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1. LC Advanced Bubble Control ABC USER MANUAL Fully Automatic IBC and Calibrator Cage Control For Blown Film Production Lines FL al c N L EE f ON Te E E r J E Le E A j ee A Ce 4 L 4 a I wm T Manual Number ABC203 P O B 1122 Afula Illit 18550 Israel Phone 972 4 6405857 Fax 972 4 640591 1 info sysmetric ltd com www sysmetric ltd com October 25 2013 User Manual ABC Table of Contents L l 1 2 1 3 1 4 1 5 1 6 T 2 4 2 2 2 3 2 4 2 9 2 6 Dots 3 1 3 2 2 9 3 4 2 9 3 6 4 4 2 4 3 4 4 4 5 oui Generar Description E 4 EE EE 4 Width EE 5 Calibrator Cape Control EE 6 Blowers and Balancing EE 7 EE 8 Modelin E EE 9 Operator EET e Nis asain dic AE RR E Ee Ee 10 1 7 1 Main Sereen EE 1 EN E Kerg EE 12 UNE GENEE ee 13 1 7 4 SEELEN 14 ER IB Sinees EE 15 1 7 6 General Service o Cee EE 16 T CAAT OM eegener Eege EE Ee 17 Radius SEMS OFS INSA ANON eege 17 Compensation sensor ThStallalQf sec ics en RTE TE OEE EE 18 COPE SCNSOVS TNS IAN GUION ee rette b Oups EE 19 DBC Instaltatomandisensor Wiring aea oes UI IRL PO TEE DUI IUE LEV ERIS E sa E weenie uud 2l Control EE 22 JI Eege 23 2 6 1 Sensors dnd DBC Ee 23 2 6 2 Balancime Valve ME 23 2 6 3 Power Mulier c Hcc 23 2 6 4 oisi PER ACIDO ee 23 instalation Parainete s usse Rue tu ets die Mies A IM E p EIU aa 29 eeh Sensors Installation
2. ABC User Manual 2 7 Installation Parameters Several control parameters should be entered during the installation of the system via the Service screens These parameters include sensor installation parameters production line dimensions and more 2 1 Sensors Installation Parameters Press SERVICE on the main screen enter the password 4321 and press SENSOR to switch to the Sensor Service screen an LZ wi 1 0048 gg g MAN SENSOR er eie is H J 1 20 Ns NT BR cE Uk 999 9 290 Ns wr eR ce g 300 9 809 g Ns wr em ce Uk 999 9 80 999 9 88 8 NS NT 250 0 250 0 Ns NT BR CE Ux Figure 2 7 1 Sensor screens 1 Press Radius Sensors and enter the installation distance of each sensor For the radius sensors Radius 1 2 and 3 it is the distance from the face of the sensor to the center of the die For the compensation sensors Ref 4 it 1s the distance from the face of the sensor to the reference target 2 Press Cage Sensors and enter the installation distance of the cage sensors Cage 5 6 and Gap 7 8 This 1s the distance from the face of the sensor s housing to the face of the cage s rolls the distance to the bubble Note although each sensor can have a different installation distance it 19 important that each group of sensors will have the same installation distance the groups are radius sensors 1 2 3 the cage sensors 5 6 and the gap sensors
3. If the automatic calibration is installed it can be operated by switching its control switch in the calibration control screen Press the Cal button in the General Service screen to reach the automatic calibration control switch we a 98 m min IL na 39 M min Wm ET Figure 5 5 1 Automatic Width Calibration Control When the automatic width calibration is enabled and the system reaches a stable width it will start the automatic calibrations An Automatic flag will indicate that the automatic mode is on the manual calibration will lock and a small flag EL in the example below will indicate that the actual width 1s now received from the web guiding system 35 Ammin Figure 5 5 2 Automatic Width Calibration Note the automatic width calibration option is not included in the standard ABC system Contact Sysmetric regarding the addition of this option to the system www sysmetric ltd com zeli s User Manual ABC 6 Service and Maintenance 6 1 Alarms An alarm condition exists whenever the system recognizes that a fault has occurred When an alarm condition occurs the system does the following A corresponding alarm message appears on the display The alarm is written in the alarm log The alarm button on the operator display turns red The system tries to maintain the correct width The alarm output in the PLC turns on This output can be wired to an external alarm device light siren or any cen
4. Manual ABC 1 General Description 1 1 Principle of Operation The basic IBC Internal Bubble Cooling operation is to synchronize the volume of cold air pumped into the bubble with the volume of hot air being drawn out of the bubble To increase the bubble width the exhaust rate should be reduced correctly or intake increased causing the bubble to inflate by the extra air intake to the right size The Opposite action is carried out in order to reduce web width To improve the accuracy by enabling fast reaction a balancing valve is added and located usually on the exhaust pass Since the width accuracy and stability highly depends on the calibrator cage position it should be fixed to an optimum diameter There are two basic cage bubble relationships Cage Gap The first and most widely used is whereby the cage acts as a calibrator meaning that the bubble is blown into the cage and freezes in it The second is when the cage 1s larger than the bubble and only supports the bubble While the first Cage Gap produces better accuracy it may also lead to some scratches and marks on the web Sysmetric s ABC system controls all these variables It uses eight ultrasonic sensors that measure the frozen bubble size the calibrator cage diameter the cage bubble distance Gap and compensate for atmospheric changes The ABC system uses modeling technique This technique is the most advanced control method available on the mar
5. User User Blowers Ratio Control Range Control Ratio Actual Ratio In Blower Ramp Time Max Speed 1 000 2 000 User User User User User System User User User System System System User System User System User Tower Height Collapsing Frame Feedback Width Error TH Line Speed Maximum Line Speed Actual Control Manual Control Auto Control Continue Control I Control II Control III Set Width Actual Width Set Gap Actual Gap Calibrate On Off 10 to 20mm Set Width Minimum Width Maximum Width User User System 500 1000mm 5s www sysmetric ltd com ABC User Manual Appendix C Assembly Example The following drawings show an example of the ABC system assembly on a blown film production line Note that different lines may require different assembly Radius Sensors 1 2 3 V Cage Sensors 5 6 Compensation Sensor 4 Gap Sensors 7 8 Intake Blower N ez Balancing Valve nl lt A Exhaust Blower 4 ABC System Assembly General View www sysmetric ltd com _55 User Manual ABC Radius Sensors 1 2 3 and Compensation Sensor 4 Assembly mmm Cage Sensors 5 6 and Gap Sensors 7 8 Assembly ate emer reer reer reer ences eee esses eee RRR RRR RRR RRR RRR RRR RRR EEE RRR RRR RRR RRR RRR RRR RRR RRR RRR EEE RRR RRR RRR RRR RRR RRR RRR RER RRR RRR RRR EEE RRR RRR RRR EEE RRR RRR RRR EEE RRR RRR RRR RRR RRR RRR RRR EEE RR
6. to the sensors screen check which error flag 1s on and act accordingly e For NS error check the electrical wiring If they are intact replace the sensor If the electrical wiring is intact and the error remains after replacing the sensor replace the DBC card e For NT BR and CE errors clean the sensor and check that it is perpendicular and facing directly to the center of the bubble If this does not solve the error replace the sensor Note use a dry rag for cleaning the sensors Do not use any chemical substance it can damage the sensors BUBBLE WIDTH ALARM When the continuous control mode is off the system stops moving the calibrator cage 10 minutes after entering control stage III If during production in this mode the width error is greater than defined in the Width Error Threshold the system triggers the bubble width alarm Action e Try to identify the source of the width error Usually it happens if one of the production conditions changes such as temperatures line speed production capacity etc e Check the value of the Width Error Threshold and increase it if necessary e If the production is not stable enough either increase the value of Width Error Threshold or turn on the continuous control mode so that the system can keep adjusting the calibrator cage position and maintain the required width www sysmetric ltd com AR User Manual ABC BUBBLE BREAK If during production the radius sensors stop detecting the
7. useful for tracking the system s performance Service includes several screens for setting the system s parameters The Service screens are used during installation tuning and maintenance of the system Pressing Alarms opens the alarm log of the system 1 7 2 Width Graph The Width Graph screen shows the width error and the movements of the calibrator cage opening and closing This graph is useful for verifying the accuracy of the width The graph can show the last 5 minutes or the last 60 minutes Maximum Cage Minimum Opened Cage Closed Figure 1 7 4 Width Graph Smin shows a graph of the last 5 minutes 60min shows a graph of the last 60 minutes EXIT closes the graph screen Maximum the maximum value on the error axis Press it to change the value Minimum the minimum value on the error axis This value updates automatically according to the maximum value 2955 www sysmetric ltd com ABC User Manual 1 7 3 Service Screen The Service Screen enables changing the display s data date and time brightness and contrast and selecting the interface language A set of service screens are available from this screen SENSOR IBC and GENERAL Figure 1 7 5 Service Screen Date amp Time set the current date and time used in the alarm log Brightness select high middle or low display brightness Contrast select high or low display contrast Language select the inter
