Plasticolor 2000 GR
Contents
1. MOTOR O K NPN MOTOR ENABLE POWER SUPPLY 24VDC POWER SUPPLY 0VDC 10 PIN PLUG www plastore com SYSMETRIC January 7 2006 MANUFACTURER _ 48 Plasticolor User Manual SMART 11 12 20 PIN SOCKET PRODUCT PAGE POWER SUPPLY OVDC O 7 gt 7 January 7 2006 POWER SUPPLY 24VDC a a 2 O lt LL 2 z lt gt SYSTEM SWITCH ON SYSTEM SWITCH DRAIN TEACH CONVEYER YELLOW SWITCH ps LEVEL PROXIMITY TQ SWITCH GRAY SYSTEM WHITE SWITCH LAMP GRAY CONVEYER a WHITE SWITCHLAMP ORANGE S2 59 WEIGHING BUCKET FILL VALVE WHITE BLUE 2 62 CONVEYER VALVE WHITE BROWN 9 2 10V 10 0 10 S WHITE BLACK BLUE 10 0 OV 10 0 10 S WHITE BLACK YELLOW 10V 10 0 10 S WHITE BLACK ORANGE 10 x 0 ANALOG 0 10V BLACK 4 ANALOG 0V AINO SHIELD SHIELD www plastore com 49 Plasticolor User Manual SYSMETRIC January 7 2006 LOADCELL AMPLIFIER MANUFACTURER PURPLE CONVEYER VALVE WEIGHING BUCKET FILL VALVE CONVEYER SWITCH LAMP ORANGE SYSTEM SWITCH LAMP LEVEL PROXIMITY SWITCH YELLOW CONVEYER SWITCH SYSTEM SWITCH DRAIN TEACH SYSTEM SWITCH ON 20 PIN PLUG www plastore com 50 Plasticolor User Manual Appendix D2. System Specification Power supply e High voltage model 200 240Volt 50 60Hz 2Amp e Low voltage model 100 120Volt 50 60Hz 4Amp Air Supply e 6 8Bar dry air e amp mm fast connector Control servo Modeling technique for accurate and stable system control Backlit graphical display with keypad and function keys Multi language simple interface Galvanic isolation on all inputs and outputs analog and digital Isolated 10 100Mps Ethernet network connection Integrated machine data acquisition Remote PC control compatibility with Minuman and Injmon software Weighing and Feeding Unit e Rigid mechanical structure Automatic material parameter tuning Easy material emptying and system cleaning 0 1g weighing resolution Loss in weight measurement technique Stepper motor operated 1600 steps per revolution Screw speed control 1 600 0 3 225rpm Typical flew rate 0 05 30K g Hour Material Conveying e Build in ventury material conveyer 3 meter flexible hose The SMART control and Hopper is manufactured by Sysmetric Ltd P O B 1122 Afula 18550 Israel Phone 972 4 6405857 Fax 972 4 6405911 info sysmetric ltd com www sysmetric ltd com www plastore com 51 Plasticolor User Manual www plastore com 52
3. you need to change the system configuration or o k F6 to complete the system configuration If the SMART is connected to an Ethernet or Modbus network press Comm F4 to configure the communication settings Refer to chapter 7 regarding data addresses in the SMART www plastore com 10 Plasticolor User Manual 3 2 7 Communication Settings Press the corresponding F key to configure the communication settings F2 to change the IP address of the SMART F3 to activate the Modbus communication Refer to chapter 7 regarding data addresses in the SMART 3 2 8 IP Address Use the keypad to enter IP address Subnet Mask and Default Gateway for the SMART Press after typing each value to move to the next value When finished press Back F6 to return to the Communication screen If you use TCP IP communication it is recommended to enable the Link Lost to automatically reconnect a lost Ethernet connection Note Link Lost can interfere with UDP communication so it is recommended to disable the Link Lost when using UDP communication 3 2 9 Modbus Use the keypad to set ID number of Retries and the Timeout of the Modbus communication Press k after typing each value to move to the next value Press Open Modbus F3 to activate the Modbus communication When finished press Back F6 to return to the Communication screen There are two options for Modbus communication with the SMART e Using the network por
4. 23 6 2 1 EMP uu a DRE E a ee Ra atau 23 6 2 2 COBVE VeL ku 23 6 2 3 Exceptional Load Voltage uo uuu uu 23 6 2 4 DAES CES CHEW Needed DE RE nm E hatun pi 24 6 2 5 rawr Screw 24 6 2 6 No au Be sae ce i pi as Wee errant oe to Tenn tre tt 24 6 2 7 Exceptional Injection Tinkuy u uk 24 6 2 8 Exceptional Plast li Cation TIO uuu ma otc ho m Onboard Res 24 6 2 9 PELC Battery LOW dam etri do EO E fb 24 6 2 10 a ala o tute det SU dE a tocado M tlt ai 24 urit ertet ua aaa ato arbol nu as ad i a 25 7 t k S 26 POTD h O S u oaa det tale oii be a al ELS GU eat Aa eae 26 Talat a a e 26 Talii Anaoa Mode 26 T3 Analog Mode Pere Cia Lc uo bei iai eat san nei tns 27 Foe AS Codes and 27 8 Service and a da tai 28 MEME aA srl pee 28 8 1 1 Service MUS suyuyman ME 28 62122 28 8 1 3 Model 1 Flow and Smaple Rate Parameters 29 8 1 4 Model 2 Weighing Bucket and Hoppe
