As 30 Pattern Controller

Instructions
Pattern Control AS 30
Edition 2.3
Translation of Original Instructions
Please place this instruction file in index 2 of your instructions.
Manufacturer Robatech AG
Pilatusring 10, CH-5630 Muri, Schweiz
Description Pattern control
Machine type AS (entire series)
Software AS30-Main from Version 2.06
Complete Documentation Part. No. 147138
Instructions Part. No. 155398
Publisher:
Robatech AG, Pilatusring 10, CH-5630 Muri, Schweiz
Phone +41 56 675 77 00

Fax +41 56 675 77 01
Email info@robatech.ch
Internet www.robatech.com
Date of issue April 2014
© Copyright by Robatech AG
All rights reserved. Without Robatech's written approval it is not permitted to copy and
distribute this instructions or parts thereof in any form whatsoever, or to transmit it by means
of electronic systems.
The illustrations and information contained in this instructions are subject to technical
alterations necessary for the enhancement of the appliance.
Table of Contents
1 Product Description __________________________________________________________________ 7

1.1 Intended Use ................................................................................................................................................. 7
1.2 Improper Use ................................................................................................................................................ 7
1.3 Operating manual .......................................................................................................................................... 8
1.3.1 How to use this operating manual ................................................................................................... 8
1.4 Identification of the appliance ...................................................................................................................... 8
1.5 Technical data ............................................................................................................................................... 9
1.5.1 Environmental conditions.............................................................................................................. 10
1.6 Conformity, standards complied with ......................................................................................................... 10
2 Safety_____________________________________________________________________________ 11
2.1 General regulations on safety...................................................................................................................... 11
2.2 Responsibility of the operator ..................................................................................................................... 11
2.3 Qualified personnel ..................................................................................................................................... 12
2.4 Personal protective equipment .................................................................................................................... 12
2.5 Warnings on the product ............................................................................................................................. 12
3 Structure of the control ______________________________________________________________ 13

3.1 Description .................................................................................................................................................. 13
3.2 Description of functions.............................................................................................................................. 13
3.3 Hotmelt system diagram ............................................................................................................................. 13
3.4 Coldglue system diagram............................................................................................................................ 14
3.5 Operating unit ............................................................................................................................................. 15
4 Installation ________________________________________________________________________ 16
4.1 Place of Installation .................................................................................................................................... 16
4.2 Dimensions ................................................................................................................................................. 17
4.3 Assembly material ...................................................................................................................................... 18
4.4 Mains connectio .......................................................................................................................................... 19
4.5 Signal cables: Wiring in compliance with EMC ......................................................................................... 19
4.6 Control connections .................................................................................................................................... 20
4.6.1 Applicator head outputs X8 ........................................................................................................... 20
4.6.2 Trigger inputs X4 .......................................................................................................................... 21
4.6.3 Encoder inputs X1, X2 .................................................................................................................. 22
4.6.4 Digital inputs on X6 ...................................................................................................................... 25
4.6.5 Digital outputs on X7 .................................................................................................................... 25
4.6.6 Analogue output X14 .................................................................................................................... 26
4.6.7 RS232 interface X17 ..................................................................................................................... 26
4.7 Downloading a software update.................................................................................................................. 28
4.7.1 Preparation .................................................................................................................................... 28
4.7.2 Download software update using “UpDown” into FLASH-EPROM ........................................... 28
4.7.3 Checking ....................................................................................................................................... 29
4.7.4 Other points to note ....................................................................................................................... 29
4.7.5 Error during update ....................................................................................................................... 29
4.8 Connector pin assignment ........................................................................................................................... 30
4.9 Connection to PLC control ......................................................................................................................... 33
5 Operation _________________________________________________________________________ 34
5.1 Switching on ............................................................................................................................................... 34
AS 30 / v2.3 Product Description 3

5.2 Access blockage.......................................................................................................................................... 34
5.3 Starting automatic mode ............................................................................................................................. 35
5.3.1 Checks before starting for the first time ........................................................................................ 35
5.3.2 Starting automatic mode ................................................................................................................ 35
5.4 Messages ..................................................................................................................................................... 36
5.4.1 Status codes ................................................................................................................................... 36
5.4.2 Error messages .............................................................................................................................. 36
5.4.3 Troubleshooting ............................................................................................................................ 37
5.5 Manual valve actuation ............................................................................................................................... 38
5.5.1 Switching ON via pattern control .................................................................................................. 38
5.5.2 Switching ON via solenoid valve key ........................................................................................... 38
5.6 Setting the operating parameters ................................................................................................................. 39
5.6.1 Retrieving and altering parameters ................................................................................................ 39
5.7 Programs ..................................................................................................................................................... 40
5.7.1 Selecting a program ....................................................................................................................... 40
5.7.2 Saving parameter settings as the basic setting ............................................................................... 40
5.7.3 Copying programs ......................................................................................................................... 41
5.7.4 Deleting programs ......................................................................................................................... 41
5.7.5 Deleting all programs and setting parameters to the default values .............................................. 42
5.7.1 Delete all programs via TRM and set parameters to their default values ...................................... 42
5.8 Command parameter ................................................................................................................................... 43
5.8.1 Parameter 101: Command ............................................................................................................. 43
5.8.2 Parameter 102: Command »Copy« ............................................................................................... 43
5.8.3 Parameter 103: Target program save ............................................................................................. 43
5.8.4 Parameter 104: Execute command ................................................................................................ 43
5.8.5 Default program number ............................................................................................................... 43
5.9 Cover slides with coldglue heads ................................................................................................................ 44
5.9.1 Parameter 120: Cover slide holding time ...................................................................................... 44
5.9.2 Parameter 121: Cover slide input .................................................................................................. 44
5.9.3 Parameter 122: Cover slide release speed ..................................................................................... 44
5.9.4 Parameter 123: Delay between cover slide and applicator head ................................................... 44
5.10 Application head outputs ............................................................................................................................ 45
5.10.1 Parameter 132: Allocation to the channel ..................................................................................... 45
5.10.2 Switch-on and switch-off compensation ....................................................................................... 46
5.10.3 Parameter 140: Switch-on compensation ...................................................................................... 46
5.10.4 Parameter 150: Switch-off compensation ..................................................................................... 46
5.11 Channel parameters..................................................................................................................................... 47
5.11.1 Parameter 161: Release speed vmin .............................................................................................. 47
5.11.2 Parameter 162: Behaviour on blocking ......................................................................................... 47
5.11.3 Parameters 163 and 164: Release input 1 and 2 ............................................................................ 47
5.11.4 Parameter 165: Trigger source ...................................................................................................... 47
5.11.5 Parameter 166: Distance between trigger and application head .................................................... 48
5.11.6 Parameter 168: Display the channel status .................................................................................... 48
5.11.7 Parameter 169: Glue application length as time or distance .......................................................... 48
5.12 Trigger inputs.............................................................................................................................................. 49
5.12.1 Parameter 170: Trigger blockage length ....................................................................................... 49
5.12.2 Parameter 171: Operating mode / trigger edge .............................................................................. 49
5.12.3 Parameter 172: distance between trigger switch-on and switch-off point t ................................... 50
5.12.4 Parameter 173: Trigger control input ............................................................................................ 50
5.12.5 Parameter 174: Distance Glue trigger – control trigger................................................................. 50
5.12.6 Parameter 175: Control tolerance .................................................................................................. 50
5.12.7 Parameter 176: display of measured product length [mm] ............................................................ 50
5.12.8 Parameter 177: Maximum trigger length (lockout) ....................................................................... 51
5.12.9 Parameter 178: Minimum trigger signal length ............................................................................. 51
4 Product Description AS 30 / v2.3

5.12.10 Parameter 179: Minimum product length ...................................................................................... 51
5.13 Encoder inputs ............................................................................................................................................ 52
5.13.1 Parameter 180: Encoder operating mode ...................................................................................... 52
5.13.2 Parameter 181: Encoder, detection of direction of rotation ........................................................... 52
5.13.3 Parameter 182: Maximum speed vmax ......................................................................................... 52
5.13.4 Parameter 183: Display of machine speed .................................................................................... 53
5.13.5 Parameter 184: Display current encoder impulse .......................................................................... 53
5.13.6 Parameter 185: Encoder transmission ........................................................................................... 53
5.14 Various parameters ..................................................................................................................................... 54
5.14.1 Parameter 190: Switch mode with manual valve actuation ........................................................... 54
5.14.2 Parameter 191: Flushing function ................................................................................................. 54
5.15 Glue pressure via proportional valve .......................................................................................................... 55
5.15.1 Parameter 200: Display nominal glue pressure ............................................................................. 55
5.15.2 Parameter 206: Pressure at max. output signal .............................................................................. 55
5.15.3 Parameter 213: Pressure release input ........................................................................................... 55
5.15.4 Parameter 214: Pressure release speed .......................................................................................... 55
5.15.5 Parameter 220: Glue pressure in manual operation ....................................................................... 55
5.15.6 Parameter 221: Minimum glue pressure ........................................................................................ 55
5.15.7 Parameter 222, 226: Glue pressure ................................................................................................ 56
5.16 Palletising function / counter function ........................................................................................................ 57
5.16.1 Parameter 230: Palletising function............................................................................................... 57
5.16.2 Parameter 231: Palletising function sequence ............................................................................... 57
5.16.3 Parameter 232: Number of products with glue application n1 ...................................................... 57
5.16.4 Parameter 233: Number of products without glue application n2 ................................................. 57
5.16.5 Parameter 234: Counter reading of products with glue application .............................................. 57
5.16.6 Parameter 235: Counter reading of products without glue application ......................................... 58
5.16.7 Parameter 236: Counter reset input ............................................................................................... 58
5.17 Parameter 240…243: Configuration of external outputs ............................................................................ 59
5.18 External program selection ......................................................................................................................... 59
5.18.1 Parameter 260…266: Program selection inputs ............................................................................ 59
5.18.2 Parameter 269: Display the current program number.................................................................... 59
5.19 Parameter 280…295: Display internal status .............................................................................................. 60
5.20 Glue application .......................................................................................................................................... 61
5.20.1 Different methods of application ................................................................................................... 61
5.21 Intermittent glue application ....................................................................................................................... 62
5.21.1 Basic aspects ................................................................................................................................. 62
5.21.2 Entering the application pattern .................................................................................................... 62
5.21.3 Stitching the application pattern .................................................................................................... 63
5.22 Application at the start and end of product ................................................................................................. 65
5.22.1 Basic aspects ................................................................................................................................. 65
5.22.2 Entering the application pattern .................................................................................................... 65
5.23 Glue fill level monitoring ........................................................................................................................... 66
5.23.1 Parameter 320: Digital glue fill level input ................................................................................... 66
5.24 Ethernet Settings ......................................................................................................................................... 67
5.24.1 Parameter 603: Monitoring SNMP – communication ................................................................... 67
5.24.2 Parameter 682: User parameter ..................................................................................................... 67
5.24.3 Parameter 683: Display of the SNMP operating state ................................................................... 67
5.25 Parameter 900…914: Software key ............................................................................................................ 68
5.25.1 General .......................................................................................................................................... 68
5.25.2 Parameter 900: Access code .......................................................................................................... 68
5.25.3 Parameter 901, 902: Test operation ............................................................................................... 68
5.25.4 Parameter 903…907: Software key............................................................................................... 68
5.25.5 Parameter 913: InfoPlus option ..................................................................................................... 68

5.25.6 Parameter 914: Display and enter application channels ................................................................ 68
6 Maintenance _______________________________________________________________________ 69
7 Appendix__________________________________________________________________________ 71
7.1 Settings for hotmelt and coldglue heads ..................................................................................................... 71
7.2 Spare parts .................................................................................................................................................. 71
8 Key word index ____________________________________________________________________ 72

1 Product Description
1.1 Intended Use

The AS 30 is a distance-based pattern control for varia-
ble machine speeds in hotmelt and coldglue systems.
Subject to compliance with the technical data (see
chapter 1.5) the AS 30 is intended for the following ap-
plications:
The AS 30/4 allows the control of up to four applica-
tion head outputs for the application of adhesives in
various programmable patterns.
The large number of accessories allow the control to be
finely adjusted to suit the current production require-
ments (see Robatech product structure, chapter H183).
The device may be operated only indoors.
1.2 Improper Use

– Any use other than “intended use” which does not have the written approval of the manufacturer or any use
outside the technical specifications is deemed to be improper use.
– It is strictly forbidden to make changes or alterations without the written approval from Robatech.
– The operation and use of the appliance by non-qualified personnel is prohibited.
– Failure to observe the safety and operating instructions, the regulations on occupational health and safety and
on the prevention of accidents, and local legal regulations is deemed to be improper use.
– If the unit is not used in accordance with the operating manual, then the protection provided may be inhibit-
ed.