8. 0 seconds will reduce the system s performance and will extend the time for reaching a correct lay flat width 3 4 Balancing Valve 1 Make sure the intake blower is off 2 In the main screen press SERVICE enter the password 4321 select the JBC screen and press the Balancing Valve button 3 Change the value of Zero Position and check that the balancing valve changes its position as follows e At 096 the valve should be completely open air will flow freely in the pipe e At 100 the valve should be closed the valve is blocking the air flow If the valve does not move check the electrical wiring If the valve moves to the opposite position change the Valve Type 4 Set the Zero Position back to 50 0 1 9090 um Figure 3 4 1 Checking the Balancing Valve s 30 www sysmetric ltd com ABC User Manual 3 5 Calibrator Cage Control l 2 3 Make sure that the take off nip is off In the main screen press SERVICE enter the password 4321 select the JBC screen and press the Cage Control button Press and hold the Open Cage for more than 2 seconds and check that the cage opens Press and hold the Close Cage for more than 2 seconds and check that the cage closes If the cage does not change position or moves in the wrong direction check the electrical wiring liz Bm A Dose Cage Figure 3 5 1 Checking the Calibrator Cage Control 3 6 Sensors l 2 In the main
9. 7 8 Use a different installation distance only if there are mechanical limitations in the installation www sysmetric ltd com 25 User Manual ABC 2 2 IBC Blowers and Balancing Valve Installation Parameters Initial values should be set for the IBC blowers and the balancing valve These initial values are for starting the ABC control and they should be adjusted later as explained in the Tuning chapter Press IBC to switch to the IBC service screen from the main screen first press SERVICE and enter the password 4321 Figure 2 7 2 IBC screen Press Balancing Valve and enter the following parameters e Zero Position 50 0 This will set the balancing valve to its center position e Valve Type normally open or normally closed according to the valve s type The type of the valve indicates its position when the control signal is zero To change the type press the Normally Open button Note Sysmetric s balancing valve is a normally open valve Press IBC Blowers and enter the following parameters e Blowers Ratio 1 000 This will make the exhaust blower speed the same as the intake blower speed e In blower 2 000M s This is the intake blower capacity the exact capacity will be adjusted later e Ramp Time the time of accelerating the blowers from zero to full speed and decelerating from full to zero The ramp time is a parameter of the blowers motors drivers The ramp time must be equal for accel
10. Cage Factor and it can be found using the Cage Factor screen In the BC screen press the Cage Factor button and follow this procedure to find the cage factor 1 Place a target in front of the gap sensors 7 and 8 The best method is to assemble the IBC pipe on the die 2 Press and hold Close Cage to close the calibrator cage until both sensors 7 and 8 show readings 3 Press and hold Close Cage for about 7 second and release The system will show a value at Calculated Factor 4 Press and hold Open Cage for about 7 seconds The system will update the Calculated Factor 5 Repeat opening and closing the cage several times and check the Calculated Value It is recommended to test the factor at longer and shorter movements of the cage and at different positions of the cage The Calculated Factor will later be used as the Cage Factor ml 234 1mm 231 omm Open Cage Figure 4 1 1 Cage Factor Tuning www sysmetric ltd com Nom User Manual ABC 4 2 Blowers Ratio and Intake Blower Capacity 6 Open the calibrator cage to its maximum position 7 Select MANUAL mode in the General Service screen 8 In the Balancing Valve screen set Maximum Travel to 0 9 In the JBC Blowers screen set Control Range to 0 and set Intake Blower capacity to 2 000M s 10 Start the line with a safe bubble width a medium size width For stability use only about 20 intake blower speed and the line speed should be about 10 15 M Min
11. Paramelefs tee 25 24142 IBC Blowers and Balancing Valve Installation Parameters 26 Del Generat dial TTT 27 CHECKING the Systeri M Y 28 Lieu RE EE 28 Ph Sec TT al TU E 29 Injake and Exhaust e eer Aerer 29 EE 30 Calibrator Case CONT EE EE 31 SENSORS ago abate itai EIL Eee Ee ACER TES ee om MCE ACO tA OA cute actae e doi 31 Kr e 32 Case FactorcsCoQunse x UN O TTT 33 Blowers Ratio and Intake Blower Capacity geya R Tao YOT E TT aN TENE TEER 34 balancina Valve EE 35 Cde FT aclor Pine TUNING ee Ee ee Ee 36 Finishing th Tuning ProcedWre ue n i sve N E AE eU OE E sie Sout CEO AE Deu 36 5ystem CUE PAULO WE 37 Sarme EE 37 www sysmetric ltd com ABC User Manual 5 2 Control Mode and TE 38 5 3 Changing Product Changing Wd seins e co pte tete mda Pea eee 39 S Wah CAUTION eode anos CC MU ae ie Ot dU DIL n ds 40 2090 vANOmatic Mat C ANOTOU ON ohh teat eee Eo aou ectig teres beans eebe era beta ts an apa eios 41 6 Service and NEMEI 42 Oa EE 42 6 1 1 ADM EE du e Ace I uie Due d EpL CP UOTE CE 42 6 1 2 Alarms EE 43 O2 E C SCS OTS 47 0 3 CUDnDEUIOF EE 49 04 JJroubleshOONH uec uisi etd sait mum Usa ai cs m etse cs e 50 Appendix A LEE 52 Appendix B Parameters Synopsis and Common Values eee e ee eee eee ee eee e eee e estes eese ssss eee eeee 53 Appendix Assembly E 55 www sysmetric ltd com oe User
12. R RRR RRR HEHEHE HEHEHE HEHEHE RRR RRR RRR RRR HEHEHE HEHEHE HEHEHE OHHH HEHEHE HEHEHE HEHE HEHEHE HEHEHE EEE EEE EOD If you have any further questions please do not hesitate to contact us info sysmetric com wWw sysmetric com Phone 972 4 6405857 Fax 972 4 6405911 Besser RRR RRR RRR RRR RRR RRR RRR RRR RRR RRR ER RRR RRR RRR RRR RR RRR RRR RRR RRR RRR RR RRR RRR RRR RRR RRR RRR RRR ER RRR RRR RRR RRR rer rer rere errr ER RRR RRR RRR RRR ER RRR REER RRR RRR RRR RRR RRR RRR RRR RRR RRR RRR RRR RRR RRR RRR RRR RER RRR RRR RRR RRR RRR RRR RRR RRR RER RRR RRR RRR RRR RRR RRR RRR RRR RER RRR RRR RRR RER sss 56 www sysmetric ltd com NOTES
13. The valve should run a test cycle in which it first goes to its center point 45 opens all the way closes all the way and then goes back to the position defined in the Zero Position parameter in the balancing valve screen e Check the electrical wiring between the PLC and the balancing valve e Open the cover of the valve s controller Check that the power green LED on the bottom electronic card is on If not check the 24VDC power supply from the main cabinet e Check that the 5V power green LED on the top electronic card is on If not replace the electronic card e Check that the yellow LED marked ON is lit Change the Zero Position parameter in the balancing valve screen The yellow LED should turn off while the valve moves to the new position and then turn on again Test the valve at different positions by setting different values between 0 and 100 in the Zero Position parameter If there is a position in which the yellow LED does not turn on replace the actuator motor of the valve 46 www sysmetric ltd com ABC User Manual AUTOMATIC CALIBRATION ERROR This alarm indicates an error in the automatic width calibration Action e Check that the automatic width source is working properly the web centering unit e Check the electrical wiring and communication units between the PLC and the automatic width source the web centering unit This alarm is relevant only if the automatic width calibration option is installed an
14. Wait until the width stabilizes This might take several minutes and the actual width will not necessarily be equal to the set width If the bubble does not stabilize increase the Intake Blower capacity parameter 11 While monitoring the bubble increase the intake blower speed to some average normal operating speed about 40 50 The width will change and stabilize after some minutes 12 When the width is stable copy the Actual Ratio parameter into the Blowers Ratio parameter This should bring the actual width close to the set width If needed wait several minutes and repeat this step The expected width accuracy at this phase is 20mm or better 13 While the line is running enter a new Set Width and monitor the width change The system should react to the new width within 5 seconds and the change should be fast The bubble should be as close as 40mm before the initial width gets to the nip 14 If the change is too big the width overshoots then the Intake Blower capacity should be increased and vice versa Repeat this step 3 to 4 times until fast stability is achieved The test can be performed in both directions Make sure that during the change the exhaust blower will not run below 20 or above 80 If it does then longer stability time is normal and expected Note if at this stage the width varies a lot and it takes a very long time for the width to stabilize check the Tower Height and Collapsing Frame Height parameters in the General