5. 3 3 4 A S RE eee b e RE reete OR EA ep 13 FTA roata dt atatia ll 14 3 4 1 Manr 14 3 4 2 11 0 11 eode u af it aa x re PIE Duc CO M d Lx Cd 14 p JANGIOS Mode 15 3o 15 3 952 151 OUTRE ER 15 3 9 3 Materia a Suyu Sus ocu u ML M LM 15 240 ginuloseMode Percentage usos naa iau newts eise ob i at d i a 16 3 6 1 M T 16 3 6 2 li ele ORD UR NT c LET 16 3 6 3 16 4 Screw Selection and Installation 2202 17 lat oct 17 4 1 1 Output at Injection uu uuu ss t 17 qu SSO ani a CLIE EM EM M n 17 LS MEME TITLE 16 5 Plasucolor Operation iio dc esate u o fo doa codo co 21 Odo 22 GSM Roy Lun yu ene 22 6 eT m 23 aa 23 www plastore com mm Plasticolor User Manual Qu
6. a 2 lt 9 a www plastore com 4 5 INJECTION PLASTIFICATION AUTO MODE EXTRUDER ON COMMON INPUTS 19 11 NOT USED MOTOR O K SysStep MOTOR DRIVER LEVEL PROXIMITY SWITCH CONVEYER SWITCH SYSTEM SWITCH DRAIN TEACH SYSTEM SWITCH ON MOTOR STEP COMMON INPUTS 10 18 PRODUCT MANUFACTURER SYSMETHIC January 7 2006 4 Plasticolor User Manual 2 2 O lt www plastore com COMMON OUTPUTS O13 O16 ALARM RELAY NOT USED MOTOR ENABLE SysStep MOTOR DRIVER CONVEYER VALVE WEIGHING BUCKET FILL VALVE CONVEYER SWITCH LAMP SYSTEM SWITCH LAMP COMMON OUTPUTS O2 O5 MOTOR DIRECTION SysStep MOTOR DRIVER MOTOR STEP PRODUCT MANUFACTURER SYSMETRIC January 7 2006 _ 42 Plasticolor User Manual PRODUCT SYSMETRIC January 7 2006 a a 2 O lt LL 2 z lt gt 10 0 10 LOADCELL OUT AMPLIFIER LOADCELL 0 AMPLIFIER RED O OUT ANALOG INPUTS 9 O 6 USED 0 10 www plastore com 43 User Manual Plasticolor 1 9 LYVINS 1onaoud 900c Menuer Old LdINSAS YSYNLOVANNVIN _ 44 H3AIHQ HOLOW deiss S PURPLE gt CC tc z PURPLE SLAdLNO 1 91 www plastore com Plasticolor User Manual PRODUCT 15 PIN SOCKET GR
7. actual output might be different then stated In the table above www plastore com F lt Plasticolor User Manual 4 3 Screw Installation 1 Empty all material from the Plasticolor by opening the drain port and the test port at the bottom of the Plasticolor 2 Loosen and remove one of the motor hinge bolts and swing the motor aside 3 Pull the feeder screw out of the body housing gt le J 979 AN 802 9 GZ pm CN ip 4 Loosen the locating knob on top of the feeder and pull the sleeve out of the housing PE op d J s www plastore com _ 18 Plasticolor User Manual 5 Insert the new sleeve and tighten back the locating knob Make sure that the cutout in the sleeve 1s facing downwards and aligned with the test port 6 Insert the new feeder screw Note never mix up screw and sleeve combinations They are color coded for easy identification 7 Turn motor shaft so that one of the coupling cogs points toward the motor hinge knob Slide the feeder screw with the flex coupling and housing seal out toward the motor coupling Verify that the motor cogs fit into the flex coupling and slowly swing the motor back into position AU Oa LR ee 7 www plastore com 19 Plasticolor User Manual 8 Re insert and tighten the motor hinge knob www plastore com 20 Plasticolor User Manual 5 Plasticol
8. for injection molding machines The additive 15 fed according to plastification injection cycles of the injection molding machine e Continuous mode for continuous extrusion The additive is fed continuously at given Kg Hour e Analog Mode for continuous extrusion The Plasticolor s output is defined by Kg Hour or by percentage of the extruder s output and controlled by analog input 0 10Volt 1 Features Servo Modeling technique for accurate and stable system control Backlit graphical display with keypad and function keys Multi language simple interface Galvanic isolation on all inputs and outputs analog and digital for electrical protection Isolated 10 100Mps Ethernet network connection for TCP IP and Modbus communication Integrated machine data acquisition Remote PC control compatibility with Minuman and Injmon software Rigid mechanical structure Automatic material parameter tuning Easy material emptying and system cleaning 0 1g weighing resolution Loss in weight measurement technique Stepper motor operated 1600 steps per revolution Screw speed control 1 600 0 3 225rpm Typical flew rate 0 05 30K g Hour Note this manual contains information for correct and safe installation and operation of the Plasticolor Read this manual entirely before first operation of the Plasticolor www plastore com 4 Plasticolor User Manual Installation 1 Feeding Unit Installation 2 2 1 Remove the mater
9. must be pressed after typing numeral values in order to set the new value to the controller data ESC key this key is used to cancel numeral value typing Pressing the ESC key during numeral value typing will cancel the typing and the data will return to its previous value In addition quick double click on the ESC key will switch the display to the main menu screen Arrows keys up arrow down arrow left arrow and right arrow are used to switch between variables in screens with more the one variable SMART controller www plastore com 8 Plasticolor User Manual 3 2 System Configuration The SMART controller supports different modes of operation which are set during manufacturing according to the costumer specifications but can be reconfigured at any time To enter the system configuration hold pressed together ESC and F1 keys for 3 seconds until the language screen appears 3 2 1 Operation Language Using the arrows keys move the curser to select the operation language and press After selecting operation language the SMART will switch to Feeder Type screen 3 2 2 Feeder Type Press the corresponding F key to select the system s feeder type F2 Belt feeder F5 Screw feeder After selecting feeder type the SMART will switch to Operation Mode screen 3 2 3 Operation Mode Press the corresponding F key to select the system s operation mode F2 for injection molding machine F5 for continuou
