Operating Manual

Pattern controls
ICS-IK 42, 44, 46, 48
Part No. 112537 / Edition 4.5
Program ICS-MAIN from version 3.13
Program ICS-JUMBO from version 3.07
Please place this manual in index 2 of your manual folder.

Publisher:
Robatech AG
Pilatusring 10
CH 5630 Muri
Switzerland
Phone
Fax
Email
Internet

+41 (0)56 675 77 00

+41 (0)56 675 77 01
info @ robatech.ch
www.robatech.com

Date of issue April 2005

Copyright by Robatech AG
All rights reserved. Without the written approval of Robatech this manual or parts thereof may not be
copied in any form, or distributed or transferred by means of electronic systems.
Illustrations and information contained in this manual are subject to technical alterations which become
necessary for the enhancement of the appliance.

Table of contents
1

Product description __________________________________________________________________3

1.1

Use for the intended purpose ........................................................................................................................3

1.2

Improper use .................................................................................................................................................3

1.3

Operating Manual .........................................................................................................................................3

1.3.1 How to use this manual ...................................................................................................................4
1.3.2 Modifications in the program ..........................................................................................................4

1.4

Overview of the control ................................................................................................................................4

Design and specifications______________________________________________________________5

2.1

System drawing.............................................................................................................................................5

2.2

Design of the hardware .................................................................................................................................5

2.3

Operating unit ...............................................................................................................................................6

2.4

Technical specifications................................................................................................................................7

Installation _________________________________________________________________________9

3.1

Remarks before the installation.....................................................................................................................9

3.2

Block diagram.............................................................................................................................................10
3.2.1 Inputs for encoder, light barrier and system interface ...................................................................10
3.2.2 Fill level supervision, proportional valve and application heads...................................................11
3.2.3 Connection of SPC control............................................................................................................12

3.3

Signal descriptions ......................................................................................................................................14

3.3.1 View of ICS-EXT1........................................................................................................................14
3.3.2 Encoder inputs...............................................................................................................................14
3.3.3 Trigger inputs (release of the hotmelt application)) ......................................................................16
3.3.4 System interface inputs..................................................................................................................16
3.3.5 System interface outputs................................................................................................................17
3.3.6 Proportional valve output ..............................................................................................................18
3.3.7 Application head valve outputs .....................................................................................................19

Operation _________________________________________________________________________21

4.1

Entering of parameters ................................................................................................................................21

4.1.1 Access blockage ............................................................................................................................21
4.1.2 Entering of parameter values.........................................................................................................22
4.1.3 Parameter 100: Program number...................................................................................................22
4.1.4 Parameter 101: Switch-on delay time ton......................................................................................23
4.1.5 Parameter 102: Switch-off delay time toff.....................................................................................23
4.1.6 Parameter 103: Glue pressure factor .............................................................................................24
4.1.7 Parameter 104: Encoder transmission ...........................................................................................24
4.1.8 Parameter 105: Maximum speed vmax .........................................................................................24
4.1.9 Parameter 106: Minimum speed vmin...........................................................................................25
4.1.10 Parameter 107: Evaluation G-ENABLE and behaviour v < vmin ................................................25
4.1.11 Parameter 108: Trigger input ........................................................................................................26
4.1.12 Parameter 109: Offset distance......................................................................................................26
4.1.13 Parameter 110: Blockage length trigger input 1 ............................................................................26
4.1.14 Parameter 111: Blockage length trigger input 2 ............................................................................26
4.1.15 Parameter 112: Trigger edge / operating mode trigger input 1......................................................27
4.1.16 Parameter 113: Trigger edge / operating mode trigger input 2......................................................27
4.1.17 Parameter 114: Selection of parameter storage .............................................................................27
4.1.18 Parameter 115: Output voltage channels VALVE14.................................................................28

ICS-IK 4248 / v4.5

Tabel of contents

4.1.19
4.1.20
4.1.21
4.1.22
4.1.23
4.1.24
4.1.25
4.1.26
4.1.27
4.1.28
4.1.29
4.1.30
4.1.31
4.1.32
4.1.33
4.1.34

Parameter 116: Output voltage channels VALVE58.................................................................28

Parameter 117: Encoder input .......................................................................................................28
Parameter 118: Proportional valve output .....................................................................................29
Parameter 119: Release of pattern control.....................................................................................29
Parameter 120: Minimum glue pressure [%] .................................................................................29
Parameter 121: Pressure relief time after blockage .......................................................................29
Parameter 122: Configuration of manual valve actuation..............................................................30
Parameters 131138: Channel allocation of the outputs VALVEx .............................................30
Parameter 140: Distance between switch on and off point Trigger 1 ............................................30
Parameter 141: Distance between switch on and off point Trigger 2 ............................................30
Parameter 142: Channel specific trigger blockage length .............................................................31
Parameter 150: Stitching ...............................................................................................................31
Parameter 151: Stitching: interval length ......................................................................................31
Parameter 152: Stitching: glue length............................................................................................31
Parameter 180: Display of channel status......................................................................................32
Parameter 181: Active program number........................................................................................32

4.2

Heating zone release and preheating...........................................................................................................33

4.2.1 Parameter 200: Existence ICS-EXT1, evaluation H-ENABLE 13............................................33
4.2.2 Parameter 201207: Programming the release of heating zones .................................................33
4.2.3 Calling up the release of the heating zones....................................................................................34
4.2.4 Parameter 280: Status of the heating zone release inputs ..............................................................34

4.3

Selecting program numbers.........................................................................................................................35

4.3.1 Selection via keyboard ..................................................................................................................35
4.3.2 Selection via the interface inputs...................................................................................................35

4.4

Programming of application patterns ..........................................................................................................36

4.4.1 Different application modes ..........................................................................................................36
4.4.2 Intermittent glue application..........................................................................................................37
4.4.3 Application at the start and at the end of the product ....................................................................39
4.4.4 Clearing an application pattern......................................................................................................40

4.5

Manual valve actuation ...............................................................................................................................41

4.6

Error messages............................................................................................................................................41

Key word index ____________________________________________________________________43

Table of contents

ICS-IK 4248 / v4.5

1 Product description
1.1

Use for the intended purpose

The pattern control ICS-IK 4x is an option for hotmelt applicators with the program ICS-MAIN or
ICS-JUMBO of Robatech and an extension of the standard temperature control. Subject to the technical specifications (see chapter 2.3) the control is intended for the following applications:
The pattern control ICS-IK 4x permits the activation of up to eight application heads for the application
of hotmelt in different, programmable patterns.
The control ICS-IK is available in four versions for controlling of up to two, four, six or eight application heads
(IK-42, IK-44, IK-46 or IK-48). A multitude of accessories permit to adapt the control ideally to the production
requirements in question (see chapter 11. Accessories, in the manual for the basic appliance).

1.2

Improper use

Any use other than that "for the intended purpose" without the written approval of the manufacturer, or the operation outside the technical specifications, is deemed to be improper.

1.3

Operating Manual

This manual complements the Operating Manual for the basic Concept or Jumbo appliance. The information contained in this manual refers to:

The integrated ICS-IK 4x pattern controls for hotmelt applicators of Robatech

with the program ICS-MAIN from version 3.13 or ICS-JUMBO from version 3.07
This manual is available in the languages German, English, French, Italian and Spanish; other languages on request from the Robatech representative for the country in question.
The operating manual is part of the appliance. Please place this manual in your file with the Operating Manual
for the basic appliance. Keep the manuals ready to hand so that you can look up information quickly at any time.
The manual must be understood and observed in all points by those persons who are responsible for the installation, operation and repair of the appliance.

Warning

General reference
Make absolutely certain you observe not only the safety references contained in
this manual, but also chapter 2 Safety in the operating manual for the basic unit.
Knowledge of the dangers of handling the appliance and of the appropriate measures is an essential prerequisite for a safe and proper operation of the appliance.