1.3 Operating manual
The details in this operating manual refer to:
The Robatech AS 30 pattern control with program version 2.06
The operating manual is available in German and English, other languages available on request
This operating manual forms part of the system. Keep the operating manual readily available until the system is
to be disposed of, so that information can be looked up quickly at any time. This operating manual is to be
passed on with the system in the event that the system is sold or lent out.
The operating manual must be understood and complied with in every respect by those persons responsible for
installation, use and maintenance of the appliance.
Contact Robatech without fail if any points in this operating manual are not fully understood. Robatech is also
welcomes suggestions and criticisms.
1.3.1 How to use this operating manual

Chapters 1 and 2 provide the essential basic knowledge which each user must have if he is to carry out his du-
ties with the pattern control.
Chapters 3, 4 and 5 contain information which describe the structure of the control, its installation and its oper-
ation.
1.4 Identification of the appliance

The type label is located on the side of the appliance.
Designation: Designation
Type: Type
Part no.: Article number
Serial no.: Serial number
Year: Year
Power: Electrical operating voltage

1.5 Technical data
Power supply 100…240 Volt AC, 50-60 Hz ±10%, max.75Watt, 2 A
Overvoltage category Category II: Primary circuits of a device connected to an outlet with a pow-
er cord
Pollution degree Degree 2. Normally only nonconductive pollution occurs.
Occasionally a temporary conductivity caused by condensation
Speed range 0…400 m/min
Recommended speed up to 300 m/min
Distance trigger - glue head max. 9999 mm or 32000 path impulses
can be individually programmed for each head
Products between
max. 31 products per trigger input in queue
trigger and glue head
Distance start of product – end
max. 9999 mm and/or 32000 path impulses
of glue
Precision max. ±1 encoder impulse
Storable glue patterns Approx. 90 can diversify from version to version
Number of glue beads per head 32 glue beads (optionally interrupted) with programmable glue duration
and/or glue length and adjustable interval length
Application head outputs 1 to 4 valve outputs, output voltage 24 Volt DC
Output current: max. 800 mA per output,
several similar valves per output possible
Switch-on/ switch-off compen- 0.00…30.00 ms, resolution 0.01 ms
sation can be set individually for each channel
Encoder inputs 2 logic encoder inputs for evaluation, HTL signal level,
speed transmission is programmable: 10…3000 mm per 1000 impulses,
Detection of direction of rotation via A+B-track
power supply output 24 Volt*
Trigger inputs 2 trigger inputs, programmable allocatable to the application heads
release selectable either by positive or negative signal edge,
PNP signal (pos. switched): 18…36 VDC
Power supply output: 24 VDC*
Proportional valve output 1 output at X14, selectable 4…20 mA or 0…10 V signal,
Power supply output 24 VDC*
Output signal (=glue pressure) proportional to the product speed, propor-
tional factor is adjustable
Cold glue nozzle cover slides 1 output, freely allocatable to outputs OUT 1…4 on X7
default is no allocation
External program selection Freely allocatable to external inputs IN1…8 on X6,
default is no allocation
Palletising function: with glueing: 1…1000 products
Pre-selection range of the without glueing: 0…1000 products
Palletising function: freely allocatable input to inputs IN1…8 on X6,
Counter reset input default is no allocation , input switched on = counter reset
Ingress protection IP 54
Dimensions L×W×H 264 × 232 × 124 mm
Weight 2.8 kg
* All 24V outputs can in total be loaded with 1.2 A.

1.5.1 Environmental conditions
Ambient temperature +5 to +40 °C / 41 to 104 °F

Humidity 80% for temperatures up to 31 °C, 50% at 40 °C
Altitude for operation Up to 2000 m above sea level
1.6 Conformity, standards complied with

The pattern control complies with all relevant basic safety and health requirements. The appliance has been de-
veloped, constructed and manufactured in agreement with the EU directives listed below. This declaration loses
its validity should changes be made to the product which have not been agreed with Robatech.
Directive 2004 / 108 / EC relating to electromagnetic compatibility

Directive 2006 / 95 / EC relating to electrical equipment designed for use within
certain voltage limits (low voltage equipment)
EN 61010-1:2001 Safety requirements for electrical equipment for measurement,
control and laboratory use

2 Safety
In order to work safely and avoid accidents make sure you read chapter 2 “Safety” in
the operating manual on the basic appliance. It contains important information on the
risks associated with the appliance, on the safety features, on personal safety equip-
ment and on the procedure to follow in an emergency.
The AS 30 pattern control, hereafter referred to as the appliance, corresponds with the latest state of technology
and with the recognised technical safety regulations. It is simple and safe to operate by qualified users. However
inadequately trained users can cause damage to property and persons as the result of incorrect actions. This chap-
ter provides information on the safety concept and on the requirements for safe and optimum use.
All persons authorised to install and use the appliance are required to read this chapter.
2.1 General regulations on safety

Make sure you comply with the following general safety regulations:
– The appliance is only to be used, maintained and repaired by trained and authorised persons.
– The appliance may only be used when it is in a fault-free condition and must be operated in full compliance
with this operating manual. If it can be assumed that risk-free operation can no longer be assured then the
system must be shut down and secured against being switched on again unintentionally.
– The housing cover of the appliance must be secured against any unauthorized opening. Use appropriate tools
to securely lock the housing cover.
Proceed as follows (depending on the version of the pattern control):
 Pattern control with screwed cover
Lock the screwed cover using the 4 screws in the cover of the pattern control
 Pattern control with hinged cover
Lock the hinged cover using the main turn lock of the pattern control
– In addition to the operating manual it is important that you comply with your own country’s legal require-
ments and provisions concerning the prevention of accidents and the protection of the environment.
– It is forbidden to make structural changes to the appliance without written permission from Robatech.
– Should during operation of the appliance major technical faults, defects or abnormal stresses be identified
then the operator must report this to Robatech without delay.
2.2 Responsibility of the operator

– The operator is required only to allow persons to work on the appliance who are authorised and trained to do
so. These persons are further required to familiarise themselves with the generally applicable rules and regu-
lations on safety at work, the prevention of accidents and the protection of the environment.
– The appliance may only be used when it is in a safe working condition and must be operated in full compli-
ance with this operating manual. If it appears likely that a risk-free operation can no longer be assured then
the appliance must be shut down and secured against being switched on again.
AS 30 / v2.3 Safety 11
2.3 Qualified personnel
All persons who are required to work with the appliance must first read those chapters in this operating manual
which relate to their work, and in particular the must read regulations on safety.
The appliance may only be installed and operated by trained and authorised persons. The physical suitability,
training and experience of these persons must be such as to allow them to install and operate the appliance safe-
ty. The qualified personnel must be familiar with the regulations on safety and prevention of accidents and must
be aware of the company’s own internal working instructions. The operator of the appliance is responsible for
the training of the personnel. The level of training may be reviewed and determined by means of a product-
specific training course provided by Robatech.
Operator of the appliance
The operator must be so familiar with the appliance that he is able to use it together with any fitted accessories
for production work without any difficulty. This requires a sound technical understanding and the operator at
least having read and understood chapters 1, 2, 3 and 5 in this operating manual.
Robatech service technician
The Robatech service technician must have been trained at Robatech and must have an extensive knowledge of
the appliance. He must have completed basic electrical and mechanical training and also have a general
knowledge of pneumatics and hydraulics, so that he is in a position to be able to install, set up, maintain and re-
pair the whole system. He must read and understand all the chapters in this operating manual.
2.4 Personal protective equipment

Hotmelt systems: Risk of hot parts of the appliance and hot splashes of
glue! When working on the appliance make sure that clothing is worn
which covers the arms and legs.
Hotmelt and coldglue systems: whenever working on those parts of the ap-
pliance which are hot and/or under pressure, make sure that gloves and
protective goggles are worn. This particularly applies to installation,
maintenance and repair work. Risk of splashes and burns!
Robatech offers suitable protective equipment for this: Art. No. 100660:
this consists of a pair of protective gloves, protective goggles and 6 nozzle cleaning needles.
2.5 Warnings on the product
G11163
No. Symbol Significance and consequences in case of non-observance
Warning against dangerous electrical voltage.

1
Risk of injuries including death and destruction of the device
12 Safety AS 30 / v2.3
3 Structure of the control
3.1 Description
– The AS 30 is a path-based adhesive pattern control for variable machine speeds.
– The control also has a stitch mode and a palletising function.
3.2 Description of functions

The machine transports a product to be glued on a conveyor belt to the glue application heads. As soon as the
product reaches the photoelectric cell (trigger) the transmitted light is reflected and the AS 30 pattern control be-
gins to work through the programmed glue-application pattern. In doing so the pattern control reaches the
switch-on points and the switch-off points of each individual application head, having made due allowance for
the programmed or registered transport speed and the offset distance.
3.3 Hotmelt system diagram
6
AS 50 2
Air
(6 bar)
4
3
1 Pattern control AS 30 4 Applicator head

2 Air unit with proportional valve 5 Photoelectric sensor (trigger)
3 Adhesive melter 6 Encoder, measures the machine speed
AS 30 / v2.3 Structure of the control 13

3.4 Coldglue system diagram
1 Coldglue pump 6 Photoelectric sensor (trigger)

2 Pattern control AS 30 7 Solenoid valve for nozzle cover slide
3 Air unit with proportional valve 8 Applicator head ACX with nozzle cover slide
4 Glue pressure regulator 9 Encoder, measures the machine speed
5 Glue distributor
14 Structure of the control AS 30 / v2.3

3.5 Operating unit
1 Display and selection of the functions
2 Display and input of the values with display of
the unit of measurement
3 Display and selection of the application head or
trigger input
4 Switching between continuous or interrupted glue
bead (stitching)
5 Display of the glue application positions
6 Selection of the parameter and glue application
beads
7 Shift key for normal or manual operation
8 Activation of the applicator heads in the manual
operation mode
AS 30 / v2.3 Structure of the control 15

4 Installation
The control must be installed and put into operation for the first time by a trained
and experienced Robatech service technician. The information contained in this
chapter must be read through before installing the appliance. Incorrectly connecting
up the appliance will lead to faults or even to a complete breakdown of the appliance.
Electrical shock
Operating voltage 100...240 volt. Touching live components can result in death.
Danger The protective covers may only be removed if the unit is disconnected from the
power supply. The wiring of the control to the power mains or other tasks at the
electrical circuit of the unit is restricted to personnel with the requisite level of
training and experience that allows them to identify risks and avoid hazards asso-
ciated with electricity. Apart from the instructions in this manual, the generally
valid safety and accident prevention regulations also must be complied with.
4.1 Place of Installation

