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MC18-Micro User manual 1.08.UK.00 - Dryers-Loaders

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1. APPENDIX E MC18 Micro Declaration of Conformity DECLARATION OF CONFORMITY According to 98 37 EC Annex 1 Manufacturer s name MOVACOLOR BV Address i P O Box 3016 8600 DA Sneek The Netherlands Declare under our sole responsibility that the product Name i Movacolor Model i MC 18 Micro Year 205 Serial nr EE Complies with the definition of the Machine Directive 98 37 EC and complies with the national legislation to enforcement of this directive complies with the requirements of Low Voltage Directive 73 23 EEC EMC Directive 89 336 EEC complies with the following standards or other normative documents NEN EN 292 1 2 Safety of machinery part 1 2 Signature Place Sneek the Netherlands Managing Director Date June 16 2011 sr vet 23
2. See appendix A The controller itself gives a beeping signal and the alarm LED will lighten up ME settings Configuration 1 3 and 4 see paragraph 6 3 amp 6 4 Press to change ME hopper loader settings the display will show in following order On Off Press ola to switch the ME hopper loader On or Off and press to acknowledge FILt Fill time sec during this time the system blows material into the hopper of the dosing unit Press o o to change the time and press to acknowledge Recommended basic setting 15 sec FILA Fill Alarm fi if sensor is NOT covered within this time the alarm starts Press to change the time and press to acknowledge Recommended basic setting 30 sec 13 6 10 Keyboard lock 1 0 Lock Unlock Display shows L ON L OFF 14 7 Alarms 7 1 General To cancel an alarm press enter SI When an alarm is active there will be a 24VDC signal between connection 18 and 19 on the main board to activate the flash light See appendix A The controller itself gives a beeping signal and the alarm LED will lighten up 7 2 Filling alarm FILA optional The MC 18 is able to give an alarm when there is not sufficient material inside the hopper Alarm settings when using a automatic hopper loader See paragraph 6 9 Alarm settings manual hopper filling without automatic hopper loader In case of manual filling of the hopper the hopper loader
3. followed by the selected motor type Lo Low Torque and HI High Torque motor After that the configuration mode CON will be shown Configuration Type of Production Input signal Hopper loader 1 Injection Molding Timer none or ME when connected 2 Injection Molding Timer none or MV when connected 3 Extrusion Relay none or ME when connected 4 Extrusion Tacho none or ME when connected 5 Extrusion Relay none or MV when connected 6 Extrusion Tacho none or MV when connected is deactivated When the MC 18 is set to configuration 3 to 6 the time function key C When a deactivated key is pushed the unit will give a beeping signal 6 4 Configuration For changing the unit configuration keep speed and enter pressed while switching on the main power The configuration number will be displayed press 1 o to switch between the possible configurations and press to acknowledge The software version will be displayed Configuration data is normally entered once and it remains the same for subsequent operation The data entered during configuration is saved in memory and remains in the memory even when the unit is shut off or unplugged Timer mode is used for injection molding with a relay input signal When the relay contact is made the unit will start dosing according the number of seconds that has been set with the time function Relay A relay signal can be used when working in extruder mode With the relay input the unit w
4. and disconnect the mains power plug from electrical power before performing maintenance Ensure that all parts are securely fixed to the extruder or injection molding machine gt gt gt gt Dangerous voltages are present inside the control cabinet for up to 2 minutes after it has been switched off 2 2 Certification The Movacolor dosing unit is designed and produced in conformity with the following European regulations e C standards for machinery health safety environment e EMC electromagnetic compatibility e VEM safety electric material e 98 37 EC Annex 1 See the declaration of conformity Appendix E 2 3 Operating environmental conditions e The unit must be protected against weather conditions e Operating temperature 20 to 70 degr C e Protection class IP 50 3 Capacities Capacity graph Capacity Gram Second 60 80 100 120 140 160 180 200 Motorspeed RPM Note measured with normal granular masterbatch 0 8 kg dm3 Note measured with free flowing powder 0 65 kg dm3 Note only available with high torque 4 5 Amp stepper motor The actual capacity of the dosing system depends on The volume weight of the material bulk density The specific weight of the material specific density The granular shape of the material The granule size The surface structure of the material Granular material can be normal or micro The granu