ICS-IK 4248 / v4.5

Product description

1.3.1

How to use this manual

Chapters 1 and 2 provide the necessary basic knowledge which every user must have to be able to work with the
pattern control.
Chapters 3 and 4 contain information describing the installation and operation of the control.
At the end of the manual is information facilitating the use of the Instruction Manual such as e.g. a key word index and the table of parameters.

1.3.2

Modifications in the program

From program ICS-MAIN version 3.12 to version 3.13:

Lower input range of parameter 104 has changed: 10.0 (as yet 100.0)
Input range of parameter 107 added with UU and UI. Evaluation of the speed can be switched off.
From program ICS-MAIN version 3.05 to version 3.08:
New parameter 122: Configuration of the manual actuation of the application heads. Manual actuation of the
application head remains switched on, until the key is pressed again (On) or the application head is active, as
long as the key is pressed (OFF).

1.4

Overview of the control

The pattern control ICS-IK4x is of a modular structure and available in different executions. The control can be
made up of the following components (see also chapter 2.1):
Designation
ICS-EXT1
PLD 2
PLD 4

Function
Printed circuit board
IC for the activation of 2 application heads
IC for the activation of 4 application heads

Part No.
112370
112782
112783

The commponents can be combined as follows:

Designation / application

ICS-EXT1

PLD 2 (Place)

PLD 4 (Place)

Only heating zone release

(without pattern control)

IK-42: Control of 2 application heads

1 PLD2 (IC1)

IK-44: Control of 4 application heads

2 PLD2 (IC1+IC2)

IK-46: Control of 6 application heads

IK-48: Control of 8 application heads

1 PLD4 (IC1)

1 PLD2 (IC1) and

1 PLD4 (IC2)

1 PLD2 (IC2) and

1 PLD4 (IC1)

2 PLD4 (IC1+IC2)

Product description

ICS-IK 4248 / v4.5

2 Design and specifications

2.1

System drawing

Drawing of a typical system

2.2

Design of the hardware

1.
2.
3.
4.
5.

ICS-IK 4248 / v4.5

Main control ICS-MAIN

Control board ICS-EXT1
Two card slots (IC1 and IC2) for the PLDs for activation of the application heads
Connecting terminals for encoder, trigger and system interface
Connecting terminals for valves of the application heads

Design and specifications

2.3

Operating unit

1.
2.
3.
4.
5.
6.

Additional operating field for the pattern control

Display and entry of the values
Display and selection of the functions
Schematic presentation of the appliance with indication of the heating zones
Display and selection of the heating zone numbers
Selection of the program function

Design and specifications

ICS-IK 4248 / v4.5

2.4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Technical specifications
Operating temperature
Storage temperature
Number of application heads
Number of application lines per
channel
Number of programs

060 C
-40+85 C, avoid high temperatures
0, 2, 4, 6 or 8
31
Optional chopping mode (stitch) with selectable resolution
87
Selection via inputs PROG1PROG6 or via keyboard
Speed range
0300 m/min
Accuracy
Shifting of the application pattern: max. +1 encoder increment
Length rounding error: max. -1 encoder increment
Maximum distance between trigger 9,999mm (or 32,000 encoder impulses)
and application head
Individually programmable for each channel
Max. distance product start
9,999 mm (or 32,000 encoder impulses)
application end
Max. number of products within
10 per trigger input
distance trigger - application head
Valve outputs
One output per channel
Several identical valves possible per output
Protected against short circuit
Status indication by LED
Output voltage:
24 VDC during 2.42,8 ms (Lowering voltage < 12 Volt)
resp. 4.85.6 ms after switching on, then lowering to a programmable voltage (6, 9, 12, 15, 18, 21, 24 V).
Lowered voltage adjustable per channel group 14 and 58.

12.
13.

Switch-on and switch-off compensation

Trigger inputs

Output current < 1.4 A / output,

Output currents 1+2, 3+4, 5+6, 7+8 < 1.8 A
total continuous capacity of all outputs:
max. 25 Watt with power supply 40 Watt (Concept X/2 and X/4)
max. 45 Watt with power supply 60 Watt (Concept X/6 and X/8)
max. 85 Watt with power supply 100 Watt (Option)
030 msec., 0.1 msec resolution,
individually adjustable per channel
2 DC-decoupled inputs (only in case of external supply), with common minus-connection
Status indication by LED

14.

Trigger modes

1027 VDC, source (PNP), Rin = 2.7 kOhm

Selectable:
Application of a predefined glue pattern, start with positive edge
Application of a predefined glue pattern, start with negative edge
Continuous application with presence supervision (direct drive of the
application head outputs)
Length measuring of the product with dynamic adaption of the glue
length to the product length

ICS-IK 4248 / v4.5

Design and specifications

15.

Encoder input

1 Input with 2 DC-decoupled input signals A, B (only in case of external supply), with common minus-connection
Optional detection of direction of rotation with evaluation of the two
90 phase-shifted input signals A and B
max. stored backwards path: 31 encoder impulses
max. frequency: 30 kHz
Status indication by LED

16.

17.

System interface inputs

(PROG1PROG6,
H-ENABLE1H-ENABLE3,
G-ENABLE, RESINP2)
System interface outputs
(TANK EMPTY, TANK FULL,
OUT1OUT6)

2027 VDC, source (PNP), Rin = 1.8 kOhm

11 DC-decoupled inputs with common minus-connection
Status indication by LED
1027 VDC, source (PNP), Rin = 2.7 kOhm
8 DC-decoupled source outputs (PNP)
Status indication by LED
Supply voltage: 1127 VDC
Output current: max. 150 mA/output, short circuit-proof

18.

19.
20.
21.

Power supply output for the optional supply of

Encoders
Trigger light barriers
Inputs and outputs of the system interface
Proportional valve
Glue release input
G-ENABLE
Heating release inputs
H-ENABLE1H-ENABLE3
Proportional valve output
A-OUT

Output voltage: supply voltage - 1.7 VDC

24 VDC, Imax < 0.4 A

Function programmable
maximum reaction time: 8 msec
Selection of 7 programmable heating zone release combinations
Speed-proportional output signal with minimum valve limitation for
the activation of a proportional valve
optional

1.)
2.)

420 mA, RLast = 0600 Ohm

010 V, ILast < 10 mA

Design and specifications

ICS-IK 4248 / v4.5

3 Installation
Danger

Electrocution
Mortal danger exists on touching of live components (operating voltage 400 Volt).
The protective covers may only be removed if the appliance is disconnected from
the power supply.

Wiring of the control may only be carried out by trained personnel, e.g. electrical
fitters. Apart from the information contained in this manual, the generally applicable safety and accident prevention regulations must be observed.

3.1

Remarks before the installation

Normally, the ICS-IK control is already installed in the basic Concept appliance. Subsequent installation,
however, is also possible. In this case the installation procedure is described in the applicable retrofit manual.
The complete cabling of the printed circuit board of the pattern control ICS-EXT1 must be effected with
shielded cables. Wrongly connected or unshielded cables may interfere with the functions of the appliance or
influence other devices. Correct wiring is described in chapter 5 of the operating manual for the basic appliance.
The minimum equipment is a light barrier and an application head that the pattern control functions.

ICS-IK 4248 / v4.5

Installation

3.2
3.2.1

10

Block diagram
Inputs for encoder, light barrier and system interface

Installation

ICS-IK 4248 / v4.5

3.2.2

Fill level supervision, proportional valve and application heads

ICS-IK 4248 / v4.5

Installation

11

3.2.3

12

Connection of SPC control

Installation

ICS-IK 4248 / v4.5

ICS-IK 4248 / v4.5

Installation

13

3.3

Signal descriptions

3.3.1

View of ICS-EXT1

3.3.2

Encoder inputs

The encoder serves to measure the speed of the system, for example of the conveyor belt. This measurement
permits to maintain the same glue length and the same glue quantity while the speed varies. No encoder is required if the transporting speed is constant. In this latter case the speed is determined by the value in parameter
105, vmax. The Robatech encoder generates 1,000 impulses per revolution.
X1
1
2
3
4
5
6

Designation
0V
0V
+24 VDC
ENCODER COMMON
ENCODER A
ENCODER B

I/O
Output
Output
Output
Input

LED

Input
Input

D1
D2

Function
Power supply (0V)
Power supply (0V)
Power supply (24 VDC)
Common 0V connection of the inputs
ENCODER A and ENCODER B
Encoder signal A
Encoder signal B

Use only encoders with detection of the direction of rotation (evaluation of A/B signals).
These are less sensitive to interferences and thus increase the operational safety.

