED beams from the lens When the adhesive with luminescence is detected a red LED at the to of the Sensor will flash or be lighted depending on the amount of the luminescence detected by the Sensor The signal from the Sensor is scaled in the PLC from 0 to 1000 and displayed on the Glue Detect Screen CONNECT AMMETERTO OUTPUT SIGNAL FROM THE SENSORS Press K2 from the Main Menu to view the Glue Detect Screen and monitor the Glue Amount value Connect an Ammeter leads in series with the Top Sensor output using 0 200 ma scale Remove the Yellow wire from Upper I O Terminal 15 Connect the Black Probe to Upper I O Terminal 15 and the Red Probe to the Yellow wire Perform the tests below to evaluate the Sensor output Connect an Ammeter le
58. he 856 glue detection unitis a revolutionary system that will detect the amount of glue oneach finger jointend even atextremely high speeds Notonly can the 856 determine ifthere is no glue or glue itcan also determine what amount of glue is being applied to each individual piece The Glue Detect screen allows the operator to monitor a numerical value that corresponds to the amount of glue applied The same screen allows the operator to set a threshhold value that will determine which boards have an inadequate application and correspondingly reject them 856 Ver x xD Glue Detection and Board Skip The 856 glue detection unit with board skip unit combines the two features of glue detection and board skip capability All the functions of the 856 Version B and Version C will work together in one unit Please refer to the two descriptions listed above Many of these functions can be combined to provide the optimal in glue application for your mills needs Please consult an Apquip representative to learn the possibilities that are available For Example 856FM Ver x xAF Basic Gluing Operation with Flow Meter 856F2 Ver x xCF GLue Detection Operation with Flow Meter 1 856 0412 0_ 12 0 ELECTRICAL INSTALLATION Two electrical connections are needed for the APQUIP Control Enclosure NOTE The Apquip 856 Control Enclosure may be supplied power at 24VDC 115VAC or 230VAC The Control Enclosure is configured for the correct supply voltage when
59. he Applicator Valve assembly is composed of two subassemblies the Air Cylinder and the Adhesive Valve Body The moving parts are the Air Piston and Valve Spool The Air Piston drives the Valve Spool towards the Applicator Head to open the Adhesive Valve and away from the Applicator Head to close the Adhesive Valve The Valve Spool is designed to create a sniffing action when the Adhesive Valve is closed to draw the adhesive back into the Adhesive Head to reduce waste and prevent drips The parts subject to wear in normal operation are the Valve Spool Part 206 07 or 206 26 and any of the Adhesive Valve s Seals and O Rings If the Adhesive Valve leaks adhesive in its OFF position it indicates that Spool Seals are worn If adhesive backs up into the Air Cylinder this condition indi cates worn Spool Seals and a worn U Cup Seal Part 258 24 or 268 37 Adhesive in the Air Cylinder will cause valve operation to be sluggish giving an indication of an electronic timing problem Take the Adhesive Valve apart and thoroughly clean all the pieces Inspect the Spool and Seals and replace parts which show wear Use only APQUIP replace ment Seals and O Rings Other Seals though they look the same will not offer the same resistance to chemical attack or mechanical wear due to compound characteristics IMPORTANT NOTE Observe the correct orientation of the Spool Seal Part 206 14 and other two part seals that consist of a modified U cu
60. ill not be stored and the pattern will remain at the previously programmed value Sih Tey Fi Total Pieces in Series Title FlKey F4 Key Function K eys ESC Key F a A aw eo l A g g g pe SCROLL DN Key Numeral K eys _3 E E NTER Key E i q g yfe DEL HELP g OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS SERIESPROGRAM EXAMPLE Enter Sides to Glue 3 Enter 0 for the board Program for board 1 on the Enter Sides to Glue Screen This will be the dry board Board 1 of 6 is displayed on the Enter Sides to Glue Screen The cursor will blink at the Side to Glue value The screen may display 0 or or any previously programmed value Press numeral 0 and then press enter to store the new value for Sides to Glue for board 1 Press F4 lt NEXT gt to move to the next board in the series NOTE Itis very important that you press enter after every pattern value change in order for the PLC to accept the new value If you do not press enter your change will not be stored and the pattern will remain at the previously programmed value If you make a mistake press the correct numeral key and press enter again Press F3 lt PREV gt to move to the previous board in the series Key in the correct option 0 1 2 or 3 press enter to store the correction Press F3 or F4 to move in the series to make corrections o Glueon Board 1 F1Key tie ey Function K eys i E
61. ill produce some thing like the starting pattern shown below This illustration shows a right hand application A left hand application would show the direction of travel reversed as well as directions A and B The A direction points downstream with the travel toward the leading edge and as sembly section and the B direction points upstream against the travel toward the trailing edge and feeder station All subsequent application adjustment illustrations will show right hand application examples only 856 0412 O_ 12 01 10 67 DYNAMIC ADJUSTMENT These adjustments must be made with the jointer running GLUE START If the leading edge A or start of the glue pattern is too far away from the edge of the block as shown below then decrease the numerical value of the GLUE START DELAY setting This will reduce the size of the gap from the edge of the block to the start of the glue pattern Continue adjusting the setting until the glue pattern is 1 8 from the block s leading edge GLUE LENGTH Examine the length of the Adhesive Pattern If the trailing edge of the glue pattern is too far from the back edge B of the block length is not long enough then increase the numerical value of the GLUE LENGTH DELAY setting This will cause the glue pattern length to extend farther toward the trailing edge of the block Continue adjusting the setting until the glue pattern is 1 8 from the block s trailing ed