The following requirements must be met:
– Ensure an optimal accessibility and readability of the display. Select a suitable location.
– Select a location such that operating the mains isolator is not impeded.
– Avoid long cables. Select a location, from which the system components as trigger, applicator head and en-
coder are nearby.
– Stable mounting surface, free of vibrations
– Protect against humidity and splashing water. Protection class of housing and cable feedthroughs is IP 54.
– Avoid extreme ambient temperatures.
16 Installation AS 30 / v2.3
4.2 Dimensions
AS 30 / v2.3 Installation 17
4.3 Assembly material
The following accessories are available for assembling the AS 30 control:
Pos. 1 Pos. 2…4 Pos. 5
Part No. Description Position

143193 Fixing strap (4 no.) 1
142964 Cable inlet port 2
142965 Cable port 2× Ø 5 mm 3
142966 Cable port 2× Ø 6 mm (1× included in delivery) 3
142967 Cable port 4× Ø 3 mm 3
149366 Cable port 6× Ø5.2mm, 2× Ø6.4mm, 2× Ø9.4mm 3
142970 Plug Ø 3 mm, white 4
142971 Plug Ø 4 mm, white (4× included in delivery) 4
144173 Wall mounting bracket 5
149366 Cable bushing, multiple, 6x5.2mm/2x6.4mm/2x9.4mm 6
4.4 Mains connectio
– The connecting cable must comply with the national legal requirements.
– The device must be installed with a lockable load break switch or with a mains isolating switching device in
accordance with EN 60204-1:2006 !
– Operating voltage is 100…240 Volt AC, 50-60 Hz.
– The mains connection is made at the three terminals
labelled L1, N and PE.
– The pattern control has a 75 Watt power pack.
– The housing cover of the appliance must be secured

against any unauthorized opening.
Connecting terminals on the inside of the appliance
4.5 Signal cables: Wiring in compliance with EMC

The electromagnetic compatibility or abbreviated EMC refers to the ability of an appliance to correctly operate
in an environment with other electrical devices without itself generating any interferences. Correct wiring of the
signal cables is an important part of this. Please observe the following points:
– Only use shielded signal cables which have been

stripped as follows. The dimension X depends on
the position of the terminal.
Stripped signal cable
– The signal cable is fed through the cable guide port
into the inside of the controller.
– The stripped cable shielding is connected with a ca-
ble tie to the housing of the appliance.
– The cable shielding must be earthed at the start and
end of the cable. This is important when connecting
to higher level control stations! Only then is an at-
tenuation of the electromagnetic interference as-
sured. A shield connected on one side only provides
poor screening, whilst a shield which is not con-
nected at all will not suppress any electromagnetic EMC-appropriate signal cable connection
interference.
4.6 Control connections
– The connections for the external control components are located on the control board on the green contact
strips and the plug contacts.
– At least one trigger and one applicator head are necessary for the operation of the pattern control.
4.6.1 Applicator head outputs X8

Description:
– The adhesive is applied to the products by the applicator head. Activation of the applicator head is effected
by an air-controlled solenoid valve.
– There are 4 connections available for solenoid valves on the X8 contact strip. Several valves can be connect-
ed at the same time for each applicator head output.
Installation and programming:

– Four valve outputs VALVE 1…4 on contact strip X8.
– Constant output voltage 24 Volt DC
– Max. output current: 800 mA per channel (= max. 19.2 Watt)
Short circuit and overload protected
– Each individual output is programmable with the parameters 132,
140 and 150.
- Assignment to a glue channel
- Switch-on and switch-off delay
– If the output is active the corresponding LED D25…D28 is lit.
– The outputs can be switched on manually.
4.6.2 Trigger inputs X4
Description:
– The trigger identifies the products which must be glued and emits the corresponding signals to the pattern
control.
– Reflexion light scanners or reflexion light barriers can be used as trigger. Different sensors are available de-
pending on the constitution of the product and the light ratio in the immediate vicinity. A selection of sensors
can be found in the Robatech product structure in chapter »H183«.
– Two trigger inputs are available for the glueing of complex products or for the simultaneous work on two
production lines.

– Two trigger inputs TRIGGER 1…2 at contact strip X4
– The trigger inputs are programmable in the parameters 170...176:
- block the trigger inputs during a section
- operating mode, evaluation of the trigger signal
– With active input signal the corresponding LED D5 or D6 is lit.
– PNP signal (pos. switched): 18…36 VDC, Rin = 5.8 kOhm
– Power supply output: 24 VDC. All 24V outputs can in total be
loaded with 1.2 A.
4.6.3 Encoder inputs X1, X2
Description:
– The encoder registers the movement of the product on the conveyor belt. It measures the machine speed and
emits the corresponding position signals to the pattern control. By means of these signals the pattern control
calculates the right moment for the activation of the glue applicator head.
– Robatech encoders generate 1000 impulses per revolution.
– Two encoder inputs are available for the glueing of complex products or for the simultaneous work on two
production lines.

– Two encoders with 24 Volt HTL signal level can be connected at contact strips X1 and X2.
– If no encoder is connected and assigned in parameter 180 = 0 then the value of »v max« is used as the constant
machine speed in parameter 182.
– #Info: The connection between X1.3 and X1.4 is not necessary
in case of an encoder supply by an external voltage supply.
– The use of the inputs via SPS control is shown in chapter 4.9
– Parameter 180 defines the number and operating mode of the
encoder(s) connected.
– The encoder input is programmable using the parameters
180…185:
- Transmission Transport length per 1,000 encoder signals
- Operating mode
- Evaluation of the detection of the direction of rotation
- Maximum speed
– If encoder signals are present then the corresponding LEDs
are lit. Encoder 1: D1 + D2, Encoder 2: D3 + D4
Encoder at X1:
Isolated inputs
Signal: 18…27 VDC, Rin = 1.6 kOhm, 30 kHz
Power supply output: 24 Volt DC. All 24V outputs can be load-
ed with maximum 1.2 A..
Encoder at X2:
signal: 18…36 VDC, Rin = 5.8 kOhm, 30 kHz
power supply output: 24 Volt DC. All 24V outputs can be load-
ed with maximum 1.2 A..
4.6.3.1 Recognition of direction of rotation
The AS 30 allows the direction of rotation of the encoder to be evaluated. Optionally the two phase-shifted en-
coder signals A and B are evaluated and the direction of rotation determined. During a backwards movement
(max. 16,383 path impulses) the pattern control reacts as during a stoppage. With the subsequent forward move-
ment the normal function of the control is reactivated and the control behaves as during a normal run.
If possible use an encoder which can identify the direction of rotation. Your opera-
tion is sensitive to faults and this increases operational reliability. To do this set pa-
rameter 181 to »Ab«.
Check the encoders direction of rotation. The normal direction of rotation with the
view to the shaft is counterclockwise. If the encoder turns, but no machine speed is
indicated, the wires with the A- and the B-signal must be changed.
4.6.3.2 Mechanical assembly

– Install the encoder at a protected location, where it
can be tightened without vibrations.
– Protect the encoder against water and dust. Protec-
tion class of the encoder is IP 65.
Encoder with coupling for the drive shaft
1. Best position:
– directly onto the drive shaft of the conveyor belt
– directly onto the drive axle of the electric motor
2. Non-optimal position
with metering wheel onto the drive belts of the electric
motor
– with metering wheel onto the inside of the con-
veyor belt
Encoder with metering wheel
3. Worst position (a lot of dust and dirt)
– With metering wheel onto the outside of the con-
veyor belt
4.6.3.3 Electrical connection
Various extensions can be used to modify the encoder connection to suit the prevailing requirements.
With the extension cables (Pos.4) the connection can e.g. be extended as required whilst the distribution box
(Pos.5) allows two different controls to be connected to the same encoder.
Direct connection:
Wire colour Signal

White 0 Volt
Brown + 24 Volt
Green A signal
Yellow B signal
Art. No.: Description Position

100824 Encoder 1000 pulses/rev, AB-Signal, max. 100mA 1
112988 Encoder cable without plug, 3 m 2
Extended connection:
At a minimum the positions 1, 3 and 6 are required.
Part No. Description Position

100824 Encoder 1000 pulses/rev, AB-Signal, max. 100mA 1
112661 Encoder cable with plugs, 3m 3
112660 Encoder cable with plugs, 5 m 3
118365 Encoder cable with plugs, 15 m 3
112662 Encoder extension cable, 2m 4
122622 Encoder extension cable, 5 m 4
114230 Encoder distribution box, 1 input, 2 outputs 5
117090 Encoder distribution box, 1 input, 6 outputs (5)
114627 Encoder adapter cable, 1m 6
4.6.4 Digital inputs on X6
– At contact strip X6 eight freely programmable, DC-isolated source inputs with a common 0V are available.
– #Info: The connection between X6.3 and X6.4 is not necessary in case of an input supply by an external
voltage supply.
– The use of the inputs via PLC control is shown in chapter 4.9
– The 8 inputs are freely programmable for the

Nozzle cover slides (para. 121)
Glue application release (para. 163, 164)
Flushing function for the application heads (para. 191)
Pressure release (para. 213)
Palletising counter reset (para. 236)
External program selection (para. 260…266)
Digital glue level monitor (para. 320)
– If an input signal is present the corresponding LED D13…D20
lights up.
– Signal PNP 10…27 VDC, Rin = 2.7 kOhm
– Power supply output 24 Volt DC. All 24V outputs can be loaded
with maximum 1.2 A.
4.6.5 Digital outputs on X7

– At contact strip X7 four freely programmable, DC-isolated PNP source outputs with a common supply are
available.
– #Info: The connection between X7.3 and X7.4 is not necessary in case of an output supply by an external
voltage supply.
– The use of the outputs via PLC control is shown in chapter 4.9
– The outputs can be freely programmable using parameters
240…243. Either for the
- cover slides for coldglue heads
- glue pressure relief
- pressure release
- display of faults, readiness for operation, the current program
number, a fill level warning, an empty glue tank or if counter
reading of palletising is reached.
– If an output is active the corresponding LED D21…D24 is lit.
– Output supply voltage 11…27 VDC
– Output voltage Supply voltage –1.7 VDC
– Output current: Max 150 mA per output / short-circuit protected
4.6.6 Analogue output X14
Description:
– A proportional valve can be connected to plug X14 to determine the nominal glue pressure. A proportional
valve converts an electrical signal into an pneumatic pressure. They are used in the control of the operating
pressure of a piston pump or of a glue pressure regulator, depending on the measured machine speed.
– They are available in current- (I/P) and voltage-controlled (U/P) versions.
– The output can be operated either as a current output (4...20mA)

or as a voltage output (0...10V).
– Depending on the connected cable, the selected analogue signal
is sent to the appropriate proportional valve.
– adapter cable 143216: signal: 0…10 Volt, ILoad = -5..10 mA
– adapter cable 143217: signal: 4…20 mA, RLoad ≤ 600 Ohm
– The proportional valve is programmed in the parameters 200 to
226.
4.6.7 RS232 interface X17
– This serial interface allows communication with a higher level

control or PC. An update of the control program can be down-
loaded via this serial interface, e.g. with the aid of a PC (see
chapter 4.7).
The housing lid of the control system must be closed and always secured against unauthori-
sed opening.
Use appropriate tools to securely lock the housing cover.
Proceed as follows (depending on the version of the pattern control):

 Pattern control with screwed cover:
Lock the screwed cover using the 4 screws (1) in the cover of the pattern control
 Pattern control with hinged cover:
G11166
Lock the hinged cover using the main turn lock (2) of the pattern control
.
4.7 Downloading a software update
– The AS 30 pattern control is provided with a flash
program memory.
– No components need to be replaced in the event of
a program change. A software update is download-
ed directly via the RS232 interface into the AS 30
control through use of the special Robatech soft-
ware »UpDown« or »RobaPar«.
– To download a new program please also refer to
the separate instruction manual for the »Up/Down«
or the »RobaPar« software.
4.7.1 Preparation
Required:
– AS 30 pattern control
– PC with the »UpDown« or »RobaPar« program installed.
– RS232 cable (D-SUB9, extension cable m/f, 1:1, Robatech Art.No.122515)
4.7.2 Download software update using “UpDown” into FLASH-EPROM