14

Installation

ICS-IK 4248 / v4.5

3.3.2.1

Direct connection

Two cables of different length are available for direct connection of an encoder to control board ICS-EXT1. An
extension of this connection is not possible.

1 - Encoder

2 - Encoder cable

No. 100824

No.112988 / 3 m
No. 112989 / 5 m
No.117077 / 20 m

3.3.2.2

Extended connection

Various extensions serve to adapt the encoder connection to particular requirements.

By means of the extension cables (pos. 3) the connection can be extended at will, for example, or the distributor
box (pos. 4) allows the connection of two hotmelt applicators to the same encoder. The encoder cable (pos. 2)
and the adapter cable (pos. 5) are required for all variants.

1 - Encoder

2 - Encoder
cable

3 - Extension
cable

4 - Encoder
distributor box

5 - Adapter cable

No.100824

No.112660 / 5 m

No.112662 / 2 m

No.114230

No.114627

No.112661 / 3 m

No.122622 / 5 m

No.118365 / 15 m

No.122623 / 10 m
No.122624 / 15 m

ICS-IK 4248 / v4.5

Installation

15

3.3.3

Trigger inputs (release of the hotmelt application))

Release of the hotmelt application is normally by means of a photoelectric cell, but it can also be effected by a
proximity switch or similar device. You will find a selection of sensors and corresponding accessories in chapter
11 of the manual for the basic appliance.
X1
7
8
9
10
11
12

3.3.3.1

Designation
0V
0V
+24 VDC
TRIGGER COMMON
TRIGGER 1
TRIGGER 2

I/O
Output
Output
Output
Input
Input
Input

Pin
1
2
3
4

Colour
white
brown
green
shield

Assignment
0 Volt
+ 24 Volt
Signal PNP

Marking
+
PNP

System interface inputs

11 freely configurable inputs are available on board ICS-EXT1

The configuration of the inputs is effected with parameters 530 to 555 (the table shows the default values)
Inputs PROGx to select a program number
Inputs H-ENABLEx for switching on and off or preheating of the heating zones
Inputs G-ENABLE for switching off of the glue application
X1
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

16

D3
D4

Function
Power supply (0V)
Power supply (0V)
Power supply (24 VDC)
Common 0V connection of the inputs X1.11 and 12
Release of the application head
Release of the application head

Adapter cable contact assignment (No.112992)

View of the solder connection ends:

3.3.4

LED

Designation
0V
0V
+24 VDC
EXTINP COMMON
PROG 1
PROG 2
PROG 3
PROG 4
PROG 5
H-ENABLE 1
H-ENABLE 2
H-ENABLE 3
G-ENABLE
RESINP 1
RESINP 2

I/O

Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input

LED Default function

Power supply (0V)
Power supply (0V)
Power supply (24 VDC)
Common 0V connection of the inputs X1/1727
D5 Program selection, significance 1
D6 Program selection, significance 2
D7 Program selection, significance 4
D8 Program selection, significance 8
D9 Program selection, significance 16
D10 Heating zone release, significance 1
D11 Heating zone release, significance 2
D12 Heating zone release, significance 4
D13 Release of application, function as per parameter 107
D14 Reserve input 1
D15 Reserve input 2

Installation

ICS-IK 4248 / v4.5

3.3.5

System interface outputs

8 freely configurable outputs are available on board ICS-EXT1

The configuration of the outputs is effected with parameters 520 to 527 (the table shows the default values)
Output TANK EMPTY switches on when the tank is empty (fill level sensor required)
Output TANK FULL switches on when the tank is full (fill level sensor required)
Output PTEMP-READY switches on when the preheated heating zones have reached their temperatures
X1
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45

Designation
0V
0V
+24 VDC
OUTGND
OUTGND
OUTVIN
OUTGND
TANK EMPTY
TANK FULL
OUTGND
OUT 1
PTEMP-READY
OUTGND
OUT 3
OUT 4
OUTGND
OUT 5
OUT 6

ICS-IK 4248 / v4.5

I/O

Output
Output

Output
Output

Output
Output

Output
Output

LED Default function

Power supply (0V)
Power supply (0V)
Power supply (24 VDC)
Output supply (0V)
Output supply (0V)
Output supply (12..24 VDC)
Output supply (0V)
D16 Tank empty (signal from tank fill level sensor)
D17 Tank full (signal from tank fill level sensor)
Output supply (0V)
D18 Preheated heating zones have reached the nominal temp.
D19
Output supply (0V)
D20
D21
Output supply (0V)
D22
D23

Installation

17

3.3.6

Proportional valve output

Proportional valves convert an electrical signal to an analog pneumatic pressure. They are available as currentcontrolled (I/P) and as voltage-controlled (U/P) executions. Their area of application in Robatech equipment is
the closed loop control of the system pressure at pneumatic piston pumps in dependence of the machine speed
measured by means of the encoder. This permits to achieve a constant glue quantity at different speeds.
X1
46

Designation
A-GND

I/O
Output

47
48

+24 VDC
A-OUT

Output
Output

X6
1-2
2-3

LED Function
Power supply (0V),
GND for analog output A-OUT
Power supply (24 VDC)
Analog output: 4..20 mA (jumper X6, 1-2)
0..10 V (jumper X6, 2-3)

Function: Jumpers for configuration of the analog output A-OUT

Position 1 and 2 plugged in: 4...20 mA
Position 2 and 3 plugged in: 0...10 V

3.3.6.1

Connection
Robatech recommends the use of a type SMC ITV2000 proportional valve. Dedicated operating instructions exist for this converter. As regards the connection of
the older type SMC ET200, please get in touch with our after-sales service department.

In the case of the ICS-IK application controls the proportional valve is connected on the extension board EXT-1.
An adapter cable (Part No.113002) is required for the connection. The connection is made on the terminals bearing the numbers 46, 47 and 48 according to the following diagram:

Deliverable accessories and spare parts:

Part No.
113002
100667
116258
119445
109067
120219
120241

18

Designation
Adapter cable electro-pneumatical converter on EXT1
Extension cable 2 m converter
Extension cable 7 m converter
(Connection between connection and adapter cable)
Converter connection cable with plugs, 3 m
Distribution box for UP-converter signal, 1 input, 2 outputs
Operating instructions SMC ITV2000 German
Operating instructions SMC ITV2000 English

Installation

ICS-IK 4248 / v4.5

3.3.7

Application head valve outputs

To connect the application heads please also take note of the technical specifications in chapter 2.4.

X1
50
51
53
54
56
57
59
60
62
63
65
66
68
69
71
72

Designation
VALVE 1
+ VALVE 1
VALVE 2
+ VALVE 2
VALVE 3
+ VALVE 3
VALVE 4
+ VALVE 4
VALVE 5
+ VALVE 5
VALVE 6
+ VALVE 6
VALVE 7
+ VALVE 7
VALVE 8
+ VALVE 8

I/O

LED Function

Output

D72 Application head valve output 1

Output

D73 Application head valve output 2

Output

D74 Application head valve output 3

Output

D75 Application head valve output 4

Output

D76 Application head valve output 5

Output

D77 Application head valve output 6

Output

D78 Application head valve output 7

Output

D79 Application head valve output 8

The connections 49, 52, 55, 58, 61, 64, 67 and 70 for the cable shield exist only on older printed circuit boards
and comply no longer with current regulations. An EMC-compatible operation is only assured if the cable shield
is connected to the appliance housing (see chapter 5.8.6 in the Operating Manual for the basic appliance).

