Operating instructions Gravimetric blending system Graviblend

Transcription

Operating instructions
Gravimetric blending system
Graviblend®
with C2 Mega Touch controller
64.10-0235GB11
03/03
®
MEGA TOUCH
Colortronic GmbH
Graviblend
Colortronic GmbH
Otto-Hahn-Straße 10-14
61381 Friedrichsdorf
USA
Colortronic, Inc.
155 E. 9th Avenue
Runnemede, NJ 08078
Telephone (0 61 75) 7 92-0
Telefax (0 61 75) 7 92-1 79
Email [email protected]
Http://www.colortronic.com
Telephone (856) 312 9600
Telefax (856) 312 9696
Our service department can be contacted under:
Service department
Telephon (0 61 75) 7 92-2 22
Telefax (0 61 75) 7 92-1 19
Spare parts department
Telephon (0 61 75) 7 92-3 33
Telefax (0 61 75) 7 92-1 08
Edition: 03/03
Ordernumber: 64.10-0235GB11
Order Confirmation No: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
This operation manual is for*:
(*Please fill in personally)
Serial number:
Built in:
64.10-0235GB11
03/03
Date of delivery:
Number of delivery:
Date of commissioning:
Location:
Group of machines:
II
64.10-0235GB11
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Graviblend
Colortronic GmbH retains all rights to change the Copying, translation or publication in any form exinformation in these operating instructions at any cept for personal use of purchaser requires aptime without notice.
proval from Colortronic GmbH.
We assume no liability for any errors or direct or in- All rights reserved.
direct damage resulting in context with these operating instructions.
III
Graviblend
Table of contents
Chapter 1.
General instructions
Version: 64.10-0195GB10
Warnings and Symbols
2
Explanations and Information
3
Legal basis
3
Fields of applications
4
Notes on usage
4
Chapter 2.
Safety Instructions
Version: 64.10-0195GB10
For Your Safety
2
For the Operating Safety of the Equipment
5
Chapter 3.
C2 Mega Touch
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Version: 64.10-0235GB11
General information
1
Menu overview
6
The main menu
9
The submenus - loss in weight feeders
Dosing unit menu general description
Dosing unit menus
11
11
12
The submenus - external control of dosing units
Dosing unit menu general description
Dosing unit menus
18
18
19
Expanded menus
System
Creating a recipe
Alarm Log
Event Log
Passwords
Service
Trend Plot
23
24
34
36
37
38
39
40
Active recipe
42
General operation
Entries
Touch Screen
43
43
44
Normal operation
Editing active recipe “online”
Creating new recipe in the recipe memory
Selecting recipe from the memory
Start/stop
45
45
46
47
48
Glossar
49
Table of contents IV
Graviblend
Chapter 4.
Error and error correction
Version: 64.10-0235GB11
Alarm messages - loss in weight feeders
Clearing alarms
Alarm delay time
Alarm texts
Alarm messages - external control of dosing units
Clearing alarms
Alarm delay time
Alarm texts
Chapter 5.
2
3
3
3
10
11
11
11
Initial operation
Version: 64.10-0235GB11
Check mounting
2
Check electrical connections
2
Switching on the power supply
2
Passwords
2
Checking the load cells in the system
3
Check the direction of rotation of the dosing motors
5
Check refilling
8
Refill material
10
Calibrating a dosing station (Determining the feed factor)
11
For external guidance (level sensor)
12
For manual setpoint specification operating mode.
No external guidance (Level sensor)
13
Start dosing
13
Chapter 6.
Maintenance
Maintenance Schedule
3
Checking the Load Cell
4
Checking the feeders
4
Exchanging the Fuses in the Cable Distributor
Replacing the Fuses on the Motherboard
Replacing the Fuse on the Motor Card
5
6
7
Adjusting the level sensor
8
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Version: 64.10-0195GB10
V
Graviblend
Chapter 7.
Description of Function
Version: 64.10-0195GB10
Dosing Principle
2
Operating Modes
3
Dosing Accuracy
3
Irregularities Caused by External Influences
4
Design of the Dosing System
Feeders
Weighing Container
Weighing Unit
Collecting Tank
Level Sensor (Optional)
Supporting Frame
Switch Cabinet
Displays of the Motor Drive Card
Refilling System (Optional)
Chapter 8.
5
7
8
8
9
9
10
10
10
10
Transport, Assembly and Storage
Version: 64.10-0195GB10
Transport and Packing
2
Assembly
2
Storage
4
Chapter 9.
Installation Instructions
Version: 64.10-0195GB10
Dosing System
2
Refilling System
3
Control System
3
Electrical Connection
Grounding the Equipment Against Electrostatic Charging
4
6
Removing Safety Devices for Transport from the Load Cells
6
Chapter 10.
Technical Data
Graviblend Plus
2
C2 Mega Touch
4
Accessories
4
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Version: 64.10-0235GB11
VI
Graviblend
Chapter 11.
Spare Parts List
Version: 64.10-0195GB10
Mechanics
2
Switching Cabinet and Operating Unit
4
Accessories
4
Chapter 12.
Accessories
Version: 64.10-0195GB10
o C-Flex
o CT 22
o CT 36
o CD 65
o CS 65
o Level sensor
o ____________________
o ____________________
Chapter 13.
Wiring diagramms
Version: 64.10-0195GB10
o Connection diagram no.: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
64.10-0235GB11
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o Currently not available; will be delivered at a late date !
VII
Graviblend
Index
A
Act. feed factor
Activate recipe
Actual value
Actual value deviation
Addressing
Alarm delay setting
Alarm delay time
Alarm Line stop
Alarm text
Allowed refill time
Chp 3-Pg 13
Chp 3-Pg 42/Chp 11-Pg 45/
Chp 3-Pg 46
Chp 3-Pg 9/Chp 3-Pg 11
Chp 3-Pg 6
Chp 3-Pg 15
Chp 3-Pg 28
Chp 3-Pg 14
F
Feeder empty
Feeders
Filling level
Chp 3-Pg 14
Chp 3-Pg 26
G
Gear reduction
Gross weight
Chp 3-Pg 16
Chp 3-Pg 15
H
Host interface
Chp 3-Pg 32
B
Balance
Blender control
Chp 3-Pg 30
I
Initial feed factor
Initial operation
Input field
Chp 5
Chp 3-Pg 44
C
Calibrate dosing unit
Calibration
Calibration drive command
Cancel alarms
Consumption
CSL
CSL configuration
CSL error
CSL overflow
CSL underflow
Chp 3-Pg 11
Chp 3-Pg 16
Chp 11-Pg 45
Chp 3-Pg 15
Chp 3-Pg 15
Chp 4-Pg 7
Chp 4-Pg 8
Chp 4-Pg 8
L
Language
Level mode
Level sensor
Level sensor mode
Line
Line setpoint
Line stop at
Lock opened
D
Date
Deadband
Dosing unit is empty
Drive command
Chp 3-Pg 25
Chp 4-Pg 5
Chp 3-Pg 14/Chp 3-Pg 20 ???
M
Maintenance
Massflow
Massflow error
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E
Extruder frequency
Chp 3-Pg 29
Chp 3-Pg 25
Chp 3-Pg 29
Chp 3-Pg 16
Chp 3-Pg 26
Chp 3-Pg 46
Chp 3-Pg 30
Chp 3-Pg 11
Material
Measuring noise
Min. drive command
Motor gain
Motor speed
Chp 6
Chp 6-Pg 3
Chp 3-Pg 20
Chp 4-Pg 12
Chp 3-Pg 46
Chp 3-Pg 14
Chp 3-Pg 16
VIII
Graviblend
N
Net weight
Niveau
Niveau delta
Niveau gain
Niveau mode
Niveau setpoint
Nominal setpoint
Chp 3-Pg 11/Chp 3-Pg 15 ???
Chp 3-Pg 29
Chp 3-Pg 29
Chp 3-Pg 29
Chp 3-Pg 29
Chp 3-Pg 29
Chp 3-Pg 46
O
Operating menus
Chp 3-Pg 44
P
Percentage setpoint
Pert
Perturbation
Print alarms
Print events
Printer
Pulse generator
Chp 3-Pg 13
Chp 3-Pg 14
Chp 3-Pg 33
Chp 3-Pg 33
Chp 3-Pg 33
Chp 3-Pg 16
Q
Quantity mode
Chp 11-Pg 45
S
Save
Scale range
Screen shot active
Setpoint
Setpoint (Dosing unit
operates in line)
Setpoint (Dosing unit
operates locally)
Software
Span
Speed pickup
Speed too high
Speed too low
Start
Start delay setting
Stop
Store feed factor
Store refill levels
Chp 3-Pg 46
Chp 3-Pg 15
Chp 3-Pg 33
Chp 3-Pg 25
Chp 3-Pg 15
Chp 3-Pg 16
Chp 3-Pg 48
Chp 3-Pg 48
Chp 3-Pg 26
Chp 3-Pg 26
T
Tare
Tare weight
Time
Total consumption
Totalizer
Totalizer to zero
Chp 3-Pg 15
Chp 3-Pg 15
Chp 3-Pg 25
Chp 3-Pg 9
Chp 3-Pg 42
R
Recipe name
Refill complete weight
refill delay
Refill request weight
Refilling
Refilling time error
Regrind
U
Units
Chp 3-Pg 26
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Restart at
Chp 3-Pg 46
Chp 3-Pg 14
Chp 3-Pg 14
Chp 3-Pg 14
Chp 3-Pg 9
Chp 3-Pg 4
Chp 3-Pg 46
Chp 3-Pg 30
IX
1. General instructions
Version: 64.10-0195GB10
These operating instructions are to be used by all persons assigned activities connected with the equipment.
64.10-0195GB10
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»
These instructions apply to all persons within the range of action of the equipment.
Chapter 1.: General instructions, Page 1
Warnings and Symbols
1.1. Warnings and Symbols
The following warnings and symbols are used in these operating instructions:
»
L
F
This symbol indicates danger to life! Fatal or serious injury is possible if the corresponding instructions, regulations or warnings are not observed.
This symbol indicates that serious injury is possible if the corresponding instructions,
regulations or warnings are not observed.
This symbol indicates that extensive damage to the equipment is possible if the corresponding instructions, regulations or warnings are not observed.
This symbol indicates information important for becoming familiar with the equipment,
i.e. technical correlations.
$
This symbol indicates that a technical term is explained at this point.
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&
Explanations and Information
1.2. Explanations and Information
Various terms and designations are used in these operating instructions to ensure clarity. Therefore
please note that the terms used in the text stand for the corresponding explanations listed below.
•
Equipment
“Equipment” can mean an individual unit, a machine or an installation.
•
Operating personnel
The “operating personnel” are persons operating the equipment on their own responsibility or
according to the instructions.
•
Operator
The “operator” of the equipment (production
manager, foreman, etc.) is the person responsible for all production sequences. The operator instructs the operating personnel of what is
to be done.
•
Operating Instructions
The “operating instructions” describe the interaction of the equipment, production sequences
or methods. The operating instructions must
be compiled by the operator of the equipment.
•
Equipment Foreman
When several operating personnel work on
one machine, the “equipment foreman” coordinates the sequences. The equipment foreman
must be appointed by the operator.
•
Trained Personnel
“Trained personnel” are persons who, due to
their training, are authorized to carry out the required work.
1.3. Legal basis
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See “Manufacturer’s Certificate” resp. “Certificate of Conformity”.
Fields of applications
1.4. Fields of applications
Graviblend Plus, developed especially for continuous extrusion processes in the plastics industry, uses
loss-in-weight technology.