5. control of the MC 18 is used to generate the filling alarm A sensor and an alarm output is needed Use the settings below ME ME hopper loader ON FILt 0 1 FILA 0 2 The Filling alarm is self eliminating this means that the alarm will stop automatically when the sensor is covered with material If an alarm is canceled by pressing enter I the next alarm will come if the sensor is still not covered with a delay of 60 seconds This gives the operator the time to manual fill the hopper without having the alarm on 7 3 Motor connection failure ErrO ErrO Motor connection failure Make sure the motor is connected Check cable and connectors for damage Press enter to stop the alarm When the MC Micro unit is supplied excluding dosing unit only hopperloader no dosing motor ErrO is disabled Jumper 1 JP1 on the Mainboard is placed in the OFF position This jumper is located on at the upper right side of the Mainboard To activate the motor alarm ErrO jumper 1 must be placed in the ON position 15 8 System performance The following variables may influence the accuracy and repeatability of the system Material properties Easy flowing non sticky and non static material that comes in the form of small regular shaped granules or powder can be dosed very accurate and regular Periodical cleaning of the dosing cylinder and seals is necessary for proper operation Extreme vibrations and
6. shocks can have negative influence on system performance An unstable relay signal has a negative influence on the repeatability With injection molding the shot to shot accuracy depends besides the variables mentioned so far on the shot time in combination with granule size and weight If relatively big and heavy granules have to be dosed in a very short time it will influence the shot accuracy and repeatability because if only a few granules are dosed during the shot one granule more or less makes a big difference on the total shot weight Vacuum or overpressure in the neckpiece caused by driers or hopper loaders Bridging or rat holing of the material inside the hopper can happen if the material is not free flowing Bridging or rat holing of the material inside the hopper can happen if the material is extremely static Extremely static material can contaminate the dosing cylinder In case of water cooled neckpiece check if there is material build up around the dosing cylinder and the water cooled pipe Check also the water supply to the neckpiece 16 9 Maintenance hopper loaders 9 1 Preventative maintenance schedule e Daily Clean the conveying filter If you are running a dusty material or regrind you may need to check and clean the filter more often The filter should be cleaned whenever you change materials 147 10 Troubleshooting hopper loaders 10 1 Conveying problems and
7. IX B MC18 Micro Technical Specifications 20 APPENDIX C MC18 Micro Technical Specifications Hopper loaders 21 APPENDIX D MC18 Micro Drawing General Dimensions 22 APPENDIX E MC18 Micro Declaration of Conformity 23 1 Introduction Thank you for purchasing a Movacolor metering device This manual is addressed to operators and qualified technicians taking care of the metering of dry additives to ensure correct use of the Movacolor dosing unit IMPORTANT NOTE THIS MANUAL MUST BE READ BEFORE INSTALLING THE DOSING UNIT KEEP THIS MANUAL IN A PLACE ACCESSIBLE FOR ALL OPERATORS 1 1 Symbols Important note A Attention safety regulations for the operator 1 2 Terms Operator A person charged to operate adjust maintain and clean the machine Qualified Technician A specialized suitable trained person authorized to execute the installation non routine maintenance or repairs requiring special knowledge of the machine and how it operates 2 General information 2 1 Safety A The equipment is only designed and may only be used for the dosing of dry additives Any use that does not conform to the instructions is considered improper and as such releases the manufacturer from any liability in regard to damage to things and or persons Before switching on the unit for the first time ensure that the mains power voltage applied is between 80 and 260Vac Always switch off the Movacolor control cabinet