62. izes Screen sizes are 16 30 and 50 mesh Refer to Drawing 600B for part numbers 856_0412_0_ 12 01 10 95 PRESSURE TANKS See Assembly Drawing 582 All Adhesive Pressure Tanks have a maximum working pressure of 125 PSIG which is set by Federal safety standards Do not remove or alter the safety Relief Valve which is a required part of the Adhesive Pressure Tank Assembly A typical operating pres sure is 20 PSIG for a low viscosity adhesive in a warm mill Higher viscosity glues and lower operating temperatures will require higher tank pressures Under no circum stances should 125 PSIG tank pressure be exceeded If an application requires a greater pressure than 125 PSIG then the positive dis placement Adhesive Pump Part 522 will be required 856_0412_0_ 12 01 10 96 SPECIAL ADHESIVES The Apquip System is quite versatile in that it may be used with many different types of adhesives Systems may be capable or running a completely different adhesive with only afew modifications With over twenty five years of experience in woodworking applications a quick phone call fax or e mail may make your adhesive switch a much nicer experience We have worked with isocyanate melamine polyurethane PVA resorcinol and soy based adhesives Please consult with an Apquip representative if you are planning on switching adhe sives 856 0412 O_ 12 01 10 97
63. ly of dry clean air must be connected to the barbed fitting marked Supply on the 820 Air Electric Solenoid from the Coalescer Regulator Set the air pressure on the Coalescer Regulator to 60 psi Itis critical that the air supply to the 820 valve is dry and oil free as possible It is highly recommended that a water trap is installed just prior to the air supply connection to the Coalescer Regulator 1 4 air lines will need to be run from the 820 Air Electric Solenoid bottom right corner of the 856 Enclosure to the 268 Adhesive Valve These lines will control the opening and closing of the Adhesive Valve An air line will need to be run from the barbed brass fitting marked A on the 820 solenoid to the air fitting on the cap of the Air Cylinder on the 268 Valve An air line will also need to be run from the barbed brass fitting marked B on the 820 Air Electric Solenoid to the air fitting on the main body of the Air Cylinder on the 268 Valve Air Supply from Coalescer 856_0412_0_ 12 01 10 SENSOR INSTALLATION The Wood Sensor should be located approximately 1 upstream of the applicator head The Sensor lens should be 1 5 from the top surface of the wood The Sensor should be mounted in a location that will allow it to clearly see the edge of the wood but not the top of the lug This is critical otherwise the Adhesive Dispensing System will extrude glue even if the lug is empty If you are running thin blocks 4 4 a
64. m from the glueing position The actual marking or removal equipment will vary according to different customer requirements The Glue Meter allows a measurable amout of adhesive to flow through the rotating meter gears The Glue Meter Sensor detects the number of gear rotations providing a signal pulse for each gear tooth The number of sensor pulses corresponds to a spefic volume of glue through a set of mathematical equations performed by the PLC The user must provide specific data such as GWT Gallon Weight in pounds for the adhesive being used and KFT K Factor for the Meter which determines the number of pulses which results in a cubic centimeter for the adhesive being measured Factors which cause changes in viscosity can affect the GWT or KFT directly and therefore cause incorrect volume measurements xr SATO OPT A Calibration procedure is used to confirm or correct the flow measurement accuracy During the procedure the operator will dis pensing aspecific volume of adhesive into a beaker If the volume does not match the vol ume displayed on the screen then the op erator will key in the actual volume into the PLC The PLC uses the measurement data and resulting volume to determine the proper KFT value m at a d 5 a E La 5 q i u 856_0412 O_ 12 01 10 50 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS GLUE METERING Setup and Installation Attach the Meter in the glue supply line between the Adhesi
65. manu factured The required connections are 1 aconstantAC or DC Supply to power the system and 2 an AC or DC Supply signal when the Lug Chain Drive or Conveyor Drive is powered The AC Supply is wired to the AC Input Terminal Strip terminals 2 amp 3 with the hot wire on Terminal 2 The Lug Chain Drive ON is wired to the Chain Relay Base Al amp A2 The Relay is not polarity sensitive for DC Chain voltage Ground is connected to Terminal 1 For wiring of periferal components such as Sensors Air Electric Valves and Indicators refer to the Program Version Specific Wiring Drawing provided with your 856 Control System The below drawing shows all possible periferal connections and does not represent any Program Version of the 856 Control System wiring DIN RAIL I O TERMINALS WHI BLU CHAIN INPUT V 0 o ooo CONNECTION ae AC INPUT ds n TERMINALS 856 0412 O_ 12 01 10 PNEUMATIC INSTALLATION A supp
66. minals 2 and 3 on the AC Input Terminal Strip Line Voltage should be present as determined by your electical installation A reading of OVAC indicates your plant supply is not providing power to the Control Enclosure PLACE DOOR SAFETY SWITCH TO OVERRIDE POWER SWITCH TO ON With Line Voltage at terminals 1 and 2 pull the Door Safety Switch plunger to override Pull the plunger button with insulated pliers or pull the 6 screw attached to the plunger outward about 1 4 The override position closes the Door Safety Switch and allows the Enclosure to operate with the Door open Rotate the Power Switch to ON OBSERVE INTERFACE SCREEN LIGHTED DARK CHECK INPUT AGAIN THEN DOORSWITCH amp FUSES The Interface Panel front of Enclosure Door screen will light when powered up If not recheck the AC voltage between the lower terminals of the Fuseholders Line Voltage should be present If the voltage is OVAC then disconnect power and check continuity through the Door Switch while operating the switch Replace the Switch if there is no continuity when the Switch is pulled to override If Line Voltage is present check the upper terminals of the Fuseholders If the voltage is OVAC then replace one or both 3A Fuses in the Fuseholders PERFORM FLUSH OPERATION Press the FLUSH Switch to perform a FLUSH Operation Systems with multiple Valves will flush all valves in a Flush Operation All Air Electric Solenoids will activate with a click so