10. supports TCP IP UDP and Modbus communication which can be used to set and read all working parameters of the Plasticolor using a remote PC See chapter 3 2 7 regarding communication configuration 7 1 Data addresses 7 1 1 Continuous ia Modbus G NE RI EEE FIRE s HW s 000 000 999 999K g 7 1 2 Analog Mode din si Modbus eae EU PRICE E www plastore com 26 Plasticolor User Manual 7 1 3 Analog Mode Modbus Ss ES a 000 0 999 9K g Hour e After writing new output set Set New Output bit to 1 MB62 The SMART will update the new values and will clear the bit back to 0 e In order to reset the totals set Reset Totals bit to 1 MB63 The SMART will reset the totals and will clear the bit back to 0 7 2 Alarms Codes and Bits The SMART alarms are indicated in two methods a code which indicates the current active alarms and bits which indicates the status of each alarm Both the code and the status bits can be used to indicate alarms 1n the remote control unit The following table details the code of each alarm as read in ML100 and the status bits Code Alarm PLC T Acti Modbus vini 0 NoAlm J O o sn C 0105 3 BucketAlam MBIIO IBit Read OI PLC Battery Low
11. the output pins of the weighing amplifier If using a different weight the voltage will be different accordingly Use only 100 500g weight 12 Close back the operation panel 13 Perform weighing calibration as detailed in 8 1 2 22 2 www plastore com Plasticolor User Manual Cal Trimmer Power 0 Gain Jumper an Clm SE Soo 1 V Output Pins wc OVolt i 2972 0 10Volt p Loadcell Output Zero Trimmer 1 LI 8 m Li L 7 k 1 P x 4 Qs e MI SYSMETRIC 2 LOADCELL HPLIFIERSESE ELC Me Offset Jumpers Weighing Amplifier 8 2 2 Loadcell Output and Offset Jumpers Normal loadcell voltage output with no load at the weighing bucket is about 1 2mVolt When the loadcell is damaged it usually has some offset and will output a higher voltage This will disturb calibrating the weighing amplifier If during weighing amplifier calibration it 1s impossible to get OVolt when trying to calibrate the zero check the loadcell output voltage If the voltage 1s more then the normal 2mVolt it is recommended to replace the loadcell unit Another option instead of replacing the loadcell unit is to use the offset jumpers to compensate the loadcell offset The offset jumpers affect the voltage in different intensities jumper A Is th
12. 140 0141 Teach Failed MB145 0146 ss Exceptional Plasi ezion Time MBISS Bit Red 0136 NE NM 10 www plastore com Plasticolor User Manual 8 Service and Maintenance 8 1 Service Screens 8 1 1 Service Menu Pressing SERVICE F6 at the main menu screen will switch to the service menu screen The service menu enables weighing calibration and access to operation parameters of the Plasticolor Take extra care using the service screens Setting incompatible values can reduce system performance Note entering Service screen requires access code The default code is 1234 8 1 2 Weighing Calibration Weighing calibration 1s preformed in order to ensure that the system reports the correct weight of material in the weighing bucket Weighing calibration 1s preformed during manufacturing yet it 1s advised to perform calibration before first operation of the system Recalibration should be done in the following cases e fany inaccuracy in the Plasticolor s output is noticed If the SMART controller has been replaced If the weighing amplifier has been replaced If the weighing loadcell has been replaced AMP weighing amplifier voltage WEIGHT current weight in weighing bucket REF reference weight used for the calibration Weighing calibration 1s performed by the following steps 1 Stop the system turn system switch to OFF and conveyer switch to 0 2 Empty mate