8. MC 18 needs an input signal from the production machine in order to operate Three different input signals can be used to control the MC 18 1 A potential free relay contact Use the white and brown wire for the potential free contact 2 A relay signal up to 24 Volt DC In case of a powered relay signal connect the white wire to 24 VDC and the yellow wire to side Note potential contact Guaranteed OFF 0 8VDC Guaranteed ON 18 30VDC 3 A tacho signal up to 30 Volt DC This is used when the MC 18 needs to be connected to an extruder that has a generator that produces a voltage linear to the extruder speed When using a Tacho generator signal connect the white and brown wire connect green to VDC and yellow to side of the generator See Paragraph 6 6 for information about the configuration of the tacho parameters The maximum voltage that can be applied to the MC 18 is 30 VDC The tacho voltage has to be reduced to 30 VDC if the tacho generator has a higher voltage output than 30 VDC at the maximum extruder output capacity See the diagram below Green wire Input Resistor Rx Tacho generator connection rz Yellow wire EXTRUDER Rx kilo Ohm 2 684 x Max tacho output VDC 5 66 5 Installation hopper loader optional 5 1 Mechanical installation The Hopper loader lid fits directly on the hopper of the dosing unit To fix the ME hopper lid the quick release clamps o
9. MOVACOLOR COLOR IN CONTROL MC18 Micro User manual 1 08 UK 00 Software Version V1 08 u1 00 Manual Revision 00 Datum June 2011 Movacolor B V Koperslagersstraat 31 8601 WL Sneek The Netherlands Internet www movacolor com Email info movacolor com ax 31 0 515 570020 re 31 0 515 570021 INDEX 1 2 INDEX 3 Introduction 2 General information 3 2 1 Safety 3 2 2 Certification 3 2 3 Operating environmental conditions 3 Capacities 4 Installation 5 4 1 Transport 5 4 2 Receipt 5 Installation hopper loader optional 7 5 1 Mechanical installation 7 5 2 Compressed air installation 7 5 3 Connecting material line 7 5 4 Adjusting compressed air flow 8 5 5 Sensor adjustments 8 Operation 9 6 1 The Interface 9 6 2 General 9 6 3 Start up 10 6 4 Configuration 10 6 5 Speed Se and timer 10 s69 Tacho function 11 6 7 Production Motor On Off 11 6 8 Test material output 12 6 9 Automatic hopper loaders optional 13 6 10 Keyboard lock 14 Alarms 15 7 1 General 15 7 2 Filling alarm FILA optional 15 7 3 Motor connection failure ErrO 15 System performance 16 9 Maintenance hopper loaders 17 9 1 Preventative maintenance schedule 17 10 Troubleshooting hopper loaders 18 10 1 Conveying problems and solutions 18 APPENDIX A MC 18 Wiring Diagram 19 APPEND
10. d The air flow will determine how much material will be transferred and how fast the dosing unit will be replenished with material with each loading sequence The best is to adjust the air setting to its lowest possible level in order to conserve compressed air energy Parameters such as distance material line bends the flow characteristics of the material and vertical rises in the flex hose all play a part in finding the proper setting Ultimately trial and error settings over several loading sequences will work best to determine the right air level Too low of a setting may not move material effectively enough to satisfy demands cycle after cycle Too much air will waste energy and cause the filter on the lid to prematurely blind in an attempt to evacuate excess air 5 5 Sensor adjustments Sensor Depending on the material you may need to adjust the sensitivity of the sensor which is delivered with the hopper loader At the back of the sensor is a small screw that can be used to adjust its sensitivity To adjust fill the hopper with material until the sensor is just covered and turn the screw until the light on the sensor goes on Because the sensor is in direct contact with the material it is recommended that the sensor will be initially adjusted for sensitivity and then re adjusted once the sensor becomes coated with typical material fines common to plastics conveying Capacitive Sensor Adjustment The LED is ON when material