 Switch off AS 30 power supply at the main appliance switch
 Connect the RS232 interface on the PC with the desired AS 30 control
 Switch on the AS 30 power supply again, keeping the button highlighted held down
for 3 seconds - no messages should appear on the operating unit!
 Start the program “UpDown” on the PC
 Wait for the message “Connection ready” to appear

If the message “Connection: ready” does not appear then programs cannot be downloaded!
If “Ready” does not appear:
– check the power supply
– check the cable connections
– check the PC interface, the COMx interface and if necessary change the “Transfer/Settings” in the menu.
– switch on the control and press down the button shown above for 3 seconds.
 In the menu “File - open…” select
 The file AS 30MAIN_Vx.xx.msn and activate the “Open” button
 Check the program description and version shown.
 Select the button with the red arrow or the menu item “Transfer – send file2 and then press “Send”
– the program is downloaded into the FLASH-EPROM
 Switch of the power supply when the transfer process has been completed successfully
 Disconnect the RS232 interface from the PC
4.7.3 Checking
– Switch on the power supply
– All the LEDs on the AS 30 light up for one second, and at the same time the software version of the control is
displayed. Another display option is offered by the selection of parameter 290(software type) and parameter
291(software version).
4.7.4 Other points to note

– As a rule all stored parameters and data are retrieved in a software update. Exceptions are larger program
changes where all parameters have to be initialised again in accordance with the operating manual.
4.7.5 Error during update

If the control does not start, the program has not been correctly downloaded or only partly downloaded. Then
the automatic start-up of the program must be prevented and the program must be downloaded again.
– When switching on the power supply for 3 seconds press and hold down the button to
the top left (arrow upwards). Then repeat the download process as described in chapter
4.7.2.
4.8 Connector pin assignment
Danger Electrocution
Operating voltage 230 volts. Mortal danger exists if live components are touched.
Only remove the protective cover when the appliance has been disconnected from
the power supply.
The electronic switches are components which are sensitive to electrostatic ener-
gy. Discharge the circuits of any static loads before touching them, do this by
touching the earth terminal on the appliance.
reverse polarity pro-
current I max. [mA]
protective link inte-

overload proof and
short-circuit proof
grated Y/N
tected Y/N
LED
I/N
X1 Encoder input 1 A
X1.1 – 0V
X1.2 A +24 VDC # Y
X1.3 – 0V
X1.4 E ENC1-COM
X1.5 E ENC1-A D1
X1.6 E ENC1-B D2
X2 Encoder input 2 A
X2.1 – 0V
X2.2 A +24 VDC # Y
X2.3 E ENC2-A D3
X2.4 E ENC2-B D4
X4 Trigger inputs 1 and 2
X4.1 – 0V
X4.2 A +24 VDC # Y
X4.3 E TRIGGER 1 D5
X4.4 E TRIGGER 2 D6
X6 Digital inputs
X6.1 – 0V
X6.2 A +24 VDC # Y
X6.3 – 0V
X6.4 E IN GND
X6.5 E IN1 D13
X6.6 E IN2 D14
X6.7 E IN3 D15
X6.8 E IN4 D16
X6.9 E IN5 D17
X6.10 E IN6 D18
X6.11 E IN7 D19
X6.12 E IN8 D20
X7 Digital outputs
X7.1 – 0V
X7.2 A +24 VDC # Y
X7.3 – 0V
X7.4 E OUT GND
X7.5 E OUT GND Y
X7.6 E OUT VIN Y
X7.7 A OUT1 D21 150 Y
X7.8 A OUT2 D22 150 Y
X7.9 A OUT3 D23 150 Y
X7.10 A OUT4 D24 150 Y
reverse polarity pro-
current I max. [mA]
protective link inte-

overload proof and
short-circuit proof
grated Y/N
tected Y/N
LED
I/N
X8 Application head outputs
X8.1 A – VALVE 1
X8.2 A + VALVE 1 D25 800 Y Y
X8.3 A – VALVE 2
X8.4 A + VALVE 2 D26 800 Y Y
X8.5 A – VALVE 3
X8.6 A + VALVE 3 D27 800 Y Y
X8.7 A – VALVE 4
X8.8 A + VALVE 4 D28 800 Y Y
X14 Analogue output
X14.1 – 0V
X14.2 A +24 VDC # Y
X14.3 E 0…10 Volt I Load = –5…10 mA
X14.4 E 4…20 mA R Load <= 600 Ohm
X16 Power supply 24 volt DC from the power pack
X17 RS-232 interface
X26 Extension interface
X27 Connection for operating unit
IC 47 Temperature sensor
measures the internal temperature of the control display in parameter 280
# Total current of all 24V supplies = max. 1200 mA
4.9 Connection to PLC control
– Fuse 1AF Art. 111202; supplier e.g. Schurter type SP 0001.1004

– Suitable holder for the fuse: Art. 144459
– If the activation is made by means of an PLC control, the voltage supply from the PLC control must be fed
to the AS30-MAIN board.
– For wiring, please observe the remarks concerning electromagnetic compatibility (EMC) in chapter 4.4
5 Operation
5.1 Switching on
– The control is switched on by the green toggle switch on the front side of the appliance.
– After switching on the current version of the software is displayed.
– Then the display shows the current program number, provided P00 has not been selected.
The control is then ready for operation and displays the current machine speed. If the control is used without
an encoder but with a fixed machine speed then the machine speed is displayed as vmax from parameter 182.
– When switching on, the control checks the amount of memory still available. Therefore the time taken to
switch on can vary.
5.2 Access blockage

In order to prevent unintended or unauthorised changes to the data all the values can only be changed after the
access block has been lifted. »Loc1« or »Loc2« appears when changing the values.
Lifting »Loc1« Lifting »Loc2«

Changing of all data, except the configuration of the Changing all data.
glue pressure control, the glue level monitor and the Press these buttons together:
entering the software key.
Press these buttons together:
1000 Ex/h 1000 Ex/h
m/min Job number m/min Job number
mm mm
msec msec
bar x x bar x x
% %
Error Error
Line / Parameter Line / Parameter
Parameter Parameter
Activate »Loc1 and Loc2«

Press these buttons together:
1000 Ex/h
m/min Job number
mm
msec
bar x x
%
Error
Line / Parameter
Parameter
– If no button has been pressed within two minutes the access block is automatically activated.
34 Operation AS 30 / v2.3
5.3 Starting automatic mode
5.3.1 Checks before starting for the first time

The following installations and settings must be made or checked before starting the appliance for the first time
to allow a fault-free functioning of the control:
Installation:
– At least one trigger and one application head are needed for operation of the AS 30 control.
– One trigger (light sensor etc.) is correctly installed (see chapter 4.6.2)
– One application head has been correctly installed (see chapter 4.6.1)
– All other optional components (encoder, pressure sensor etc.) have been correctly installed (see chapter 4).
Parametrising:
– The desired program has been selected in which all settings have been stored.
– The speed of the production unit is fixed and recorded in parameter 182 or the speed is measured by an en-
coder and is correspondingly evaluated (see chapter 5.10).
– The distance between the trigger and the application heads selected is large enough, it has been measured and
recorded in parameter 166.
– The desired mode of operation is selected in parameter 171
– An application pattern has been recorded (depending on the operating mode in parameter 171).
5.3.2 Starting automatic mode

The application control works through the programmed glue application pattern provided the following condi-
tions have been met:
– The glue system is ready for operation and the AS 30 pattern control is switched on.
– At least one trigger and one application head have been correctly installed and programmed.
– As soon as the photoelectric cell (trigger) has detected a product and has issued the appropriate signal the
pattern control works through the programmed glue application pattern.
– The pattern control calculates the switch-on and switch-off points of the application head after allowing for
the transport speed and the offset distance.
AS 30 / v2.3 Operation 35
5.4 Messages
5.4.1 Status codes

Status Description
A18 Break in communication on the Ethernet connection
A19 Manual operating mode is active (display – – – – )
5.4.2 Error messages

Besides the following messages related to the AS 30 pattern control please also note
the standard appliance messages described in the operating manual for the basic ap-
plication unit.
Errors E100…E109, E120, E123, E124, E128….143 are reset by pressing the (+) button.
Error Description Cause and remedy

Error in software key Test mode expired
E90
(appears when switching on 2s) or erroneous software key loaded
Short circuit in the vent or cable
Outputs 1 are overloaded
E108 Disconnect cables of allocated outputs (par. 240). Measure
(Aux-Output,)
cable and valve with Ohmmeter.
Temperature in the casing > 65ºC
E110 Excess temperature
Environmental temperature too high
Voltage of the internal 24 VDC power supply Supply voltage is <20 volt.
E112
too low Check power pack.
A glue pattern was entered which cannot be executed due to
the internal calculation. Parameters like TON, TOFF and
Length error.
E120 Vmax may have been changed after the glue pattern was al-
The glue pattern affected is deleted
ready programmed.
Correct values or glue pattern.
Encoder 1: Speed larger than permitted max-
E121 Measured encoder speed is larger than value in para. 182.
imum speed vmax
Adjust encoder translation in parameter 160 and/or maxi-
Encoder 2: Speed larger than permitted max-
E122 mum speed in parameter 182.
imum speed vmax
maximum permitted pressure deviation time
E123
1 (Parameter 212) exceeded Possible blockages in the system
maximum permitted pressure deviation time Rinse system with cleaner
E124
2 (Parameter 212) exceeded
E125 tank empty (actual fill level < Para. 325) Refill adhesive or faulty level sensor.
E128 Trigger monitoring error on trigger input Re-position trigger, since product is not always detected, or
…
E131 1…4 faulty trigger sensor.
E140 Measure product length <P170. - Trigger sensor has not measured the whole product.
…
E143 (For automatic length correction |--|) - Product was incorrect (too short)
- P170 (minimum product length) is erroneously config-
ured.
5.4.3 Troubleshooting
Problem Possible Cause Correction
Application heads are Glue system not ready for op- Check status or error messages on the unit introduce
not applying any glue eration appropriate measures
Application head is switched Application head must be assigned to a trigger pa-
off rameter 165 must not be set to off
No trigger signal present Optics on the trigger are dirty clean the lens.
Check trigger input For product identification the
corresponding LED D5…D6 on the MAIN-Print
must light up and go out (or go out and light up).
Check the wiring of the trigger. Connection to inputs
X4.
Trigger mounted too close to the application head.
On and off times cannot be compensated Increase
distance between trigger and application head and
correct parameter 166.
Solenoid valve connected in- Press the manual actuation head on the solenoid valve
correctly or solenoid valve de- The valve must be heard to switch Otherwise check
fective the compressed air feed
Switch on the solenoid valve manually from the pat-
tern control The valve must be heard to switch. Oth-
erwise check the wiring.
Problems with the glue system Check screw connections and hoses for leaking glue
Check power cable, connecting cable and pneumatic
hoses
Application heads do Trigger is incorrectly mounted Install trigger in accordance with the manufacturer’s
not always switch on or set up Some products are de- recommendations Make sure to comply with detec-
tected, others not tion range
Carry out trials to check the optimum position of the
machine.
Avoid transfer of vibrations to the trigger. Select ap-
propriate means of securing.
Too many products between Maximum 32 products allowed. Otherwise mount
trigger and application head trigger closer to the application head.
Nozzle or glue filter blocked up Check nozzle and glue filter for blockages
If necessary clean or replace them
Glue pattern applied Incorrect offset distance Measure the distances between trigger and applica-
does not match the tion heads and record the values in parameter 166
programmed pattern Incorrect machine speed Measure transport length per encoder revolution and
enter in parameter 160.
Incorrect values for the switch- Enter correct values for each application head in pa-
on and switch-off compensa- rameters 140 and 150. Recommended setting for SX
tion for the solenoid valve extrusion heads = 6.0 msec
5.5 Manual valve actuation
– In manual operating mode the application heads can be tested for their functioning and a residual glue pres-
sure can be released whilst the pump is switched OFF.
– During manual mode the normal glue application is interrupted and all photoelectric detector trigger inputs
are blocked.
Risk of splashes and burns!