67. n ssessssssrseessssrsrrrereesrrrrrrneessrrrrereessss 80 Troubleshooting WOOD Sensor Output Signal cceececccssseeeeeeeeeeeseseeeeseeeeeaeas 81 Troubleshooting LIQUID LEVEL Sensor Output Signal serren 82 Troubleshooting LIQUID LEVEL Sensor Output s sssssssrrsreersrssrrrrrrerrrrrrrrerrenrn 83 Troubleshooting PLC Output Signals sssssssssssssssssrrrerersrsrrrerersrrrrrrrersserrrerresseerns 84 Troubleshooting Chain Relay srrsssiorirosoioisiienieiiiiin iniii a iaiia E aiia 86 Troubleshooting Board Skip Series Function ss sssssssssrrrreresrssrrrrreerrrrrrrreersern 87 Troubleshooting Glue Detect Function essssssssssssssrsrrrrressrsrrrrrersrsrrrrneesssrrrrrresss 88 Troubleshooting Glue Detect Marker Function ssssrrserrrrrnrsrrrrerrrrrrrrrrrerrrrrena 91 APPLICATOR VALVE ASSEMBLY niaro ceca tee ia ea a iE ER 93 OPTIONALVALVE PARTS terse ccc a donton aa a E aa a a a i a 94 ADHESIVE FILTER serisinin a ia aE EE ERREA E EAA A a ER 95 PRESSURE TANKS oireena EE aae aE A E EE 96 SPECIALADHESIVES reisuren eani anir e A a EE OKARA 97 C2 OVERVIEW The 856 Control Enclosure is an extremely fast PLC controlled unit capable of many functions to provide accuracy flexibility and monitoring of your glue applicators for use with finger jointers edge and face lamination applications We utilize an operator interface panel that allows the operator to quickly interact with the PLC to change values and settings Because the
68. nal EO l 856 0412 O_ 12 01 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS SERIESPROGRAM EXAMPLE Enter Sides to Glue continues 11 Observe the program as boards are sent through the system The screen below shows that the next board to pass through is board 2 in a series of 6 boards and glue will be applied to the right side of the board As the second piece passes the board sensor is activated and glue is applied to the right side of the board The board count will increment ee Tl i ae alo i l Glue Right Side Lie of Board 2 of 6 Menu Title F2 Key F4 Key Function K eys ESC Key a fa A a a SCROLL DN Key N umeral K eys _4_ a wf NTER Key lt a 856_0412 _0_ 12 01 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS SERIESPROGRAM EXAMPLE Enter Sides to Glue continues 12 Observe the program as boards are sent through the system The screen below shows that the next board to pass through is board 3 in a series of 6 boards and glue will be applied to the right side of the board As the third piece passes the board sensor is activated and glue is applied to the right side of the board The board count will increment lt SATO Glue Right Side of Board 3 of 6 Menu f Title F2Key FA Key ESC Key a fa A a SCROLL DN Key Numeral K eys _ el yw NTER Key lt a 856_0412 _0_ 12 01 OPERATOR INTERFACE FEATURES OPTIONAL
69. nd below it may be necessary to slightly angle the sensor upstream so that the sensors do not detect the bottom of an empty lug due to beam reflection off the shiny aluminum It may be necessary to mount the sensor so that itis aimed at only the finger section of the block This will eliminate any false readings from the lugs or lug chain Example if the lugs are on 6 centers and maximum board width is 2 the Sensor centerlines should be no more than 3 99 apart To be on the safe side the sensors should be located 3 center to center Please contact your Apquip representative for more about positionig of the Wood Sensor 856F M Control i m Enclosure Foot JREF Ela oF a Wood a Sensor r U Glue Sensor 856 0412 O_ 12 01 10 CONTROL ENCLOSURE FEATURES The Apquip 856 Control Enclosure operates a precise adhesive applicator system For proper installation and to maintain this system at optimum performance the operator must have a basic understanding of how this applicator system works Let s start by examining the controls OPERATOR DOOR INTERFACE LATCH O COALESCER FILTER REGULATOR ASSEMBLY Apqui
70. nsor gain is required to allow detection of the adhesive as far as possible inside the tank Improper adjustment and adhesive residue along the inner surfaces of the tank may cause inaccurate level readings P lease contact your A pquip representative with questions regarding Liquid L evd M onitor 856_0412_0_ 12 01 10 18 OPERATOR INTERFACE FEATURES ADDITIONAL FEATURES CHAIN BREAK DELAY The Chain Break Delay Function allows gluing for a fixed amount of time after the chain signal is cut off This is useful in the event a board enters the gluing station just as the power is cut off to the chain Without the Chain Break Delay the board may be partially glued and unusable The Chain Break Delay allows the board to be completely glued if it has started This all depends on how far the chain moves when power is removed To access the Chain Break Delay parameters from the Main Menu press F4 to display the Service Screen then press the DN arrow to move down to the Chain Break Delay parameter screen Use the DN arrow to position the cursor on the parameter you wish to change then key in the new value and press enter to store the change Parameters for the Chain Break Delay Function Name Units Initial Value Chain Break Delay 10 x 10 msec 100 msec Resume Length 1 x 1 msec 1 msec The Chain Break Delay is the amount of time that gluing will be allowed to continue after the Chain power is removed Set this time to the amount of time
71. o cess Press F2 to stop the Calibration Place agraduated beaker to catch the discharge of adhesive from the output of the Adhesive Valve Beaker gradu ations can be from 0 250ml Press the Flush Switch to fill the bea ker to apredetermined amount 150ml for example You will see the old Glue Volume reading change as the glue is dispensed into the beaker 55 856 0412 0 12 01 10 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS GLUE METERING Calibration Screen continues 4 Note Observe the value of the old Glue Volume reading at the lower left of the Cali bration Screen This is the amount of Glue according to the Meter Key in the actual measured amount of Glue in the beaker at the lower right on the Calibra tion screen As you key in the beaker Glue Volume on the screen the new KFT value will change from 0 0 to a new value based on the new Glue Volume and the num ber of Meter Sensor tics in the PLC memory for the amount of glue dispensed into the beaker Press F4 to accept the new KFT and use it in place of the old KFT The old KFT will change to the new value and all the other variables will be reset to 0 0 After returning the the Main Menu cycle the Power Switch of the 856 Enclosure to allow the new KFT to take effect Moving away from the Calibration screen during a Calibration process will ter minate the Calibration process If you do n
72. oard Count ESC Key 7 a q A i A ws 4 SCROLL DN Key Numeral K eys _ i i H a NTER Keyz g 856_0412_0_ 12 01 10 OPERATOR INTERFACE FEATURES BASIC FUNCTIONS AND ADJUSTMENTS Glue Length Delay Press the F2 function key top row second from the left to access the Glue Length Delay Menu If in a sub menu the F2 key may be assigned to another purpose Return to the main menu as described on Main Menu in this Manual and view the F1 F4 function key assignments then press F2 The Glue Length adjustment also ranges from 1 to 1000 the greater the number the longer the glue pattern Use the Down Arrow to move the cursor to the value field The delay value Second line on the display is preset to 1 if no value has been previously entered Key in the desired numerical value using the ten digit keys and press ENTER This will immediately change the timing of the desired glue length If your glue pattern ends too early that is the glue pattern does not extend to the end of the board key ina larger number and press ENTER Conversely if the glue pattern extends beyond the trailing edge of the board too much glue at the end of the board key in a smaller number and press ENTER Example If your setting is at 433 and the glue is ending early too far in from the trailing edge press F2 key in 470 and press ENTER Now if you find the glue pattern is ending a little late glue is extruding beyond the edge of the board key in 4