3.3.7.1

Connection of the valves

Cable socket MAC valves

Cable socket Brkert valves

Connection assignment:
1
2

ICS-IK 4248 / v4.5

Installation

white
brown
Earth /ground

19

20

Installation

ICS-IK 4248 / v4.5

4 Operation
4.1

Entering of parameters

The basic settings of the ICS-IK4x pattern control are made with the parameters 100152.

Setting of parameters may only be done by an experienced technician. Wrong entries lead to disturbances or the failure of the appliance.
Saving and loading of the parameter settings and of the programmed glue patterns is described in the manual to the basic unit.

4.1.1

Access blockage

To prevent unintentional or unauthorized alteration of the data, all values can only be altered after the access
blockage has been lifted. On altering of the values the display shows Loc1 or Loc2.
Lifting Loc1
Press these keys simultaneously:

Lifting Loc2
Press these keys simultaneously:

Activating the access blockages

Press these keys simultaneously:

Lifting Loc2 lifts always Loc1 too.

The access blockage is activated automatically if no key is actuated within two minutes.
Data access can also be blocked via a key switch (see manual of the basic unit).
If the PROFIBUS board is installed, the access blockage LocE is displayed. The data input via operating unit
is blocked. To lift LocE set parameter 400 to OFF (see also Profibus manual).

ICS-IK 4248 / v4.5

Operation

21

4.1.2

Entering of parameter values

Select function Parameter with the keys (1)

With certain parameters, values must be entered for

each individual application head (also channel).
The desired application head or A for all is selected with the keys (4) and displayed in the field
(5).

Display (6) shows the set parameter value. After

lifting of the access blockage the value can be altered with the keys (7).

Select the parameter number with the keys (2). The

number comes up in the display (3).

4.1.3

Parameter 100: Program number

The application control features over 87 programs for storing application patterns including the parameters. All
inputs always refer to the current program number. The program number is selected with parameter 100. If the interface inputs PROG1PROG6 of the board ICS-EXT1 are switched on, the program selection is effected over
these inputs (Program selecting see also chapter 4.3). Alteration after lifting of access blockage Loc1.
Input range
P 0P 86

22

Function
Selected program number

Default
P0

Operation

ICS-IK 4248 / v4.5

4.1.4

Parameter 101: Switch-on delay time ton

The control compensates the switch-on delay of the electric valves by switching the corresponding solenoid valve
on already before the start of the glue application. The switch-on delay time ton [msec] can be entered for each
application head individually. Alteration after lifting of access blockage Loc1.
Input range
0.030.0 [msec]

4.1.5

Function
Switch-on delay time ton

Default
0.0

Parameter 102: Switch-off delay time toff

The switch-off delay time toff [msec] can be entered individually for each channel. The control compensates the
switch-off delay in that the corresponding valve is already switched off ahead of the end of the glue application.
Alteration after lifting of access blockage Loc1.
Input range
0.030.0 [msec]

Function
Switch-off delay time toff

Default
0.0

Explanation of the function of the switch-on and switch-off delay time

Due to the inertia, all electrical valves feature a constant inherent switching time. The properties of the glue and
the execution of the application head may cause an additional extension of the inherent switching times of the entire application head. These time lags must be compensated under all circumstances to make sure that the application pattern corresponds to the programmed distances also at high machine speeds.

Effective glue application

Switch-on time of the solenoid valve

The following values can be assumed as basic

settings: ton = 6.5 msec / toff = 7.5 msec

The compensation time can be calculated as follows:

Application of a glue pattern at two different transport speeds.
(Length difference [mm] 60) : speed difference [m/min] = delay [msec]

ICS-IK 4248 / v4.5

Operation

23

4.1.6

Parameter 103: Glue pressure factor

Only with proportional valve! The value of the speed-proportional analog signal A-OUT (=proportional valve
pressure, glue quantity) can be made weaker or stronger in percent, relative to the maximum speed.
Alteration after lifting of access blockage Loc1.
output value [%] = [glue pressure factor] (v : vmax)
Input range
0200 [%]

Function
Glue pressure factor

Default
100

By means of further parameter 120 the glue pressure can be limited to a minimum value.

4.1.7

Parameter 104: Encoder transmission

Channel-related input of the transport length in mm per 1000 encoder impulses. Values up to 999.9 mm are displayed in 0.1 mm, greater values with a resolution of 1 mm (watch the decimal point).
If no encoder is used (internal time basis), the encoder transmission of channel 1 must be set to OFF. In this
case vmax (Parameter 105) is used as the machine speed for all channels. Alteration after lifting of access blockage Loc1.
Input range
OFF
10.03,000 [mm]

Function
No encoder, v = vmax in Parameter 105
Transport length per 1,000 encoder impulses

Default
1,000

All length values are internally converted into encoder impulses. The greater the length
per encoder impulse, the more inaccurate is the path resolution (rounding error).
Robatech encoders (100824) emit 1,000 encoder impulses per revolution. The transport length, therefore, is to be
measured per revolution. If another encoder is used, the transport length has to be converted.
The following procedure can also be adopted if the transport length cannot be measured precisely:
Set an estimated value for the machine speed. Next, use a speed measuring device to determine the exact product
speed while the machine is running. If the measured speed deviates from the speed shown in the control display,
the encoder transmission must be adjusted until the values correspond. If no measuring device is available it is
also possible to compare the set application length with the actual application length (at a very low speed).

4.1.8

Parameter 105: Maximum speed vmax

The maximum admissible speed vmax [m/min] is used in the calculation of the admissible input values. The error
E103 is displayed if the maximum speed is exceeded. If the encoder transmission (parameter 104) is put on internal time basis OFF, the value vmax is used as the machine speed. Alteration after lifting of access blockage
Loc1.
Input range
5.0300.0 [m/min]

24

Function
Maximum speed vmax

Default
150.0

Operation

ICS-IK 4248 / v4.5

4.1.9

Parameter 106: Minimum speed vmin

A minimum speed vmin [m/min] can be defined for each channel. If it is fallen short of, the corresponding output
is switched off. Depending on the status of parameter 107 the sequence is cleared or remains stored (-> application is resumed on exceeding of the minimum speed). If the minimum speed is put on 0.0, the corresponding
output remains switched on also in standstill. Alteration after lifting of access blockage Loc1.
Input range
0.0150.0 [m/min]

Function
Minimum speed vmin

Default
0.0

4.1.10 Parameter 107: Evaluation G-ENABLE and behaviour v < vmin

For each single channel it is possible to define the evaluation of release input G-ENABLE and the behaviour in
case the minimum speed defined in parameter 106 is fallen short of.
Alteration after lifting of access blockage Loc1.
Display
U

UU

UI

IU

II

Condition
Speed < vmin
(G-ENABLE is not
evaluated)

Behaviour
Application head output is switched off
Glue application is stopped, stored triggers are
cleared
Triggering is blocked
Application head output is switched off
Speed < vmin
(G-ENABLE is not
If speed > minimum speed, the glue application is
evaluated)
continued
G-ENABLE switched off
Application head output is switched off
(Speed < vmin is not
Glue application is switched off, stored triggers
evaluated)
are cleared
Triggering is blocked
G-ENABLE switched off
Application head output is switched off
(Speed < vmin is not
If G-ENABLE active, the glue application is conevaluated)
tinued
Speed < vmin
Application head output is switched off
or G-ENABLE switched off Glue application is switched off, stored triggers
are cleared
Triggering is blocked
Speed < vmin
Application head output is switched off
or G-ENABLE switched off If speed > minimum speed and G-ENABLE input
active, the glue application is continued

ICS-IK 4248 / v4.5

Operation

Default

25

4.1.11 Parameter 108: Trigger input

Every release of the application head can be switched off or take place via trigger input 1 or 2. OFF switches
off the application head output. Alteration after lifting of access blockage Loc1.
Input range
OFF
1
2

Function
Triggering blocked
Triggering by trigger input 1
Triggering by trigger input 2

Default
1

4.1.12 Parameter 109: Offset distance

The distance between the light barrier and the application head is called the offset distance and can be defined
individually for each application head. This means that the glue application for each application head can always
be calculated starting from the product edge. Alteration after lifting of access blockage Loc1.