11. d with compressed air via the supplied tubing Loader will not cycle Are all electrical connections correct Check to make the sensor is connected to the control and the solenoid is connected to the control Filter clogs frequently Is there too much compressed air flow Adjust the air flow to minimum possible level to prevent excessive dusting and filter clogging 18 APPENDIX A MC 18 Wiring Diagram Input start signal Jumper settings To switch from stepper motor 2A to stepper motor 4 5A ON e Stepper motor 4 5A e Stepper motor 2 A Potential free contact Potential contact ne Min 18VDC to Max 24VDC Min OVDC to Max 30VDC Sensor input 24VDC INP2 Gnd 24VDC Inp 2 Q t gt eo DE 5 2 E p Capacity f os sensor D MOE Coil 1 Coil 2 Motor Internal wires main power switch lt oO ea gt TEE Output Output 1 2 Outputs 24 VDC White Brown 20 White Brown To open the control cabinet Power Supply use the 4 bolds on the top and Western Europe USA Canada Mexico bottom side not the 6 bolds at Mid America Japan Taiwan the front side PE N L 1 Black WARNING 2 White Do not make any changes to 3 Green the main board components ore warranty will lapse Green Yellow APPENDIX B MC18 Micro Technical Specifications Controls Speed Man
12. ill start dosing when the relay contact is made and will stop when the relay contact is interrupted 6 5 Speed 9 and timer Speed and dosing time can be altered time only in case of injection molding Activate by pressing 4 or acknowledge 10 6 6 amp Tacho function The tacho function is available in configuration 4 amp 6 This function can be used with extrusion when it is necessary that the dosing rate is automatically adjusted to the extruder speed In tacho mode an input voltage is coupled to a dosing speed setting If the extruder speed changes the tacho input voltage and speed of the dosing unit will change accordingly A linear correlation between extruder speed tacho input signal and the needed dosing speed is assumed See graph Tacho graph Example 12 14 18 20 22 24 226 78 30 Tacho input voltage VDC Press to make the tacho function active The display will show a numerical value that represents the current voltage of the tacho input signal When is pressed the current voltage P1 in the graph is coupled to the set speed P2 in the graph During production the speed P2 can be changed The new speed is coupled to the previous stored voltage and the graph will change accordingly During production the voltage P1 can be adjusted to the current tacho input voltage by pressing followed by The new voltage is coupled to the previous stored speed and the graph will change acco
13. ion 1 amp 2 Injection Molding The unit will dose at the set speed Z and time Configuration 3 to 6 Extrusion The unit will dose for 30 seconds at the set speed Emergency stop If the test is activated press stop amp to cancel a test 12 6 9 Automatic hopper loaders optional Hopper loader settings This part of the manual describes how to make the hopper loader settings For further technical information about the hopper loader consult the specific hopper loader manual General The hopper loader is only activated when the motor is On Emergency stop To stop the hopper loader during production press select Off by pressing o or o and press L to acknowledge Input signal sensor Depending on the material you may need to adjust the sensitivity of the sensor which is delivered with the hopper loader At the back of the sensor is a small screw that can be used to adjust its sensitivity To adjust fill the hopper with material and turn the screw until the light on the sensor goes on Output signals During fill time FILt there will be a 24VDC signal between connection 20 and 21 on the main board to activate the pneumatic solenoid valve See appendix A The hopper loader LED on the front of the controller indicates the status of the valve output When the Fill Alarm FILA is active there will be a 24VDC signal between connection 18 and 19 on the main board to activate the flash light