15. adings allow 2mm difference Their reading should be the distance between the cage s rolls and the IBC pipe If the readings are wrong or not equal check installation distance parameters If there are no readings check the electrical wiring Figure 3 6 1 Checking the Sensors 4 Tuning After installing and checking the ABC system it is now ready for first time operation During the first operation some of the system s parameters need to be tuned in order for the system to control correctly Tuning the parameters requires the following steps 1 Finding the Cage Factor for the calibrator cage 2 Calibrating the Exhaust Ratio and the Intake Blower Capacity parameters 3 Tuning the balancing valve control parameters 4 Adjusting the Cage Factor parameter The following explanations describe how to tune the system In some cases the explanations give some common initial values for some of the parameter Note that different lines might need different values It also assumes that all the installation parameters are set as explained in the installation chapter lt 3 www sysmetric ltd com ABC User Manual 4 1 Cage Factor Coarse Tuning When controlling the calibrator cage position the actual cage position feedback has a long delay For this reason the system uses a pulse technique to operate the cage motor according to a fixed ratio between the cage position error and the motor operation time This ratio is called
16. ameters and varies from one production line to another In most cases the width can be changed without changing any other parameters www sysmetric ltd com 36 User Manual ABC 5 4 Width Calibration As the bubble moves away from the die and towards the reception unit the plastic cools down and causes the width to shrink The ABC system features a simply calibration procedure to compensate for this shrinkage effect and to ensure correct width production After the width stabilizes carry out the following to calibrate the width 1 Measure the lay flat width at the feedback point 2 Enter the measured width in the Width Calibration in the display A Value Accepted flag will indicate that the calibration succeeded and the calibration value will reset back to zero CI Jl ALARMS Figure 5 4 1 Width Calibration Note some production parameters such as line speed and production capacity affect the shrinkage factor After changing any production parameter verify the product width and calibrate if necessary Once the production is stable the shrinkage is stable and the system will maintain the correct width 40 www sysmetric ltd com ABC User Manual 5 5 Automatic Width Calibration When a web guiding system is installed its reading can be directed to the ABC system for automatic calibration This allows the system to automatically update the shrinkage parameter of the product and maintain accurate lay flat width
17. and 6 should be 100 200mm above the top arm at a distance of 80mm from the bubble Measuring surface Direction K Arms e The bottom sensors sensors 7 and 8 Binding Bar should be at about the same height of the bottom rolls at the same 80mm distance usually they will be mounted on the second row of x rolls e Make sure that the sensors do not collide with any part of the cage mechanism when opening the cage to its maximum diameter and when closing the cage to its minimum diameter e The sensors are supplied with standard brackets but depending on the arm mechanism some cages might need special brackets Arms hinge Top support ring About 10mm NU Ring CE Cage Sensor roller area back view Bubble he side view Cage Rollers D Bubble 9 Figure 2 3 1 Cage Sensors Installation www sysmetric ltd com 19 www sysmetric ltd com ABC User Manual 2 4 DBC Installation and Sensor Wiring The Digital Bubble Controller DBC is Sysmetric s special electronic controller for operating the ultrasonic sensors The DBC is installed in a protective box Junction Box that should be mounted on the cage After mounting the junction box on the cage wire the 8 sensors 3 radius sensors the compensation sensor and the 4 cage sensors to the DBC and wire the DBC to the PLC See electrical drawings for details Figure 2 4 Digital Bubble Control
18. and then press GENERAL Turn on the take off nip Increase the take off speed and verify that the Actual Line Speed in the display is correct matches the real speed of the nip If not check the electrical wiring the line on signal and the line speed signal and the value of Maximum Line Speed Turn off the take off nip Note it is recommended to measure at this time the real line speed with a tachometer directly on the take off nip Errors in the line speed will reduce the performance of the system and will be hard to detect afterwards E Del DS Figure 3 1 1 Checking the Line Speed _ 98 www sysmetric ltd com ABC User Manual 3 2 Extruder On Signal l S Press Main in the control display to switch to the main screen 2 Turn on the take off nip and the extruder 3 4 Set the take off speed above 5 Meter min Make sure that stage I flag starts blinking If not check the electrical wiring and that the line speed 1s above 5Meter min Turn off the take off nip and the extruder and make sure that the stage I flag turns off d ER Stage I Flag Figure 3 2 1 Checking Extruder On 3 3 Intake and Exhaust Blowers l 2 3 Make sure that the take off nip is off In the main screen press SERVICE enter the password 4321 and then press JBC Make sure that Blowers Ratio is 1 000 In Blower is 2 000M s and that Ramp Time and Max Speed are set correctly as explained in the
19. atio alarm indicates that the Control Ratio parameter reached the limit defined by the Control Range parameter With respect to the last example it means that the value of Control Ratio reached either 0 800 or 1 200 By principal the ratio between the intake and the exhaust blower cannot change It 19 determined by their physical structure Actually the ratio depends on some production parameters such as temperature and the blowers speeds and it varies during production especially when the exhaust pipes start containing production remains such as wax and plastic pieces Assuming that the Blowers Ratio parameter was set correctly during the installation and tuning of the system if the Control Ratio has reached the limit of the Control Range it must be a consequence of some mechanical change in the production 44 www sysmetric ltd com ABC User Manual line For example if a plastic piece accidently enters the exhaust pipe and is now blocking some of the air flow the exhaust blower will need to run faster in order to drive the same amount of air In such a case the system automatically increases the Control Ratio to compensate for that air blockage Action e Search for the origin of the problem and try to identify the cause of the change in the blower ratio Common problems are o Ar leaks in the exhaust pipes o Something clogs the exhaust pipes such as wax plastic pieces a bent pipe etc o Something clogs the balancing valve o Signif
20. ay where the button appears Changing numeric values is carried out by gently pressing on the display where the value IS Written Different sizes of display are available 5 8 10 and 12 inch The commonly used display is the 5 inch The 10 inch display is used where the ABC is part of a full line control system The advantage of the 10 inch display 1s the ability to contain a great deal of data in one screen This is useful mainly during the installation of the system and for monitoring the system when trying to identify a source of a control error For normal operation the 5 inch display is as good as the 10 inch For convenience only this manual uses pictures of the 5 inch screens in the explanations and examples The 10 inch display holds the same data although it is arranged differently in the screens General views of the 10 inch screens are shown in the appendix Several screens have one or more editable numeric items e g the required lay flat width To modify the value of an item take the following steps 1 Select the item that you want to edit by pressing gently on the display where that item is Written A numeric keypad will appear on the display 2 Enter the new value using the numeric keypad 3 Press the Enter key to confirm the change The keypad screen will close and the item will receive the new value Cancel editing by pressing the X button in the keypad screen 10 www sysmetric ltd com ABC User Manual Figu