73. oards are sent through the system The screen below shows that the next board to pass through is board 6 in a series of 6 boards and glue will be applied to the right side of the board The board count will increment to the beginning of the series as there are no more boards leftin the series i l oA T i l Glue Right Side of Menu Board 6 of 6 Title F2 Key F4 Key Function K eys ESC Key a fa A a SCROLL DN Key Numeral K eys _ a ae NTER Key g lt a 856_0412 _0_ 12 01 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS GLUE DETECTION FUNCTION The Glue detection functions of this unit will allow the operator to determine if the proper amount of glue has been applied to a given work piece either a finger jointed block or an edged glued strip Once a proper threshold level has been determined for a given species of wood and glue type the operator can seta numeric value through the operator interface panel If the adhesive reading on the given work piece drops below the set level the board will be rejected Conversely if the reading on the given work piece stays above the given threshold the board will continue through the manufacturing process If the work piece is rejected the board will either be marked or physically removed from the manufacturing process The marking or removal output from the PLC can be delayed so that the dye nozzle or removal equipment can be located downstr
74. or is blocked the voltage will be about OVDC When the Sensor is unblocked the voltage will be VDC or 20VDC to 24VDC If not check wiring of the following points When the Sensor is blocked if Input 10 0 indicator on the PLC does not go OFF check wiring of the following points Lower I O Terminal 5 Wht Upper I O Terminal 5 Wht PLC Terminal 10 0 Wht NOTE The Wood Sensor is adjusted for Dark detection the signals work as follows The White Output wire will be atOVDC when the Sensor is blocked and VDC when the Sensor is unblocked Reference is DC Common on the Sensor s Black wire 81 856_0412_0_ 12 01 10 TROUBLESHOOTING TROUBLESHOOTING LIQUID LEVEL SENSOR FUNCTION PLACE DOOR SAFETY SWITCH TO OVERRIDE POWER SWITCH TO ON With Line Voltage at terminals 1 and 2 pull the Door Safety Switch plunger to the override Pull the plunger button with insulated pliers or pull the 6 screw attached to the plunger outward about 1 4 The override position closes the Door Safety Switch and allows the Enclosure to operate with the Door open Rotate the ON OFF Switch to ON The Operator Interface display will light REFER TO DRAWINGS 856 AND 856 32 FOR COMPONENT AND TERMINAL IDENTIFICATION Before checking the operation of the Liquid level sensor verify that the Sensor is wired as follows I O Terminal 3 Blue I O Terminal 2 Black I O Terminal 10 Red Examine the mounting of the Sensor and confirm that the LED at th
75. ose Return to the Main Menu using any method described on Main Menu in this Manual and view the F1 F4 function key assignments then press F1 The Start Delay adjustment ranges from 1 to 1000 the greater the number the longer it will take for the glue valve to open Use the Down Arrow key to move the cursor to the value field The delay value second line on the display is preset to 1 if no value has been previously entered Key in the desired numerical value using the ten digit keys and press ENTER This will immediately change the timing of the desired glue start If your glue pattern starts too early with excess glue at the start of the board key ina greater number and press ENTER Conversely if the glue pattern starts too late with no glue on the leading edge key in a smaller number and press ENTER Example If your setting is at 345 and the glue is starting late too far in from the leading edge press F1 key in 300 and press ENTER Now you find the glue pattern is starting a little early glue is starting to extrude before the leading edge of the board key in 325 and press ENTER This can be continued until pattern is set exactly where you want the glue to start Menu Title Numerical Value for Glue Start Board Count Title Numerical Value for Board Count FlKey E F i F unction K eys ESC Key 7 a a A E ESC EErEE E e E SCROLL DN Key Numeral Keys f E 20 y e ae g 10 i
76. ot wish to change the KFT then just exit the screen or press F2 to end the process Calibration in Calibration be A v 2 lt 4 E lt q l po 856 0412 0 12 01 10 B process 56 complete OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS GLUE METERING Board Marker The Board Marker output is used to mark boards or blocks that have low glue as measured by the Flow Meter Glue flow thatis below your Reject Threshold level will trigger the Marker output The output although referred to as a marker can be used for various output devices The output may be linked to either a dye valve hence the term marker a signal light an audio signal a pneumatic cylinder to kick the defective work piece clear of the production process or an air Kicker to remove the defective work piece clear of the production process The output has a variable delay so that the marker or removal system can be located slightly downstream of the detection unit The output duration may be changed to fit your needs Press K3 from the Main Menu to access the Board Marker Screen This will bring up the Glue Metering Board Marker Screen if you do not have the Glue Detection option If you have the Glue Detection option then you will be on the Glue Detection Board Marker Screen Press the F4 or the DN arrow Key to move to the Glue Metering Board Marker Screen Press the F1 Key to return to the Main Menu The flashing
77. p LLC Ver x x Service 831 642 6565 5 Harris Court Bldg Q Monterey CA 93940 F1 F2 F3 F4 K1 K2 K3 K4 4 1 2 3 A 4 5 6 lt j gt 7 8 9 V 0 SHIFT ner HELP LL POWER SWITCH lo O F ERROR FLUSH SWITCH SY STEM NAMEPLATE amp SERIAL 3 856 CONTROL ENCLOSURE FEATURES e Power Switch On Off Switch Supplies power to the Control Enclosure electronics when in the ON position De energizes the Control Enclosure when in the OFF position NOTE Line voltage 115 VAC or 220VAC depending on your configuration is still present inside the enclosure even with the Power Switch in the OFF posi tion Power ON Indication The Operator Interface display is lighted when the Power Switch is in the ON position and the Door Safety Switch is closed e Manual Valve Operator Flush Operation Press the FLUSH Switch on the Control Enclosure to operate the Air Electric Solenoid The Air Electric Solenoid Val