14. is detected by the sensor uaa The LED is OFF when no material is detected by the sensor Sensitivity adjustment More sensitive Less sensitive 6 Operation 6 1 The Interface Input LED Input LED is lighted when pr input signal is made MOVACOLOR T Increase Decrease value TO bs Set dosing speed RPM m AS g Set dosing time sec ae Set Tacho voltage VDC Set hopper loader Start LED blinking Motor Standby waiting on start signal Start LED lighted continuously Motor is runnina 6 2 General e Connect motor before switching on the controller e All changes o o have to be entered to acknowledge e A blinking value means the changed data is not entered e To cancel a changed value press the specific function button Z or 2 again e Most functions have a designated key and a LED on the interface When a function is activated the LED of that key function will light up e All functions except the test 4 function can be activated when the unit is started depending on the chosen configuratio n e Only one of the following functions zlo can be active at the same time This means no other function can be activated before the active function is deactivated The unit can be set to different configurations see paragraph 6 4 6 3 Start up The MC 18 software version is displayed shortly when the unit is switched on
15. lar material and powder material has to be free flowing non static and not sticky To determine the kind of material in your application use the description below Material types Normal Granules NG Micro Mini Granules I MG N an The term Micro Mini Granules also includes free flowing powder g lt 2 5mm L lt 3mm 4 Installation 4 1 Transport To protect the Movacolor unit against damage during transport the unit is packed in a cardboard box filled with polyurethane foam Delivery terms are Ex Works Sneek The Netherlands Buyer is responsible for the transport Movacolor cannot be hold liable for any damage during transport 4 2 Receipt Check the unit thoroughly upon receipt Pass any remarks to the local agent or Movacolor within 8 days upon receipt of goods 4 3 Electrical installation The MC 18 controller is standard equipped with 3 connections 1 Mains power cable Before switching on the unit for the first time ensure the mains power voltage being applied is between 80 and 260Vac 2 Input cable 3 Motor cable Optional are 4 Sensor complete with cable 5 Alarm flash light complete with cable 6 Compressed air solenoid valve complete with cable for automatic hopper loader Mains power switch On Off See appendix A for wiring diagram 4 Sensor input 24VDC i 3 Motor cable 2 Input see installation 1 Mains power cable Input start signal The
16. n the dosing hopper are used 5 2 Compressed air installation The ME loader uses compressed air to move material The inlet for your compressed air supply line is on the solenoid valve The air connection diagram can be found on the valve s body 1 Connect the compressed air to the 8x6 compressed air connection on the solenoid valve The compressed air source must deliver a maximum of 4 8 bar of clean dry non lubricated air pressure 2 Make connections from the solenoid and the ejector pipe with the provided compressed air tubing Quick disconnect fittings are provided for these connections The tubing should be cut to length for maximum efficiency of the system Use straight cuts to assure a good square tubing end Confirm a good connection A CAUTION Be sure to provide hazard free routing of the tubing to keep it away from hot or moving surfaces and out of the way of personnel 5 3 Connecting material line The flexible hose need to be attached over the inlet pipe of the ME hopper lid and ejector pipe Secure the hose with a hose clamp Reduce flex hose down to the shortest possible length to avoid wasting compressed air energy IMPORTANT The material line should be as straight as possible Avoid loops and S curves in flexible hose This can hurt conveying performance 5 4 Adjusting compressed air flow Adjusting compressed air flow It is advised to use a flow regulator for the compressed air not include
17. rdingly The maximum voltage that can be applied to the MC 18 is 30 VDC See paragraph 6 4 for information about the correct electrical connections of the tacho signal and information about connecting a higher then 30 Volt DC input signal 6 7 Production Motor On Off Press XX to start production The start LED will start blinking when the unit is waiting for an input signal The unit is dosing if the start LED is lighted continuously fq 6 8 Test material output The test function is used to calibrate the MC 18 The test function can only be used when the motor is stopped How it works Determine the dosing unit RPM entirely manual This can be done by drawing up the dosing characteristic manually or by recording the relation of the RPM versus the system output in a chart With this multipoint chart it is possible to determine the rpm that corresponds to the dose amount This must be repeated for every dosing setting because the dosing conditions and the used materials are usually very different Manual made dosing graph made at 3 sec dosing time grams per shot RPM Test procedure to determine output of dosing system Place dosing unit horizontally leveled water level surface gt Set the speed and or time gt Press LJ for Test gt Weigh the material dosed during test gt Adjust speed or time and repeat CX Test if necessary Note Configurat