13. Clean the weighing chamber Verify no residual material between the chamber walls and the loadcell and weighing bucket Switch the controller display to weighing calibration screen Press SERVICE at the main menu and CALIBRATION at the service menu At this state when the weighing bucket is empty the amplifier voltage AMP should read 0 0 1 Volt If not verify again no residual material presses weighing bucket or the loadcell If necessary calibrate the weighing amplifier as described in 8 2 1 Wait for about 10 seconds and press Zero to remove tare weight The value WEIGHT will show 0 Hysterasis check repeatability gently press the weighing bucket and release The WEIGHT 1n the calibration screen should rise and drop back to zero allow 2g tolerance Gently pull the weighing bucket The WEIGHT should drop below zero and rise back to zero allow 2g tolerance Calibration check press Zero to clear any residual offset from the previous check Place a reference weight in the weighing bucket and verify the REF value corresponds with the reference weight The WEIGHT value should match the reference weight allow 20 tolerance If not perform weighing calibration as detailed In 8 1 2 Linearity check put weight different then the reference weight in the weighing bucket and verify correct WEIGHT value It Is recommended to repeat this check with several different weights to check all working range Take off the weight and cl
14. EEN YELLOW SYSMETRIC GROUND January 7 2006 NEUTRAL BLUE MANUFACTURER ALARM DRY CONTACT COMMON 0VDC COMMON 24VDC OPTION EXTRUDER ON PURPLE AUTO MODE PLASTIFICATION bE BROWN INJECTION WHITE GREEN NOT USED NOT USED BLACK WHITE SHIELD SHIELD ANALOG 0V ANALOG 0 10V www plastore com 45 Plasticolor User Manual N E ANALOG 0 10V xi 00 H a lt ANALOG BLACK S E e Lu 5 E SHIELD zi CN USED INJECTION PLASTIFICATION EXTRUDER ON AUTO MODE COMMON 24VDC OPTION COMMON 0VDC ALARM DRY CONTACT 2 0 75 2 1 lt 3x0 75mm 15 PIN PLUG www plastore com NEUTRAL GREEN A o O 7 gt 7 January 7 2006 a a 2 O lt LL 2 z lt gt Plasticolor User Manual SYSMETRIC January 7 2006 10 PIN SOCKET MANUFACTURER POWER SUPPLY 0VDC POWER SUPPLY 24VDC MOTOR ENABLE MOTOR O K NPN COMMON lt YELLOW 24VDC MOTOR DIRECTION O1 ORANGE 69 MOTOR STEP ANALOG 0V PURPLE Q ANALOG 0 10V AOUTO ACOM 00 www plastore com d Plasticolor User Manual MOTOR DRIVER 12x6005 P ANALOG 0 10V PURPLE ANALOG 0V MOTOR STEP ORANGE MOTOR DIRECTION COMMON YELLOW 24VDC A MOTOR O K PNP
15. Mode White 19 6x6005 B4 Plastification 1 White Brown 0 5mm B5 Injection 1 Green White Green Bo NotUsedInput 16 Bue B7 04 White Black B8 Shield Shield Shield B9 AnaoglnptOV Back ag BIO Analog Input 10V AINI 1 Plug PB Wire Color Wire Color ee ESE e ONERE AI OVDC Bc Black _ A2 24VDC Red Red X A3 Analog Enable White White Red Black A4 AlarmNPN Brown Orange AS AlarmPNP _A6_ 24 0 _ Yelow A8 MotorStep Orange A9 AnalogSpeedOV Blue ACOM Analog Speed 0 10V Purple White Yellow www plastore com 25274 Plasticolor User Manual Plug PC Wire Color Wire Color Funcion Te mamei Cable Type IA OVDC Bak Black 2 24VDC Red Red 3A SystemSwith On White H Brown 4A System Switch Drain Brown D Gren 5A ConveyerSwich Gren B Yellow 6A Level Proximity Switch Yelow Gray 7A System Switch Lamp Gray O2 White Gray l5x0 5mm 8A ConveyerSwitch Lamp Orange White Orange 9A Slide G
16. Plasticolor 2000 GR PLASTORE USER MANUAL Stepper Manual Number G202 1570 Georgetown Road Hudson OH 44236 Phone 330 653 3047 Fax 330 653 3052 info plastore com www plastore com January 9 2006 Plasticolor User Manual Table of Contents 1 acil ewig Een 4 4 2 Installatioti oe aaa t u atu alu aa aa 5 2 1 Feeding Unit Installation u tandi I MEE 5 Zas sala ON a aaa kuwa 6 3 SMAR P Conntioler u u x aaa uda 8 2 CG T E am amna NA ELEME ti a bau a la Bi EM 2225 ASN CON OUTA LO UR 9 92221 Operation pa 9 22222 oder N Aa e HM 9 29 252 Operation 9 3 2 4 lecion Mode isi uu ullu l Dae 10 3 255 ANIOS MOUE Cus deas u usu aD a kahuk tU 10 3 2 6 10 3 2 1 COMUNICAC mot a a aaa kam wu awa ate a An atu blat 11 3 2 8 daia 11 3 2 9 RR d E TR a RA E AR 11 DESEE UT UD DRITTEN 12 So Ma MeNi asqa eee 12 3019 2 J GU US 12 3 33 Ji c 819 ROI RR 13
17. TOCK estimation is depended on the calibration of hopper stock parameter See chapter 8 1 4 for details Note Resetting the counter requires reset code Default code 1s 1234 For changing the reset code contact Sysmetric www plastore com 16 Plasticolor User Manual 4 Screw Selection and Installation 4 1 Screw Selection Selecting the appropriate screw for the feeding unit is done according to the outputs required from the Plasticolor If the Plasticolor Is working at continuous mode on extrusion machine select a screw that will fit the expected outputs If the Plasticolor 1s working at injection mode on injection molding machine compute the continuous output in order to select an appropriate screw 4 1 1 Output at Injection Mode In order to select an appropriate screw for the feeding unit of the Plasticolor when working at injection mode compute the continuous output of the screw according to the following formula Output Product x x Fill Time 1000 e Output by Ke Hour e Product weight by gram e Additive by percentage e Fill Time by seconds 4 2 Screw Types The following table details the available screws for the Plasticolor and their typical outputs Screw 6 12 8 15 10 17 13 20 15 22 17 25 Type White Silver Orange Purple Gold Red Output Kg Hour 0 05 1 3 0 1 3 7 0 2 7 7 0 3 14 0 5 21 Note the screw output 15 depended on material characters shape size volume etc so the