21. bubble the system triggers the bubble break alarm Action e Restore the bubble EXHAUST BLOWER TOO FAST This alarm indicates that the exhaust blower is running at more than 95 of its maximum speed Action e Decrease the intake blower speed and the system will decrease the exhaust blower speed accordingly e Verify that the balancing valve is not blocked e Clean the exhaust blower and all the exhaust pipes from production remains such as plastic pieces and wax PLC BATTERY LOW The PLC has a backup battery to maintain data while the power supply is off This alarm indicates that the power in the backup battery is running low Action e Replace the backup battery in the PLC Note use only Omron s original battery 3G2A9 BATOS EXCEPTIONAL BLOWERS RATIO The system determines the required exhaust blower speed according to the Blowers Ratio parameter but since this ratio depends on various production parameters and varies with time the system automatically adjusts this parameter in order to find the correct value In order to do this the system first copies the Blowers Ratio into the Control Ratio parameter when the operation starts and then during the production it adjusts the Control Ratio within a range defined by the Control Range parameter For example if the preset Blowers Ratio 1s 1 000 and the Control Range is 0 200 then the system can adjust the Control Ratio to a value between 0 800 and 1 200 The exceptional blowers r
22. by the cage might collide with the bubble or when the cage s position disturbs the normal cage control These situations are more common during control stage I when the system tries to stabilize a new width When the system bypasses the normal cage control it lights a corresponding indication flag in the Cage Control screen If the cage seems to freeze in its place or it opens closes unexpectedly switch to the Cage Control screen to check if it is a control bypass The bypass indication flags are e TO Too Open The cage is too open and the cage sensors do not see the bubble The system will force the cage to close until getting readings from the cage sensors e CR Collision Recover When the system detects that the cage collides with the bubble it forces the cage to open After such event it does not allow the cage to close until a full bubble height has run through the cage e TC Too Close The system detects that the cage is too close and it disables further closing until the bubble draws away e FL Frost Line When the frost line is too high relatively to the cage position it can create a situation in which at the top side of the cage the bubble radius 19 large and the bubble is close to the cage while on the bottom side of the cage the bubble radius is small and the bubble is far away from the cage In such case the system does not allow the cage to close until the frost line is taken back down and the bubble s ra
23. d activated 6 2 Ultrasonic Sensors The ultrasonic censors are operated and controlled by the Digital Bubble Controller unit DBC As part of the control process the DBC monitors each read cycle of the digital ultrasonic sensors Thus in addition to measuring the distance to the target it indicates each sensor s status and gives specific alarms for different error conditions in the sensors For each error condition in the sensor the system will raise a corresponding error flag in the Radius Sensors and Cage Sensors screens In addition the system monitors the percentage of faulty read cycles and alarms for a sensor error if the error percentage goes above 50 20 for the radius sensor during control stage I This means that more than 50 of the sensor s read cycles are faulty The alarm goes off if the error percentage goes below 30 The error conditions and its corresponding error flags are e NS No Sensor The DBC does not detect any sensor wired to it e NT No Target The sensor does not see any target no echo is returned e BR Bad Reading The sensor receives bad echo signal e CE Cov Error The DBC receives bad signal from the sensor The error flags might flash on and off during normal operation but as long as the errors are minor and the error percentage remains zero no action is needed If the error percentage is not zero it is recommended to check the sensors even if the error percentage is below 50 and the sys
24. dius 1s similar along the cage e WM Wait for Model When decreasing the required width the system does not allow the cage to close to its new radius before the model control has decreased the bubble s width using the blowers and it is less than 100mm from the required new width Figure 6 3 1 Cage Control Bypass Flags Example of CR shown www sysmetric ltd com 49 User Manual ABC 6 4 Troubleshooting The following table lists some error conditions in which the system does not work well without alarming for any errors Symptoms Possible Cause Take off nip signal is off Check the electrical wiring System does not respond Conte stus Tilasdsott Extruder signal is off Check the electrical wiring Check the electrical wiring Wrong Blowers Ratio Tune the Blowers Ratio parameter Wrong Intake Blower capacity Tune the Intake Blower capacity parameter The width is jumping up and Wrong line speed Calibrate the line speed down e E T H E Fi h T e System hangs in control stage I and it takes a long Wrong Tower Height ix the Tower Height parameter The width is stuck on wrong value Check the cage and increase the Factor is too low Cage Factor parameter to its set radius low to its set radius low System hangs in control stage II The actual gap is not equal to The balancing valve response is Check the valve and its parameters Poo adana T aaia 50 www sysmetric ltd com ABC User Manual Sympt
25. e system brings the bubble to the required width only by controlling the speed of the exhaust blower 2 Auto and Continue the system brings the bubble to the required width by controlling the speed of the exhaust blower and by positioning the calibrator cage in the correct diameter 3 Auto Continue is off same as Auto and Continue mode but 10 minutes after reaching the required width the cage control is disabled The normal operation of the ABC system is Auto and Continue control mode Manual mode can be used if there is a problem with the calibrator cage and the cage cannot be moved In some cases mechanical backlash in the calibrator cage or instability in the production process can cause the system to continuously move the cage in and out as it tries to find the correct position that yields the correct width In such cases the Auto mode Continue is off can be used and it might improve the system performance In this mode after the cage has been locked the ability of the system to keep the required width is limited so set a value in the Width Error Threshold parameter to trigger an alarm in case there is a large width error 35 Bain Cal A SE Figure 5 2 1 Control Mode Selection 38 www sysmetric ltd com ABC User Manual Depending on the control mode the ABC system has up to 4 control stages The three control stage flags I II III indicate the current control of the system The following table details the diff
26. eight the height of the production tower Collapsing Frame the height of the collapsing frames Feedback the distance to the feedback point Width Error Threshold a threshold for width error alarm Maximum and Actual Line Speed the maximum and the current line speed Manual Auto and Continue control modes of the ABC system I II III indication flags showing the current control stage of the system Set and Actual Width and Gap the set and the actual width and gap Cal width calibration value 16 www sysmetric ltd com ABC 2 2 1 User Manual Installation Radius Sensors Installation The three radius sensors sensors 1 2 and 3 are 30mm cylindrical ultrasonic gages They should be mounted on top of the calibrator cage with the following points taken into consideration The sensors should be pointing at the bubble s center and placed at about 120 from each other They should be mounted 250 400mm above the top bubble supporting arm The minimum distance between the gage and bubble surface should be 250mm when producing the maximum lay flat width The maximum reading distance is 1500mm different gages can be used for larger smaller bubbles The exact distance from the gages to the center of the die should be measured and entered as the installed distance parameter at the radius sensors service screen The system is supplied with standard brackets for the radius sensors Some ca
27. erating and decelerating and it must be 26 www sysmetric ltd com ABC User Manual equal in the intake blower and the exhaust blower For best performance of the ABC system the ramp time should be as low as possible recommended values are 5 10 seconds Note the blowers need braking resistors to enable short ramp time Max speed is the resolution of the blowers speed usually the resolution of the analog input and output of the PLC In the standalone version of the ABC system the resolution is 2047 2 3 General Parameters Press General to switch to the General Service screen from the main screen first press SERVICE and enter the password 4321 and enter the following parameters Tower Height the distance from the radius sensors the top of the calibrator cage to the take off nip Collapsing Frame the height of the collapsing frames Feedback the distance from the radius sensors the top of the calibrator cage to the calibration point whereby the width is measured for calibrating the shrinkage parameter Maximum Line Speed the maximum speed of the take off nip F igure TER General screen www sysmetric ltd com Norm User Manual ABC 3 Checking the System After completing the installation of the ABC system follow these steps to verify correct installation and operation of the system 3 1 Line On and Line Speed Signals l 2 3 4 In the main screen press SERVICE