The material flow is constantly monitored and regulated by innovative gravimetric technologies:
changes in bulk density, pellet size or other changes in material characteristics have no effect on accuracy.
The Graviblend Plus blending system ensures quality end products and thorough documentation
through state of the art controls and loss-in-weight technologies.
Applications:
•
Blown film
•
Wire and cable coating
•
Cast film
•
Masterbatch manufacturing
•
Cast sheet
•
Fiber and filament
•
Foam sheet, foam panel
•
Compounding
•
Profile extrusion
•
Co-extrusion
•
Pipe and tubing
•
If the unit has not been installed yet, observe
the instructions in the chapters “Transport, Assembly and Storage” and “Assembly Instructions”.
1.5. Notes on usage
Experienced operators can begin directly with
the chapter on “C2 Touch” resp. “C2 Mega
Touch” if the unit has been properly installed.
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•
2. Safety Instructions
Version: 64.10-0195GB10
»
These safety instructions apply to all persons within the range of action of the equipment.
Please inform all persons within the range of action of the equipment of the direct and
indirect hazards connected with the equipment.
Knowledge of the English language is prerequisite.
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Ensure in each case that the operating personnel are familiar with the operating instructions and the function of the equipment.
Chapter 2.: Safety Instructions, Page 1
For Your Safety
2.1. For Your Safety
General safety
•
The operating personnel of this equipment
must be at least 16 years old.
•
Please read these operating instructions carefully before taking into operation for the first
time. Observe all points. Contact us should
questions arise. This avoids injury and damage to the equipment!
These operating instructions must be kept
available at all times at the place of operation of
the equipment. Improper operation results in
danger of accidents!
•
Please note that, for reasons of clarity, not all
conceivable cases regarding operation or
maintenance of the equipment can be covered
in these operating instructions.
•
Please observe all safety instructions and
warnings on the equipment. This avoids injury
and damage to the equipment!
All work on the equipment is to be carried out
by persons whose qualifications are specified
in the pertaining chapters of the operating instructions. Improper operation results in danger of accidents!
•
The proper work clothes are to be worn during
any work on the equipment. This avoids injury!
•
Compare the connected loads with those of the
main power supply. Danger of injury through
electrical shock!
•
Disconnect electrical components from the
main power supply before work is carried out
on these components. Caution: danger to life
through electrical shock!
•
The local regulations and codes pertaining to
this equipment must be observed.
•
Compile detailed process operating instructions based on these machine operating instructions for the sequence of procedures to be
carried out on this equipment.
Improper operation results in danger of accidents!
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•
•
For Your Safety
Installation
•
Compare the connected loads with those of the
main power supply. Danger of injury through
electrical shock!
•
The equipment may only be operated when all
the associated components are properly connected up and in accordance with the relevant
regulations.
•
When using lifting gear, please observe the
pertaining regulations. Caution: danger of accidents!
•
Operate the equipment only when all machine
components are grounded. Caution: danger of
electrical shock!
•
Do not modify, add other equipment or change
the design of the equipment without the approval of the manufacturer. Caution: danger of
accidents!
•
Please note for installation that the equipment
is top-heavy. Danger exists that it may topple
over!
•
Attachments not supplied by Colortronic must
be manufactured in accordance with safety
regulation EN 294. Caution: Danger of accidents!
•
Check all lines, hoses and screwed
connections regularly for leaks and obvious
damage. Repair damage immediately.
Caution: danger of accidents!
•
Wait at least 1 minute before beginning with
works on the cable distribution box.
Danger to life! High-voltage discharge is possible.
Maintenance
Depressurise all compressed air piping before
starting maintenance work. Caution: danger of
accidents!
•
Before starting maintenance work, appoint a
supervisor.
•
Inform the responsible personnel before maintenance work that the system is started.
•
Disconnect the equipment from main power
supply before starting maintenance procedures to ensure that it cannot be switched on
unintentionally. Caution: danger of accidents!
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•
For Your Safety
Continuous operation
•
Never remove the protective cover on the feed
screws during operation (Graviblend M/L).
Caution: danger exists that limbs may be
caught!
•
When the main switch is switched off for reasons pertaining to safety, it must be secured
against unauthorized activation.
•
Never remove the feed chuts during operation
(Graviblend M/L). Caution: danger exists that
limbs may be caught!
•
Never operate the equipment when partially
dismantled. Caution: danger exists that limbs
may be caught; danger of electrical shock!
•
Never reach into the weighing container during
operation or without switching off the main
switch. Caution: danger exists that limbs may
be caught!
•
In case of malfunction, shut down the equipment immediately. Have malfunctions corrected before resuming operation.
•
Never reach into the flat side valve of the refilling system. Caution: danger exists that limbs
may be caught!
•
The equipment is intended only for processing
granulated plastics and additives. Other use of
the equipment is contrary to its specifications.
•
Operate the equipment only when all machine
components and cover plates are installed.
Caution: danger exists that limbs may be
caught!
•
This equipment is not suitable for foods processing.
•
The safety instructions of the connected machines must be followed.
•
Dosing stations with an an intermediate piece
for dosing may only be put into operation if the
cover is in place or a weighing container is in
the intermediate piece for dosing.
Caution: danger of squeezing!
Appoint an equipment foreman to be responsible for the equipment.
•
Ensure that the operating personnel are provided detailed instruction in the operation of the
equipment. Improper operation results in danger of accidents!
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•
For the Operating Safety of the Equipment
2.2. For the Operating Safety of the Equipment
•
Never change settings if the consequences are
not precisely known.
•
Use only shielded cables for the signal lines
(Graviblend).
•
Use only original Colortronic spare parts.
•
The adjusting rings of all load cells must move
absolutely smoothly.
•
Please observe the maintenance schedule.
•
Keep record of all maintenance and repair procedures.
•
Ensure that the weighing containers and feed
chutes do not contact or push against other
components (Graviblend).
•
Please note that electronic components may
be damaged by static discharge.
•
Ensure that the feed chutes are installed in
their proper positions (Graviblend M/L).
•
Check all electrical connections for proper fit
before the equipment is placed into operation
for the first time, and at regular intervals thereafter.
•
Use only flexible cable for grounding the weighing containers (Graviblend).
•
Please note that the control system may be located at a maximum distance of 60 m from the
feeders, and the operating unit at a maximum
distance of 500 m from the control system
(Graviblend).
•
When dimensioning the refilling system, please
note that a maximum of 40 refilling cycles per
hour are permitted (Graviblend). More than this
number will affect feeder accuracy.
•
Note down all setup data.
Never adjust sensors without exact knowledge
of their function.
•
The control system may be operated only at
temperatures from 0 to 50°C (120° F).
•
The control system may only be stored at temperatures from -20 to +70°C (-4 to +160°F).
•
Use only original Colortronic cables for installation or repairs, as these are adapted specially
to the equipment.
•
Remove safety devices for transport of the load
cells only after the equipment has been installed.
•
Please note the carrying capacity of the extruder flange during installation.
64.10-0195GB10
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•
General information
3. C2 Mega Touch
Version: 64.10-0235GB11
3.1. General information
»
F
$
Before adjusting the control system, the Graviblend system has to be duly mounted
and connected.
Observe all safety instructions of the Graviblend system.
When starting up the Graviblend system for the first time:
Follow the instructions in the ”Initial operation” chapter step by step.
The graphical representation of the system depends on the number of dosing units
(see possibilities of configuration)!
In these operating instructions systems with 3 and more dosing units (loss in weight
feeders, external control of dosing units) per line are described separately.
The manual describes the operation of 1 dosing line.
64.10-0235GB11
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Please make sure that for your control unit, the representation of the dosing units is coherent and analogous to the number of dosing units.
Chapter 3.: C2 Mega Touch, Page 1
General information
Possibilities of configuration:
1 dosing line with 10 dosing units (with level sensor control)
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1 dosing line with 10 dosing units (without level sensor control)
General information
2 dosing lines with 6 dosing units
with level sensor control
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without level sensor control
General information
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General information
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Menu overview
3.2. Menu overview
Representation of systems with up to 4 dosing units
Page 23
Page 45
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Page 12
Menu overview
Representation of systems with 5 and more dosing units
Page 23
Page 45
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Page 12
Menu overview
Systems with external control of loss in weight feeders
Page 23
Page 45
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Page 18
Chapter 3.: C2 Touch, Page 8
The main menu
3.3. The main menu
U
S
N
MUSTER
A
P
B
C
D
G
H
I
E
F
O
T
Q
J
P
K
L
R
+
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A
Refilling has been triggered (Cover opened)
B
Net weight (material weight)
C
Refilling has been enabled (Cover grey, without
lock)
D
Filling level of the material in the dosing unit between min. and max. refill weight
E
Drive command of the dosing motor
F
Blue line:
Dosing unit is part of the line
No visible line:
Dosing unit does not depend on the line
(operation mode: local)
G
Percentage setpoint of the dosing unit
H
Setpoint of the dosing unit in kg/h
I
Actual value of the dosing unit
J
Percentage line setpoint
K
Line setpoint in kg/h
V
L
Actual value of the line
N
Green: Operation
Grey: Stopped
Red: Incoming alarm
O
Refilling is switched off for this dosing unit (discharging)
P
Balance visible: gravimetric mode
Balance invisible: volumetric mode
Q
Number of the dosing unit
R
Total consumption of the line
S
Expanded menus
T
Collecting tank
U
Name of actual recipe
V
Ramp mode + / Ramp mode -
The main menu
T
Collecting tank
Operation without level sensor, without ramp
mode
T
T
T
Collecting tank
Operation without level sensor, with ramp mode
T
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T
Collecting tank
Operation with level sensor
or
Operation with external guidance
T
T
3.4. The submenus - loss in weight feeders
3.4.1. Dosing unit menu general description
B
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
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C
R
T
B
Close menu. Back to the main menu
C
Blue line:
No line:
Dosing unit is independent of the line
D
Select dosing unit beforehand / select dosing unit
afterwards
E
Display of the entered value
F
Other tabs of the submenus
G
Net weight (material weight) of the dosing unit
H
Lock opened: automatic refilling enabled / lock
closed: automatic refilling disabled.
Change-over by pressing ”Lock”
I
Upper refilling limit (refill complete weight)
J
Balance visible: gravimetric mode
Balance invisible: volumetric mode
Change-over by pressing ”Weigher”
K
Filling level of the material between min. and max.
refill weight
L
Lower refilling limit (refill request weight)
M
N
Motor speed of the feed screw
O
Percentage setpoint for the line mode
P
Setpoint
Q
Actual value
&
Actual value = 0 if alarm text “Dosing unit
is empty” appears
R
Calibrate dosing unit
T
Reset totalizer
3.4.2. Dosing unit menus
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Materialname (see page 45, 46)
Operation mode: line
Operation mode: local
Setpoint (Dosing unit operates in line)
Setpoint (Dosing unit operates locally)
The calculated setpoint for the dosing unit will be Enter the setpoint.
displayed.
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Massflow
Act. feed factor
The current throughput of the dosing unit will be The current maximum possible throughput for the
displayed.
dosing unit is displayed.
Will be recalculated every 2 seconds.
Net weight
The current weight of the material in the dosing unit Pert value
will be displayed.
The measuring noise of the weighing cell will be indicated.
Drive command
This value indicates the percentage of the maxi- Totalizer
mum possible rotational speed at which the dosing The amount of material metered since the last reunit is currently operated. The drive command is set by the dosing unit will be indicated.
proportional to the rotational speed of the dosing
Calibrate
unit.
Calibrates the feeder automatically.
Motor speed
The dosing motor is triggered for 1 minute approx.
The current rotational speed of the dosing unit is using a calibration drive command (see page 16).
displayed. The rotational speed is proportionate to The determined value will automatically be saved
the drive command.
as initial feed factor.