78. p and O ring expander The open side of the seal that contains the O ring MUST face toward the incoming adhesive pressure The correct orientation of seals is well illustrated in Drawing 268 Lubricate all parts with Silicone Grease which is available from Apquip DO NOT USE PE TROLEUM BASED GREASE Therefore when installing the Spool Seal Part 206 14 in the Valve Body Inlet Part 206 05 the lips of the Seal must enter the cavity first However in the Valve Body Mounting Segment Part 258 04 the inner Seal the face which contacts the Valve Body Inlet is installed with the heel entering first while the outer Seal the lips are inserted first Note that the U Cup Seal Part 258 24 or 268 37 for the Air Cylinder must have its open side face the incoming air pressure to seal properly 856_0412_0_ 12 01 10 93 OPTIONAL VALVE PARTS Optional Parts If the Valve Spool Part 206 07 is experiencing unusual wear because if its use with a filled or abrasive adhesive then use of the ceramic coated version of the Valve Spool Part 206 26 is recommended This special Valve Spool is normally keptin stock Part 206 14 is the standard Spool Seal Black in color that are normally installed into new Part 268 Adhesive Valves Optional Seals are available that may last longer with your adhesive There are two optional Spool Seals Part 268 31 Orange in color and Part 268 33 White in color that m
79. pplication within 2 of the Luminescence Sensor the Glue Amount on the Glue Detect Screen should be at or near 1000 The Ammeter will display at or near 9 10 ma Place a50 luminescent sample within 2 of the Luminescence Sensor the Glue Amount on the Glue Detect Screen should be at or near 500 The Ammeter will dis play ator near 4 6 ma If the Ammeter reading is correct but the Glue Amount display is incorrect verify all wiring connections to the Analog I O Module CHECK THE SENSOR POTENTIOMETERS The Luminescence Sensors have two Potentiometers located at the bottom end of the Sensor near the cable connection They are used for Sensitivity and Response Time The Response Time Potentiometer is always adjusted to minimum or the lowest set ting This is to provide the fastest data to the PLC regarding the actual glue amount on the joint Setting the potentiometer to any other positions would cause the Sensor to miss small sections of the joint with no glue The Sensitivity Potentiometer is normally set to display 1000 when the Sensor is monitoring a joint with 100 glue coverage Therefore when the joint has less than 100 glue coverage lower readings will be displayed The Sensitivity Potentiometer may be checked for linearity by placing a joint with 100 glue coverage in front of the Sensor and adjusting the potentiometer slowly from minimum to maximum The display should start at zero and move slowly to 1000 This will typically
80. r to the override Pull the plunger button with insulated pliers or pull the 6 screw attached to the plunger outward about 1 4 The override position closes the Door Safety Switch and allows the Enclosure to operate with the Door open Rotate the ON OFF Switch to ON The Operator Interface display will light REFER TO DRAWING 856 AND 856 32 FOR COMPONENT AND TERMINAL IDENTIFICATION Before checking the operation of the 822 sensor verify that the Sensor is wired as follows I O Terminal 5 White I O Terminal 6 Black I O Terminal 8 Red Examine the mounting of the Sensor Housing and confirm that the red LED at the back end of the Sensor Housing is lighted It will light when there is no wood within range of the Sensor beam This is the normal unblocked condition for the Sensor Bring a wood target within 1 1 2 inches of the Sensor Housing When the wood is detected the red LED at the back end of Sensor Housing will extinguish This is the normal blocked condition for the Sensor The LED will be litonly when wood is NOT being detected If this is not the case replace the Sensor assembly NOTE Under certain low voltage conditions the Sensor LED will go into a blinking state This is a circuit protection function for the Sensor To restore normal operation remove power to the Control Enclosure wait 5 seconds then restore power If this does not restore normal function to the Sensor check the DC Power Supply output volt
81. reen may display 0 or or any previously programmed value Press numeral 2 and then press enter to store the new value for Sides to Glue for board 6 Press F4 lt NEXT gt to move to the next board in the series NOTE It is very important that you press enter after every pattern value change in order for the PLC to accept the new value If you do not press enter your change will not be stored and the pattern will remain at the previously programmed value If you make a mistake press the correct numeral key and press enter again Press F3 lt PREV gt to move to the previous board in the series Key in the correct option 0 1 2 or 3 press enter to store the correction Press F3 or F4 to move in the series to make corrections a pn i Glue R ight Side of Menu Title Board 6 FAK F1lKey F3Key a O Er jo 2 wn m i ESC Key 7 a o SCROLL DN Key Numeral K eys 7 NTER Key g f 35 856 0412 0 12 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS SERIESPROGRAM EXAMPLE Enter Sides to Glue continues 9 Verify the board program for each board back to board 1 Press F3 lt PREV gt to move to the previous board in the series Board 5 should have 2 as the Sides to Glue value Press F3 lt PREV gt to move to the previous board in the series Board 4 should have 2 as the Sides to Glue value Press F3 lt PREV gt to move to the p
82. removed The beam centerline should be 1 or less UPSTREAM of the centerline of the applica tor head The bottom edge of the sensor housing should be 1 1 2 above the wood sur face This distance should be measured when the hold RED REAM down section is adjusted for a given thickness of wood The 1 1 2 edge of the block should be parallel to wood travel The beam diameter is small enough so that it can be mounted with the beam located between the edge of the hold down flex strip and the edge of the lug If you are having difficulties with reflection from the lugs try angling the sensor beam cranir cabs upstream slightly If you run blocks with significant wane you may want to angle the sensor upstream so you are actually targeting the block halfway down the side of the block This will eliminate the sensor not picking up the front section of the board that has the top corner of the leading edge missing Edge Gluing Because the edge glue lines often run at much higher speeds it may be necessary to mount the sensor anywhere from 1 to 15 upstream of the Applicator Head 65 856_0412_0_ 12 01 10 SENSING COMPONENTS CHECK Before proceeding to adjustment a quick check of the sensing electronics will verify that the system is set up correctly The following check is made without the Lug Chain or Conveyor moving The Air Lines from the Air Electric Solenoid may be connected to the Adhesive Valve but you shoul