28. erent control stages of each control mode and describes the system function at each stage re Manual LH LO Off Off Control is off See Bringing bubble to the correct width 50mm 0 Off Off Off Control is off Bringing bubble to the correct width x 50mm Auto Bringing cage to its set radius 5mm and On Blink Off Adjusting cage position for correct width Continue Bringing gap to its set value 5mm Adjusting cage position for correct width Keeping gap in its set value r oe The control is off Bringing bubble to the correct width 50mm Auto Blink om on Bringing cage to its set radius 5mm Adjusting cage position for correct width Continue To on or Bringing gap to its set value 5mm is off Adjusting cage position for correct width Keeping gap in its set value Keeping gap in its set value cage is locked 5 3 Changing Product Changing Width Changing the set width does not require any significant change in the production While the line 1s still running carry out the following Enter the new width 2 If necessary change the gap 3 After the width has stabilized measure the produced lay flat If it is not equal to the actual width showed on the ABC screen perform a width calibration Note changing the width while the line 1s running might require lowering the line speed and or the intake blower speed until the system stabilizes the new width This depends on the initial speeds and other production par
29. face language contact Sysmetric for additional languages SENSOR switch to the Sensor Service screen e BC switch to the blowers balancing valve and cage service screen e GENERAL switch to a service screen with general control data www sysmetric ltd com Nm User Manual ABC 1 7 4 Sensor Service Screen The Sensor Service screen shows the current reading of each sensor Pressing Radius Sensors and Cage Sensors buttons opens detailed service screens for the sensors It is used during installation and for maintenance See the relevant chapters for further details 1 0048 m ee a i Si s R Cf D Figure 1 7 6 Sensor Service Screen Radius I 2 3 three radiuses of the bubble measured by sensors 1 2 and 3 Reference 4 the distance measured by the compensation sensor 4 Cage 5 and 6 the gap between the rolls and the bubble at the top of the cage Gap 7 and 6 the gap between the rolls and the bubble at the bottom of the cage Barometric Factor a calculated factor for compensating barometric effects on the measured bubble s radius DER www sysmetric ltd com ABC User Manual 1 7 5 IBC Service Screen The IBC Service Screen is used for controlling the IBC blowers the balancing valve and the calibrator cage Pressing Balancing Valve Cage Control or IBC Blowers opens detailed service screens for the balancing valve the cage and the blowers accordi
30. ges might require different brackets Max 1500mm Min 250mm Figure 2 1 2 Radius Sensor www sysmetric ltd com es User Manual ABC 2 2 Compensation Sensor Installation The compensation sensor sensor 4 used for compensating barometric effects reads a fixed known distance It should be installed close to the radius sensors on top of the cage with the following points taken into consideration 18 It should be mounted in front of a static 100x 100mm rectangular target The path to the target should be clear from any objects The distance to the target should be 200 300mm The exact distance should be measured and entered in the Reference Target parameter in the Service screen The system is supplied with a bracket for the compensation sensor 200 300mm Figure 2 2 1 Compensation Sensor Installation Figure 2 2 2 Compensation Sensor www sysmetric ltd com ABC User Manual 2 3 Cage Sensors Installation The four cage sensors sensors 5 6 7 and 8 should be mounted on the arms of the calibration cage so that they move with the cage as it opens and closes They can be mounted on the cage either vertically or horizontally with the following points taken into consideration e The sensors should be installed vertically above vertically below for sensors 7 and 8 the center of the roller area e The sensors must point to the center of the bubble e The top gages sensors 5
31. gnals Wiring a Line speed an analog signal 0 1OVDC from the take off nip motor driver to the PLC This signal indicates the current speed of the line the speed of the take off nip where OVDC is when the line is at zero speed and 10VDC is when the line is at maximum speed b Intake blower speed an analog signal 0 IOVDC from the intake blower motor driver to the PLC This signal indicates the current speed of the intake blower where OVDC is when the blower is at zero speed and 1O0VDC is when the blower is at its maximum speed c Exhaust blower speed an analog signal 0 10VDC from the PLC to the exhaust blower motor driver This signal controls the speed of the exhaust blower where UY DC is zero speed and 10VDC is maximum speed d Opening and closing the calibrator cage the manual opening and closing signals from the buttons or joystick on the operator panel should be wired to the PLC and the PLC should be wired to the contactors that open and close the cage In this www sysmetric ltd com 229 User Manual ABC way during manual operation when the line is off the PLC opens and closes the cage according to the commands of the operator and during automatic operation when the line is working manual commands are ignored and only the PLC controls the cage e Line On and Extruder On signals these two on off signals indicate when the take off nip is working and when the extruder is working Ax www sysmetric ltd com
32. icant change in the temperature of the air in the IBC o Significant change in the raw material or the production capacity e If the exhaust blower runs at a relatively high speed above 80 try to decrease its speed decrease the intake blower speed and the system will decrease the exhaust s speed accordingly In some blowers the capacity is not linear and it drops down at high speeds This can cause a high Control Ratio when the blowers run at high speeds e To fix the error during production take the half way value between the Blowers Ratio and the Control Ratio and set it as the new value of the Blowers Ratio For example if the Blowers Ratio is 1 000 and the Control Ratio is 1 200 change the Blowers Ratio to 1 100 Remember the original value of Blowers Ratio and once production is stopped re enter the original value and search for the origin of the problem as explained in the previous note BUBBLE WAVES This alarm indicates that the surface of the bubble below the cage in front of the gap sensors 7 and 8 19 waving This can reduce the width stability When such an error occurs the system automatically reduces the balancing valve reaction level until the bubble re stabilizes Action e Check the calibrator cage height The gap sensors 7 and 8 should be at about the height of the frost line If the calibrator cage 1s too high it will cause the bubble to wave e Decrease the Control Value of the balancing valve e Check the balancing
33. ing frame height e F the feedback distance either manual or automatic The modeling control follows the reading taken from the bubble all along the production line This enables very accurate control according to the actual effecting parameters For example when a temporary width error occurs it usually copies itself as it gets to the take off nip This effect extends the stability time Modeling waits until the interference reaches the nip and at the right time it changes the air flow in the opposite direction Thus if any interference occurs the bubble will stabilize immediately Modeling even takes into 3 p consideration the fact that the bubble flows into the nip via the collapsing frame that gradually folds the web The same technique is used to synchronize the exhaust blower to the intake blower speed It enables vast changes in blower speed with minor effect on the lay flat width It is so stable that for many processes the T balancing valve can be eliminated Figure 1 6 1 Modeling Control www sysmetric ltd com 9 User Manual ABC 1 7 Operator Display NS5 V2 NS8 V2 NS10 V2 NS12 V2 5 inch Model 8 inch Model 10 inch Model 12 inch Model Figure 1 7 1 System Display The system display is Omron s standard industrial color touch screen panel Every operation on the display is carried out by gently pressing on the display Activating a button is carried out by gently pressing on the displ