Initial feed factor
Totalizer to zero
This value indicates the maximum possible Reset of the consumption display unit.
throughput of the dosing unit.
The initial dosing factor may be entered manually
or may be automatically determined by means of
the ”Calibration” function.
In case the material weight in the dosing unit does
no longer reach this value, the refilling will be
started. The set value depends on the size of the
dosing unit. This value must be larger than the
value for “Feeder empty”.
If the material weight in the dosing units has
reached this value, the refilling process will be
stopped. The set value depends on the size of the
dosing unit. The average is 80 % max. of the dosing hopper volume.
Allowed refill time
Time during which the refilling procedure has to
be terminated. In case the set maximum is not
reached during this time, an alarm will be issued.
Default setting: 30 s
Massflow error +
This value specifies the deviation range of the current actual value from the setpoint for which an
Post refill delay
alarm will still not be triggered.
This value specifies how long the unit is to remain Default setting: 10 %
in the volumetric mode after the refilling procedure.
Massflow error This value specifies the deviation range of the curAlarm delay setting
rent actual value from the setpoint for which an
This value specifies for how long an error has to be alarm will still not be triggered.
present until an alarm is sent.
Default setting: 10 %
Perturbation limit
Start delay setting
This value specifies the maximum permissible disEnter for how long after the start of the unit the turbance for the weigher (measuring noise of the
alarm messages are to be suppressed.
weighing cell), before an alarm will be output.
Default setting: 200
Max. drive command
Feeder empty
Maximum permissible value for the drive com- If the material level falls below this value the alarm
mands
message “Dosing unit is empty” (see chapter 4,
page 5) will be displayed. If the function “Alarm
Line Stop” has been activated (see page 24) the
Min. drive command
Minimum permissible value for the drive com- line stops.
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mands
Default setting: 1%
Scale range
The scale range of the weighing cell is displayed
here. The value corresponds to the maximum permissible load of the weighing cell.
Gross weight
The current weight of the dosing unit is displayed.
Net weight
The current weight of the material within the dosing
unit is displayed.
Tare weight
Gross weight of the dosing unit (without material).
The value may be entered manually or may be determined automatically via the ”Tare” function.
Span
By means of this value, the display of the net
weight may be calibrated (see Initial operation).
CSL On/Off
Modifications only according to prior agreement by
the Colortronic service!
By means of this key, the weighing cell may be
switch on/ off.
In case a weighing cell is switched off, ”0” will be
displayed in the ”Configuration” display first and ”-“
instead of the number of the weighing cell.
CSL configuration
The addresses of the weighing communicating
permanently with the C2 box will be displayed
here. In case the communication and the addressing of the weighing cells is correct,
-1234567——— will be displayed (for seven connected dosing units)
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Tare
Tare dosing unit.
Massflow filter
Modifications only according to prior agreement
with the Colortronic service!
Parameters for the control algorithm of the motor
control.
Motor gain
Parameters for the control algorithm of the motor
control.
Total gear reduction
Enter the value for the gear reduction of the dosing
unit. If the setting is “1” the motor speed is displayed.
Default setting: 1
Speed pickup
Enter the number of pulses the pulse generator
provides per rotation.
Default setting:
100 (Bison-Motor)
50 (Engel-Motor)
Full Scale Drive CMD
Enter the drive command frequency to be sent to
the motor to make it turn at maximum speed.
Default setting: 10000 Hz
Nominal setp.
For dosing units:
This value limits the maximum feeding rate independently of the specified ”setpoint”. The dosing
unit may only start if this value is larger than ”0”.
Deadband
Level sensor mode only!
Enter the hysteresis of the level sensor signal.
Default setting: 100 Hz (0,1 kHz)
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Screw Type
Enter, if desired, designation of dosing screw (see
name plate).
Calibration drive command
Enter the calibration drive command.
During calibration, the dosing motor will be triggered for 1 minute approx.with the value set in this
field (see page 13). The determined value will
autmatically be saved as initial feed factor.
In case there is an alarm present at the dosing unit,
it will be displayed here.
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Cancel alarms
The alarm is cleared, i.e. the alarm is no longer visible within the control unit and the alarm output (relay) will be switched off.
In case the alarm is still present within the system,
it will be displayed again immediately and the
alarm output will be active at the end of the alarm
delay time.
3.5. The submenus - external control of dosing units
3.5.1. Dosing unit menu general description
B
D
E
F
M
O
P
Q
C
T
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B
F
Close menu. Back to the main menu
Other tabs of the submenus
C
M
Blue line:
No line:
O
Dosing unit is independent of the line
Percentage setpoint for the line mode
P
D
Select dosing unit beforehand / select dosing unit Setpoint
afterwards
T
Reset totalizer
E
Display of the entered value
3.5.2. Dosing unit menus
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Materialname (page 45, 46)
Operation mode: line
Operation mode: local
Setpoint (Dosing unit operates in line)
Setpoint (Dosing unit operates locally)
The calculated setpoint for the dosing unit will be Enter the setpoint.
displayed.
Massflow
Totalizer
The current throughput of the dosing unit will be The amount of material metered since the last redisplayed.
set by the dosing unit will be indicated.
Drive command
Totalizer to zero
This value indicates the percentage of the maxi- Reset of the consumption display unit.
mum possible rotational speed at which the dosing
unit is currently operated. The drive command is
proportional to the rotational speed of the dosing
unit.
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Initial feed factor
This value indicates the maximum possible
The initial dosing factor may be entered manually
or may be automatically determined by means of
the ”Calibration” function.
Alarm delay setting
This value specifies for how long an error has to be
present until an alarm is sent.
Start delay setting
Enter for how long after the start of the unit the
Max. drive command
Maximum permissible value for the drive commands
Min. drive command
Minimum permissible value for the drive commands
Default setting: 1%
Massflow error +
This value specifies the deviation range of the current actual value from the setpoint for which an
Massflow error This value specifies the deviation range of the current actual value from the setpoint for which an
Nominal setp.
For dosing units:
This value limits the maximum feeding rate independently of the specified ”setpoint”. The dosing
unit may only start if this value is larger than ”0”.
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Enter the drive command frequency to be sent to
the motor to make it turn at maximum speed.
In case there is an alarm present at the dosing unit,
it will be displayed here.
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Cancel alarms
The alarm is cleared, i.e. the alarm is no longer visible within the control unit and the alarm output (relay) will be switched off.
In case the alarm is still present within the system,
it will be displayed again immediately and the
alarm output will be active at the end of the alarm
delay time.
Expanded menus
3.6. Expanded menus
&
System: Basic settings such as language, date, time, interface, system configuration
Recipe: Creating and editing recipes
Alarm Log: System errors
Event Log: System messages
Password: User login
Service: Display of the actual inputs resp. outputs of the system.
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Trend plot: Graphical display of processing data.
Expanded menus
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3.6.1. System
Expanded menus
General
Language
Select the language of the menus.
System
Enter the name of the unit .
Date
Enter the current date.
Time
Enter the current time.
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Software
The number of the software version will be displayed.
Expanded menus
Configuration
= These values are preset on the delivof the device and just have to be
F *ery
checked.
Feeders*
Select the number of connected feeders.
Units*
Select the mass unit in the display.
Store refill levels
Click here to have the refill levels displayed in the
recipe memory (see page 34).
Store feed factor
Click here to have the feed factor displayed in the Significance
recipe memory (see page 34).
Modifications may be performed only on consultation with the Colortronic service department!
Level sensor mode*
Parameter activation for the control algorithm of
Click here if a level sensor or an external guide the material feeding of the roving haul-off.
value is available.
The line set point is determined using this function. Digital Setpoint Control
Level sensor inactive: Entries in the “Line set Modifications may be performed only on consultapoint” field can be made. The line set point has to tion with the Colortronic service department!
be entered manually (must be activated if operated Activation of the external setpoint control by the
without the level sensor).
digital inputs.
Level sensor active: Entries in the “Line set point”
field cannot be made. The line set point is deter- Extruder Control (option)
mined externally (level sensor) or via an external Manual Refill (option)
guide value, e.g. the extruder speed.
Quantity mode
Click here to activate the quantity mode.
mode, the dosing stops afset quantity has been dosed.
F Interthethequantity
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Line actual output (option)
Expanded menus
Configuration
= These values are preset on the delivof the device and just have to be
F *ery
checked.
Operation mode
Select for each feeder the operation mode:
Loss in weight feeder = Standard setting,
Operation mode for gravimetric controlled feeders;
External control = external controlled feeders (for
example: liquid feeders),
no gravimetric control, the control of the feeder
takes place by internal control;
Loss in weight line setpoint = function at the moment not activated.
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wrong choose of the operation mode rethe functioning of the system !
F Aduces
Expanded menus
Alarm Line Stop
Alarm Line stop
Select which feeder is to trigger a line stop for
which error (Motor fault, Feeder is empty or Mass
Flow Error).
F The line stops in case of an alarm.
Start Delay
The feeder start is delayed. Enter the start delay
time in seconds.
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Stop Delay
The feeder stop is delayed. Enter the stop delay
time in seconds.
Expanded menus
Niveau
Niveau mode
Click here to activate the level mode.
sensor mode only!
F Level
The closed-loop level control should only
be activated by Colortronic service personnel.
&
Only for special processes with an extremely high and great variations in
throughput.
Niveau
Set point for level in the material container,
0 - 10000 Hz = empty - full;
Setting range: 3000 - 8000 Hz
Niveau delta
Hysteresis of the level sensor signal.
Level mode
Click here to activate the level mode.
F The niveau mode must be active!
&
The calculation of the niveau set point depends on the extruder speed.
Extruder frequency
Display of the current extruder frequency.
Niveau gain
Modifications may be performed only on consulta- Deadband
tion with the Colortronic service department!
Hysteresis of the extruder signal.
Parameters for the control algorithm of the material
in the accumulator tank.
Niveau setpoint
Enter the desired value for the line throughput.
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Nominal setpoint
This value will be calculated by the control system
and should not be changed.
Expanded menus
Blender control
Click here to activate the blender control.
&
Prevents the accumulator tank from being
overcharged, if, for example, the extruder
is stopped and the dosage is still in the
continuous operation.
Line stop at
The line will be stopped when the filling level
reaches the value entered in this field.
&
0 - 10000 Hz = empty - full;
Restart at
The line will be started when the filling level
reaches the value entered in this field.
&
0 - 10000 Hz = empty - full;
Recipe Quality
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Recipe Quality Time
Expanded menus
Ramp mode of the line setpoint
function can not be activated in level
sensor mode !
F This
Ramp mode
Click here to activate the ramp mode of the line
setpoint.
ü
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Ramp Step
Desired setpoint increasement resp. setpoint
decreasement.
By clicking the button + / - the line setpoint will be
changed.
Expanded menus
Host interface
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Host interface
Click the host interface required.
Expanded menus
Printer
sure a printer (option) is connected
to the parallel port.
F Make
&
To print out screen shots you either need
a HP Desk Jet, a HP compatible printer,
which supports the PCL procedure, or a
Postscript printer.
Select one of the connected printers:
HP black/white
HP compatible printer which supports the PCL procedure.
Postscript
Postscript printer.
HP 3 color
3-color Desk Jet Printer
(1 color cartridge in the printer).
HP 4 color
4-color Desk Jet Printer
(1 color and black / white cartridge in the printer).
&
To print out online alarms or events, you
either need a dot-matrix printer (immediate printout) or a printer conforming to ISO
8859-1 (printout as soon as the print
buffer is full).
Print alarms
Click here to print out online alarms.
Print events
Click here to print out online events.