83. res have a remote Flush Switch mounted on the enclosure door Pressing the Flush Switch will activate the Flush Input of the PLC and the PLC will activate the Air Valve to open the Adhesive Valve and Flush or Purge the adhesive through the system Use the Flush Switch to prime the adhesive delivery system or purge air from the Applicator when starting gluing operations Use the Flush Switch when performing a cleaning operation using warm water to remove adhesive or adhesive residue from the supply lines and Adhesive Valve as an end of day or end of week maintenance or prior to performing a rebuild maintenance on the Adhesive Valve Press the F4 function key top right corner of the keypad to acess the Flush Screen ifin any F1 F4 Screen On some screens the F4 key may be assigned to another purpose Return to the main menu as described on Main Menu in this Manual and view the F1 F4 function key assignments then press F4 to access the Service Screen While on the Service Screen press F4 to move to the Flush Screen Shown on the next page Once the flush screen shown on next page is displayed press the F4 key to hold the Adhesive Valve in the open position and flush the valve Release the F4 key to close the valve and end the flush operation Menu ____ Title F4 Key Function K eys ESC Key 7 g A ESE ae 4 gt SCROLL DN Key Numeral K eys it E kd NTER Key 856 0412 0_ 12 OPERATO
84. revious board in the series Board 3 should have 2 as the Sides to Glue value Press F3 lt PREV gt to move to the previous board in the series Board 2 should have 2 as the Sides to Glue value Press F3 lt PREV gt to move to the previous board in the series Board 1 should have 0 as the Sides to Glue value Press F1 lt UP gt to move up to the Program Series Data screen Press F1 lt UP gt again to move up to the Series Status screen gt i Numeral K eys E Ee Y NTER Key Ti Fa DEL HELP g o 9 a 8 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS SERIESPROGRAM EXAMPLE Enter Sides to Glue continues 10 Observe the program as boards are sent through the system Setup the System to run boards for this test Place the System in either Constant Width or Variable Width Mode Press K4 to view the Series Status screen Press F2 lt RST gt on the Series Status screen to reset the program to the first board in the series The screen below shows that the next board to pass through is board 1 in a series of 6 boards and glue will be applied to no sides of the board As the first piece passes the board sensor is activated and no glue is applied to the board The board count will increment i No Glue on M enu Aod ut R oard 1 of 6 Title es F4 Key Function K eys ESC Key amp e A ae das Se gt B SCROLL DN Key Numeral K eys iol Y NTER Key i
85. rom the hose If the gauge indicates 20 PSI and there is no flow then turn the tank air supply off and depressurize the tank Turn the valve at the bottom of the tank off and then check the condition of the filter inside the brass T body A plugged filter screen will prevent adhesive flow Remove the filter screen and clean with water and a small brush If the filter screen cannot be cleaned replace it with a new one Refer to drawing 600 which lists the three sizes of available filter screens If there is adhesive flow then refer to Manual Section TROUBLESHOOTING APPLICA TORVALVE ASSEMBLY Pressure R egulator Gauge Assembly Fae 1E D Adhesive flow Adhesive F ilter 856_0412_0_ 12 01 10 TROUBLESHOOTING TROUBLESHOOTING APPLICATOR VALVE ASSEMBLY Shut off the air supply to the Control Enclosure and Pressure Tank Disconnect the two 1 4 air control lines to the Adhesive Valve see Manual Section on Air Controls for instructions on disconnecting air lines from quick release fittings Hold the ends of the control lines in your hand Reapply air to the Control Enclosure at 20 psi Air should exhaust from the OFF B line Press the FLUSH Switch to perform the FLUSH operation Air should now exhaust from the ON A line to the valve If air still exhausts from the OFF line when the Flush Switch is pressed then pro ceed with Manual Section TROUBLESHOOTING ELECTRICAL CONTROLS Reconnect the air lines to the
86. s at 831 642 6565 with your questions We will then walk you through the programming of your 856 Control System 856_0412_0_ 12 01 10 16 OPERATOR INTERFACE FEATURES ADDITIONAL FEATURES REMOTE FLUSH OR PURGE The Remote Flush Switch Inputcan be used for flushing operations without going through the HMI menus When connected per theWiring Diagram the Remote Flush Switch can be mounted to the 856 or wired to another more convenient switch box This will re duce repeated use of the HMI membrane switches and extend the life of the HMI The Remote Flush Switch Input can also be connected to external controls and to allow an external control system to initiate a Flush operation using the 856 This method may be used by third party meter mixer devices to purge the adhesive lines before the mixed adhesive begins to set up P lease contact your A pquip representative with questions regarding R emote F lush P urge 856_0412_0_ 12 01 10 17 OPERATOR INTERFACE FEATURES ADDITIONAL FEATURES LIQUID LEVEL MONITOR The Liquid Level Sensor is used when itis important to know that the adhesive level is approaching a low level condition The Sensor detects the presence of the adhesive in a tank and as long as the adhesive is above the location of the Sensor there is no error When the level falls below the position of the Sensor the Red Lamp on the side of the 856 will light to indicate a low level condition Careful adjustment of the Se