Warning When manually activating the application heads there is a risk of burns from hot
splashes. The operator is responsible for ensuring that no other persons remain
within the range of splashes from the application heads. Protective goggles and
protective gloves must be warned during all adjusting work to the application
heads.
5.5.1 Switching ON via pattern control
 Pressing button (1) switches the control to manual

mode. The LED on the button lights up.
 Use the buttons (2) to select the desired application
head Display (3)
 Pressing button (4) activates the desired application

head.
 Pressing button (1) again exits manual mode.
5.5.2 Switching ON via solenoid valve key
The solenoid valve can also be switched ON manually

without the pattern controller:
 Press in the activation button directly on the sole-
noid valve (refer to picture). With button pressed
the solenoid valve switches ON.
5.6 Setting the operating parameters
– Modification of the control to suit the operating conditions is made by setting the parameters.
– The parameter settings are stored under the current selected program.
– The change becomes active as soon as a parameter has been changed. No special store command is needed.
– Storing, copying and deleting parameters is described in chapter 5.4 Programs.
Setting the parameters may only be carried out by a trained Robatech service techni-
cian. This training includes having read this chapter. Incorrect input can result in
damage to the appliance.
Make sure you record all the stored parameters in the table of parameters at the end
of this operating manual.
5.6.1 Retrieving and altering parameters

The parameters are protected against unintended or unauthorised alteration by the access blocks »Loc1« and
»Loc2« (see chapter 5.2). The parameters are retrieved and altered as follows:
Always make sure that all changed values are entered in the table of parameters.
 Select function Parameter with the keys (1)

 Select the parameter number with the keys (2).
The number comes up in the display (3).
 With certain parameters, values must be entered
for each individual application head, trigger or
channel. The desired number or »A« for all is se-
lected with the keys (4) and displayed in the field
(5).
 Display (6) shows the set parameter value. After
lifting of the access blockage »Loc1 or Loc2« the
value can be altered with the keys (7).
 Beware of wrong inputs! The new value is auto-
matically active after every alteration. An abor-
tion of the input is not possible. This is why all
data must always be recorded in the parameter
list!
5.7 Programs
– The pattern control has place for more than 100 programs for storing the parameters and application patterns.
The number of possible programs can differ from software version to version.
– All input always refers to the current program number.
– In the interest of convenient handling the parameters can be stored under a selectable program number, cop-
ied to a new program number or cleared completely.
5.7.1 Selecting a program

 Use the select buttons (1) to select the job num-
ber function.
 The display (2) shows the number of the current
program. A-Once the access block “Loc1” has
been lifted another program can be selected using
the buttons (3).
 After quitting the program selection the last pro-
gram displayed is selected and all input then refer
to this number.
5.7.2 Saving parameter settings as the basic setting

The parameter settings in the current program can be saved as the basic settings. The command “Copy b1” can
always be used to load the basic setting stored into a program again.
 Use the buttons (1) to select parameter.

 In field (2) select parameter 101 and in field (3)
select the STORE function.
 In parameter 103 select the value 56.
 Pressing the button (4) stores the data in the pro-
gram “b1”. Successfully storing the program is
confirmed by the display 2222.
5.7.3 Copying programs
All the settings in the current program can be saved to a different program number. Small program changes can
thus be made very quickly, leaving the original data unchanged.
Function Copy: The program defined in parameter 102 is copied into the current program.
Function Copy2: The program defined in parameter 102 is copied into the program that is selected in parameter
103.

select the COPY or COPY2 function.
 In parameter ‹102›, select program number ‹P
XX› or the basic setting ‹b1› which is to be copied
(original).
 In the case of COPY2 the target must be defined
in parameter 103
 Pressing the button (4) copies the data to the tar-
get. the display 5555 confirms the data has been
copied successfully.
5.7.4 Deleting programs

The data of a program can be deleted.
Function CLEAR: The data of the current program is deleted.
Function CLEAR2: The data of the program selected in parameter 103 is deleted.
select the CLEAR or CLEAR2 function.
 In the case of CLEAR2 select the program to be
deleted in parameter 103.
 Pressing the button (4) deletes the data. The dis-
play 1111 confirms the delete process was suc-
cessful.
5.7.5 Deleting all programs and setting parameters to the default values
 Attention! This command deletes all stored pro-
gram data. It cannot be undone. The parameters
entered will also be reset to their default values!
Duration of the delete process can be up to 1 mi-
nute! This process is necessary in case of bigger
software updates.
select the InitA function.
 Pressing the button (4) deletes all data for good.
The display 8888 confirms the delete process was
successful.
5.7.1 Delete all programs via TRM and set parameters to their default values
All program settings can again be reset to their default
values –
the basic values of the control system.
The program settings stored with "2222" by the opera-
tor are retained.
 Switch the unit off.
 Press the four highlighted keys (1) at the same ti-
me and switch the unit back on. Hold the four but-
tons pressed down for at least ten seconds until
"8888" appears on the display.
 All data are now deleted and the basic settings of
the control are reloaded
.
5.8 Command parameter
5.8.1 Parameter 101: Command
Parameters 101…103 can be used to copy the program data, store it and delete it (see also chapter 5.3).
Input range Function Default

Copies all the data from the selected program using parameter 102 into
Copy
the current program
Clear Deletes all data in the current program
Store Stores the current program as the basic setting b1
InitA Deletes all stored data, parameters reset to default
CoPY2 The program selected in Pa102 is copied into the program selected in
Pa103.
CLEA2 Program selected in Pal03 is deleted
5.8.2 Parameter 102: Command »Copy«

Parameter 102 is only used together with the »Copy« command in parameter 101.

The program defined here is copied into the current program number.
P 00…P111
The basic setting of the parameters (see parameter 101, »Store«) is cop-
b1
ied into the current program number.
5.8.3 Parameter 103: Target program save

Parameter 103 is only used in connection with the »Copy2« and »Clear2« command in parameter 101
Input range Unit Function Default

- Target - Program by „copy2“(program is saved)
P xxx
- Program to be deleted by Clea2“
5.8.4 Parameter 104: Execute command

After entry of the corresponding code the function selected in parameter 101 is executed.

1 Copy, display on completion «5555»
1 Clear, display on completion «1111»
1 Copy2, display on completion «5552»
0
1 Clear2, display on completion: »1112«
56 Store, display on completion: »2222«
363 InitA, display on completion: »8888«
5.8.5 Default program number

The current program can be selected via parameter 110 instead of via the
function “Job number”.
P 00…P92 P 00
If the program is selected via the external inputs a right decimal point
lights up on the program display.
5.9 Cover slides with coldglue heads
The cover slides on coldglue heads prevent the glue nozzles from drying out during longer periods of machine
down times. They switch on with:
– a positive signal edge to a trigger input
– a positive signal edge on the cover slide input (see parameter 121)
– when a programmed cover slide release speed is exceeded (see parameter 122)
– and in manual operation.
5.9.1 Parameter 120: Cover slide holding time

The four freely configurable outputs OUT1…4 at terminal X7 can be used for the control of cover slides on
coldglue heads. With the first valid signal (input defined in chapter 5.6) the output is switched on and the cover
slide opens by means of a solenoid valve. If the glue application is finished the output is switched off after the
programmed holding time and the cover slide is closed again.

0.0…20.0 sec. Holding time until the slide output is switched off. 1.0
5.9.2 Parameter 121: Cover slide input

The cover slide output switches on if a programmed machine speed is exceeded (see parameter 122) or with a
positive signal edge on a cover slide input which can be selected using parameter 121.

OFF No input selected
1
1…8 External input IN1…IN8 (X6.5…X6.12)
5.9.3 Parameter 122: Cover slide release speed

All cover slides open, if the machine speed exceeds the value here.

OFF Function switched off
0.5
0.5…100.0 m/min Cover slide release speed
5.9.4 Parameter 123: Delay between cover slide and applicator head
This parameter is only shown when the trigger P171 is set to continuous. It prevents glue being applied before
the cover slide is opened by delaying the activation of the applicator head. This delay can be adjusted in steps of
8ms.

OFF
0…100 ms Delay between cover slide and head
P123 enables the application in continuous mode without a second trigger. This is
however only suitable for uses in which the start of application does not have to be
exact or for a simplified hand application with a switch!
5.10 Application head outputs
5.10.1 Parameter 132: Allocation to the channel

Settings of this parameter are only necessary for complex applications! Normally the basic setting is suffi-
cient.
This allocation permits address several application head outputs to be addressed under one channel. For the basic
setting: Application head output = channel. The allocation can be programmed for each individual application
head. Parameters 160…168 are e.g. channel-specific and can be related to several application heads if so defined
here. The manual release of the heads and the programming of application patterns is also related to channels.

Head 1 = 1
OFF
The application head is controlled through the selected channel Head 2 = 2
1…4
Head …
Combination of the parameters and application channels:

– The two trigger inputs can activate any channels.
– The channels can activate any applicator heads again.
– Be carefully when programming the parameters 165 and 132. Changing the default values can lead to
confusion. With the trigger input 2 e.g. the channel 3 can be activated and this again can activate the head
outputs 1 and 4.
5.10.2 Switch-on and switch-off compensation
All solenoid valves and coils have an inertia-related reaction time. The characteristic of the glue and the design
of the application head can lead to an additional increase in the reaction time. In order for the application pattern
to agree with the programmed distances at every machine speed it is absolutely essential that this reaction time
be compensated for.
Signal and actual glue application with compensation

for the switch-on and switch-off delays ton and toff.
1 Effektive adhesive application
2 Switch-on time of the solenoid valve
Increasing the switch-on compensation shifts the glue stroke to the start of the prod-
uct. Increasing the switch-off compensation reduces the glue stroke.
If an application pattern is programmed then the application is checked after input

has been completed. If the value of vmax is too high and the application cannot be
carried out then the glue application is deleted and error E120 appears. The compen-
sation times “ton / toff” are too long or the glue application length is too short.
5.10.3 Parameter 140: Switch-on compensation

The switching times must be entered individually for applicator head output.

0.00…30.00 msec Switch-on compensation of the valve outputs 5.00
The compensation time can be calculated as follows:

Apply a glue bead using two different transport speeds.
(Difference in length of the glue stroke [mm] × 60) : Feed difference [m/min] = delay [ms]
! Typical settings for hotmelt and coldglue heads can be found in chapter 6.1.
5.10.4 Parameter 150: Switch-off compensation

0.00…30.00 msec Switch-off compensation of the valve outputs 4.00
5.11 Channel parameters
Parameters 160 to 168 are channel-specific. Where no changes have been made to parameter 132 each channel
corresponds with the application head output (channel 1 = application head 1 etc.).
The parameters can be programmed for each individual application head (or channel) or for all together.
5.11.1 Parameter 161: Release speed vmin

The glue application remains blocked as long as the measured machine speed is less than the release speed en-
tered here.

0.0…vmax m/min Release speed vmin 0.5
5.11.2 Parameter 162: Behaviour on blocking

When an application head is blocked due to the speed dropping below the release speed the glueing is terminated
or remains stored (the glueing is continued after the block has been lifted).

0 The glueing is terminated
0
1 The glueing remains stored
5.11.3 Parameters 163 and 164: Release input 1 and 2

Two release inputs can be defined and individually assigned to each application channel. The glue application is
only possible if the release input is switched on.

BUS Release over communication interface (profibus, ethernet)
OFF
5.11.4 Parameter 165: Trigger source

The application channels are activated by a trigger signal. A trigger source must be assigned to each active appli-
cation channel.