Screen shot active
Click here to print out screen pages.
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Press the “!” key to start the printout.
MEGA TOUCH
Expanded menus
3.6.2. Creating a recipe
“Store feed factor” and “Store refill levels” not activated (see page 26)
$
This function is available in 2 menus:
“Online”:
Percentages can be entered here
(for a detailed description, please refer to page 45)
Percentages or units, e.g. kg/h can be entered here
(for a detailed description, please refer to page 46)
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“In the recipe memory”:
Chapter 3.: C2 Touch, Page 34
Expanded menus
“Store feed factor” activated (see page 26)
“Store feed factor” and “Store refill levels” activated (see page 26)
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“Store refill levels” activated (see page 26)
Expanded menus
3.6.3. Alarm Log
The malfunctions of the last three days will be shown including date and time as well as a text display.
Example:
Fdr.
Start
End
3
2
11:28:16
11:28:34
Speed too high
Alarm message no. 3: On 00-09-13, at 11:28:16, the “Speed too high” error occurred for feeder
2. At 11:28:34, the error was remedied.
100 messages can be stored per day.
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&
Expanded menus
3.6.4. Event Log
The events of the last three days will be shown including date and time as well as a text display.
Example:
Fdr.
Time
old
new
22
0
16:00:13
0.00
100
RFS
Recipe Setpoint
Event message no. 22: On 00-04-11, at 16:00:13, the “Recipe Setpoint” for feeder 0 (= line) was
changed from 0.00 to 100.0.
100 messages can be stored per day.
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&
Expanded menus
3.6.5. Passwords
&
You can protect the access to the set values of the control system by different access
levels.
At initial operation there is unlimited access to the set values.
The operator ADMIN has unlimited access.
To be able to enter new users and user levels (password configuration), you must have
logged on as ADMIN.
Enter users / user levels:
Enter “ADMIN” and the password.
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Click the “Login” button.
&
The “Password configuration” menu opens.
Expanded menus
3.6.6. Service
&
Display of the actual digital resp. analogue inputs / outputs of the system.
LED red: digital output activated
Display of the incoming frequencies
Display of the outgoing frequencies
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LED green: digital input activated
Expanded menus
3.6.7. Trend Plot
&
Graphical display of processing data:
The last 6 operation minutes are displayed.
Max. 3 trend plots can be displayed at the same time.
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Every 2 seconds the display is made topical.
Expanded menus
Choices:
Scale
•
Type of trend plot:
Massflow Deviation,
Drive Command,
Net Weight,
Act. Feedfactor,
Pert. Value,
Level probe,
Off = no display
•
Display dosing unit resp. line
Display dosing unit = Entry “feeder no.”
Diplay line = Entry “0”
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•
Active recipe
3.7. Active recipe
A
B
C
D
A
Lock opened: Refilling enabled
B
Lock closed: Refilling disabled
C
Blue line: Dosing unit is part of the line
D
No line visible: Dosing unit does not depend on the
line (operation mode: local)
Line setpoint
The calculated line setpoint will be displayed.
In the ”Line System” operating mode, the desired
line setpoint may be entered here.
Nominal setp.
This value should exceed the extruder throughput
by 10-20% approx. This value limits the total feeding rate.
Setp. %
Totalizer
Enter the part of the respective dosing unit (comThe material consumption of the line since the last
ponent).
reset will be displayed.
Setp. kg/h
The calculated setpoint throughput is displayed.
Totalizer to zero
The display of the material consumption will be reset.
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Regrind
Click here if the present feeder changes over to the
Quantity mode
regrind mode.
Enter the quantity to be dosed.
The control system ensures that, despite the
regrind, the recipe will be strictly observed (recipe
& The present menu will only be displayed if
entries >100 % are possible).
the quantity mode is active (see page 26).
The quantity mode stops the dosage after
Material
the set quantity has been dosed.
The name of the material may be entered here.
Activate recipe
Line %
The total of the percentages of all dosing units of Click here to activate changes in the recipe.
the line will be displayed here. The total has to
amount to 100, otherwise the recipe is not correct.
General operation
3.8. General operation
A
Touch Screen
B
Numerical entry keyboard
C
Start key
Starts the line
D
Enter key
Acknowledges entries
E
Stop key
Stops the line
F
Escape key
Aborts entries
G
Prints screen shots (if function activated,
see page 33)
H
Backspace key
Deletes the last entry in the input field
MEGA TOUCH
A
B C D E FG H
3.8.1. Entries
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All entries will only be accepted after being acknowledged by means of the Enter key.
General operation
3.8.2. Touch Screen
The operating menus will be directly selected by touching the symbols with the finger tips. Entries are
made by means of the numerical keyboard.
As soon as a symbol has been touched, the respective menu will appear.
As soon as an input field has been touched, it will be activated and be ready for input.
Open menus:
Scroll
MEGA TOUCH
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Close menus:
MEGA TOUCH
Normal operation
3.9. Normal operation
3.9.1. Editing active recipe “online”
Nominal setpoint
Setpoint %
Enter the percentage of the respective dosing unit This value should exceed the extruder throughput
by 10-20% approx. This value limits the total feed(component).
ing rate.
Setpoint kg/h
The calculated setpoint throughput will be dis- Totalizer
The material consumption of the line since the last
played.
reset will be displayed.
Regrind
Click here if the present feeder changes over to the Totalizer to zero
The material consumption display will be reset.
regrind mode.
regrind, the recipe will be strictly observed (recipe Quantity mode
Enter the quantity to be dosed.
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Material
&
The present menu will only be displayed if
the quantity mode is active (see page 26).
The quantity mode stops the dosage after
the set quantity has been dosed.
Line 100%
The total of the percentages of all dosing units of
the line will be displayed here. The total has to Activate recipe
amount to 100, otherwise the recipe is not correct. Click here to activate changes in the recipe.
Line setpoint
The calculated line setpoint is displayed.
Normal operation
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3.9.2. Creating new recipe in the recipe memory
Set point %
Enter the percentage for the respective feeder
(component). Set point kg/h: The calculated set
point throughput will be displayed.
or
Set point kg/h
Enter the throughput in units such as kg/h. Set
point %: The calculated percentage for the respective feeder will be displayed.
Line 100%
The total of the percentages of all dosing units of
the line will be displayed here. The total has to
amount to 100, otherwise the recipe is not correct.
Regrind
Click here if the present feeder changes over to the
regrind mode.
regrind, the recipe will be strictly observed (recipe
Nominal setpoint
by 10-20% approx. This value limits the total feeding rate.
Material
Save
Click here to save this recipe.
Line kg/h
Activate recipe
Click here to activate this new recipe.
Recipe name
Enter the recipe name.
If you click a keyboard appears on the display.
Press ENTER-key to confirm.
Normal operation
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3.9.3. Selecting recipe from the memory
Normal operation
3.9.4. Start/stop
Line
Press the Start key
or
MEGA TOUCH
the Stop key
MEGA TOUCH
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Local dosing unit (is not operated in the line mode)
Press Start or Stop in the dosing unit menu.
Glossar
3.10. Glossar
Act. feed factor
The current maximum possible throughput for
the dosing unit is displayed.
Will be recalculated every 2 seconds.
Page 13
Activate recipe
Click here to activate changes in the recipe.
Page 42, 46
Alarm delay setting
This value specifies for how long an error has
to be present until an alarm is sent.
Page 14, 21
Alarm Line stop
Select which feeder is to trigger a line stop for
which error (Motor fault, Feeder is empty or
Mass Flow Error).
Page 28
CSL On/Off
by the Colortronic service!
By means of this key, the weighing cell may be
switch on/ off.
In case a weighing cell is switched off, ”0” will
be displayed in the ”Configuration” display first
and ”-“ instead of the number of the weighing
cell.
Page 15
Deadband
Level sensor mode only!
Enter the hysteresis of the level sensor signal.
Default setting: 100 Hz (0,1 kHz)
Page 16
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Digital Setpoint Control
Allowed refill time
Activation of the external setpoint control by
Time during which the refilling procedure has to the digital inputs.
be terminated. In case the set maximum is not Page 26
reached during this time, an alarm will be isDrive command
sued.
This value indicates the percentage of the maxDefault setting: 30 s
imum possible rotational speed at which the
Page 14
dosing unit is currently operated. The drive
Calibrate
command is proportional to the rotational
Calibrates the feeder automatically.
speed of the dosing unit.
The dosing motor is triggered for 1 minute
Page 13, 20
approx. using a calibration drive command (see
Extruder Control (option)
page 16). The determined value will automatiPage 26
cally be saved as initial feed factor.
Feeder empty
Page 13
If the material level falls below this value the
Cancel alarms
The alarm is cleared, i.e. the alarm is no longer alarm message “Dosing unit is empty” (see
visible within the control unit and the alarm out- chapter 4, page 5) will be displayed. If the function “Alarm Line Stop” has been activated (see
put (relay) will be switched off.
In case the alarm is still present within the sys- page 24) the line stops.
tem, it will be displayed again immediately and Page 14
the alarm output will be active at the end of the
alarm delay time.
Page 17, 22
Feeders*
Select the number of connected feeders.
Page 26
CSL configuration
The addresses of the weighing communicating
here. In case the communication and the addressing of the weighing cells is correct,
-1234567——— will be displayed (for seven
connected dosing units)
Page 15
Enter the drive command frequency to be sent
to the motor to make it turn at maximum speed.
Page 16
Glossar
Gross weight
The current weight of the dosing unit is displayed.
Page 15
Host interface
Click the host interface required.
Page 32
Initial feed factor
This value indicates the maximum possible
The initial dosing factor may be entered manually or may be automatically determined by
means of the ”Calibration” function.
Page 13, 20
Language
Select the language of the menus.
Page 25
Level sensor mode*
Click here if a level sensor or an external guide
value is available.
The line set point is determined using this function.
Level sensor inactive: Entries in the “Line set
point” field can be made. The line set point has
to be entered manually (must be activated if
operated without the level sensor).
Level sensor active: Entries in the “Line set
point” field cannot be made. The line set point
is determined externally (level sensor) or via an
external guide value, e.g. the extruder speed.
Page 26
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Line %
The total of the percentages of all dosing units
of the line will be displayed here. The total has
to amount to 100, otherwise the recipe is not
correct.
Page 42
Line 100%
The total of the percentages of all dosing units
of the line will be displayed here. The total has
to amount to 100, otherwise the recipe is not
correct.
Page 45, 46
Line actual output (option)
Page 26
Line kg/h
In the ”Line System” operating mode, the desired line setpoint may be entered here.
Page 42, 45, 46
Manual Refill (option)
Page 26
Massflow error This value specifies the deviation range of the
current actual value from the setpoint for which
an alarm will still not be triggered.
Page 14, 21
Massflow error +
This value specifies the deviation range of the
current actual value from the setpoint for which
an alarm will still not be triggered.
Page 14, 21
Massflow filter
Parameters for the control algorithm of the motor control.
Page 16
Massflow
The current throughput of the dosing unit will
be displayed.
Page 13, 20
Material
Page 42, 45, 46
Max. drive command
Maximum permissible value for the drive commands
Page 14, 21
Min. drive command
Minimum permissible value for the drive commands
Default setting: 1%
Page 14, 21
Motor gain
Parameters for the control algorithm of the motor control.
Page 16
Motor speed
The current rotational speed of the dosing unit
is displayed. The rotational speed is proportionate to the drive command.
Page 13
Glossar
In case the material weight in the dosing unit
does no longer reach this value, the refilling will
be started. The set value depends on the size
of the dosing unit. This value must be larger
Nominal setp.