18. activated when the bucket is full with material check the weighing amplifier and the weighing loadcell and perform weighing calibration See chapter 8 2 6 2 2 Conveyer Alarm Indicates that the system failed to fill the conveyer hopper the material level proximity switch does not detect material e Check that material flows freely during conveying e Check air supply and pressure e If this alarm is activated when the hopper is full with material verify intactness of the material level proximity switch See chapter 8 4 6 2 3 Exceptional Load Voltage Indicates that the voltage from the loadcell amplifier 1s too high or too low Check the amplifier voltage at the calibration screen and e Ifthe voltage is above 8 00Volt and the bucket 15 full with material www plastore com m Plasticolor User Manual o Check intactness of the slide gate between the weighing bucket and the conveyer hopper o Check the air supply and pressure e Clean the weighing bucket and the weighing chamber and make sure nothing presses the loadcell or the weighing bucket so that they move freely up and down e Check the weighing amplifier voltage and the weighing loadcell See chapter 8 2 6 2 4 Larger Screw Needed Indicates that the required output exceeds the system s capability e Change the feeder screw See chapter 4 e Seta lower value for the system output 6 2 5 Smaller Screw Needed Indicates that the required output is lower then the system s mini
19. al voltage Note an exceptional voltage from the weighing amplifier 1s usually a consequence of mechanical interference in the system Before calibrating the weighing amplifier in such case locate and fix the mechanical interference first Calibrating the amplifier without finding the real cause of the exceptional voltage will solve the problem temporarily Weighing amplifier calibration procedure 1 Stop the system turn system switch to OFF Empty all material form the system Open the operation panel of the system The weighing amplifier 1s behind it Verify that the two green LEDs 8V and 8V are lit If not check the power supply voltage on the power pins There should be two 10 supplies If not check the 10 0 10 transformer and its fuse in the SMART cabinet Verify the gain jumper is at the center position closing the pins marked 102 Verify the offset jumpers A B C are at the center position marked 0 Turn Zero trimmer 20 turns left counterclockwise Turn Cal trimmer 20 turns left counterclockwise Using a voltmeter read the voltage on the output pins of the weighing amplifier and turn the Zero trimmer right clockwise until the voltage reads 020 1 Volt If you can not get OVolt at this stage see the next chapter for checking the loadcell output and adjusting the offset jumpers 10 Turn Cal trimmer 20 turns right clockwise 11 Gently place a 200g weight the weighing bucket and verify a 3240 5 Volt on
20. alues can reduce system performance DM DS ACTIVE the current value of the flow parameter DM DS MINIMUM lower limit for the flow parameter Recommended value 100 DM DS MAXIMUM upper limit for the flow parameter Recommended value 2000 Sample Rate Parameter The sample rate parameter determines the rate of sampling and adjusting the flow parameter The value of the sample rate parameter can be adjusted but this should be done only at exceptional conditions Setting incompatible values can reduce system performance DM TH the sample rate of the system Recommended value 10 0g Note the Plasticolor is set to work with output lower then 0 1Kg Hour it is recommended to change the sample rate parameter to 5 0g www plastore com 29 Plasticolor User Manual 8 1 4 Model 2 Weighing Bucket and Hopper Stock Weighing Bucket The parameters of the weighing bucket determine the thresholds of filling the bucket with material When the weight of material in the weighing bucket goes below the minimum threshold the system starts filling the bucket When the weight in the bucket goes above the maximum threshold the filling is stopped The values of the weighing bucket parameters can be adjusted but this should be done only at exceptional conditions Setting incompatible values can reduce system performance BUCKET the current weight of material in the weighing bucket BUCKET MIN start filling threshold Recommended value 100