Contrary to all other parameters, the altered value of the offset distance is only
taken over after the parameter input is quit!
Input range
09,999 [mm]

Function
Offset distance between light barrier and application head

Default
200

Calculating the offset distance:

The distance must be selected long enough so that the reaction times of the application heads can be taken into
account. Approx. 1/5 of the maximum machine speed can be assumed as offset distance.
E.g. vmax = 200 m/min, offset distance = 40 mm
The minimum offset distance (without safety reserve) can
also be calculated precisely:

The minimum distance between light barrier and application head depends on the
maximum machine speed and the switch-on compensation ton.

4.1.13 Parameter 110: Blockage length trigger input 1

4.1.14 Parameter 111: Blockage length trigger input 2
After release, the trigger inputs are blocked for a certain distance. The blockage length [mm] is defined individually for each trigger input. Independently of this parameter, the trigger input is always blocked from product start
to product end. Alteration after lifting of access blockage Loc1.
Input range
09,999 [mm]

26

Function
Blockage length of trigger inputs 1 or 2

Operation

Default
0

ICS-IK 4248 / v4.5

4.1.15 Parameter 112: Trigger edge / operating mode trigger input 1

4.1.16 Parameter 113: Trigger edge / operating mode trigger input 2
Releasing of the glue application is effected by a light barrier signal at the trigger input. The parameters 112 and
113 determine the evaluation of the light barrier signal edge at the two trigger inputs. The application head outputs are assigned to a trigger input by means of parameter 108.
Alteration after lifting of access blockage Loc1.
Display
_ _|
| _
--|-|

Function
Intermittent application (normal case),
Release with rising edge (off-on)
Intermittent application
Release with falling edge (on-off)
Continuous application with presence check
Glue application only as long as a signal is present
One application at the beginning and end of the product.
Automatic adaptation of the application length to the
product length by through application.

Remarks

Default

Programming
see chapter 4.4.2
Example
see chapter 4.4.1
Programming
see chapter 4.4.3

_ _|

4.1.17 Parameter 114: Selection of parameter storage

In the basic setting the parameters are stored jointly for all programs. At option, certain parameters can also be
stored program-related. Alteration after lifting of access blockage Loc2.
Display
OFF
1

2
3

Program-related storage of the parameters

Parameters are stored for all programs
Parameter 108: Trigger input
Parameter 109: Offset distance
Parameter 110: Blockage length trigger input 1
Parameter 111: Blockage length trigger input 2
Parameter 103: Glue pressure factor
Parameter 105: Maximum speed vmax
All parameters of 1 and 2 in this table

ICS-IK 4248 / v4.5

Operation

Default

OFF

27

4.1.18 Parameter 115: Output voltage channels VALVE14

4.1.19 Parameter 116: Output voltage channels VALVE58
On switching-on, 24 Volts are present at the valve output during a few milliseconds in order to achieve a short
switch-on time of the solenoid valves. This voltage is called the overexcitation voltage. Afterwards the voltage
is reduced to the extent that the valve remains only just switched on. This voltage is programmable and is called
the output voltage. It can be set for the valve group 14 and 58. Alteration after lifting of access blockage
Loc2.

Lowering of the voltage is recommended under all circumstances in the interest of

a reduced power consumption and a faster switch-off.

Input range
68
911
1214
1517
1820
2123
24

Output
voltage
6.3 Volt
9.3 Volt
12.3 Volt
15.2 Volt
18.2 Volt
21.2 Volt
23.6 Volt

Standard setting for typical valves:

Time between switching on

and voltage lowering
2.42.8 ms

4.85.6 ms

Power requirement
(compared to 24VDC)
6%
14%
25 %
39 %
56 %
76 %
100 %

Part No.100605: MAC Type 100, 24VDC, 8.5 Watt

Part No.100606: MAC Type 100, 24VDC, 17.1 Watt

Default

12

18 [Volt]
12 [Volt]

The output voltage must never be higher than the valve's nominal voltage, otherwise
the valve will be destroyed. This is why you must mark the programmed output voltage on each valve connection cable.

4.1.20 Parameter 117: Encoder input

At option, a detection of the encoder's direction of rotation is effected with evaluation of the two 90 phaseshifted input signals A and B. Alteration after lifting of access blockage Loc2.
Input range
A
Ab

Function
No detection of direction of rotation
Evaluation of encoder input ENCODER A
Detection of direction of rotation (is recommended)
Evaluation of the encoder inputs ENCODER A and ENCODER B

Default
A

If detection of the direction of rotation is activated, both input signals must be available with the correct phase offset. In case of wrong phase position (=wrong direction
of rotation), the two input signals must be swapped.

28

Operation

ICS-IK 4248 / v4.5

4.1.21 Parameter 118: Proportional valve output

At option, the proportional valve output can be configured as current output (420 mA) or as voltage output
(010 V). For this purpose the appliance must be disconnected from the mains supply and opened, and jumper
X6 on the ICS-EXT1 printed circuit board must be placed either in position 1+2 for current output or 2+3 for
voltage output (see also chapter 3.3.6). Alteration after lifting of access blockage Loc2.
Display
420
010

Function
420 mA current output (normal case)
010 V voltage output

Default
420

4.1.22 Parameter 119: Release of pattern control

The pattern control is normally blocked for as long as the appliance is not ready for operation (LED Ready is
not lit). By means of parameter 119 the control can be released independently of the readiness for operation. Alteration after lifting of access blockage Loc2.
Display
OFF
On

Function
Release only if ready for operation (LED Ready is lit)
Release independent of readiness for operation

Default
OFF

4.1.23 Parameter 120: Minimum glue pressure [%]

Only with proportional valve! The value of the analog signal A-OUT (=proportional valve pressure, glue quantity) can be limited downwards to a minimum value [% of the maximum glue pressure]. Alteration after lifting of
access blockage Loc1.
Input range
0100 [%]

Function
Minimum glue pressure

Default
0

4.1.24 Parameter 121: Pressure relief time after blockage

After the blockage of the glue application of an application head output (v < vmin or G-ENABLE off) the pressure build-up valve (output P-VALVE) is switched off during the time defined in parameter 121 and thereby the
glue pressure is relieved. The function is only active if board ICS-PINT is not installed.
Setting after lifting of input blockage Loc2.
Input range
OFF
110 [sec]

Function
No pressure relief
Pressure relief time

ICS-IK 4248 / v4.5

Default
OFF

Operation

29

4.1.25 Parameter 122: Configuration of manual valve actuation

Function of the key
Input range
OFF
On

at manual actuation of the application head (see chapter 4.5).

Function
Application head is active as long as key is pressed
Application head keeps active, until it is switched off via key (Flip-flop)

Default
OFF

4.1.26 Parameters 131138: Channel allocation of the outputs VALVEx

Settings at these parameters have to be made in case of complex applications
only! In the normal case the basic setting is sufficient!
With this allocation it is possible to detect several application head outputs under one channel. The following applies in the basic setting: Application head output = channel. The allocation is programmable for each individual
application head. The parameters 101, 102, 104 and 106109 are channel-specific and can, if defined here, relate to several application heads. Manual triggering of the heads and the programming of application patterns are
also effected channel-related. Setting after lifting of the input blockage Loc2.
Input range

Function

18

Channel which activates

the application head
output VALVE x

Parameter
131
132
133
134
135
136
137
138

Application head output

VALVE 1
VALVE 2
VALVE 3
VALVE 4
VALVE 5
VALVE 6
VALVE 7
VALVE 8

Default
1
2
3
4
5
6
7
8

4.1.27 Parameter 140: Distance between switch on and off point Trigger 1
4.1.28 Parameter 141: Distance between switch on and off point Trigger 2
Parameters only appear when parameter 112/113 = | |.
In operating mode Glue application at start and end of the product the distance between the switching-on and
switching-off point of the trigger can be set and compensated. The switching tolerance of the trigger sensors can
be compensated. Setting after lifting of input blockage Loc1.
Input range
070 [mm]