OFF Activation of the application channel is switched off
1
1…2 This trigger input activates the application channel
5.11.5 Parameter 166: Distance between trigger and application head
The distance between the trigger photoelectric detector and the application head must be defined separately for
each head. This means that the application of glue for each application head can always be set starting from the
edge of the product. The shortest distance depends on the maximum speed.

0…9,999 mm Distance between trigger source and application head 200
Estimating values:
The distance should be selected so that it is large enough so that the switch-on times of the application heads can
be taken into account. It may be necessary to mount the photoelectric detector at a larger distance from the appli-
cation heads. It can be assumed that the minimum distance is ~1/5 of the maximum machine speed (e.g. v max =
200 m/min, distance = min. 40 mm)
The smallest distance (without any safety margin) can also

be calculated precisely.
5.11.6 Parameter 168: Display the channel status

Input range Function
0 Glueing enabled
1 Manual operating mode is active
2 Glueing blocked via release input
3 Glueing blocked because v < release speed (parameter 161).
4 Channel switched off due to errors E148…E151
5.11.7 Parameter 169: Glue application length as time or distance

For each application channel the length of the glue application can be defined as time [0.1 ms] or distance [mm].
In normal case the applied glue length is entered in millimetres. But if alway the same amount of glue shall be
applied (independent of the product speed), the glue length can be entered in milliseconds.

OFF Glue application length in millimetres (resolution 1 mm)
OFF
On Glue application length in milliseconds (resolution 0.1 ms)
5.12 Trigger inputs
– The parameters can be programmed either for each trigger input or for all together.
5.12.1 Parameter 170: Trigger blockage length

Following activation the trigger block lengths can be blocked by the photoelectric cell for a specific distance. In
every case the trigger input is blocked from the start of product to the last glue application.

0…9,999 mm Trigger block length 0
5.12.2 Parameter 171: Operating mode / trigger edge

The glue application is activated by the trigger signal. In evaluating the signal the following different types are
distinguished:
Intermittent glue application (normal operation): The trigger signal starts a stored application pattern consist-
ing of individual glue strokes. The lengths and pauses can be programmed.
Continuous glue application: The application head remains switched on as long as the trigger signal is present.
Automatic glue length correction: The application length is dynamically adapted to the product length based
on the time the trigger input is switched-on and switched-off

intermittent glue application
1 _ _| ¯
activation with increasing edge (off-on)
2 _ _| ¯
1= encoder 1, 2= encoder 2
intermittent glue application
1 ¯ ¯| _
activation with decreasing edge (on-off)
2 ¯ ¯| _
continuous glue application: 1 _ _| ¯
1–––
glue application only as long as a signal is present.
2–––
Automatic glue length correction:
1|–| 1 application at the start and end of the product dynamic adaptation of
2|–| the application length to the product length for continuous glue stroke
5.12.3 Parameter 172: distance between trigger switch-on and switch-off
point t
Display only if parameter 171 = | – |
In the operating mode “automatic glue length correction” the distance between the switch-on and switch-off
point of the trigger can be entered and compensated for. The tolerance on switching the trigger sensor can be
compensated for in this way.

0…70 mm Distance between trigger switch-on and switch-off point 0
5.12.4 Parameter 173: Trigger control input

– The product detection and releasing of the glue ap-
plication is effected by a trigger signal (see parame-
AS30
ters 165 and 171). With an additional trigger the
faultless function of this glue trigger can be con-
trolled.
– The control trigger must be positioned after the glue
trigger. The distance between both triggers is freely
selectable in parameter 174. The control trigger
may also be positioned after the glue head.
– With the control trigger a normal glue application Pa.174
Pa.166
can be released as well.
Function of the trigger controlling:
Product detected by: Glue application

Glue trigger and control trigger Product is glued
Only glue trigger Error message E128…135, but product is glued
Only control trigger Error message E128…135, product is not glued

OFF No trigger controlling
1…2 Controlling of the selected triggr input with the defined OFF
trigger input
5.12.5 Parameter 174: Distance Glue trigger – control trigger

50…5000 mm Distance between glue trigger and control trigger 300
5.12.6 Parameter 175: Control tolerance

5…100 mm The product must be detected by the control trigger within
40
this tolerance.
5.12.7 Parameter 176: display of measured product length [mm]

P176 displays the measured product length if the operating mode (P171) is not continuous.
5.12.8 Parameter 177: Maximum trigger length (lockout)
If the maximum allowable trigger length defined in P177 is exceeded, all valve outputs affected are switched off
and the errors 'E148'..'E155' (Trigger 1..8 too long) displayed. The valve outputs remain blocked till the error is
acknowledged.

OFF Blocking of the valves when defined length is exceeded
OFF
1…9999 mm
5.12.9 Parameter 178: Minimum trigger signal length
If this is less than the length defined in P178, no triggering occurs or the glue application is broken off. In con-
trast to minimum product length, no error is triggered.

OFF Filtering of error signals
OFF
1…500 mm
5.12.10 Parameter 179: Minimum product length
If the length of product is less than the minimum length defined in P179, all gluing affected is broken off and the
logical outputs LMERROR1'..'LMERROR4' (26..29) are switched on. These are switched off again after the
next, correct trigger signal.
If P170 > 0, the errors 'E140'..'E143' (trigger length < P179) are also displayed. The error display is automatical-
ly deleted 2 seconds after the next correct trigger signal or after a manual acknowledgement.

OFF Monitoring the product length
OFF
1…9999 mm
5.13 Encoder inputs
5.13.1 Parameter 180: Encoder operating mode

The pattern control can be operated with one or two encoders, but also with no encoder (see also chapter 4.6.3).
Parameter 180 defines the number and operating mode of the connected encoder(s).
Input range Encoder Function Default

0 – Internal path impulse (v = value in parameter 182 vmax)
0
1 1 Encoder X1 (24 V / HTL)
0 – Internal path impulse (v = value in parameter 182 vmax)
0
1 2 Encoder X2 (24 V / HTL)
5.13.2 Parameter 181: Encoder, detection of direction of rotation

There is the option to add a detection of direction of rotation at the encoders with an evaluation of the two 90-
degree phase-shifted signals A and B.

No detection of direction of rotation
A–
Evaluation of the encoder signal ENCODER A
Ab
Detection of direction of rotation (recommended)
Ab
Evaluation of the encoder signals ENCODER A and B
5.13.3 Parameter 182: Maximum speed vmax

When the maximum speed is exceeded the glue application is blocked and the error message “E121” displayed.
The maximum permitted speed vmax is also used in the calculation of the permitted glue lengths and pause
lengths (see note).
If the control is operated without an encoder but with a fixed machine speed then the machine speed vmax is
used. The parameter 180 must be appropriately programmed.

5.0…400 m/min Maximum speed 150.0
With a defined machine speed of 60 m/min, 1 millimetre glue length corresponds to

an operating time of 1 millisecond ( 1 mm = 1 ms at v 60 m/min). Example: in order
to switch on the application head for 0.5 seconds ( = 500 ms) a 500 mm length glue fil-
let has to be programmed.
If an application pattern is programmed then the application is checked after input

has been completed. If the value of “vmax” is too high and the application cannot be
carried out then it is deleted and error E120 displayed. The compensation times “ton /
toff” are too long or the job length selected is too short.
5.13.4 Parameter 183: Display of machine speed
The current machine speed is shown.

0.0…vmax m/min Current machine speed
5.13.5 Parameter 184: Display current encoder impulse

The current display of the encoder impulses per second is shown.

0.0…vmax impulses/sec Current display of the encoder impulses
5.13.6 Parameter 185: Encoder transmission

This defines the transport length of the product in mm per 1,000 encoder impulses. Values up to 999.9 mm are
displayed with a resolution of 0.1 mm, higher ones with a resolution of 1 mm (watch the decimal point).
If no encoder is used, the default value can be left standing as it is. Parameter 180 defines the operating mode of
the encoder.

10.0…3,000 mm Encoder transmission 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 er-
ror).
The Robatech encoder (No.100824) emits 1,000 impulses per revolution. The transport length, therefore, has to
be measured per revolution. If another encoder is used, the transport length may have to be calculated in another
manner.
If the transport length cannot be measured precisely, the following procedure can also be adopted:
An estimated value is set for the machine speed. Next, with the machine running, determine the exact product
speed using a speed measuring device. If the measured speed deviates from the speed shown in the control dis-
play, 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 slow speed).
5.14 Various parameters
5.14.1 Parameter 190: Switch mode with manual valve actuation

Function of the button for manual activation of an application head (see chapter 5.21).

OFF Application head remains active as long as button is pressed down
Application head remains active until switched off again with the button OFF
On
(flip-flop)
5.14.2 Parameter 191: Flushing function

All valves can be flushed via an selectable input. In case of an active input all valve outputs are switched on. In
manual operating mode the flushing function is switched off.

OFF
5.15 Glue pressure via proportional valve
The AS 30 allows control of the glue pressure via proportional valve, dependent on the product speed.
5.15.1 Parameter 200: Display nominal glue pressure

Displays the nominal glue pressure at the current product speed.
Display range Unit Function

0…Pmax bar Displays the nominal glue pressure
5.15.2 Parameter 206: Pressure at max. output signal

Nominal pressure at 20 mA or 10 Volt at the proportional valve output.

1.0…500.0 bar Pressure at 20 mAmpère or 10 Volt output signal 100.0
5.15.3 Parameter 213: Pressure release input

An input for the release of the glue pressure is freely programmable. The defined input must be switched on, so
that the proportional valve is active and the glue pressure is built up.

OFF
5.15.4 Parameter 214: Pressure release speed

At speeds below this pressure release speed the glue pressure is reduced to 0.

0.0…vmax m/min Pressure release speed 0.0
5.15.5 Parameter 220: Glue pressure in manual operation

The glue pressure in manual activation of the application heads (the key lights up) can be defined here.

0.0…Pmax bar Glue pressure in manual operation 50.0
5.15.6 Parameter 221: Minimum glue pressure

The lower limit of the glue pressure is set to this value.

0.0…Pmax bar Minimum glue pressure 0.0
5.15.7 Parameter 222, 226: Glue pressure
The speed-dependent nominal glue pressure is given by
two points. The nominal pressure is linearly inter-
polated between the points.
After the last defined point the pressure remains con-
stant. If for example only glue pressure v0 is set in
parameter 222 (parameter 226 = OFF), the pressure
remains the same over the whole speed range.
5.15.7.1 Parameter 222: Glue pressure v0

Depending on parameter 226, the value in parameter 222 defines the pressure either over the whole speed range
or only for v 0.

Glue pressure v0
0.0…2× P max bar v0…v max if parameter 226 = OFF 100
v0 if parameter 226  OFF
5.15.7.2 Parameter 226: Glue pressure vmax

Glue pressure at maximum product speed (parameter 182).

OFF Glue pressure v0 over whole speed range
OFF
0.0…2× P max bar Glue pressure at maximum speed vmax
5.16 Palletising function / counter function
Normally after the glue application has been activated by a trigger input, every product is glued. The palletising
function starts a counter when the trigger input occurs. This makes it possible to glue a specific number of prod-
ucts and also not to glue a specific number of products. The sequence “glue – don’t glue” is reversible and de-
fined by parameter 231. After the counter reading at channel 1 has been reached (parameter 232 and 233), a suit-
ably configured output is switched on. Configurable over parameter 240…247, via value 19
5.16.1 Parameter 230: Palletising function

Switches the palletising function on and off.

OFF
On Palletising function switched on
5.16.2 Parameter 231: Palletising function sequence

Sets the sequence of the items to be glued and not to be glued

The first n1 items are glued, the following n2 items are
0 item
not glued
0
The first n2 items are not glued, the following n1 items
1 item
are glued.
5.16.3 Parameter 232: Number of products with glue application n1

Sets the number of products with glue application.