This value should exceed the extruder through- than the value for “Feeder empty”.
put by 10-20% approx. This value limits the to- Page 14
Regrind
tal feeding rate.
Click here if the present feeder changes over to
Page 42, 45, 46
the regrind mode.
Nominal setp.
For dosing units:
regrind, the recipe will be strictly observed (recThis value limits the maximum feeding rate inipe entries >100 % are possible).
dependently of the specified ”setpoint”. The
dosing unit may only start if this value is larger Page 45, 46
Net weight
The current weight of the material in the dosing
unit will be displayed.
Page 13, 15
than ”0”.
Page 16, 21
Pert value
The measuring noise of the weighing cell will
be indicated.
Page 13
Perturbation limit
This value specifies the maximum permissible
disturbance for the weigher (measuring noise
of the weighing cell), before an alarm will be
output.
Default setting: 200
Page 14
Post refill delay
This value specifies how long the unit is to remain in the volumetric mode after the refilling
procedure.
Page 14
Quantity mode
Click here to activate the quantity mode.
Page 26
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Recipe name
Enter the recipe name.
If you click a keyboard appears on the display.
Press ENTER-key to confirm.
Page 46
If the material weight in the dosing units has
reached this value, the refilling process will be
stopped. The set value depends on the size of
the dosing unit. The average is 80 % max. of
the dosing hopper volume.
Page 14
Save
Click here to save this recipe.
Page 46
Scale range
The scale range of the weighing cell is displayed here. The value corresponds to the
maximum permissible load of the weighing cell.
Page 15
Screw Type
Enter, if desired, designation of dosing screw
(see name plate).
Page 16
Setp. %
Enter the part of the respective dosing unit
(component).
Page 42, 45
Setp. kg/h
The calculated setpoint throughput is displayed.
Page 42, 45
Significance
Parameter activation for the control algorithm
of the material feeding of the roving haul-off.
Page 26
Software
The number of the software version will be displayed.
Page 25
Span
By means of this value, the display of the net
weight may be calibrated (see Initial operation).
Page 15
Glossar
Tare
Speed pickup
Enter the number of pulses the pulse generator Tare dosing unit.
Page 15
provides per rotation.
Default setting:
Time
100 (Bison-Motor)
Enter the current time.
50 (Engel-Motor)
Page 25
Page 16
Total gear reduction
Start delay setting
Enter the value for the gear reduction of the
Enter for how long after the start of the unit the dosing unit. If the setting is “1” the motor speed
is displayed.
Default setting: 1
Page 14, 21
Page 16
Store feed factor
Totalizer
Click here to have the feed factor displayed in
The material consumption of the line since the
the recipe memory (see page 34).
last reset will be displayed.
Page 26
Page 42, 45
Store refill levels
Click here to have the refill levels displayed in
the recipe memory (see page 34).
Page 26
System
Enter the name of the unit .
Page 25
Totalizer to zero
The display of the material consumption will be
reset.
Page 42, 45
Totalizer
The amount of material metered since the last
reset by the dosing unit will be indicated.
Page 13, 20
Units*
Select the mass unit in the display.
Page 26
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Tare weight
Gross weight of the dosing unit (without material). The value may be entered manually or
may be determined automatically via the ”Tare”
function.
Page 15
Totalizer to zero
Reset of the consumption display unit.
Page 13, 20
4. Error and error correction
Version: 64.10-0235GB11
»
This chapter is intended for the operating personnel of the equipment.
General knowledge on the handling of gravimetric dosing and blending systems is required in this chapter.
The “Start-up” description must have been read and understood.
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Ensure in each case that the operating personnel are sufficiently informed.
Chapter 4.: Error and error correction, Page 1
4.1. Alarm messages - loss in weight feeders
Alarm messages will be
indicated in the main
menu by means of a red
square and a red menu
bar. The alarm text will be
displayed on the alarm
page of the dosing unit
menu.
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There is the possibility either to clear or to acknowledge the alarms.
4.1.1. Clearing alarms
Click “cancel alarms”.
&
The alarm is cleared, i.e. the alarm is no longer visible within the control unit and the
alarm output (relay) will be switched off.
In case the alarm is still present within the system, it will be displayed again immediately and the alarm output will be active at the end of the alarm delay time.
4.1.2. Alarm delay time
Default setting 30 sec.
An alarm has to present within the system for the set time until it will be passed on to the alarm relay (external alarm light or horn).
Exceptions are those alarms relating to the load cells (CSL) and the alarm “refilling time error”. They will
be passed on to the alarm relay immediately.
4.1.3. Alarm texts
4
5
5
6
6
7
7
8
8
9
9
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Massflow error +
Massflow error Speed too high
Speed too low
CSL (load cell) error
CSL (load cell) underflow
CSL (load cell) overflow
Scales error
Motor error
This alarm message appears
•
if the net weight still falls short of the minimum
refilling level at the end of the set refilling time
(no material has been refilled).
•
if the net weight has not reached the upper refilling limit within the set refilling time.
•
only if the dosing unit is running.
•
only if the refilling has been enabled.
The ”End of refilling time” alarm is not subject to
the alarm delay time.
The alarm will automatically be cleared if the upper
refilling limit has been reached for the next refilling
within the permissible refilling time.
Remedy:
Check material supply.
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Check refilling time.
Massflow error +
This Alarm message will appear if
The alarm message will be displayed if
•
the dosing unit has been started.
•
•
the refilling release is ENABLED.
•
the actual value exceeds the setpoint by the set
value of the max. actual value deviation in %.
In case the actual value deviation is detected for an
the net weight undershoots the value “Feeder interval which is longer than the set alarm delay
time, the alarm output will be activated.
empty” (see chapter 3, page 10).
The alarm message will be displayed immediately
without taking into account the alarm delay time
and the alarm output will immediately become active.
In case the refilling is disabled (refilling release disabled), the alarm message on the display will be
cleared and the alarm output will be deactivated.
In case the alarm has been cleared but is still present, the alarm message will immediately be shown
on the display again and the alarm output will be
activated.
No alarm message, if the dosing unit is operated in
the volumetric mode.
Remedy
Dosing station correctly calibrated ?
Compare initial feed factor to the current feed factor.
In case the initial feed factor, compared to the current feed factor, shows a larger deviation check the
dosing station for mechanical contacts.
The alarm output may be deactivated by acknowl- Wrong feed screw mounted ?
edging the alarm.
Check motor governor card (Compare drive comIn case the dosing unit is stopped, the message mand and rotational speed feedback).
will be cleared and the alarm output deactivated.
Check level sensor
(significant variations in the command variable?).
F Actual value: “0” will be displayed
Remedy
Immediate refilling of the material required.
Does the refilling unit close properly?
(does material drip?).
Check max. actual value deviation in %
(set too low?).
Check refilling unit (compressed air, solenoid
valve).
Dosing station not correctly tarred ?
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Check material supply.
Massflow error -
Speed too high
This alarm message will be activated if
•
•
the actual value undershoots the setpoint by
the set value of the min. actual value deviation
in %.
the dosing unit is triggered by means of a drive
command which exceeds the set value of the
”Alarm limit max. drive command”.
In case the actual value deviation is detected for In case the alarm message is present for a longer
an interval which is longer than the set alarm delay interval than the set alarm delay time, the alarm
output will be activated.
No alarm message if the dosing unit is operated in
Remedy
Remedy
Check max. drive command and alarm limit (set
too low ?)
Check feed screw (too small ?).
In case the initial feed factor, compared to the current feed factor, shows a larger deviation check the Does the refilling unit close correctly ? (does material drip ?).
Check motor governor card (Compare drive com- In case the initial feed factor, compared to the curmand and rotational speed feedback).
rent feed factor, shows a larger deviation check the
Check level sensor
(significant variations in the command variable ?). Check feed factor.
Is the feed factor smaller than the setpoint of the
Motor control card defective. Compare drive com- dosing unit ?
mand and rotational speed feedback.
Wrong feed screw mounted ?
Check max. actual value deviation in % (set too
low?).
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Does the refilling unit close properly ? (does material drip?).
Speed too low
CSL error
•
•
command which undershoots the set value of
the ”Alarm limit min. drive command”.
the communication between the load cell and
the controller is either interrupted or faulted.
In case the alarm message is present for a longer load cell errors will be indicated immediately and
interval than the set alarm delay time, the alarm the alarm output will be activated immediately.
This is valid for running or stopped dosing units.
Clearing the alarm:
In case the error message is acknowledged and
the load cell error is still present, the alarm output
will remain active and the message will remain on
the display.
Remedy
Check feed screw (too large ?).
Remedy
Check communication between the load cell and
the C2 box.
In the ratio mode (level sensor), the alarm limit is to
be set to 0.
Restart the system.
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Check min. drive command and alarm limit (set too Check the power supply of the motor box.
low?).
Check the load cell.
Check feed factor
In case the feed factor exceeds the setpoint of the
dosing unit by 98 %, the feed screw is too large.
Replace the feed screw by a smaller one.
CSL underflow
CSL overflow
This alarm message will be activated
•
•
the gross weight (the weight resting on the load
cell) is less than 0.00 kg.
The load cell has no bias.
the gross weight (the weight resting on the load
cell) is larger than the scale range of the load
cell.
The dosing unit has been overcharged.
The error message ”load cell underflow” will be displayed immediately and the alarm output will be The error message ”load cell overflow” will be disactivated immediately. This is valid for running or played immediately and the alarm output will be
activated immediately. This is valid for running or
stopped dosing units.
stopped dosing units.
Clearing the alarm:
In case the error message is cleared and the error Clearing the alarm:
is still present, the alarm output will remain active In case the error message is cleared and the error
is still present, the alarm output will remain active
and the message will remain on the display.
and the message will remain on the display.
Remedy
Remedy
Check bias of the load cell.
Check refilling.
The gross weight for a dismantled dosing station Check tare. Tare in case the dosing unit has been
emptied.
should range from 0 to 0.5 kg.
Restart system (Switch off the power supply and
switch it on again after 5 sec. approximately).
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Check load cell.
Scales error
Motor error
•
•
The dosing unit is active and the current pert
value is higher than the entered “pert limit”.
The scales error is subject to the alarm delay time.
Additional a grey square is displayed in the dosing
menu “Pert Value” (see below).
The dosing unit has been started, assigned an
adjusting command and no speed feed back
message is sent to the C2 box. The motor is
triggered but does not turn.
Remedy
Check the gear cover at the motor.
Remedy
Check the safety switch at the gear cover.
Check the free movement of the dosing unit (meCheck the motor card. If the red LED is lit up reset
chanical contact ?)
the control unit (switch OFF/ON).
Does the refilling unit close properly?
Check the speed sensor at the motor.
(Overflowing material ?).
Extremely high and quick changes in the desired Check the feed screw (if too large, the adjusting
command will be set to small), recalibrate if necesvalue in the “Level sensor” mode ?
(The linear nominal desired value is set too high. sary.
Dead range of the level sensor too narrow).
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Very high vibrations which are transmitted from the
environment to the dosing stations ?
4.2. Alarm messages - external control of dosing units
Alarm messages will be
indicated in the main
menu by means of a red
square and a red menu
bar. The alarm text will be
displayed on the alarm
page of the dosing unit
menu.
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There is the possibility either to clear or to acknowledge the alarms.
4.2.1. Clearing alarms
Click “cancel alarms”.
&
The alarm is cleared, i.e. the alarm is no longer visible within the control unit and the
alarm output (relay) will be switched off.
In case the alarm is still present within the system, it will be displayed again immediately and the alarm output will be active at the end of the alarm delay time.
4.2.2. Alarm delay time
Default setting 30 sec.
An alarm has to present within the system for the set time until it will be passed on to the alarm relay (external alarm light or horn).