30

Function
Distance between switching-on and switching-off point of the trigger

Operation

Default
0

ICS-IK 4248 / v4.5

4.1.29 Parameter 142: Channel specific trigger blockage length

Parameter only appears when parameter 112/113 = | |.
In operating mode Glue application at start and end of the product a trigger blockage lenght can be defined for
each applicaton head. After release, the trigger input of the corresponding application head is blocked during the
programmed length in parameter 142. Setting after lifting of input blockage Loc1.
Input range
OFF
09,999 [mm]

Function
No trigger blockage length
Channel specific trigger blockage length

Default
OFF

4.1.30 Parameter 150: Stitching

Parameters 150152 only have a function when parameter 112 and/or 113 = __| , |_ or
Every glue application can be programmed as uninterrupted application, or it can be stitched further. More information are listed in chapter 4.4.2. Setting after lifting of input blockage Loc1.
Input range
OFF
On

Function
Uninterrupted glue application
Stitching switched on

Default
OFF

4.1.31 Parameter 151: Stitching: interval length

Parameter 151 only appears when parameter 150 = On
Input of the repeating interval length when stitching a glue application (see chapter 4.4.2). Setting after lifting of
input blockage Loc1.
Input range
x1,000 [mm]

Function
Interval length when stitching (minimum length x is calculated)

Default
10

4.1.32 Parameter 152: Stitching: glue length

Parameter 152 only appears when parameter 150 = On
Input of the repeating glue length when stitching a glue application (see chapter 4.4.2). Setting after lifting of input blockage Loc1.
Input range
x1,000 [mm]

Function
Glue length when stitching (minimum length x is calculated)

ICS-IK 4248 / v4.5

Operation

Default
10

31

4.1.33 Parameter 180: Display of channel status

The status of the selected application head is displayed.
Display
0.xx
1.xx
2.xx
3.00

Function
Normal glue application, trigger input released
xx = number of copies in the waiting queue
Glue application stopped, trigger input blocked
xx = number of copies in the waiting queue
Glue application interrupted, trigger input blocked
xx = number of copies in the waiting queue
Glue application stopped, trigger input blocked
Appliance not ready for operation (LED Ready is not lit)

4.1.34 Parameter 181: Active program number

The active program number is shown. When the program number is selected by the interface inputs PROG1 to
PROG6 a dot is lit on the right side. Display range P 0P 86.

32

Operation

ICS-IK 4248 / v4.5

4.2

Heating zone release and preheating

The inputs H-ENABLE13 on board ICS-EXT1 permit switching on and off as well as preheating of each individual heating zone (tank, heated hoses and application heads) by a higher-ranking control. With the parameters
201...207 at the device, up to seven different combinations can be defined and activated via the three inputs.

4.2.1

Parameter 200: Existence ICS-EXT1, evaluation H-ENABLE 13

To permit activation of the heating zones with the inputs H-ENABLEx, the existence of board EXT1 must be defined first.
Input range
OFF
On

4.2.2

Function
Board ICS-EXT1 not existing or no evaluation
of the release inputs H-ENABLE 13 and parameters 201207
Board ICS-EXT1 existing and evaluation
of the release inputs H-ENABLE 13 and parameters 201207

Default
OFF

Parameter 201207: Programming the release of heating zones

Each individual heating zone can be switched on/off or preheated in the parameters 201207.
Input range
OFF
On
P

Function
Heating zone is switched off
Heating zone is released
Heating zone is preheated

Default
On

Switching heating zones on/off with On or OFF

All heating zones put On are heated up and must have reached their nominal temperature for the appliance release Ready. Heating zones which are not required must be put OFF. In the basic setting all heating zones
are On.
Preheating of heating zones with P
Heating zones can already be heated up while a production with other active heating zones is in progress. In the
condition P the corresponding heating zones are heated up, but the release of the appliance depends only on the
condition of the heating zones put On. The readiness of the preheated heating zones is indicated over the interface output OUT1. The output switches on when all heating zones put on P have reached their nominal temperatures. This enables a switch-over without interruption.
Switching-over is to be effected as follows:
1. Selection of a combination of heating zones in which the currently used heating zones are put On and the
heating zones required later are put P.
2. Wait until the output OUT1 indicates the readiness of all heating zones put P.
3. Selection of a new combination of heating zones in which all used heating zones are put On.

ICS-IK 4248 / v4.5

Operation

33

Release of the heating zones is programmed as follows:

Select Parameter with the keys (1).

With the left/right keys (4), select the desired heating zone tank, heated hose or application head. In
the case of the heated hose and application head,
additionally select the number by means of the
up/down keys (5). The corresponding heated hose
or head number comes up in the display (6).

The display (7) shows the current setting of the

heating zone On, OFF or P. The selection is made
with the keys (8).

With the keys (2), select one of the possible parameter numbers 201207 display in field (3).

4.2.3

Calling up the release of the heating zones

The combinations of heating zones programmed with the parameters 201207 are activated over the interface
inputs H-ENABLE13. The parameter is determined via the following switching states:

Parameter
201
202
203
204
205
206
207

H-ENABLE 1
on
off
on
off
on
off
on

State of the inputs

H-ENABLE 2
off
on
on
off
off
on
on

H-ENABLE 3
off
off
off
on
on
on
on

All heating zones are released when the inputs H-ENABLE 1H-ENABLE 3 are switched off.

4.2.4

Parameter 280: Status of the heating zone release inputs

The coded status of the inputs H-ENABLE 1 to H-ENABLE 3 is displayed.

Display
0
1
2
3
4
5
6
7

34

Active release

Parameter 201
Parameter 202
Parameter 203
Parameter 204
Parameter 205
Parameter 206
Parameter 207

H-ENABLE 1
off
on
off
on
off
on
off
on

Operation

H-ENABLE 2
off
off
on
on
off
off
on
on

H-ENABLE 3
off
off
off
off
on
on
on
on

ICS-IK 4248 / v4.5

4.3

Selecting program numbers

Up to 87 program numbers are available for the storage of the programmed glue application patterns. Before entering or calling the application patterns it is necessary to select the program number under which the inputs are
to be processed. The following possibilities are available for this purpose:

All displays and inputs of application patterns always refer to the currently selected program number.

4.3.1

Selection via keyboard

Select the Parameter function with the keys (1).

Display (4) now shows the currently selected program number. After lifting of the access blockage
Loc1 a new number P 0P 86 can be determined
with the keys (5). Immediately the new program is
active.

Select parameter number 100 with the keys (2). The

display (3) confirms the selection.

4.3.2

Selection via the interface inputs

If the program selection is made over the system interface inputs PROG 1...PROG 6, the right decimal point is lit
in the program display. Via this inputs 26= 64 programs [P 1P 64.] can be selected. During the program change
a possibly running input is aborted and the new program number P XX. is displayed during two seconds. The
status of the inputs PROG 1PROG 6 can also be enquired via parameter number 181.

If the inputs PROG1PROG6 are used, a program selection via the keyboard is
ineffective.

Input
Significance

PROG 1
#1

ICS-IK 4248 / v4.5

PROG 2
#2

PROG 3
#4

Operation

PROG 4
#8

PROG 5
# 16

PROG 6
# 32

35

4.4
4.4.1

Programming of application patterns

Different application modes

The parameters 112 and 113 (see chapters 4.1.15 and 4.1.16) determine the operating mode of the application
heads. The following modes are possible:
Mode

Function and programmation

Example

Continuous glue application as long as the trigger is

switched on. The glue line can be stitched.
For this mode, no programming of length is necessary.

_ _|
or
| _

||

36

Intermittent glue application. The application is released by modification of the trigger.