1…1000 item Number of products with glue application 1
5.16.4 Parameter 233: Number of products without glue application n2

Sets the number of products without glue application.

0…1000 Item Number of products without glue application 1
5.16.5 Parameter 234: Counter reading of products with glue application

Displays the number of products which have been given a coating of glue
Input range Unit Function

0…1000 item Counter reading of products with glue application
5.16.6 Parameter 235: Counter reading of products without glue application
Displays the number of products which have not been given a coating of glue
Input range Unit Function

0…1000 item Counter reading of the number of products without glue
application
5.16.7 Parameter 236: Counter reset input

The counter is reset via a selectable input

OFF
5.17 Parameter 240…243: Configuration of external outputs
The outputs at the application control are freely programmable via parameters 240…243.
Para. Function Default Input range

240 OUT 1 (X7.7) OFF OFF Output switched off
241 1 Nozzle cover slide (coldglue head).
OUT 2 (X7.7) OFF
5 Pressure release
242 OUT 3 (X7.9) OFF 7 Error
243 OUT 4 (X7.10) OFF 8 Ready for operation (no errors)
9…15 Current program number bit 0…6
18 Glue tank empty
19 Palletisation: Counter reading reached
(parameters 232 + 233 of channel 1)
5.18 External program selection

The program selection can be made externally with 7 inputs. The inputs are freely programmable using parame-
ters 260…266. The standard setting is for no inputs to be defined.
5.18.1 Parameter 260…266: Program selection inputs

if the program is selected via the interface inputs a right decimal point lights up on the program display. A max-
imum of 27= 128 programs [P260…P266] can be selected via the inputs. During the program change any current
input is interrupted and the new program number “P XX.” displayed for 2 seconds. The status of the inputs can
also be retrieved via parameters 285 and 286.
Parameter Input Input range Default

260 OFF
261 OFF
262 Program selection in- OFF switched off OFF
263 puts 1…8 external input IN1…IN8 OFF
264 bit 0…6 (X6.5…X6.12) OFF
265 OFF
266 OFF
Parameter Para. 260 Para. 261 Para. 262 Para. 263 Para. 264 Para. 265 Para. 266
binary value #1 #2 #4 #8 # 16 # 32 # 64
5.18.2 Parameter 269: Display the current program number

Displays the current program number independent of the program se-
P 00…P92
lection inputs.
5.19 Parameter 280…295: Display internal status
Parameter Display Function Display range
280 Temperature inside the appliance °C
282 Voltage of the 24VDC power Volt
supply
283 Status of the outputs bit 0...3 outputs OUT1…4 on X7
(Hexadecimal) bit 4..7 outputs VALVE1…4 on X8
285 Status of the inputs bit 0, 1 Encoder signal 1 (24V / HTL)
(Hexadecimal) bit 2, 3 Encoder signal 2 (24V / HTL)
bit 4…5 Trigger inputs 1…2 (X4)
bit 6…15 always 0
286 Status of the inputs bit 0...7 External inputs IN1…8 (X6)
(Hexadecimal) bit 8...15 always 0
290 Software type
291 Software version
292 Hardware type
293 Hardware version
294 Series number MAIN board Digits 1…4
295 Series number MAIN board Digits 5…8
5.20 Glue application
5.20.1 Different methods of application

The operating mode for the trigger photoelectric detector (parameter 171) determines the mode of application,
that is, the mode of operation of the application heads. These are as follows:
Mode Function and programming Example
Intermittent glue application activated by

changing the trigger input
_ _| ¯
up to 32 freely programmable glue strokes be-
1. or
ginning at the start of product possible In addi-
¯ ¯| _ tion the glue strokes can be stitched further
(stitching)
For programming see chapter 5.18
Continuous glue application as long as the trig-

ger input is switched on. in addition the glue
2. –––
stroke can be stitched (stitching)
(see chapter 5.18.3)
No length programming is needed for this type of
application
The glue application is activated through

switching the trigger at the start and end of
product
a glue stroke at the product start and end is pos-
3. |–| sible. The distances are the same on both sides. If
the application length selected is high enough a
continuous glue application is possible. After ac-
tivation of the glueing a channel-specific trigger
block length (parameter 167) can also be defined.
For programming see chapter 5.19
5.21 Intermittent glue application
5.21.1 Basic aspects

The intermittent mode of operation (see chapter 5.17.1) allows the programming of up to 32 different glue
strokes for each activation of the trigger sensor. Before the entry of data the number and positions of the glue ap-
plications (beginning with the start of product) must be determined. The data are to be calculated as follows:
L1 distance between start of product and 1st
application
A1 length of 1st glue application
L2 distance between start of product and
2nd application
A2 length of 2nd glue application
…
Lx distance between start of product and xth
application
Ax length of xth glue application
Each application of glue can be programmed as either a continuous application (as shown above) or it can be
stitched still further. (stitching; see chapter 5.18.3)
A1 length of 1st glue application

S1 repeating pause length
S2 repeating application length
5.21.2 Entering the application pattern

The entry of an application pattern is always related to the current program number and the application head se-
lected.
Use the buttons (1) to select the function.
Use the buttons (2) to select the application head to be
programmed Display (3) If an application has al-
ready been programmed the LEDs in field (7) start
to flash.
Press the button (4). The number »1« appears on the
display (5) for the first glue application. The flash-
ing LEDs on display (7) visualise the selected dis-
tance.
The buttons (8) are used to register the desired distance
[mm] which is displayed in field (9).
Pressing the button (4) calls up the next dimension,
button (6) the previous dimension.
Delete: individual glue applications are deleted by set-
ting the last length to » «.
5.21.3 Stitching the application pattern
The glue strokes in the intermittent and continuous modes of operation can be stitched still further. The stitching
affects the whole application pattern, individual glue strokes cannot be stitched. The individual dimensions can
however be different for each application head.
 Condition: a valid application pattern must have
been programmed Check: The LEDs in field (1)
must light up
 button (2) is used to select between: continuous
glue application or stitching The LED (3) indicates
the selection made.
 Use the buttons (4) to select the function.
 The display (5) shows parameters 300, display (6)
shows the value »On«. The stitching is then
switched on. The individual dimensions such as
pause length or application length are programmed
using parameters 300 to 304.
Stitching of a glue stroke Automatically switching between stitching and

Parameters 301 to 303 define the distances of the stroke
stitching The glue length can be stored as length Above a specified speed the stitching can automati-
and/or time cally be switched to stroke application. Parameter 304
# Parameter 301 = repeating pause length defines this speed If the speed is exceeded the current
# Parameter 302 = repeating glue length application will continue to be made in stitch mode,
# Parameter 303 = repeating application duration the next application of glue in stroke application.
5.21.3.1 Parameter 300: Switching stitching on and off
Besides the button “ ” the stitching can also be switched on and off by parameter 300.
Value range Function Default

OFF Stitching switched off
OFF
On Stitching switched on
5.21.3.2 Parameter 301: Pause length
Value range Unit Function Default

1…100 mm Stitching: repeating pause length 10
5.21.3.3 Parameter 302: Application length

With stitching the repeating glue length can either be set using parameter 302 [mm] or using parameter 303 in
[msec]. If both parameters are defined the glue application is switched on as long as the application length and
the application duration have not been exceeded.

OFF Stitching: repeating application length switched off
10
1…100 mm Stitching: repeating application length
5.21.3.4 Parameter 303: Application duration

With stitching the repeating glue length can either be set using parameter 302 [mm] or using parameter 303 in
[msec]. If both parameters are defined the glue application is switched on as long as the application length and
the application duration have not been exceeded.

OFF Stitching: repeating application duration switched off
OFF
1.00…100.00 msec Stitching: repeating application duration
5.21.3.5 Parameter 304: Maximum speed

Above this speed + parameter 305 the stitching is switched to stroke application, below this speed the stitching is
switched on.

OFF Stitching: switch-over switched off
OFF
0.0…150.0 m/min Stitching: maximum speed
5.21.3.6 Parameter 305: Switching hysteresis

Switching hysteresis for switching from stitch to stroke application (see parameter 304). Where speeds vary
greatly this avoids the constant changing between stitch and stroke application.

0.1…10.0 m/min Stitching: switching hysteresis 1.0
5.21.3.7 Parameter 306: Sequential offset

Offsets the stitching by the value given in Parameter 306. This is additive for each subsequent product.

1…100 mm Stitching: Switching hysteresis OFF
5.22 Application at the start and end of product
5.22.1 Basic aspects

It is possible to apply a glue coating at the start and end of product. The distances are the same on both sides. If
the application length selected is high enough a continuous glue application is possible. After activation of the
glueing a channel-specific trigger block length (parameter 167) can also be defined.
1. One application of glue at the start and end of product

The distance from edge of product to glue application is the same on both sides as also is the application length.
L1 distance from edge of product to start of glue ap-

plication
A1 length of glue application
Condition: product length > 2 × (L1 + A1)
Offset (P166) > A1 + L1
2. Continuous glue application with automatic adaptation of the application length

If the application length selected is long enough, i.e. greater than half the effective application length then a con-
tinuous glue application is possible. The distance L1 at the start and end of product is always complied with, in-
dependent of the application length A1.
L1 distance from edge of product to start of glue ap-

plication
A1 length of glue application (programmed)
Condition: product length > 2 × (L1 + A1)
Offset (P166) > A1 + L1
3. One application of glue at the start and end of product with separate glue line length at the product end
It’s possible to set a separate glue line L2, A2 at the

product end.
Condition: Product length > L1 + A1 + L2 + A2

Offset (P166) > A2 + L2
5.22.2 Entering the application pattern

Entering the two lengths (L1 and A1) is described in chapter 5.18.1.
In addition to the two lengths a channel-specific trigger block length can also be de-
fined. After activating the glueing the trigger input of the corresponding channel re-
mains blocked for the distance defined in parameter 167.
5.23 Glue fill level monitoring
On the AS 30 MAIN board the signal from a digital fill level sensor on X6 can be evaluated.
Connection to a freely configurable input in accordance with parameter 320.
Input switched off = glue tank empty, input switched on = glue tank full
No further programming possible
5.23.1 Parameter 320: Digital glue fill level input

Selects an input for the evaluation of a digital fill level signal
Input switched on = glue tank is full. If there is no input signal the error message E125 appears.

OFF
1…8 External input IN1…8 (X6)
5.24 Ethernet Settings
5.24.1 Parameter 603: Monitoring SNMP – communication
If no valid SNMP data package is received in the time defined in parameter 603 then status 418 will be displayed
and all parameters will be set back to their original levels.