87. sult an even film of adhesive is applied toa wood finger joint with no dry spots and no drips 822 Sensor Unblocked LED lighted 268 Valve Closed START Timer Complete LENGTH Timer Complete The LENGTH setting or time interval is not necessarily of the same length as that of the START The two adjustments START and LENGTH operate independently of one another Refer to the Manual Section on ADHESIVE PATTERN ADJUSTMENT for a more detailed explanation of system operation and fine tuning 61 856_0412_0_ 12 01 10 ADHESIVE APPLICATOR HEAD The only componentin the Apquip System which requires particular alignment attention is the Applicator Head The Applicator Head must be clean and correctly aligned in order for the adhesive to be properly applied APPLICATOR HEAD ALIGNMENT Visual alignment of the Applicator Head has proved the most reliable alignment method Alignment should be performed with a wood joint stopped directly in front of the head A white card or a flashlight placed behind the joint may make it easier to check the head clearance in poorly lit environments At no point should the Applicator Head touch the wood during an adhesive applica tion The Applicator Head should not move not even slightly as the wood passes through the Applicator Head Fingers Mechanical wear caused by misalignment will reduce the usable life of the head The Applicator Head need not be realigned each time the cut
88. t 010 is designed for just this purpose The Flush Adaptor connects to acommon hose bib for easy flushing of the Applicator Head The Applicator Head can be taken apart should foreign matter get through the fluid filter and clog the Applicator Head For those plants which use two component adhe sives with a limited pot life the head can be taken apart and cleaned should the adhesive be allowed to set up inside the head Apquip Applicator Heads are machined from stainless steel and although resistant to wear they can be damaged by sharp tools Use only a soft brush to clean the head if taken apart A toothbrush or fine brass brush works well Never use a screwdriver or pick to clean the finger ports in the Applicator Head Use of silicone grease during reassembly on all screw threads and head mating surfaces will make maintenance much easier Whenever the applicator head is removed from the valve use the Apquip Valve Plug Part 011 01 to seal the valve This will prevent glue drying inside the valve 856_0412_0_ 12 01 10 64 WOOD SENSOR MOUNTING The sensor for finger jointer applications should be installed on the hold down section on the side opposite the cutter head The aluminum body which houses the sensor should be installed as follows 1 Itis preferable to place the sensor on the side of the hold down section that is away from the cutter head This offers more protection from contact by the cutter head whenever itis
89. ter heads are changed provided the dimensions of the wood joint remain the same However a check of the Applicator Head alignment with each cutter head change will also provide a quick verification of correct cutter head alignment For edge glue or face glue applications the applicator head should be 1 16 from the wood surface at an approximate 90 or 45 angle depending on the particular Applicator The Applicator must be parallel with the face of the lumber to provide an even layer or equally sized lines of glue on the lumber 62 856_0412_0_ 12 01 10 APPLICATOR HEAD ALIGNMENT Correct alignment of Applicator Head to wood jointis shown at the left Carefully note that all of the clearances between wood and metal are equal In particu lar check to see that on each finger the clearance at point a is equal to the clearance at point b Similarly the clearance at point c should equal the clear ance at point d These are the critical check points Fig A FigureA If you have difficulties getting equal clearances a b c and d above verify that the Applicator Head is at 90 with respect to the wood joint Fig B If you still have difficulties check to see that the dimensions of the wood joint are correct Figure B 63 856_0412_0_ 12 01 10 APPLICATOR HEAD CLEAN UP At the end of each day the Applicator Head must be thoroughly flushed out with water The Apquip Flush Adaptor Par
90. the ON control line to pressurize and open the Applicator Valve When the Air Electric Solenoid is deener gized the Air Electric Solenoid Valve shifts causing the air in the OFF control line to pressurize and close the Applicator Valve When either the ON or OFF air control a line is pressurized the other air control line is exhausted 7 60 SIX CONTROL STAGES DURING APPLICATION STAGE FOUR The Applicator Valve is open and the Applicator Head spreads adhesive evenly onto the wood sur faces Any width joint or length of wood can be run through the Applicator Head without readjustment of the START and LENGTH controls 822 Sensor Blocked LED off 268 Valve Open START Timer Complete STAGE FIVE The entire width length of wood has now passed the optical sensor The optical beam and the time delay circuit begins timing out the second interval The LENGTH adjustment deter mines this delay period 822 Sensor Unblocked LED lighted 268 Valve Open START Timer Complete LENGTH Timer Running STAGE SIX The LENGTH time delay circuit completes its timing cycle and the Air Electric Solenoid is deenergized The Applicator Valve closes and the adhesive flow through the Applicator Head is shut off The LENGTH adjustment syn chronizes the closure of the Applicator Valve to shut off the adhesive flow as the trailing edge of the wood passes the Applicator Head The re
91. the eye opening The LED will extinguish the Air Electric Solenoid will activate and the Adhesive Valve will shift to OPEN and glue will be dispensed while the object blocks the Sensor When the object is moved away from the Sensor the LED will relight the Air Electric Solenoid will deactivate and the Adhesive Valve will shift to CLOSE and the glue flow will be shut off 66 856_0412_0_ 12 01 10 DYNAMIC ADJUSTMENT The Apquip system employs a high speed optical Sensor and PLC with program mable timers to insure a reliable and consistent adhesive pattern Once the Applica tor Head has been aligned and the sensing components checked adhesive pattern dynamic adjustments with the jointer running can be made 1 Bleed any trapped air out of the adhesive supply line using the FLUSH Switch on the Enclosure Door This switch bypasses the sensing circuit and directly opens the applicator valve 2 Set the GLUE START DELAY numerical value to 200 this value is dependent on the horizontal distance between the Applicator Head and the Sensor and the speed of the Chain or Conveyor The greater the distance the greater the setting This setting is temporary Set the GLUE LENGTH DELAY numerical value to 200 As above this setting is dependent on the distance between the Applicator Head and the Sensor and the speed of the Chain or Conveyor This setting is also temporary Start the Lug Chain Drive The above control adjustment settings w