21. ate Valve O4 White Blue 10A Conveyer Valve Purple OS White Purple BI HOVAC White Green 10 White Black Blue B2 White Yellow 0 White Black Yellow B3 10VAC White Blue 10 White Black Orange E E Bo Amplifier Red 0 B7 Amplifier Bak j ACM Black B8 Amplifier Shield Shield Shield 7773 B 14 o o r Internal Wiring A latini Relay White Red T 06 Controller Output 00 White 10 Digital Outputs Power Supply 0VDC Bak 0 Digital Outputs Power Supply 24VDC Analog I O Power Supply 0VDC 1 Black OV Digital Outputs Common O2 05 0VDC m www plastore com 239 2 Plasticolor User Manual Appendix C Electrical Drawings PRODUCT SYSMETRIC January 7 2006 TERMINALS TRANSFORMER 10 0 10 LU x gt lt 3 Ee mz Hd UNITRONICS Vision23Q www plastore com 39 I 3 gt S L 9002 Menuep S lt LHVIAS OIHLJlNSAS 1 uaunLov adnNvIN O c2NOISIA SOINOYLINN d Od 28 Od 1 04 O O O 0 4 0D OL 2 0 3 419 AlddflS H3MOd 2 09 04 OVAO C Z N _ E 1 S lt 3 S 9 X gt S Plasticolor User Manual
22. bration of hopper stock parameter See chapter 8 1 4 for details Note Resetting the counter requires reset code Default code 1s 1234 For changing the reset code contact Sysmetric www plastore com 14 Plasticolor User Manual 3 5 Analog Mode Kg Hour When operating the Plasticolor in this mode the user defines the maximum output by Kg Hour and the SMART adjusts the output relatively to the voltage at the analog input 0 10Volt 3 5 1 Main Menu F5 setting the maximum output at 10Volt F2 following material consumption F3 watching the system s alarms F6 service and maintenance Note entering Service screen requires access code Default code 15 1234 3 5 2 Output OUTPUT 10v the system s output when the voltage at the analog input is 10Volt Use the keypad to enter the required value and press lt INPUT current analog input voltage SET set output of the system calculated automatically according to the OUTPUT 10 and the INPUT values Press Back F6 to return to the Main Menu screen 3 5 3 Material SET set value for the system output ACT actual system s output SPEED feeder s motor speed in percentage STOCK estimation of material stock TOTAL total weight of additive Press Reset F5 to reset the TOTAL counter Press Back F6 to return to the Main Menu screen Note STOCK estimation 1s depended on the calibration of hopper stock para
23. ck of the proximity switch If the status LED on the back of the proximity switch 1 light skip to step 6 Turn the sensitivity screw clockwise until the status LED lights Turn the sensitivity screw slowly counterclockwise until the status LED goes off Keep on turning the screw counterclockwise half a turn more 7 Check the operation of the proximity switch Fill the conveyer hopper with material to cover the proximity switch and verify that the status LED lights 8 Close back the operation panel and the conveyer hopper 21522 Note the calibration as described here refers proximity switches that their status LED lights when material is detected www plastore com 35 Plasticolor User Manual Appendix A Control Cabinet Electrical Wiring 3x0 75mm 77 2x0 75mm Alarm LL Contact Shield 2x0 5mm Shielded Analog OV ee 0 10V 6x6005 0 5mm Plastification 1 Brown Not Used Input www plastore com 36 Plasticolor User Manual Appendix B I O Wiring Plug PA Wire Color Wire Color Pn Fan Te VO cae Cable Tope _ Ground GreenYellow Green Yellow Neutral 1 Black N Blue J 3x075mm 2A Phas 2 L Alarm Green 52222 Dry Contact PE ee ee BI Common0VDC 1 B2 Common 24VDC option Red 7 Not Connected B3 Extruder On Automatic
24. e least influencing while jumper C 15 the most Each jumper can be in one of three positions top middle 0 and bottom 2 There are a total of 27 adjustment levels detailed in the next table Voltage decrease E gt Voltage increase _ Voltagedecrease 2 0 1 2 0 1 2 0 1 2 0 1 2 0 1 2 0 1 2 0 1 2 2 2 2 0 0 0 1 1 1 2 2 2 0 0 0 1 1 1 2 2 2 0 2 2 2 2 2 2 2 2 2 olololololololololi li Hi Offset Jumpers Note In any case 1t Is recommended to replace the damage loadcell Instead of using the offset Jumpers If the offset Jumpers are used to compensate offset the loadcell should be tested carefully to ensure correct weight measurement www plastore com 32 Plasticolor User Manual 8 2 3 Loadcell The loadcell test is preformed in order to ensure the accuracy of the system and that correct weight is reported from the weighing bucket The loadcell test has three checks 1 2 3 Hysterasis check repeatability ensures no friction disturbs the loadcell and the weighing bucket Calibration check ensures correct ratio between the loadcell voltage output and the weight reported by the system Linearity check ensure the linearity of the loadcell Loadcell test procedure 2 3 4 10 11 Stop system turn system switch to OFF Empty all material form the system Open the conveyer hopper and turn it aside to gain access to the weighing chamber