Up to 31 different glue lines are possible from the
start of product. The lines can be stitched further.
Programming see chapter 4.4.2
The application is released by the trigger at the start
and finished by the trigger at the end of the product.
One glue line at the start and at the end of the product is possible. The distances are the same on both
sides. If the application length is selected big
enough, i.e. bigger than the maximum glue application length, an uninterrupted glue application is also
possible. After release of glueing it is, additionally,
possible to define a channel-specific trigger blockage length.
Programming see chapter 4.4.3

Operation

ICS-IK 4248 / v4.5

4.4.2
4.4.2.1

Intermittent glue application

Basic aspects

The intermittent glue application (see chapter 4.1.15/.16 and 4.4.1) permits programming of up to 31 different
glue lines with every release of the application head. Prior to the data input it is necessary to determine the number and positions of the glue applications. The relevant data are to be calculated as follows:
L1
A1
L2
A2

Lx
Ax

Distance product start - 1st application

Length of 1st glue application
Distance product start - 2nd application
Length of 2nd glue application
Distance product start - xth application
Length of 1st glue application

At option, every glue application can be programmed as uninterrupted application (as illustrated above), or it can
be chopped further: (see chapter 4.4.2.3, Stitched)
A1
P151
P152

4.4.2.2

length of 1st glue application

repeating interval length
repeating glue length

Entering the application pattern

Condition: The input of a glue pattern is only possible if the operating mode (parameter 112/113) is put on intermittent.

Press key (1) in the operating field of control IK.

Press key (4). Display (5) shows the figure 1 for the
first glue application. Two LEDs in indication (6)
are flashing for Distance product start - application.

The keys (7) serve to enter the desired distance

which is displayed in field (8).

Repeated pressing of key (4) serves to call the next

dimension which is again entered with the keys (7).

Clearing: Individual glue applications are cleared

by resetting the last length.

The application head to be programmed is selected

with the keys (2) and displayed in field (3). If an
application pattern is already programmed, the
LEDs in field (6) are flashing.

ICS-IK 4248 / v4.5

Operation

37

4.4.2.3

Stitching of the application pattern

The glue lines in the intermittend and continuous application mode can be further stitched (see chapter 4.4.2.1
Basic aspect). To this effect you proceed as follows:

Select function Parameter with the keys (1)

The desired application head or A for all is selected with the keys (4) and shown in the display
field (5).

Set the parameter 150 via key (5) to On.

Select the parameter 150 with the keys (2). The

number comes up in the display (3).

Record the repeating interval length in parameter

151 and record the repeating glue length in parameter 152.

Ax
P151
P152

Length of the programmed glue application

repeating interval length
repeating glue length

On completion of the input the application pattern is checked and if the lengths or
intervals, respectively, are too short, the application pattern of the channels concerned is cleared and the error E102 is displayed.

38

Operation

ICS-IK 4248 / v4.5

4.4.3
4.4.3.1

Application at the start and at the end of the product

Basic aspects

Depending on the programming inputs, two different application modes are possible:
1. One application at the start and at the end of the product
The distances from the start of the product to the application must correspond on both sides, the lengths of the
application also.
L1
A1

Distance product start - glue line

Length of glue application

Conditions: Product length > 2 x (L1 + A1)

Offset distance > L1 + A1
2. Uninterrupted application with automatical adjustment of the length of application
If the application length is selected big enough, i.e. bigger than the maximum glue application length, an uninterrupted glue application is also possible. The distance L1 at the start and at the end of the product is always observed, independently from the length of application A1.
L1
Distance product start - glue line
A eff Length of glue application (effective)
A1
Length of glue application (programmed)
Conditions: A1 > A eff
Offset distance > L1

4.4.3.2

Entering the application pattern

For the input of the two measures L1 and A1 see description in chapter 4.4.2.2.

The input o the two measures L1 and A1 is sufficient. It is possible to enter further lengths, but they will not be considered.

Stitching of the glue lines is not possible in this application mode.

In addition to the two length dimensions it is also possible to define a channel-specific trigger blockage length.
After release of glueing, the trigger input of the corresponding channel remains blocked for the distance (length)
defined in parameter 142 (see chapter 4.1.28).

ICS-IK 4248 / v4.5

Operation

39

4.4.4

Clearing an application pattern

The following procedure must be adopted to clear a complete application pattern of an application head:

Press key (1) in the operating field of the ICS-IK

pattern control.

Select the appropriate application head with the

keys (2). Display in field (3).

No application must be selected in display (4). This

display must be empty.

Keep first key (5) and then key (1) depressed together during at least 4 seconds. The two LEDs (6)
go dark and thereby confirm the clearing process.

40

Operation

ICS-IK 4248 / v4.5

4.5

Manual valve actuation

During the manual mode the normal glue application is interrupted and all trigger inputs are blocked.

Warning

Danger of splashing and burning

In case of manual release of the application heads there is a danger of burns from
hot splashes. It is the operator's responsibility that no further persons are within
splashing range of the application heads. For all adjustment work on the application heads it is an absolute must to wear protective goggles and protective gloves.

Change to the manual mode by pressing the key (1).

The LED in the key is lit and the display (2) shows
- - - -.

With the keys (3), select the desired application

head number or A for all heads. Display in field
(4).

The displayed valve output switches on for as long

as key (5) is pressed (default) or keeps switched on
till the key (5) is pressed again (if parameter 122 =
On). Condition: The appliance is ready for operation (LED Ready is lit).

If the appliance is not ready for operation (LED

Ready not lit) and parameter 119 is OFF, the
display (2) shows -Lo- on actuation of the key
(5).

By renewed pressing of the key (1) the manual

mode is quit.

4.6

Error messages
Display
E100
E101
E102
E103

Cause
Valve outputs overloaded
System interface outputs overloaded
Application pattern cleared because lengths or intervals too short
(acknowledgment by pressing key)
Speed greater than vmax

The errors E100 and E101 remain stored until the appliance is switched off and on again.

ICS-IK 4248 / v4.5

Operation

41

42

Operation

ICS-IK 4248 / v4.5

5 Key word index

A
Access blockage ..................................................21
Application head connection...............................19
Application modes ..............................................36
Application patterns ............................................36
Application release input.....................................16
Automatic glue length adaption...........................39
B
Before the installation ...........................................9
Behaviour v < vmin ..............................................25
Block diagram .....................................................10
Blockage length trigger inputs ............................26
C
Calling up the release of the heating zones .........34
Channel allocation of the application heads ........30
Channel status .....................................................32
Clearing a glue pattern ........................................40
Compensation of valve reaction time ..................23
Configuration of manual valve actuation ............30
Connection drawings...........................................10
Copyright ..............................................................2
D
Danger of splashing and burning.........................41
Design of the hardware .........................................5
Display of channel status.....................................32
Display of external program number...................32
Distance switch on and off points Triggers 1, 2 ..30
E
Electro diagram ...................................................10
Electrocution .........................................................9
Encoder connection.............................................14
Encoder input ......................................................28
Encoder transmission ..........................................24
Entering of parameter values...............................22
Entering of parameters ........................................21
Error messages ....................................................41
Evaluation G-ENABLE.......................................25
Existence ICS-EXT1...........................................33
G
Glue at the start and at end of the product...........39
Glue pattern.........................................................37
Glue pressure factor ............................................24

ICS-IK 4248 / v4.5

H
Heating zone preheating......................................33
Heating zone release ...........................................33
Heating zone release inputs.................................16
I
ICS-EXT1 specifications ......................................7
Improper use .........................................................3
Inputs ..................................................................16
Installation ............................................................9
Intended use ..........................................................3
Interface inputs....................................................16
Interface outputs..................................................17
Intermittent glue application ...............................37
L
Loc1 / 2 ...............................................................21
LocE....................................................................21
M
Manual valve actuation .......................................41
Maximum speed vmax ........................................24
Messages.............................................................41
Minimum glue pressure.......................................29
Minimum speed vmin..........................................25
Modifications in the program................................4
O
Offset distance ....................................................26
Operating Manual .................................................3
Operating mode trigger inputs.............................27
Operating unit .......................................................6
Operation ............................................................21
Output voltage VALVEx ....................................28
Outputs................................................................17
Overview of the control ........................................4
P
Parameter 100 .....................................................22
Parameter 180181 ...........................................32
Parameter 280 .....................................................34
Parameter entering ..............................................21
Parameters 101, 102............................................23
Parameters 103105..........................................24
Parameters 106108..........................................25
Parameters 109111..........................................26
Parameters 112114..........................................27
Parameters 115117..........................................28