4.2.3. Alarm texts
12
12
13
13
14
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Massflow error +
Massflow error Speed too high
Speed too low
Motor error
Massflow error +
Massflow error -
•
•
the actual value exceeds the setpoint by the set
value of the max. actual value deviation in %.
the actual value undershoots the setpoint by
the set value of the min. actual value deviation
in %.
In case the actual value deviation is detected for an
interval which is longer than the set alarm delay In case the actual value deviation is detected for
an interval which is longer than the set alarm delay
No alarm message, if the dosing unit is operated in
No alarm message if the dosing unit is operated in
Remedy
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Remedy
Speed too high
Speed too low
•
•
command which exceeds the set value of the
”Alarm limit max. drive command”.
command which undershoots the set value of
the ”Alarm limit min. drive command”.
In case the alarm message is present for a longer In case the alarm message is present for a longer
interval than the set alarm delay time, the alarm interval than the set alarm delay time, the alarm
Remedy
Remedy
Check max. drive command and alarm limit (set Dosing station correctly calibrated ?
too low ?).
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Motor error
•
The dosing unit has been started, assigned an
adjusting command and no speed feed back
message is sent to the C2 box. The motor is
triggered but does not turn.
Remedy
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Check liquid feeder (observe the manufacturer’s
operating instructions).
5. Initial operation
Version: 64.10-0235GB11
»
This chapter is intended for persons with skills in electrical and mechanical engineering due to their training, experience and received instructions.
Furthermore, detailed knowledge on the handling of gravimetric dosing and blending
systems is required in this chapter.
Ensure in each case that the personnel are informed.
In this chapter, it is presumed that the Graviblend system has been correctly installed
and connected.
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F
Follow the instructions below step by step. Otherwise, an interference-free operation
may not be guaranteed.
Chapter 5.: Initial operation, Page 1
Check mounting
5.1. Check mounting
Check whether the unit has been mounted in a vibration-free place.
Check whether the load cell’s safety devices for transport have been removed.
Check whether all dosing stations are freely movable (i.e. do not border anywhere).
Check whether the collecting tank has been directly attached to the extruder inlet. Only in exceptional
cases and according to prior agreement with Colortronic may the construction differ.
Check whether the refilling equipment has been properly mounted.
5.2. Check electrical connections
Check whether the power supply has been duly connected. The power supply has to be stable and interference-free.
Check whether the Graviblend system has been duly grounded.
Check whether the data cables has been duly shielded (note drawing).
In case the cable has not been duly shielded, severe malfunctions may occur.
5.3. Switching on the power supply
»
The power supply may only be switched on after making sure that all electrical connections have been duly carried out.
Switch on the system via the main switch. Wait until the system has been started.
The line overview display appears on the C2 Mega
Touch operator’s communication unit.
5.4. Passwords
MEGA TOUCH
You can protect the access to the set values of the
control system by different access levels.
For further
“Passwords”.
information
see
Chapter
3,
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At initial operation there is unlimited access to the
set values.
5.5. Checking the load cells in the system
Check whether the load cells have been recognized by the system:
The addresses of those load cells communicating
here. In case the communication and the addressing of the load cells is correct, the display will be
-1234567——- (for seven dosing stations connected).
Press on dosing station 5, to check the load cells
of the dosing stations 5-8.
In case the addresses are displayed correctly, the
communication between the load cells and the C2
box is OK.
Tare all dosing stations (reset the net weight on the display to 0):
Discharge the dosing station completely.
All mechanical parts such as feed screw, gear
cover, and cover have to be mounted.
The net weight on the display will be reset to 0.00
kg.
Minor deviations such as +/- 0.500 kg are allowed
and do not have any negative effects on the dosing.
the dosing station is tared when charged
material, the following problems may
F Ifwith
occur:
Draining off of a dosing station without any
alarm message.
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Overcharging of the dosing station.
Consequence: Incorrect dosing.
Check whether the coordination of the load cells to the dosing station is correct
Put a test weight (0-10 kg approx.) on dosing unit no. 1
On the display, the net weight of the first dosing unit has to increase up to the value of the put on weight.
If this is the case, the coordination is correct.
Carry out this test for all dosing stations.
Check the span
Adjust the display to the load cell.
Put a test weight (0-10 kg approx.) on the dosing
station no.1
On the display, the net weight of the first dosing
station now has to increase up to value of the put
on weight.
In case the indicated net weight is to differ from the
value of the test weight, the display may be adjusted by means of the span correction value.
Modify the steepness value until the displayed
value corresponds to the value of the test weight.
Repeat this procedure for all dosing stations.
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weight/displayed net weight = steepness
F test
5.6. Check the direction of rotation of the dosing motors
The direction of rotation, function and coordination
of the dosing motors may be checked after the following parameters have been entered via the C2
Touch.
Setting feeder 1: “0” %
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Total amount of all feeders must
be 100 % or 0% !
over to the “Local” operating
mode is only possible if the dosing unit
F Change
has been set to 0 %.
Change over dosing unit 1 to the local mode
If the blue line is no longer visible, the
dosing unit is in the operating mode ”local”.
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&
Switch off refilling
Dosing cover changes its colour to yellow.
Changing over from the ”gravimetric” operating
mode to the “volumetric” mode.
Set the setpoint to 10 kg/h (the value will be displayed in the upper menu bar).
Set the initial feed factor to 100.
Press Enter to acknowledge.
Check direction of rotation. Correct direction of rotation if necessary.
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Start the dosing unit by pressing the green RUN
key.
Check refilling
5.7. Check refilling
Check whether the triggering and coordination of the refilling units is correct.
Make sure that there is no material in the hopper piece or in the refilling units.
Change over dosing unit 1 to the local mode (see page 6)
F
&
Change over to the “Local” operating mode is only possible if the dosing unit has been
set to 0 %.
In case the blue line is no longer visible, the dosing unit is in the local mode.
Switch off refilling (see page 7)
Dosing cover changes its colour to yellow.
Set the initial feed factor to 100.
Set the setpoint to 10 kg/h (the value is displayed
in the upper menu bar).
Press Enter to acknowledge
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Start the dosing unit by pressing the green RUN
key.
Check refilling
Activate refilling
The cover of the dosing unit opens. The refilling
unit will be triggered as soon as the cover of the
dosing unit in the representation starts to open.
The refilling unit on top of this dosing unit now has
to open.
Carry out this test for all dosing stations.
checking the refilling, malfunction
messages within the control unit will be
F When
displayed after the refilling has been activated. Reason: No material is being refilled.
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The malfunction messages are ”Dosing
unit is empty”, ”No refilling performed”
Refill material
5.8. Refill material
The dosing stations may now be filled with material.
Adjustment of the min./max. refilling level in the dosing menu
The set values depend on the respective size of
the dosing station.
For the first refilling, the material may either be refilled manually or automatically.
Manual refilling
The material may be fed manually, e.g. by opening the refilling unit, to the dosing station.
Make sure that the ”net weight” material quantity is within the set values of the min./max. refilling level.
To enable automatic refilling, the dosing station must be started and the refilling must be enabled, see illustration.
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Automatic refilling
Calibrating a dosing station (Determining the feed factor)
5.9. Calibrating a dosing station (Determining the feed factor)
To enable correct metering, the feed factor has to be determined for each dosing station.
&
The feed factor indicates the max. material quantity which can be metered by the dosing station within one hour. During future operation, the dosing factor will be calculated
automatically.
Calibrating the dosing station
Make sure that there is enough material within the
dosing station.
The net weight has to exceed the min. refilling
level.
The feeder starts and doses for a fixed time
(approx. 1 min) when using the calibration drive
command (see ch. 3, page 13).
The feed factor can be derived from the set loss in
weight.
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not possible in the continuous
operation!
F Calibration
For external guidance (level sensor)
5.10. For external guidance (level sensor)
In case there is no level sensor available, continue with step 11.
Adjustment of the level sensor. See setting instructions.
Deadband, in the level sensor mode, should be set to 100 Hz.
At external guidance, for example revolution of the extruder, deadband should be set to
0 - 5 Hz (the scaling takes place by the nominal setpoint).
Change all dosing stations over to the line mode.
Change all dosing units over to the ”gravimetric” operating mode.
Enable refilling for all dosing units.
Creating a recipe online
Creating a recipe.
The total of the percentages of the individual dosing stations has to amount to 100%.
Setting the nominal line setpoint.
The nominal line setpoint is the limit for the maximum feeding rate of the line.
by 10-20% approx.
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The setpoint calculation of the dosing will be carried out automatically, i.e. as much material will be
fed as is put through by the extruder.
For manual setpoint specification operating mode. No external guidance (Level sensor)
5.11. For manual setpoint specification operating mode. No external guidance (Level sensor)
Change all dosing units over to the line mode.
Change all dosing units over to the ”gravimetric” operating mode.
Enable refilling for all dosing units.
Create recipe.
The total of the percentages of the individual dosing stations has to amount to 100%.
Enter the nominal line setpoint
(max. limit for the line).
For the ”manual setpoint specification” mode only:
Enter the line setpoint (desired line throughput).
5.12. Start dosing
Enable the refilling.
Check whether the desired dosing stations are in the line mode (connecting line is blue).
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Check whether all dosing stations are in the gravimetric mode (weigher is visible).
Check whether the desired recipe has been entered correctly and has been activated.
Check whether the feed factor is correct.
In case all criteria have been met, the dosing procedure may be started:
Press the green RUN key on the foil keypad.
6. Maintenance
Version: 64.10-0195GB10
»
This chapter is intended for persons with skills in electrical and mechanical areas due
to their training, experience and received instructions.
Personnel using the instructions in this chapter must be instructed of the regulations
for the prevention of accidents, the operating conditions and safety regulations and
their implementation.
Ensure in each case that the personnel are sufficiently informed.
For maintenance work taking place at heights of over approx. 6 feet, use only ladders
or similar equipment and working platforms intended for this purpose. At greater
heights, the proper equipment for protection against falling must be worn.
Use only suitable lifting gear which is in proper working order and load suspension devices with sufficient carrying capacity. Do not stand or work under suspended loads!
Ensure that the electric motors/switch cabinets are sufficiently protected against
moisture.
Use only suitable workshop equipment.
Before starting maintenance work, appoint a supervisor.
Inform the responsible personnel before maintenance work that the system is started.
Never operate the equipment when partially dismantled.
All maintenance and repair works not described here may only be carried through by
Colortronic service personnel or by trained personnel authorized by Colortronic.
L
Disconnect the equipment from mains supply before starting maintenance procedures
to ensure that it cannot be switched on unintentionally.
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Before starting the maintenance work, depressurize all compressed air pipings of the
equipment.
Chapter 6.: Maintenance, Page 1
F
Please observe the maintenance schedule.
Before starting maintenance or repair work, clean the equipment of oil, fuel or lubricants.
Ensure that materials and incidentals required for operation as well as spare parts are
disposed of properly and in an environmentally sound manner.
Use only original Colortronic spare parts.
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Keep record of all maintenance and repair procedures.
6.1. Maintenance Schedule
each time material is
changed:
Check feed screws for wear
daily:
Check warning signs on equipment for good
legibility and completeness
every three months:
Check load cells
Check flexible refilling connections:
Check whether material remains in the flexible refilling
connections; if so, remove the material remaining in the connections.
Ensure that none of the flexible refilling connections
exerts pressure on the hopper.
Check feeders
Check motor drives
Check programming:
Compare all entered values of the control system with your notes.
every six months:
&
This maintenance schedule is calculated for 3-shift operation.
The given maintenance intervals are average values.
Check whether in your individual case the maintenance intervals must be shortened.