25. e screw Close the motor and tighten the hinge bolt 5 2 Switches Lamps The lamps at the operation switches of the Plasticolor are used to indicate the system status The next table describes the different indications Lamp Status off system 1s off system 1 on flashing steadily automatic mode extruder on flashing alternately system is In teach cycle system alarm Convever conveyer alarm www plastore com Plasticolor User Manual 6 Alarms The SMART is self supervised and will report any error occurred in material handling If an error occurs the SMART will switch to the Alarms screen and indicate the current alarm Alarm 15 cancelled automatically once the error 1s fixed 6 1 Alarms Screen Press Alarm Cancel F3 to close the alarm at the alarm output dry contact for 5 minutes If after 5 minutes the alarm 15 still active the alarm output will turn on again The SMART logs up to 50 alarms Press Last F4 to see the last alarm of the Plasticolor In order to clear the last alarm press Last together with Alarm Cancel Press Back F6 to return to the Main Menu screen 6 2 Alarms List 6 2 1 Bucket Empty Indicates that the system failed to fill material in the weighing bucket e Check that the conveyer is activated and that material flows freely during conveying e Check the slide gate between the hopper and the weighing bucket e Check air supply and pressure e If this alarm is
26. g BUCKET MAX stop filling threshold Recommended value 300g Note when working with materials of low density where the volume of the weighing bucket can not hold 300g the maximum threshold should be set to 250g or less if needed Hopper Stock The hopper stock parameter 1s the weight of material m the hopper after conveying This parameter 15 used for estimating the overall material stock in the system In order to set this parameter activate the conveyer before operating the system in order to fill the hopper with material drain and weight the material and set this measured weight as the hopper stock parameter The value STOCK that will be calculated based on the hopper stock parameter 15 only estimated and there can be inaccuracy of up to 100g and more from the actual material weight in the system This inaccuracy 15 a consequence of conveying material controlled by proximity switch and not by weight which result different weight of material in the conveyer hopper after each conveying cycle www plastore com 30 Plasticolor User Manual 8 2 Weighing System 8 2 1 Weighing Amplifier Calibration The weighing amplifier is first calibrated during manufacturing in order to adjust its working voltages for the loadcell and the controller Recalibrating the weighing amplifier is needed if e The weighing amplifier has been replaced e The loadcell has been replaced e Weighing calibration can not be completed due to exception
27. ge 5 Turn the system switch green switch to ON The Plasticolor will start feeding material depended on the operation mode e At injection mode according to Injection Plastification signals e At continuous mode according to Extruder On signal e At analog mode according to Extruder On signal and the voltage at the analog input During operation the green lamp will flash steadily to indicate normal operation www plastore com ee Plasticolor User Manual 6 If an alarm 15 activated during operation the system switch lamp green lamp will flash rapidly If the alarm 15 related to the conveyer conveyer switch lamp orange lamp will flash rapidly as well TEACH OFF ON CONVEYER Operation switches 5 1 Emptying material 1 Stop the Plasticolor turn system switch to OFF and conveyer switch to 0 2 Place a bucket underneath the Plasticolor and open the drain port and the test port 3 If there 15 material in the conveyer hopper turn system switch to ON order to open the slide gate between the hopper and the weighing chamber so that the material can drain from the hopper through the weighing bucket 4 Open one of the motor hinge bolts and turn the motor aside Pull out the screw and the sleeve 5 Clean any residual material using air pressure Remove the conveyer hopper lid and clean the hopper Turn the hopper aside and clean the weighing chamber 6 Close back the hopper Reinsert the sleeve and th
28. ging operation mode Entering this screen requires access code Default code 15 1234 3 3 4 Material COUNT products counter SET ACT set and actual additive weight per cycle STOCK estimation of material stock ADDITIVE total weight of additive TOTAL total weight of main material Press Reset F5 to reset the counters Press Back F6 to return to the Main Menu screen Note STOCK estimation is depended on the calibration of hopper stock parameter See chapter 8 1 4 for details Note Resetting the counters requires reset code Default code 15 1234 For changing the reset code contact Sysmetric www plastore com A ic oe Plasticolor 3 4 Continuous Mode User Manual In continuous mode the Plasticolor feeds additive continuously at a set output of Ke Hour that is defined by the user 3 4 1 Main Menu F5 setting the required output and following material consumption F3 watching the system s alarms F6 service and maintenance Note entering Service screen requires access code Default code is 1234 3 4 2 Output SET defined output Use the keypad to enter the desired value and press 4 ACT actual system s output SPEED feeder s motor speed in percentage STOCK estimation of material stock TOTAL total weight of additive Press Reset F5 to reset the TOTAL counter Press Back F6 to return to the Main Menu screen Note STOCK estimation is depended on the cali