34. installation chapter Turn on the intake blower and look at the Intake Speed value in the IBC service screen Change the intake blower speed from zero to full speed and verify that the Intake Speed value changes from 0 to 100 accordingly If not check the electrical wiring While changing the speed of the intake blower check the speed of the exhaust blower at Exhaust Speed The speed of the exhaust blower should follow 1 1 the speed of the intake blower Verify that the exhaust blower is actually running at the correct speed corresponding to the value at Exhaust Speed If not check the electrical wiring Make a rapid change in the intake blower s speed from zero to full and verify that both blowers the intake and the exhaust ramp up to the full speed by the time defined in Ramp Time Make a rapid change in the intake blower s speed from full to zero and verify that both blowers the intake and the exhaust ramp down to the zero speed by the time defined in Ramp Time If the blowers do not ramp up or down by the Ramp Time check the ramp time parameters in the blowers motors drivers or adjust the Ramp Time value Note the Model control technique of the ABC system makes fast maneuvers in the exhaust blower speed so the ramp time must be as low as possible 5 10 seconds Both www sysmetric ltd com 29 User Manual ABC blowers the intake and the exhaust must have braking resistors to enable a short ramp time Ramp time longer than 1
35. ket today It can forecast changes that will affect the web and take the required actions in time The system controls the calibrator cage motor the blowers speed and the balancing valve allowing continuous changes of any parameter during line operation ads www sysmetric ltd com ABC User Manual 1 2 Width Control Radius Sensors Four long range ultrasonic sensors Radius Sensors are statically mounted above the cage where the bubble is almost frosted Sensors 1 2 and 3 measure the distance to the bubble and by knowing their exact position three radiuses of the bubble are calculated The fourth sensor is used to calculate a barometric compensation parameter which is used for eliminating barometric effects on the width accuracy The four sensors are synchronized the sonic pulses are sequenced to eliminate any possible interference and to allow fast and stable distance reading Static target Cage Barometric E Rollers Compensation Sensor Figure 1 2 1 Radius Sensors Note barometric compensation covers temperature change as well as pressure humidity and other effects that produce sonic errors but although accurate bubble size is measured here the accurate web width cannot be calculated directly The bubble at this point is very hot and is about to shrink as its temperature reduces to the ambient temperature This shrinkage is also compensated by the ABC system as explained in the width calibration chapter www
36. l Ratio to Blowers Ratio in the IBC Blowers screen 23 Set Zero Range to 10 and Zero Integral to 10z www sysmetric ltd com Nm User Manual ABC Figure 4 3 1 Control Value and Zero Position Tuning 4 4 Cage Factor Fine Tuning During normal operation the bubble is pressed to the calibrator cage and this affects the motion of the cage Thus examination and fine tuning of the Cage Factor 1s required 24 In the Cage Control screen set the value of Calculated Factor into the Cage Factor 25 Enter a new Set Width and monitor the cage correction steps When the Cage Factor is proper the first correction cycle will bring the cage to 4mm from target If the value is too low the control will need more correction cycles to reach the Ser Radius If the value is too high the system will overshoot and will make a correction step in the opposite direction If necessary adjust the Cage Factor value and repeat this action until good cage control is achieved Easy monitoring of the cage s correction steps can be carried out using the width graph This graph shows along with the width error the cage s movements Press the Graph button in the Main screen or the Width button in the General Service screen to reach this graph 4 5 Finishing the Tuning Procedure 26 In the IBC screen set Control Range 0 200 This will start the automatic blower control process 27 In the General screen turn on the Continue control mode to enable con
37. lear relationship between the radius of the bubble and the width of the lay flat this is not true in a blown film line The radius should be controlled to a slightly larger size so that the shrinking effect caused by the temperature change will bring the lay flat to the exact required lay flat width This is done either automatically or manually 1 Automatic calibration when a web guiding system is installed its reading can be directed to the ABC system for automatic calibration This allows the system to automatically update the shrinkage parameter of the product and maintain accurate lay flat width 2 Manual calibration in manual mode the operator enters a manually measured width and the system calculates the shrinkage parameter accordingly W zixR Figure 1 5 1 Width Calibration Note the shrinkage parameter changes slightly as capacities cooling power or ambient temperature vary so it is best to have automatic feedback WR www sysmetric ltd com ABC User Manual 1 6 Modeling Control Several types of control formulas are usually used The most common is the PID control and its derivatives A better and newer control type is the Fuzzy Logic These two control formulas calculate the error between the set and the actual width and adjust the control accordingly A third control formula modeling takes into consideration the whole picture with the actual process dimensions e T the tower height e C thecollaps
38. ler DBC www sysmetric ltd com 291 E User Manual ABC 2 5 Control Cabinet Installation The control cabinet contains the PLC the operation display and terminals for wiring the ABC system The wiring includes the Digital Bubble Controller DBC Balancing valve Intake blower speed input signal from the blower s driver 0 10V Exhaust blower speed output signal to the blower s driver 0 10V Take off nip speed line speed input signal from the nip s driver 0 10V Calibrator cage position motor output signals for opening and closing the cage See electrical drawings for details Two types of layout are possible Integrated version when the ABC is part of a full line control the cabinet can be mounted close to the calibrator cage and wired via communication to the line control system Modbus Profibus Devicenet or CLK Some or all of the control signals can be sent to the ABC system through the communication instead of being wired to the ABC cabinet In this layout operation is carried out via the operation panel of the line control system Standalone version when the ABC 19 a standalone system the operation display is on the ABC cabinet and should be mounted in a position where it will be easy and convenient for the operator to reach the display In this layout all the signals will be wired directly to the cabinet Note the operation display can still be mounted remotely integrated in the main operati
39. lly closed valve Cage Control Screen 500 1500 Cage s time to movement ratio 500 1500 Calculated cage factor Cage bubble gap at sensors 7 8 IBC Blowers Screen 0 900 1 100 Intake to exhaust blowers ratio 0 100 0 200 Allowed range for the control ratio 0 800 1 200 Calculated intake to exhaust ratio Current actual blowers ratio Intake blower capacity 5 10sec Ramp time of the blowers 2047 4000 Blower s speed range AD and DA range General Screen 8 00 12 00m Height from top of cage to take off nip 2 00 4 00 Collapsing frames length 20 00 30 00 Distance to width feedback point 10 20mm Width error alarm threshold discontinue mode 100 150m sec The line speed when analog input is 10V The current line speed Disable cage control On Off Enable cage control On Off Continuous or discontinuous cage control Off Blink On System Off control stage I finish stage I Off Blink On Control stage I control stage II finish stage II Off Blink On Control stage II control stage III finish stage III The required lay flat width The actual produced width The required gap The actual gap Width shrinkage calibration Width Limits Screen The required lay flat width Minimum allowed set width Maximum set width Parameter Intake Speed Exhaust Speed Zero Position Zero Range Zero Integral Actual Zero Control Value Max Travel Open Close Valve Type User System System Cage Factor Calculated Factor Gap 7 8 User User System System User
40. lowly increase the Control Value A high value will increase the valve activity reducing the width small changes This is true until the control over reacts and the width starts to shift and jump The maximum value found should be reduced by about 40 and stored into Control Value If for example a value of 14 0 produced maximum stability and beyond that the system is not stable then a value of 10 0 should be used 22 Change the Set Gap to 5mm and check that the Actual Gap reaches 5mm in a few seconds Change the Set Gap back to zero and then to 5mm and check that the Actual Gap reaches 5mm in a few seconds If the reaction is too slow increase the Control Value of the Balancing Valve remember that a too high value will reduce the width stability If the Actual Gap responds quickly to one direction but slowly to the other direction change the Zero Position accordingly For example if the Actual Gap reacts quickly to a positive change in Set Gap changing the Set Gap from 0 to 5mm and slowly to a negative change in the Set Gap changing the Set Gap to Smm increase the Zero Position and vice versa In any case don t use Zero Position larger than 70 or lower than 30 Note changing the Zero Position of the balancing valve affects the Blowers Ratio parameter If you want to change the Zero Position first set the system back to Manual control mode Then change the Zero Position wait for the bubble to stable and copy the new ratio from Actua