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F
Check all electrical and mechanical connections for tight fit
Checking the Load Cell
6.2. Checking the Load Cell
A
A
Graviblend Plus
Graviblend M/L
Check the net weight of the feeders. Note down the value.
Weight down the weighing container with a defined test weight (please observe maximum load).
Check whether the net weight has increased by the weight of the test weight (A).
If the value does not correspond, check the feeder for free movement.
6.3. Checking the feeders
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»
Please observe the operating manual of the feeders
6.4. Exchanging the Fuses in the Cable Distributor
The cable distributor is installed in the supporting frame. The cable distributor contains the motherboard
and the motor cards.
»
Stop the continuous operation.
Wait until all feeders have come to a standstill.
Switch off the device by means of the main switch.
Interrupt the voltage supply.
Wait at least 1 minute before beginning with works on the cable distribution box.
Danger to life! High-voltage discharge is possible.
Never repair a defective fuse.
Release the four screws on the cover of the cable distributor.
Remove the cover.
Replace the defective fuse of the motherboard or of the motor cards.
Install the cover.
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Fasten the four screws on the cover of the cable distributor.
6.4.1. Replacing the Fuses on the Motherboard
Remove the defective fuse from the fuse carrier.
Install the new fuse (observe value).
&
Purchase Order Numbers
fuse 0.5 AT:
ID 96398
fuse 10 AT:
ID 85142
10 AT
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0,5 AT
Motherboard Motor card
6.4.2. Replacing the Fuse on the Motor Card
&
When the fuse of the motor card has been activated, the red LED “FUSE” goes on.
Release the two screws on the motor card carrier.
Remove the motor card from the slot.
Remove the defective fuse from the fuse carrier.
Install the new fuse (observe value).
&
Purchase Order Number
fuse 3AFF:
LED = light emitting diode
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$
ID 85141
Adjusting the level sensor
LED
"FUSE"
LED
"ALARM"
"ENABLE"
"REF"
3AFF
Motor card
Put the motor card back into the slot.
Fasten the two screws on the motor card carrier.
F
Please observe the operating manual of the level sensor.
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6.5. Adjusting the level sensor
7. Description of Function
Version: 64.10-0195GB10
Prerequisite for this description of function is general knowledge of extruders.
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»
This description of function is intended for all operating personnel of the equipment.
Chapter 7.: Description of Function, Page 1
Dosing Principle
7.1. Dosing Principle
The gravimetric dosing system “Graviblend” is designed as a differential weigh feeder and operates
continuously on a gravimetric dosing principle; i.e. the components are dosed according to weight in absolute weight values.
Continuous operation with synchronous material feed ensures that the mixing ratio in the collecting tank
is constant and exactly as specified in the formula at all times. The collecting tank functions as a static
mixer with a reduced product supply. This limits the time the material remains in the collecting tank to a
few seconds and ensures that the materials do not separate. With a throughput of 200 kg/h (450 lbs/hr)
with an bulk density of 0.5 kg/dm³ (30 lbs/ft3), for instance, the material remains in the collecting tank for
approx. 30 - 40 seconds.
$
Differential Weigh Feeder (Loss-in-weight):
a continuously operating, gravimetric dosing system
Continuous weighing during dosing monitors the reduction in weight, which is compared with the selected setting. Fluctuations are compensated by modified throughput.
Dosing is controlled by the control unit (controller). A screw feeder discharges the material. The screw
feeder is driven by a dosing motor with speed feedback signal to the controller.
The amount by which the weight of the feeder is reduced per time unit (material components + weighing
container + screw feeder), also called material flow, is registered by the weighing unit (actual value) and
forwarded to the controller. The controller compares the current actual value with the specified desired
value and regulates the motor speed of the screw feeder accordingly to maintain the material flow at the
desired value.
This weighing and controlling procedure is continuously repeated and has practically zero time loss.
With this system, only those product amounts are registered and used for the control procedure which
have actually left the weighing system (absolute measurement).
Refilling Phase
64.10-0195GB10
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The differential weigh feeder cannot measure loss of weight during the refilling phase. During this
phase, weight is increased. Dosing in the refilling phase is therefore volumetric, though refilling is normally completed in a relatively short time, so has little effect on overall accuracy.
Operating Modes
7.2. Operating Modes
The system can be operated in three operating modes.
•
In the “local feeder” operating mode, the controller controls the material flow of each screw
feeder individually. Each feeder operates independently and does not influence the other
feeders.
•
In the “local line” operating mode, the feeders
operate as one system, each feeder providing
a percentage of the specified desired line
value. The desired value can be changed in
three ways.
•
In the “line ratio” operating mode, the desired
value is specified by an external frequency signal (0 - 10 kHz) such as from a level probe or
haul off equipment on an extrusion line. The
percentage to be provided by each feeder is
entered at the keyboard.
7.3. Dosing Accuracy
Dosing is completely independent of fluctuations in bulk density, varying particle size and flow characteristics of the material. Even dust in the system does not influence long-term accuracy.
Dosing accuracy is approx. +/- 0.25 with
•
+/- 0.25 - 0.5 % linearity in reference to the set
point based on 10 samples (sampling time 1
min) in a range of control of 40:1 of the maximum throughput each feeder is capable of dosing.
$
•
+/- 0.25 - 1 % reproducibility
based on 30 subsequent samples (2 s) (sampling time 1 min).
Bulk Density
Bulk density specifies the density of the material. The unit used is kg/l or lbs/ft .
64.10-0195GB10
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3
Irregularities Caused by External Influences
7.4. Irregularities Caused by External Influences
A sophisticated software filter compensates the disturbances normally occurring during operations (vibrations, etc.). The control algorithm adapts automatically to the current operating conditions: brief disturbances, such as sudden jarring of the weighing container, are “ignored”, and continuous or longer
lasting disturbances such as building vibrations are “integrated” in the process (adaptive filter). This
helps guarantee high accuracy and reliability.
Because the extruder itself is a relatively large, solid mass, damping the Graviblend Dosing System is
normally not necessary and direct installation on the feed section of the extruder is possible. For
throughputs less than 10 kg/h (22 lbs/hr), damping of the equipment could be necessary.
64.10-0195GB10
10/02
F
For throughputs less than 10 kg/h (22 lbs/hr), damping of the equipment could be necessary.
7.5. Design of the Dosing System
The dosing system consists of the following components:
•
feeders with 1 load cell (A) per feeder (max. 8
feeders depending on supporting frame)
•
collecting tank (B) (static mixing hopper)
•
supporting frame (C)
•
control unit
A
C
B
Graviblend S
64.10-0195GB10
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A
A
C
C
B
B
Graviblend M/L
Graviblend Plus
The feeders are screwed to the supporting frame via a parallelogram. The collecting tank and the frame
are fastened to the processing machine with a base plate. The control unit is located in a cabinet.
Each feeder meters out one component. A screw feeder (dosing module) discharges the material into
the collecting tank. During this process, the weighing unit registers the reduction in weight of each
feeder per time unit, and forwards this information to the controller.
The screw feeder can be operated in three working positions: continuous mode, sampling and emptying
(Graviblend M/L). This is possible simply by repositioning the feed chute on the screw feeder.
64.10-0195GB10
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The dosing system is equipped with a flexible connection which allows it to be connected to a refilling
system (pneumatic conveying system) without disturbing the feeder scale.
7.5.1. Feeders
The feeders are comprised of
•
weighing container (A)
•
cover with flexible connection (fabric connection pieces)
•
load cell (B)
•
Graviblend M/L:
screw feeder (C) with motor (D)
•
Graviblend Plus / Graviblend S:
dosing module (E) with motor (F)
A
B
E
Graviblend S
A
A
B
64.10-0195GB10
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B
D
F
C
E
Dosierer Graviblend M/L
Dosierer Graviblend Plus
7.5.2. Weighing Container
The weighing container holds the material to be processed.
The weighing container is not positioned directly on the load cell but fastened with a bracket to a special
load suspension device for the load cell (the parallelogram).
The cover closes the weighing container from above and has an inlet opening with a flexible connection
piece (fabric connection piece).
The material to be metered is filled through the connection piece. The flexible connection piece is of nylon which is permeable to air and prevents vibrations of the refilling system from being carried over to
the weighing container. At the same time, the nylon connection piece allows overpressure in the weighing container caused by refilling to escape. For materials which form dust, the cover is additionally
equipped with a filter.
7.5.3. Weighing Unit
The load cell is a “smart force transducer”. It transduces the input quantity “force” (weight) into a proportional frequency modulation.
The frequency thus modulated is registered by the integrated microprocessor and converted into a digital signal.
64.10-0195GB10
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The linearized and temperature-compensated signal is transmitted in digital form to the controller via interface RS 485.
Load cell CSL, Graviblend M/L, Graviblend Plus
7.5.4. Collecting Tank
The collecting tank is comprised of a cone-shaped hopper (upper hopper part A, lower hopper part B)
and a hopper cover (C). The cover has inlet openings for the feed chutes (Graviblend M/L) or the screw
encasing tubes (Graviblend Plus/S).
C
C
A
A
B
Collecting Tank Graviblend M/L
B
Collecting Tank Graviblend Plus / Graviblend S
7.5.5. Level Sensor (Optional)
In order to maintain a constant level in the collecting tank, the tank can be equipped with a capacitive level sensor.
64.10-0195GB10
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The level sensor is connected to a signal converter
which supplies a continuous output signal. With
this signal, the controller controls the feeding rate
and thus ensures that the material level in the collecting tank remains constant.
Level sensor
7.5.6. Supporting Frame
The feeders are mounted on the supporting frame with the load cells. The supporting frame also contains all bus cabling and, on the outside, a cable distributor.
7.5.7. Switch Cabinet
The switch cabinet is available in a wall-mounted without base and contains the control units and opversion for 1 - 4 feeders or as a floor unit with or tional control system expansions.
7.5.8. Displays of the Motor Drive Card
ALARM
drive overload
ENABLE
motor enable
LED
"FUSE"
LED
"ALARM"
"ENABLE"
"REF"
REF
motor active
FUSE
Fusing.
It is lit when power supply
(fuse) has failed.
3AFF
Motor card
7.5.9. Refilling System (Optional)
The Graviblend refilling system allows the material hopper filling procedure to be fully automated. The
material is refilled automatically in conjunction with a conveyor unit.
64.10-0195GB10
10/02
The conveyor unit may be a Colortronic single conveyor unit or a Colortronic multiple conveyor unit. An
existing conveyor unit can also be connected by means of a universal flange.
8. Transport, Assembly and Storage
Version: 64.10-0195GB10
»
This chapter is intended for all operating personnel of the equipment.
Personnel using these instructions must be instructed in the regulations for the prevention of accidents, the operating conditions and safety regulations and their implementation.
Please inform all persons within the range of action of the equipment of the direct and
indirect hazards connected with the equipment.
64.10-0195GB10
10/02
Please observe all safety regulations for the operation of lifting equipment.
Chapter 8.: Transport, Assembly and Storage, Page 1
Transport and Packing
8.1. Transport and Packing
»
Please ensure adequate carrying capacity of the lifting equipment.
The equipment pass a rigorous operating test in the factory and are packed carefully to avoid transport
damage.
Please check packing on delivery for transport damage.
The dosing system is delivered as a complete assembly on a pallet; if a refilling system is also included
in delivery (optional), the refilling system must be mounted afterwards.
The inlet and discharge flanges are sealed with plugs, so that no dirt can enter during transport. Plugs
must be removed before assembly.
Packing materials should be disposed of according to environmental laws or reused.
Only use for transport of the equipment a suitable lifting device (e. g. a fork lift truck or a workshop crane).