Key word index

43

Parameters 118121..........................................29
Parameters 122141..........................................30
Parameters 142152..........................................31
Parameters 200207..........................................33
Photo cell connection ..........................................16
Preheating of heating zones.................................33
Pressure relief time after blockage ......................29
Product description ...............................................3
Program changes ...................................................4
Program number..................................................22
Program numbers selecting .................................35
Program selection inputs .....................................16
Program selection via interface ...........................35
Program selection via keyboard ..........................35
Programming of application patterns ..................36
Proportional valve output..............................18, 29
Publisher ...............................................................2
R
Release of control................................................29
Release of heating zones .....................................33
S
Selection of parameter storage ............................27
Signal descriptions ..............................................14
SMC ITV 2000 ...................................................18
SPC control .........................................................12
Speed vmax .........................................................24
Status...................................................................32
Status of the heating zone release........................34
Stitch ...................................................................37
Stitching of the glue pattern ................................38

44

Stitching on/off ...................................................31

Stitching, glue length ..........................................31
Stitching, interval length .....................................31
Switch-off delay time toff ...................................23
Switch-on delay time ton.....................................23
System drawing.....................................................5
System interface inputs .......................................16
System interface outputs .....................................17
T
Tank empty output ..............................................17
Tank full output...................................................17
Technical specifications........................................7
ton / toff ..............................................................23
Trigger blockage length ......................................26
Trigger blockage length, channel specific...........31
Trigger input .......................................................25
Trigger inputs......................................................16
U
Use for the intended purpose ................................3
V
v < vmin ..............................................................25
Valve actuation, manual......................................41
Valve outputs ......................................................19
VALVEx allocation ............................................30
vmax....................................................................24
W
Wiring diagrams..................................................10

Key word index

ICS-IK 4248 / v4.5

Table of parameters ICS-IK4x

Valid for pattern control ICS-IK4x; with ICS-MAIN from 3.13 or ICS-JUMBO from 3.07
On commissioning, the parameters set must be pencilled into the tables below. This means that in case of a disturbance
or after an exchange of the control, the correct values are reentered again quickly.

Program number
Pa. Function
100 Program number

Setting

Input range
P 0 P 86

Application pattern
Glue line
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Application head :
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length

ICS-IK4x / 3.13

Table of parameters

[mm]

Glue line
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

Application head :
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length
Distance sheet edge - glue start
Glue line-length

[mm]

Program related parameters

Pa.
Application head:
142 Channel-specific trigger blockage length *

150 Stitching on / off **

151 Stitching: Interval length **
152 Stitching: Glue length **

8
OFF,
[mm]
OFF,
On
[mm]
[mm]

* Parameter 142 only appears if parameter 112 and/or 113 = | |

** Parameters 150, 151, 152 only work if parameter 112 and /or 113 = __| or |_

ICS-IK4x / 3.13

Table of parameters

II

Pattern control
Pa.
100
101
102
103
104
105
106
107

Application head
Program number
Switch-on time delay
Switch-off time delay
Glue pressure factor
Encoder transmission
Maximum speed vmax
Minimum speed vmin
Evaluation G-ENABLE and
behaviour if speed < vmin

8
P0P86
0.030.0 [ms]
0.030.0 [ms]
0200 [%]
10.03000 [mm/1,000 impulses]
5.0300.0 [m/min]
0.0150.0 [m/min]
U = Sequence abortion, trigging
blocked, G-ENABLE is not evaluated
I = Sequence remains stored, GENABLE is not evaluated
U U = Sequence abortion, trigging
blocked, speed is not evaluated
U I = Sequence remains stored, speed
is not evaluated
I U = Sequence abortion, trigging
blocked, G-ENABLE and speed are
evaluated
I I = Sequence remains stored, GENABLE and speed are evaluated

109 Offset distance

OFF = no resolution
1 = release by trigger 1
2 = Release by trigger 2
09999 [mm]

110 Blockage length trigger inp. 1

09999 [mm]

111 Blockage length trigger inp. 2

09999 [mm]

112 Trigger edge / operating mode

trigger input 1

_| = intermittent, (off-on)
|_ = intermittent, (on-off)
- - - = continuous
| - | = adaption of the glue length

108 Trigger input

113 Trigger edge / operating mode

trigger input 2

OFF = none
1 = Parameter 108111
2 = Parameter 103 and 105
3 = all parameters of 1 + 2

114 Program-related parameter

storage

115 Output voltage channels 14

624 [Volt]

116 Output voltage channels 58

120 Minimum glue pressure

A = no detection of rot. direction

Ab = detection of rot. direction
4-20 = current output [mA]
0-10 = voltage output [V]
OFF = release only if Ready
On = release independently
0100 [% of maximum pressure]

121 Pressure relief time after blocking of the glue application

OFF = No pressure relief

110 [sec]

122 Configuration of manual valve

actuation

OFF = as long as key is pressed

On = till switched off via key

117 Encoder input

118 Proportional valve output
119 Release of application control

ICS-IK4x / 3.13

Table of parameters

III

Pa.

Application head

131 Channel allocation VALVE 1

132 Channel allocation VALVE 2
133 Channel allocation VALVE 3
Channel which controls the
application head output
VALVE x

134 Channel allocation VALVE 4

135 Channel allocation VALVE 5
136 Channel allocation VALVE 6
137 Channel allocation VALVE 7
138 Channel allocation VALVE 8
140 Distance switch points Trigger 1

only active if
parameter
112/113 = | |

070 [mm]

141 Distance switch points Trigger 2

142 Trigger blockage length

OFF, [mm]

150 Stichting swiched on

[On], [OFF]

151 Stiching: interval length

[mm]

152 Stiching: glue length

[mm]

180 Channel status

0.xx = number of copies in the waiting

queue , normal glue application,
trigger input released
1.xx = number of copies in the waiting
queue, glue application stopped,
trigger input blocked
2.xx = number of copies in the waiting
queue, glue application interrupted,
trigger input blocked
3.00 = Appliance not ready for operation,
Glue application stopped, trigger input
blocked

181 Program number

P 0P86

only active if
parameter 150 = On

Program related, optional parameters

The following parameters103, 105 and 108111 are only program-related saved, if parameter 114 is accordingly configured (default value of parameter 114 = OFF, all parameters are valid for all programs).
Pa.
103
105
110
111

Function
Glue pressure factor
Maximum speed vmax
Blockage length trigger input 1
Blockage length trigger input 2

Setting
[%]
[m/min]
[mm]
[mm]

Application head:

108 Ttrigger input

109 Offset distance

ICS-IK4x / 3.13

8
1/2
[mm]

Table of parameters

IV

Release of heating zones

Setup parameters
Para. Function
Evaluation of hea200 ting zone release
H-ENABLE13

Setting

Para. Function
280 State of the heating
zone release inputs

Display
0
1
2
3
4
5
6
7

Input range
OFF = No evaluation of inputs H-ENABLE 13
On = Evaluation of inputs H-ENABLE 1...3 and parameters 201207
Active release

Parameter 201
Parameter 202
Parameter 203
Parameter 204
Parameter 205
Parameter 206
Parameter 207

H-ENABLE 1
off
on
off
on
off
on
off
on

H-ENABLE 2
off
off
on
on
off
off
on
on

H-ENABLE 3
off
off
off
off
on
on
on
on

Heating zone release

Heating zone

Para. 201

Para. 202

Heating zone release

Para. 203
Para. 204
Para. 205

Para. 206

Para. 207

Tank
Heated hose 1
Application head 1
Heated hose 2
Application head 2
Heated hose 3
Application head 3
Heated hose 4
Application head 4
Heated hose 5
Application head 5
Heated hose 6
Application head 6
Heated hose 7
Application head 7
Heated hose 8
Application head 8
Premelter
On = Heating zone released, OFF = Heating zone switched off, P = Heating zone is pre-heated

ICS-IK4x / 3.13

Table of parameters