18. solutions A WARNING Disconnect power and air sources Always disconnect the loader from its main power source and compressed air course before servicing This prevents the loader from starting during servicing which could cause personal injury Problem Possible cause Solution Low or no material flow Does the filter need to be cleaned Check the filter if it is clogged with dust or fines clean the filter Are there kinks in the flex hose Check the material flex hose line for loops and S curves Remove any loops and S curves in the flex hose Try to keep the hose as straight as possible Check the material line for holes cracks Are hose connections too loose Check the material line hose connections for leaks especially at the ejector pipe connection Hose clamps should be used Are compressed air adjustments correct Check the compressed air adjustment to make sure it is properly adjusted for optimum flow Too much air will prematurely blind the filter too little air will create clogs Do you have enough material at the source Replace refill the material container Has material plugged the flexible hose Check the material flex hose line for loops and S curves Remove any loops and S curves in the flex hose Try to keep the hose as straight as possible Is the compressed air tubing connected Assure that the ejector pipe s are supplie
19. t circuit or in correct connection the power supply automatically shuts down e Opto insulated start input for connection to production machine Optional parts External Alarm Flash light External Alarm Siren 20 APPENDIX C MC18 Micro Technical Specifications Hopper loaders Loader model ME25 For normal granules and small regrind Maximum capacity with 1 8 Itr hopper Maximum Capacity value mentioned only for reference 15 kg h based on 10 seconds ON time and 3 minutes OFF time 175 kg h at continuous working Standard conveying distance 3 mtr Material hose 25mm inside diameter PVC hose with antistatic wire Maximum temperature 60 C Compressed air hose 6x1mm outside 8mm Compressed air requirements Consumption 4 to 8bar 0 25 to 0 45 m min Filter type Additional Filter Cloth for fine dust Stainless steel Perforated plate hole size 2mm Filter cloth 120x120x12mm EN779 classification G4 The capacities are measured with normal granules with a bulk density of 0 8 kg dm3 Granule size 3 4 mm De mentioned capacities are orientation values because capacity depends on material properties 21 APPENDIX D Dimensions MC18 Micro Drawing General 1 0 Ltr ABOVE SENSOR 0 8 Ltr BELOW SENSOR Nome descr GENERAL DIMENSIONS MICRO DOSER Standards
20. ual setting from 0 1 to 200 RPM max in increments of 0 1 RPM Time Manual settings from 0 1 to 999 9 sec in increments of 0 1 sec Voltage settings of tacho voltage auto detect Integrated hopper loader controller Monitoring System Information External communication 4 piece 7 segments LED at front display Man Machine interface keypad External Communication none Alarm LED Indication Internal beeper 1x external alarm output Specifications Standards amp Directives Technical data Power supply Operating power from 80 VAC to 260 VAC 50 and 60 Hz by integrated automatic voltage selector Power consumption 80 Watt maximum Stepper motor 1 8degr step max 2 Amp at 40 Volt Operating Temperature 20 to 70 degr C Input signal s Injection molding Start Stop trigger input potential free or 18 24VDC Input for level sensor Extrusion Start Stop trigger input potential free or 18 24VDC Tacho input 0 30VDC Input for level sensor Note potential contact Guaranteed OFF 0 8VDC Guaranteed ON 18 30VDC Output s Stepper motor max output 2A 40VDC Solid state 24VDC 0 5 A output for valve hopper loader Solid state 24VDC 0 5 A output for external alarm Maximum total output power 12 Watt Valve output alarm output Standard Directives Protection class IP 50 According to CE standards EN50081 2 HF radiation industry EN50082 2 HF immunity industry Safety e In case of overload due to shor

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