92. und If no sound check the solenoids by pressing the button at the end of the each black solenoid housing to feel the solenoid activate when Flush is pressed If the core doesn t move then check voltage between I O Terminals 16 amp 28 25 amp 28 26 amp 28 as determined by your system configuration Voltage will be 24VDC when the FLUSH Switch is at FLUSH If 24VDC is present for a terminal set then replace that solenoid coil CHECK AIR ELECTRIC SOLENOID VALVE If the Air Electric Solenoid activates but the air output does not shift the valve lo cated in the valve body is sticking and must be serviced or replaced If the voltage checks out then proceed with TROUBLESHOOTING SENSING ELEC TRONICS T1 856 0412 0_ 12 01 10 TROUBLESHOOTING TROUBLESHOOTING SENSING ELECTRONICS Before proceeding to troubleshooting check to see that the sensing electronic com ponents are set up correctly RED BEAM APPLICATOR HEAD 1 SENSOR POSITION The visible red beam or the center of the eye of the Sensor should be 1 or less from the centerline of the Applicator Head The lower edge of the Sensor s Aluminum Housing should be positioned 1 1 2 above the upper surface of the wood being detected NOTE If the wood blocks have much wane it will be necessary to angle the Sensor Assembly so that the detection pointis the LOWER leading edge of the block Refer to the installation notes for more detail 78 856_0
93. ve Tank and the Adhesive Valve preferably near the Adhesive Valve Verify fluid flow direction per the indication on the meter Install the Glue Meter Sensor into the Meter per the Sensor installation instructions Connectthe Sensor Cable to the Terminal in the 858 per the 858FM Wiring Diagram Attach the Sensor Connector to the Sensor Glue Supply pressure may need to be increased due to the added restriction of the GlueMeter Enter values for GWT and KFT on the Glue Metering Input Screen Perform the Calibration procedure to confirm measurement accuracy of the meter The System is now ready to operate with Glue Metering Please contact your Apquip representative with questions regarding Glue Metering setup 856_0412_0_ 12 01 10 51 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS GLUE METERING Status Press K4 to access the Glue Metering Per Piece screen from the Main Menu This screen displays the current adhesive usage since the last reset Gm Pc shows the amount of adhesive in grams used on the last board Gm 20Pcs shows the average of the amount adhesive used on the last 20 boards Total Liters shows total adhesive usage since the last reset Total Gallons shows the total Gallon usage since the last reset Fl Press F1 to go to the Main Menu F2 Press F2 to zero the Glue usage on the Reset Confirmation Screen F4 Press F4 to move down to the Glue Metering Input screen The Gm Pc value will change with each boar
94. ve determined what you feel is an insufficient amount of adhesive use a numerical value that is 2 5 numbers above that value as your reject threshold setting 856_0412_0_ 12 01 10 47 OPERATOR INTERFACE FEATURES OPTIONAL FUNCTIONS GLUE DETECTION Board Marker The Board Marker output is used to mark faulty boards or blocks seen by the detection unit Glue coverage that is below your Reject Threshold level will trigger the Marker output The output although referred to as a marker can be used for various output devices The output may be linked to either a dye valve hence the term marker a signal light an audio signal a pneumatic cylinder to kick the defective work piece clear of the production process or an air Kicker to remove the defective work piece clear of the production process The output has a variable delay so that the marker or removal system can be located slightly downstream of the detection unit The output duration may be changed to fit your needs Press K3 from the Main Menu to access the Board Marker Screen This will bring up the Glue Detection Board Marker Screen If you have the Glue Metering Option press the F4 or the DN arrow Key to move to the Glue Metering Board Marker Screen Press the F1 Key to return to the Main Menu The flashing cursor will be located on the numerical value for the Start Delay This value will set the time delay between the fault detection and the Marker output activation Set
95. ve shifts the air in the control lines to open the Adhesive Valve This will either dispense adhesive or when the Adhesive Valve is connected for flushing will flush water through the adhesive lines The Flush operation can also be performed by pressing F4 on the Operator Interface to access the Flush Menu Press F4 when at the Flush Screen to start the Flush operation Release F4 to end the Flush operation e Digital Counter Increments with each Gluing cycle providing a count of Adhesive Valve opera tions and joints glued e GLUE START Adjustment The Glue Start adjustment is provided in the Menu of the Operator Interface Screen F1 displays the current setting which can be changed by keying in the numeric value and pressing the Enter Key e GLUE LENGTH Adjustment The Glue Length adjustment is provided in the Menu of the Operator Interface Screen F2 displays the current setting which can be changed by keying in the numeric value and pressing the Enter Key 856_0412_0_ 12 01 10 OPERATOR INTERFACE FEATURES MAIN MENU The MainMenuF Function screen displays E o oaae when the power comes up on the Operator Panel Function Keys F3 and F4 share a line of text and the fourth text line contains the current Block Count When on the F1 F4 l screens a line of text displays the F1 F4 Function Key assignments which can be accessed without going to the Main Menu To access any K1 K4 Menus you must first my J J i go to the
96. with a Reject Threshold of 75 Increase the Reject Threshold setting by increments of 10 until the setting is 160 where errors begin to occur with adequately glued boards Lower the Reject Threshold to 145 and continue operations 856_0412_0_ 12 01 10 TROUBLESHOOTING TROUBLESHOOTING GLUE DETECT MARKER FUNCTION PLACE DOOR SAFETY SWITCH TO OVERRIDE POWER SWITCH TO ON With Line Voltage at terminals 1 and 2 pull the Door Safety Switch plunger to the override Pull the plunger button with insulated pliers or pull the 6 screw attached to the plunger outward about 1 4 The override position closes the Door Safety Switch and allows the Enclosure to operate with the Door open Move the ON OFF Switch to ON The Power Indicator Lamp will light REFER TO DRAWING 856 AND 856 32 FOR COMPONENT AND TERMINAL IDENTIFICATION CHECK FRAME SENSORS CHECK OUTPUT SIGNAL FROM THE LEFT SENSOR Connect the negative meter lead to Upper I O Terminal 18 and the positive meter lead to Lower I O Terminal 19 When the Sensor is unblocked the voltage will be about OVDC Have an assistant block the sensor When the Sensor is blocked the voltage will be VDC or 20VDC to 24V DC If not check wiring of the following points When the Sensor is blocked if Input 10 2 indicator on the PLC does notgo ON check wiring of the following points Lower I O Terminal 19 Wht Upper I O Terminal 19 Blu PLC Terminal 10 2 Blu CHECK OUTPUT SIGNAL FROM THE RIGH

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