OFF Function turned off
OFF
0.02…10.00 min.sec Maximum permissible time between SNMP data packages
5.24.2 Parameter 682: User parameter

The user parameter (index 11) can be set to a freely selectable value via the SNMP interface. The loaded pa-
rameter set can thus be labelled and identified. With each change to any parameter via the front plate, the value
of the user parameter is automatically reset to 0. Thus, it is easy to detect each manual change to a parameter.
5.24.3 Parameter 683: Display of the SNMP operating state

Display range Function Default
0 SNMP communication interrupted or unavaliable
1 SNMP write access blocked with parameter P600=OFF
1
2 SNMP write access blocked with logical input FBDISABLE
3 SNMP write and read access possible (bus mode active)
5.25 Parameter 900…914: Software key
5.25.1 General
– In the basic AS 30 control 1 application channel is released as standard. Every other application channel must
be purchased and is released by entering a software key in the parameters 903…907.
– The software key is a 20-digit number and is assigned by order using the AS30-MAIN-Print serial number
from Robatech.
– In test operation all four application channels can be used until the expiry of the test operation.
5.25.2 Parameter 900: Access code

– Parameters 901 to 912 are protected by an access code in parameter 900. Access is granted as follows:
 Lift access block »Loc2« (see chapter 5.2).
 In parameter »900« select the value »5630«. Parameters 901…914 can now be selected and edited.
5.25.3 Parameter 901, 902: Test operation

In test mode the customer can test all four application channels, or following replacement of a defective Print the
Robatech service technician can switch on the full control without a software key for a maximum of 310 hours.
Selection of the desired number of channels via parameter 914.
A counter is activated following activation of the test operation. The test operation expires after 310 hours of op-
eration. The software key must now be obtained and entered for further use of all application channels.
Para. Input range Function Default

OFF Switch off test operation
901 OFF
On Switch on test operation
902 0…310 hours Displays the remaining hours of test operation
5.25.4 Parameter 903…907: Software key

– The software key for releasing the application channels of the AS 30 glue pattern control is a 20-digit number
and is entered in parameters 903 to 907.
– The software key is issued by Robatech and is based on the AS30-MAIN-Print serial number
(parameters 294 and 295).
– When the key has been input the appliance must be switched off and switched on again.
5.25.5 Parameter 913: InfoPlus option

Whether InfoPlus is enabled or can be activated in test mode is displayed via Parameter 913.
5.25.6 Parameter 914: Display and enter application channels

– In normal operation parameter 914 shows the numbers of released application channels.
– In test operation (parameter 901 = On) parameter 914 is used to enter the desired number of application
channels.
6 Maintenance
The maintenance of the control system must be performed by a trained, experienced

Robatech service technician. Incorrect connection leads to equipment malfunction or
failure of the unit.
Please be certain to read Chapter 2 "Safety" in the instructions for the basic unit in
order to work safely and accident-free on the gluing system.
Danger Electric shock

Operating voltage 100-240 volt. Danger of death from electric shock.
 Touching live components can result in death.
 Product may be opened only by electrical specialists. An electrician is an
individual in possession of the requisite training, education and expe-
rience to be able to recognise the risks and avoid the hazards that can ori-
ginate from electricity.
 Switch off control system by means of device for disconnecting all poles,
isolate from the power supply network and secure against accidental
switching on before the lid or covers are removed.
 The following parts are live (100-240 volt):
Illustration 1: Live components (100-240V), application control AS30/AS50/AS50

AK, view from above with lid open
AS 30 / v2.3 Maintenance 69
After maintenance or repair work, it is necessary to ensure and check that the pro-
tective earth conductors are connected and the lid securely closed.
The housing lid of the control system must always be secured against unauthorised opening. Use a suitable tool
to securely lock the lid of the housing. Proceed as follows, depending on the control system version:
 Control system with screwed-on lid:
Lock the screwed lid using the 4 screws in the lid.
 Control system with hinged lid:
Lock the hinged lid above the central screw cap of the control system.
70 Maintenance AS 30 / v2.3
7 Appendix
7.1 Settings for hotmelt and coldglue heads

Standard values for hotmelt heads:
Head Article and solenoid valve ton toff

AX100 100606: Mac100 24Volt DC, 17 Watt 5.50 msec 7.50 msec
AX100 100605: Mac100 24Volt DC, 8.5 Watt 5.50 msec 7.50 msec
SX 130724: MacJac 24Volt DC, 4 Watt 5.70 msec 4.00 msec
SX 132978: MacJac 24Volt DC, 16 Watt 4.50 msec 4.00 msec
Standard values for coldglue heads:
Head Article and solenoid valve ton toff

ACX100 100606: Mac100 24Volt DC, 17 Watt 5.50 msec 7.50 msec
ACX100 100605: Mac100 24Volt DC, 8.5 Watt 5.50 msec 7.50 msec
These values should be considered as approximate guideline values. For applications

with the highest degree of accuracy these values should be assessed again based on a
series of trials.
7.2 Spare parts

Part No. Designation
146600 Pattern control AS30 complete
146596 Operating unit AS30 complete with cover
112067 Main switch
112068 Protective cap for main switch
146525 Power supply 75 Watt, 100…240 Volt AC – 24 Volt DC
xxxxxx Fuse 4AF H, 5×20mm
138194 Plug connector 4-pole green
AS 30 / v2.3 Appendix 71
8 Key word index
Encoder inputs ..................................................... 52

A Encoder inputs X1, X2 ......................................... 22
Access blockage ................................................... 34 Encoder operating mode ...................................... 52
Entering application pattern ................................. 61
Allocation to the channel ..................................... 45
Entering of the glue application pattern ............... 61
Altering parameters .............................................. 39
Application channels ............................................ 68 Entering the application ....................................... 62
Error messages ..................................................... 36
Application head outputs ................................. 9, 45
External outputs ................................................... 59
Application intermittent ....................................... 62
Applicator head outputs X8 ................................. 20 External program selection .............................. 9, 59
Assembly material................................................ 18
F
Automatic mode ................................................... 35
Flushing function ................................................. 54
B
G
Behaviour on blocking ......................................... 47
Glue application channels .................................... 68
C Glue application, Stand and End .......................... 65
Channel parameters .............................................. 47 Glue fill level monitoring ..................................... 66
Glue pressure regulation ...................................... 55
Channel status ...................................................... 48
Cold glue nozzle cover slides ................................. 9
I
Command parameter ............................................ 43
Conformity ........................................................... 10 Identification of the appliance ................................ 8
Connection encoder.............................................. 24 Improper use .......................................................... 7
Connector pin assignment .................................... 30 Installation ........................................................... 16
Continuous glue application ................................. 61 Intended use ........................................................... 7
Control connections ............................................. 20 Intermittent application ........................................ 62
Copying programs ................................................ 41 Intermittent glue application ................................ 61
Copyright ............................................................... 2 Internal status ....................................................... 60
Counter function .................................................. 57 IP converter .......................................................... 26
Cover slides .......................................................... 44
K
D
Konfiguration manuelle Ventilbetätigung ............ 48
Default values resetting ........................................ 42
Deleting programs ................................................ 41 L
Description of functions ....................................... 13 Loc1, Loc2 ........................................................... 34
Detection of direction of rotation ......................... 52
Different methods of application ......................... 61 M
Digital glue fill level input ................................... 66
Digital inputs on X6 ............................................. 25 Machine speed ..................................................... 53
Digital outputs on X7 ........................................... 25 Manual valve actuation .................................. 38, 54
Dimensions .......................................................... 17 Maximum speed ................................................... 52
Distance between switch-on and switch-off point Messages .............................................................. 36
trigger 1/2 ......................................................... 50 Methods of application, different ......................... 61
Distance between trigger and head....................... 48 Minimum glue pressure ....................................... 55
Distance trigger - glue head ................................... 9
N
E Nominal glue pressure ......................................... 55
Electromagnetic Compatibility ............................ 19
EMC-appropriate wiring ...................................... 19 O
Encoder inputs ....................................................... 9 Operating manual ................................................... 8
72 Key word index AS 30 / v2.3

Operating unit ...................................................... 15 S
Operation.............................................................. 34
Safety ................................................................... 11
Selecting a program ............................................. 40
P
Setting the operating parameters .......................... 39
Palletising function .......................................... 9, 57 Setting the parameters .......................................... 39
Parameter 900…914 ............................................ 68 Settings for heads ................................................. 71
Parameters 101…110 ........................................... 43 shielded cable ....................................................... 19
Parameters 120…122 ........................................... 44 Software key ........................................................ 68
Parameters 132 ..................................................... 45 Software update ................................................... 28
Parameters 140…150 ........................................... 46 Spare parts............................................................ 71
Parameters 163…166 ........................................... 47 Speed range ............................................................ 9
Parameters 170…172 ........................................... 49 Status codes.......................................................... 36
Parameters 180…182 ........................................... 52 stitch ..................................................................... 62
Parameters 183…191 ........................................... 53 Stitch .................................................................... 62
Parameters 200…221 ........................................... 55 Stitching the application pattern .......................... 63
Parameters 222…226 ........................................... 56 Structure of the control ........................................ 13
Parameters 230…234 ........................................... 57 Switching on ........................................................ 34
Parameters 240…269 ........................................... 59 Switch-on and switch-off compensation .............. 46
Parameters 280…295 ........................................... 60 System diagram.................................................... 13
Parameters 300…305 ........................................... 64
Parameters 320 ..................................................... 66 T
Place of installation .............................................. 16
Technical data ........................................................ 9
PLC control .......................................................... 33
Test operation ...................................................... 68
Power supply .......................................................... 9
Trigger block length ............................................. 49
Precision................................................................. 9
Trigger inputs ............................................. 9, 21, 49
Product Description................................................ 7
Trigger operating mode ........................................ 49
Programs .............................................................. 40
Trigger source ...................................................... 47
Proportional valve ................................................ 55
Troubleshooting ................................................... 37
Proportional valve output ................................. 9, 26
Type label .............................................................. 8
Protective equipment............................................ 12
Typical settings .................................................... 71
Q
U
Qualified personnel .............................................. 12
UP converter ........................................................ 26
R
V
Recognition of direction of rotation encoder ....... 23
vmax .................................................................... 52
Regulations on safety ........................................... 11
vmin ..................................................................... 47
Release input ........................................................ 47
Release speed ....................................................... 47
W
Reset..................................................................... 42
Responsibility of the operator .............................. 11 Weight .................................................................... 9
Retrieving parameters ......................................... 39
RS232 interface X17 ............................................ 26
AS 30 / v2.3 Key word index 73

As 30 Pattern Controller

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Instructions

Translation of Original Instructions

Please place this instruction file in index 2 of your instructions.

Robatech AG, Pilatusring 10, CH-5630 Muri, Schweiz

Phone +41 56 675 77 00

Date of issue April 2014

1 Product Description __________________________________________________________________ 7

3 Structure of the control ______________________________________________________________ 13

AS 30 / v2.3 Product Description 3

4 Product Description AS 30 / v2.3

AS 30 / v2.3 Product Description 5

8 Key word index ____________________________________________________________________ 72

6 Product Description AS 30 / v2.3

1.1 Intended Use

1.2 Improper Use

AS 30 / v2.3 Product Description 7

The Robatech AS 30 pattern control with program version 2.06

1.3.1 How to use this operating manual

1.4 Identification of the appliance

8 Product Description AS 30 / v2.3

* All 24V outputs can in total be loaded with 1.2 A.

AS 30 / v2.3 Product Description 9

Ambient temperature +5 to +40 °C / 41 to 104 °F

1.6 Conformity, standards complied with

Directive 2004 / 108 / EC relating to electromagnetic compatibility

10 Product Description AS 30 / v2.3

2.1 General regulations on safety

2.2 Responsibility of the operator

2.4 Personal protective equipment

2.5 Warnings on the product

No. Symbol Significance and consequences in case of non-observance

Warning against dangerous electrical voltage.

3.2 Description of functions

3.3 Hotmelt system diagram

1 Pattern control AS 30 4 Applicator head

AS 30 / v2.3 Structure of the control 13

1 Coldglue pump 6 Photoelectric sensor (trigger)

14 Structure of the control AS 30 / v2.3

AS 30 / v2.3 Structure of the control 15

4.1 Place of Installation

Part No. Description Position

– The housing cover of the appliance must be secured

Connecting terminals on the inside of the appliance

4.5 Signal cables: Wiring in compliance with EMC

– Only use shielded signal cables which have been

4.6.1 Applicator head outputs X8

Installation and programming:

Installation and programming:

Installation and programming:

4.6.3.2 Mechanical assembly

Wire colour Signal

Art. No.: Description Position

Part No. Description Position

– The 8 inputs are freely programmable for the

4.6.5 Digital outputs on X7

– The output can be operated either as a current output (4...20mA)

4.6.7 RS232 interface X17

– This serial interface allows communication with a higher level

Use appropriate tools to securely lock the housing cover.

Proceed as follows (depending on the version of the pattern control):

 Pattern control with hinged cover:

4.7.2 Download software update using “UpDown” into FLASH-EPROM

 Connect the RS232 interface on the PC with the desired AS 30 control

 Wait for the message “Connection ready” to appear