Transport must be shock-proofed and free from vibrations.
8.2. Assembly
»
Please ensure adequate carrying capacity of the lifting equipment.
Check the carrying capacity of the point of installation, particularly if installed on a
platform.
The main switch must be freely accessible.
The place selected for installation should be as free of vibrations as possible.
Ground the equipment against electrostatic charging.
Never fasten the transport cables at the weighing containers.
64.10-0195GB10
10/02
Note that the dosing system is top-heavy.
Assembly
Remove the safety-screws (A, B).
Fasten the transport cables at the frame (H).
During installation, ensure that the weighing containers (D) do not contact or push against other components. This is particularly important for the installation of the refilling system.
Avoid squeezing of hose and cable connections of the slide valves (E) during transport.
Remove the transport cables after set-up.
Mount the hopper loader support (G).
Mount the refilling system (F).
Mount the dosing modules (C).
Fasten the transport cables to the eyelets of the control cabinets. During transport do not contact or
push against other components with the control panels.
G
F
E
H
H
D
64.10-0195GB10
10/02
C
B
A
Storage
During installation, ensure that the weighing containers (A) do not contact or push against other components to avoid incorrect results during operation at a later point. This is particularly important for the installation of the refilling system.
A
A
Graviblend M/L
Graviblend Plus
8.3. Storage
The control system may only be stored at temperatures from -25 to +55°C (-13 to +131 °F).
64.10-0195GB10
10/02
Between delivery and machine commissioning the equipment should be stored in a dry, dust-free and
vibration-free room.
Graviblend
9. Installation Instructions
Version: 64.10-0195GB10
»
These installation instructions are intended for persons with skills in electrical and mechanical areas due to their training, experience and received instructions.
Personnel using these installation instructions must be instructed in the regulations
for the prevention of accidents, the operating conditions and safety regulations and
their implementation.
Ensure in each case that the personnel are sufficiently informed.
The installation instructions provided in the corresponding operating instructions apply for all connected equipment.
Observe the safety instructions for the handling of lifting equipment.
All installation works must be carried out without voltage and air pressure connected
to equipment.
L
For installation works taking place at heights over approx. 6 feet, use only ladders or
similar equipment and working platforms intended for this purpose. At greater heights,
the proper equipment for protection against falling must be used.
Use only suitable and technically sound lifting equipment and load suspension devices
with sufficient carrying force. Do not stand or work under suspended loads!
Use appropriate workshop equipment.
64.10-0195GB10
10/02
F
Install the equipment such that all parts are easily accessible; this facilitates maintenance and repair work.
Chapter 9.: Installation Instructions, Page 1
Graviblend
9.1. Dosing System
The dosing system is delivered as a complete assembly. The unit can be installed directly on the feed
opening of the extruder with a customer-specific base plate or on an accessible platform over the extruder.
The base plate must be at least 20 mm (8") thick and constructed of steel.
F
Please note the carrying capacity of the extruder flange or mezzanine.
Although damping the equipment against mechanical interference is not absolutely necessary, the
place selected for installation should be as free of vibrations as possible.
F
For throughputs less than 10 kg/h (22lbs/hr), damping of the equipment could be necessary.
Ensure that the base plate is sufficiently secured. The carrying capacity of the extruder flange must be
taken into consideration! If necessary, support the base plate on the extruder flange by means of gusset
plates.
After the equipment is installed, ensure that the feeders do not make contact or push against other components.
Ensure that the feed chutes do not push against the collecting tank (Graviblend M/L).
64.10-0195GB10
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Ensure that the screw tubes do not push against the collecting tank (Graviblend Plus/S).
Graviblend
9.2. Refilling System
The refilling hopper and loader (separator) is mounted on the refilling stand.
The refilling hopper and loader must not come into contact with the feeder (disturbing vibrations). This is
particularly critical if refilling systems are used other than the original Graviblend system.
The size of the refilling hopper and loader depends on the throughput of the screw feeder. The number
of refilling cycles should not exceed 40/h, as otherwise the ratio of the gravimetric to the volumetric dosing phase would be too small.
F
A maximum of 40 refilling cycles per hour is permitted!
9.3. Control System
The control units are located in a switch cabinet (wall-mounted or floor type with or without base).
The distance between control unit and feeder may not exceed 60 m. The distance between the operating unit and the control system may not exceed 500 m.
64.10-0195GB10
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Ensure that the switch cabinet is not exposed to vibrations, moisture or excessive heat.
Graviblend
9.4. Electrical Connection
»
The regulations of the local Electricity Board must be observed.
Before connection to the electricity supply, it should be ensured that the supply voltage and the power frequency are in accordance with the data on the name plate of the
machine.
The electrical connection may only be carried out by Colortronic service staff or
trained personnel authorised by Colortronic.
It is not permitted for other persons to undertake the electrical connection.
The main switch must be freely accessible.
Ground the equipment against electrostatic charging.
F
Check all electrical and screw connections regularly for proper fit.
The control unit is permanently connected.
Standard voltage is:
230 V / VAC / N / PE 50/60 Hz (Europe).
230 V / VAC 50/60 Hz (U.S.)
Special voltages are possible.
Maximum fusing is 16 A (Europe) / 15 A (U.S.).
Lay all cables of the equipment such that disturbances from other electrical equipments are avoided.
The motor drive cables and the controller signal cables may not be laid together in one cable duct.
64.10-0195GB10
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The distance between feeder and control system may not exceed 60 m.
Graviblend
F
Use only shielded cables as signal lines.
Connect shielded centrally.
64.10-0195GB10
10/02
Graviblend
9.4.1. Grounding the Equipment Against Electrostatic Charging
Considerable electrostatic charging may occur in the equipment during processing of the various materials. For this reason, all components must be sufficiently grounded.
Ensure that the regulations of the local electric supply company are observed.
Ensure that the cable used for grounding the weighing containers is sufficiently flexible; weighing results
may otherwise be inaccurate.
F
Use only flexible cables on the weighing containers!
9.5. Removing Safety Devices for Transport from the Load Cells
The load cells are equipped with safety devices for transport for protection against overloading.
64.10-0195GB10
10/02
Remove the safety devices for transport after the equipment has been installed.
Graviblend M/L
Graviblend Plus
Graviblend
10. Technical Data
Version: 64.10-0235GB11
64.10-0235GB11
03/03
»
These instructions apply to all persons within the range of action of the equipment.
Chapter 10.: Technical Data, Page 1
Graviblend
10.1. Graviblend Plus
Basic Version
• Max. eight dosing/feeder stations per blending unit
• Minimum throughput 0.25 kg/h (0.55 lbs/hr)
• Maximum throughput 7,500 kg/h (16,500 lbs/hr)
• Maximum material temperature 100°C (212°F)
• Weight with one dosing/feeding station 50 kg (110 lbs)
• Weight of one modular dosing/feeding station 15-40 kg (33-88 lbs)
• Volume of one modular feeder/dosing container 20-90 liters (0.7 cu. FT - 3.18 cu. FT)
• Operating voltage 230 V ±10%, AC, N, PE, 50/60 Hz
• Cumulative Dosing Accuracy up to ±0.1%
• Variable speed DC drive motors
• Standard dust-tight construction
• Vibrating wire load cells with a resolution of 1:1,000,000 per dosing/feeding station
Optional Features
• Twin screw feeder dosing station with built-in agitator
• Processing of liquid components
• Integrated re-fill system
• Vacuum conveying units/system for feeder refill
• Vibration damping
64.10-0235GB11
03/03
• High temperature (180°C/356°F) option available
Graviblend
Dimension sheet
64.10-0235GB11
03/03
Dimensions and data without obligation. Dimensions in mm. Specifications may be subject to alterations.
Graviblend
10.2. C2 Mega Touch
Basic Version
• TFT Touch Screen Display
• Data buffer in case of power failure
• Real-time clock
• A maximum of 4 dosing lines can be controlled
• A maximum of 12 dosing stations can be controlled
• Type of protection: IP 54
• Permissible operating temperature: -10 to +50°C / 14 to +122 °F
• Permissible storage temperature: -25 to +70°C / -13 to +158 °F
• Operating voltage: 110 - 240 VAC, N, PE, 50/60 Hz
• Connected load of control unit: 90 W maximum
• Dry contact alarm output in central control system
• Interfaces:Local I/O: RS422, RS232 (Service)
Option
RS422/485 (Host)
RS232 (Printer)
Inputs for external setpoint variables
Optional Features
• Massflow signal 0 to 10000 Hz.
(output at station # 8. Only possible when using max. 7 dosing stations)
• Host protocols via serial RS 422 interface:
64.10-0235GB11
03/03
-Modbus Modicon RTU
Modbus configuration see list Rev: 1.09.
-Siemens 3964 R RK512
Siemens configuration see list Rev 1.09.
-Profibus DP (additional hardware necessary)
configuration list profibus
-CT host protocol
-CT standard protocol
-CT 9-Bit-protocol
10.3. Accessories
&
Please observe the operating manuals.
Graviblend
11. Spare Parts List
Version: 64.10-0195GB10
»
&
This chapter is intended exclusively for use by Colortronic service personnel or by
trained personnel authorized by Colortronic.
Other persons are not permitted to carry out modifications or repair works of the
equipment.
Wear Code:
A = Wearing part, fast used up
B = Wearing part
C = Spare part, storekeeping for 1 year
D = Spare part, storekeeping for 2 years
64.10-0195GB10
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E = Spare part, storekeeping for more than 2 years
Chapter 11.: Spare Parts List, Page 1
Graviblend
11.1. Mechanics
11, 12
9, 10
20
14
17
18
1
2
19
21
3
13
6
4
64.10-0195GB10
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7, 8
5
15, 16
A
Graviblend
OrderNo.
Designation
Wear Code
1
27377
Sealing Ø 65
B
2
26025
Collar Ø 65
B
3
29332
Covering lid for collecting tank
E
4
29675
Spur wheel for motor Ø 84
D
5
26029
Contact stud for safety switch
E
6
29342
Drive motor 6:1 – 220 V
E
7
28420
Sealing ring for Ø 253 mm
B
8
85533
Tension ring for Ø 253 mm
D
9
28418
D
10
84940
D
11
28447
B
12
84613
D
13
19620
Cloth connection piece Ø 100 mm / 125 mm
C
14
20499
Cloth connection piece Ø 150 mm / 175 mm
C
15
24072
SFT - parallelogram
E
16
85505
Load cell 60 kg with cable 3 m
E
17
85504
E
18
84929
E
19
85774
Compressed-air controller
D
20
84914
Pneumatic hose blue Ø 8/6 mm
C
21
88351
Pneumatic hose blue Ø 10/8 mm
C
64.10-0195GB10
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Pos.
Graviblend
11.2. Switching Cabinet and Operating Unit
&
Note the parts list in the electrical manual.
11.3. Accessories
Please observe the operating manuals.
64.10-0195GB10
10/02
&
Graviblend
12. Accessories
Version: 64.10-0195GB10
o C-Flex
o CT 22
o CT 36
o CD 65
o CS 65
o Level sensor
o ____________________
64.10-0195GB10
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o ____________________
Chapter 12.: Accessories, Page 1
Graviblend
13. Wiring diagramms
Version: 64.10-0195GB10
»
This chapter is intended exclusively for use by Colortronic service personnel or by
trained personnel authorized by Colortronic.
Other persons are not permitted to carry out modifications or repair works of the
equipment.
o Connection diagram no.: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
64.10-0195GB10
10/02
o Currently not available; will be delivered at a late date !
Chapter 13.: Wiring diagramms, Page 1

Operating instructions Gravimetric blending system Graviblend

Transcription

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