41. ngly These screens are used during installation and for maintenance See the relevant chapters for further details Figure 1 7 7 IBC Service Screen Control Value determines the balancing valve s response level Open Close shows the current position of the balancing valve 0 the valve is completely open 100 the valve is completely closed Cage Factor this factor represents the time to movement ratio of the calibrator cage Set and Actual Radius the set and the actual radius of the calibrator cage Blowers Ratio the ratio between the intake blower and the exhaust blower Control Range the allowed range for the Control Ratio Control Ratio the calculated ratio between the intake and the exhaust blowers Actual Ratio the current actual ratio between the intake and the exhaust blowers Intake Speed the current speed of the intake blower Exhaust Speed the current speed of the exhaust blower www sysmetric ltd com 15 User Manual ABC 1 7 6 General Service Screen The General Service screen is used for entering some general control parameters and selecting the control mode of the system For convenience it also enables changing the set width and gap as in the Main screen This screen is used mainly during installation and for maintenance See the relevant chapters for further details C r1 OE A L d anual Figure 1 7 8 General Service Screen Tower H
42. oms Possible Cause The cage is closing too much and The Cage Factor is too Decrease the Cage Factor parameter oem le n NN T before fixing the width low aane i The cage is too high or Adjust cage s height so that the gap sensors too low width on discontinue mode a ee etae HE actual width measured on the lay flat calibrated Wrong Blowers Ratio Tune the Blowers Ratio parameter SR EE Wrong Intake Blower Tune the Intake Blower capacity parameter capacity www sysmetric ltd com 51 User Manual Appendix A NS10 Screens ong dung LS um EUM HR NS nom 1 Holl NSN 1 050 NOH Normally Open Balancing Valve IBC Blowers pg Amm ag Hmm ag mmm 800 imn sw ap n vs wr esce x 318 nn 800 Um ws nrl BR cE o 251 2mm 258 Amm Ns wr BR cE 1 M46 CH Du Sensors 52 Width Graph ABC EMI Tz 3D Dm C 80 Dm Cage Control www sysmetric ltd com ABC User Manual Appendix B Parameters Synopsis and Common Values The following table lists all the parameters of the ABC system with a short description and common value of each parameter It also specifies whether the parameter is controlled by the user or by the system Some values such as set width or installation distance are completely dependent on the specific production line and were therefore left blank Note for best performance each system must be tuned for its
43. on panel of the production line Contact Sysmetric regarding this option 150mm i 600mm 400mm Figure 2 5 1 ABC control cabinet Note wire entry is possible via the bottom and or top cover 209 www sysmetric ltd com ABC User Manual 2 6 Electrical Wiring Electrical wiring of the ABC system includes the following 1 Wiring the sensors to the DBC in the junction box and wiring the DBC to the PLC 2 Wiring the balancing valve to the PLC 3 Wiring power to the PLC 4 Wiring control signals between the PLC and the production line Line speed take off nip speed Intake blower speed Exhaust blower speed Opening and closing the calibrator cage Line on take off nip on and extruder on signals ono oe The following is a short description of the electrical wiring and signals Refer to the electrical wiring for details 2 6 1 Sensors and DBC Wiring Each sensor is wired with a 4 lead cable to the DBC 8 cables for wiring the sensors are supplied with the system The DBC is wired to the PLC with a shielded pair 3x2 cable The system is supplied with a 15m cable for that purpose 2 6 2 Balancing Valve Wiring The balancing valve is wired with a shielded pair 3x2 cable The system is supplied with a 15m cable for that purpose 2 6 3 Power Wiring The PLC cabinet should be wired to the power supply The power supply to the ABC system should be 110 230Volt 50 60Hz 6Amp 2 6 4 Control Si
44. re 1 7 2 Numeric Keypad Note in cases where the ABC is part of a line control system it can be equipped with a communication unit Omron CLK Devicenet Modbus Profibus etc so that the local display can be omitted and the operation will be from the line s operation panel This enables tailored adaptation by any manufacturer s line control system The following is a brief description of the screens of the ABC system More detailed descriptions appear further on in this manual in the relevant chapters 1 7 1 Main Screen The main screen 1s used in the regular operation of the ABC system This screen enables setting the required lay flat width and the bubble cage gap calibrating the width and it indicates the system s status ee Mmm Iamm Inn Dm c u o ee se 35 m min 68 2 Wi 0 s Set Act Width the set and the actual lay flat width Set Act Gap the set and the actual gap between the bubble and the calibrator cage Figure 1 7 3 Main Screen Width Calibration manual calibration of the shrinkage parameter I II III indication flags showing the current system s control stage Line Speed the current line speed www sysmetric ltd com NER User Manual ABC e Intake the intake blower s speed e Exhaust the exhaust blower s speed Pressing Graph shows graphs of the width error and calibrator cage movement This screen is
45. screen Figure 4 2 1 Blower Ratio and Intake Blower Capacity Tuning 34 www sysmetric ltd com ABC User Manual 4 3 Balancing Valve Control Value During the first control stages I and II the balancing valve control is minor During the last control stage of the system III the balancing valve control action goes into full operation The error between the set and actual gap 19 multiplied with the Control Value and the result is delivered to the valve Its activity can be seen on the display on Open Close Valve value 15 After calibrating the Blowers Ratio and the Intake Blower capacity close the calibrator cage up to the point where the rolls just start touching the bubble that is a zero gap between the cage and the bubble 16 Verify that the Actual Gap in the screen 1s zero If not check the installation and the installation distance parameter of the gap sensors 7 and 8 17 In the IBC screen verify that the Actual Radius is equal to the Set Radius allow up to 5mm error at this stage If not check the installation and the installation distance parameter of the cage sensors 5 and 6 18 In the Balancing Valve screen set the Control Value to 2 0 and the Maximum Travel to 20 096 19 Enter O in the Set Gap 20 In the General Service screen change the control mode to Automatic The system should move to the third control stage I and II flags are lit green and III 1s blinking 21 In the Balancing Valve screen s
46. screen press SERVICE enter the password 4321 and select the SENSORS screen If possible assemble the IBC pipe on the die and lower the calibrator cage so that the radius sensors will see the IBC pipe If not place some other cylinder object with a known radius in the center of the calibrator cage so that it will simulate the bubble Check the readings of the radius sensors 1 2 and 3 The three sensors should have similar readings allow 2mm difference and the average radius that they read should be equal to the radius of the IBC pipe If the readings are not equal check that all the three sensors are installed at the same distance from the center of the calibrator cage If the sensors read a wrong radius check the nstall Distance parameters of the sensors If they don t show any reading check the electrical wiring Check that the compensation sensor reads a correct distance Reference 4 should show the real distance to the reference target allow 5 error If not check the installation distance parameter Verify that Barometric Factor is 0 9500 1 0500 Note only check the barometric factor if the compensation sensor is installed and works for more than an hour If not wait and check it later Close the calibrator cage so that the cage sensors 5 6 7 and 8 will be less than 200mm from the IBC pipe www sysmetric ltd com No User Manual ABC 6 Check the readings of the cage sensors The four sensors should have similar re
47. specific production line and the values of the parameters may vary from the values given in the following table Controlled Common Parameter Function B Values Set width User Act width System Set gap User 10 to 10mm Act gap System Calibration Width User Control I System Off Blink On System Off control stage I finish stage I Control II System Off Blink On Control stage I control stage II finish stage II Control III System Off Blink On Control stage II control stage III finish stage III Line Speed User Intake User 0 100 Exhaust System 0 100 Radius 1 2 3 System Reference 4 System Cage 5 6 System Gap 7 8 System Barometric Factor System 0 9800 1 02000 Radius 1 2 3 System Install 1 2 3 User Ref 4 System Install 4 User Errors 1 2 3 4 System 0 100 Cage 5 6 System Gap 7 8 System Errors 5 6 7 8 System 0 100 DBC Error Code System User 5 10 System 30 70 User 500 1500 System System User 0 900 1 100 User 0 100 0 200 System 0 800 1 200 System www sysmetric ltd com Nm User Manual ABC Controlled e Function By Values User The intake blower speed System The exhaust blower speed Balancing Valve Screen User Start point for the valve User Allowed range for actual zero position User Zero position adjustment factor System The adjusted zero position User Valve s response level User Allowed range for the valve s position System The current position of the valve User Normally open or norma
48. sysmetric ltd com 5 User Manual ABC 1 3 Calibrator Cage Control Cage Sensors Four short range sensors Cage Sensors sensors 5 6 7 and 8 are mounted on the calibrator cage arms They measure the gap between the cage and the bubble Sensors 5 and 6 are used for positioning the calibrator cage at the correct diameter Using the readings from the radius sensors and adding to it the average top distance CP5 and CP6 the system knows the exact actual cage diameter It calculates the required diameter according to the expected radius taking into account the bubble shrinkage and the desired gap either positive or negative The required and the actual values are used for controlling the cage position and bringing it to the correct position automatically Sensors 7 and 8 measure the gap between the cage and the bubble at the bottom of the cage This gap is compared to a required gap and the error is used to control the position of the balancing valve Cage Rollers T Extruder die Figure 1 3 1 Cage Sensors Note the four cage sensors sensors 5 6 7 and 8 are optional With production lines that either do not have a calibrator cage when the cage acts only as a support the cage sensors can be omitted 6 www sysmetric ltd com ABC User Manual 1 4 Blowers and Balancing Valve Control Intake blower pushes ambient air through a heat exchanger and into the bubble while an exhaust blower pulls the hot air o
49. tem did not alarm yet Although the system is expected to work well under such conditions fixing the error will ensure the width s accuracy In order to ensure best performance of the system it is recommended to monitor the Radius Sensors and Cage Sensors screens as part of scheduled routine maintenance If an error percentage is above zero or if the system alarms for a sensor error act as follows e For NS error check the electrical wiring If they are intact replace the sensor If the electrical wiring is intact and the error remains after replacing the sensor replace the DBC card www sysmetric ltd com ay i User Manual ABC e For NT BR and CE errors clean the sensor and check that it is perpendicular and facing directly to the center of the bubble If this does not solve the error replace the sensor Note that the gap sensors 7 and 8 might need to be tilted slightly so that they will be perpendicular to the bubble s surface Note use a dry rag for cleaning the sensors Do not use any chemical substance it can damage the sensors The following example shows an NT alarm in sensor number 1 and a minor BR error in sensor number 7 Figure 6 2 1 Sensor Errors 48 www sysmetric ltd com ABC User Manual 6 3 Calibrator Cage The system sometimes bypasses the normal cage control and forces the cage to close or open or it disables the cage s movements This is done when the system detects hazardous situations where
50. tinuous control on the calibrator cage 28 Bring the production line to normal operation and test the system in various widths to verify proper operation The mentioned parameters may require minor adjustments in order to reach the best performance 36 www sysmetric ltd com ABC User Manual 5 System Operation The ABC system was designed for ease of operation and requires minimum operator supervision and intervention During normal operation only the main screen is used All other screens are for service and maintenance only 5 1 Starting Production When starting production carry out the following 1 Enter the required lay flat width 2 Enter the required gap 3 Start the production 4 After the width has stabilized measure the produced lay flay If it is not equal to the actual width showed on the ABC screen perform a width calibration een Dem Figure 5 1 1 Main screen Note the gap can be changed during production with a small temporary effect on the lay flat width A larger gap will keep the rolls away from the bubble This is useful to prevent the rolls from scratching the bubble in delicate products A smaller or negative gap will cause the cage to hold the bubble tightly and will improve the width s accuracy and stability www sysmetric ltd com Norm User Manual ABC 5 2 Control Mode and Control Stages The ABC system has 3 control modes 1 Manual calibrator cage control is disabled Th
51. tral alarm system in the factory e Pressing the ALARM button deletes the alarm message Further pressing the ALARM button toggles messages of all active alarms Arn 4 3303 Welln F LETIN N Alarm a 1mm ji i Message m pu i Figure 6 1 1 Alarm Message 6 1 1 Alarm Log The system creates an alarm log Press and hold the ALARM button for more than 1 second to switch to the alarm log screen Active Alarm Cancelled Alarm Delete Mark Mark All and e Unmark Buttons Figure 6 1 2 Alarm Log 42 www sysmetric ltd com ABC User Manual The alarm log shows the following details e The alarm that was activated e The time at which the alarm was activated e The status of the alarm red if the alarm is still active or blue if the alarm was cancelled The log can be cleared by marking some or all the alarms and pressing the delete button 6 1 2 Alarms Messages The following is a list of alarm messages that can appear on the display according to the active alarm the possible causes for the alarm and the actions to take When trying to solve an error follow and execute the recommended actions in the order they appear in this manual 1 e only try the second action if the first did not solve the problem SENSOR ERROR For all sensors 1 8 This alarm indicates an error in the specified sensor See the Ultrasonic Sensors maintenance section for more details Action Switch
52. ut The speed of the intake blower is set according to the desired cooling power and the exhaust blower speed is controlled by the system so that the speeds of the two IBC blowers are fully synchronized The blowers follow parabolic curve that perform linear cooling behavior so that the cooling power can be changed from 10 to 100 during production with minor if any effect on the bubble width To overcome the limited respond of the blowers drivers because of the blower s inertia a servo operated throttle Balancing Valve 1s mounted into the exhaust pipe and allows fast air flow changes This balancing valve is operated by a servo actuator that does not allow any backlash friction or air flow drag to reduce its accuracy The control scheme positions the balancing valve at a constant steady position until it slowly adjusts the exhaust blower s speed 0 4 20mA or 0 10V or Modbus or Devicenet 0 4 20mA or O LOV y 20mA or 0 10V Balancing Valve Figure 1 4 1 Blower and Balancing Valve Notes The throttle 1s mounted at the exhaust pipe so that the extra heat produced due to its existence will not affect the cooling power and will not change the frost level with positive gap value Unlike throttle actuators that use spring and pneumatic pistons the servo actuator always has pin point accuracy and maintains a stable position www sysmetric ltd com User Manual ABC 1 5 Width Calibration Though physics state a c
53. valve Make sure nothing disturb its movements DBC CONTROLLER ERROR This alarm indicates an error in the Digital Bubble Controller DBC Action e Ifthe alarm is persistent replace the DBC card e If the alarm was temporary read the DBC error code in the cage sensors screen and press Clear If the error returns replace the DBC card www sysmetric ltd com 45 User Manual ABC Note please advise Sysmetric of the error code when replacing a DBC card DBC COMMUNICATION ERROR This alarm indicates that the PLC fails to communicate with the Digital Bubble Controller DBC Action e In the DBC check that the green LED marked 24V is on If it 1s off check the 24VDC power supply from the main cabinet to the DBC e Check the electrical wiring between the PLC and the DBC e In the DBC check that that green LED marked COMI is on If not replace the DBC card e Check the 5VDC supply from the PLC to the DBC see electrical wiring If there is no SVDC supply replace the PLC BALANCING VALVE ERROR When the actual position of the balancing valve is equal to its set position the valve controller sends an OK signal to the PLC If this signal is missing for more than second the system triggers the balancing valve error alarms Action e Clean the balancing valve pipe butterfly and shaft and make sure nothing disturbs the valve from turning freely in the pipe e Press and hold the TEST button on the balancing valve for 5 seconds

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