29. ial hopper from the injection extrusion machine 2 Install neckpiece on the injection extrusion machine 3 Place the inlet inside the neckpiece 4 Reposition the material hopper on top of the neckpiece 5 Connect the screw feeding unit of the Plasticolor to the neckpiece Note that the unit can be connected to the neckpiece at one of four directions Pick the direction that gives best accessibility to the operation switches and the draining ports of the Plasticolor 6 Install the ventury conveyer fasten the flexible hose to the material inlet at the top of the Plasticolor s hopper Connect the compressed air pipe to the air outlet on the side of the Plasticolor s hopper 7 Connect compressed air supply to the air inlet on the side of the Plasticolor s hopper Note Supply the Plasticolor with compressed dry air 6 8bar Feeding unit installation www plastore com Plasticolor User Manual 2 2 Control Unit Installation 2 Install the control cabinet near the feeding unit Consider the controller s display accessibility when placing the cabinet Connect power supply 230Volt 50 60Hz 2Amp 3 wires cable in the main feeding cable PA e Ground green yellow wire e Neutral black wire marked with the digit 1 e Phase black wire marked with the digit 2 wire the control cable of the Plasticolor 6 wires cable in the main feeding cable PA For injection molding machine e Automatic mode signa
30. l dry contact Normally Open between the white wire and the black wire If this signal 1s not supplied connect the white wire to the black wire permanently to set the Plasticolor to automatic mode regularly e Plastification signal dry contact Normally Open between the brown wire the black wire e Injection signal dry contact Normally Open between the green wire and the black wire Injection signal is optional and is used to feed additive by the Plasticolor during injections cycles See chapter 3 2 4 for more details For extrusion machine e Extruder On signal dry contact Normally Open between the white wire and the black wire If this signal 1s not supplied connect the white wire to the black wire permanently For analog control on the Plasticolor s output wire the analog cable of the Plasticolor shielded 2 wires cable in the main feeding cable PA Analog control is by 0 10Volt Alarm if needed connect the alarm cable 2 wires cable in the main feeding cable PA to an external alarm system The alarm cable is connected to a dry contact Normally Open that closes on system alarm Plug the Plasticolor s main feeding cable to the control cabinet The plug and the socket are marked PA Plug the motor s cable to the control cabinet The plug and the socket are marked PB Plug the control cable of the feeding unit to the control cabinet The plug and the socket are marked PC Open the control cabinet rem
31. meter See chapter 8 1 4 for details Note Resetting the counter requires reset code Default code 15 1234 For changing reset code contact Sysmetric www plastore com 15 Plasticolor User Manual 3 6 Analog Mode Percentage When operating the Plasticolor in this mode the user defines the output of the extrusion machine at 10Volt and the required percentage of additive and the SMART adjusts the output relatively to the voltage at the analog input 0 10Volt 3 6 1 Main Menu F5 setting the extrusion machine output at 10Volt F2 setting additive percentage and following material consumption F3 watching the system s alarms F6 service and maintenance Note entering Service and Machine screens requires access code Default code 1s 1234 3 6 2 Machine Output MACHINE OUTPUT AT 10V the extrusion machine output when the voltage at the analog input is 10Volt Use the keypad to enter the required value and press INPUT current analog input voltage Press Back F6 to return to the Main Menu screen 3 6 3 Additive SET ACT set and actual percentage of additive Use the keypad to enter the required set percentage and press SPEED feeder s motor speed in percentage STOCK estimation of material stock TOTAL total weight of additive MACHINE the current extrusion machine output Press Reset F5 to reset the TOTAL counter Press Back F6 to return to the Main Menu screen Note S
32. mum output e Change the feeder screw See chapter 4 e Seta higher value for the system output 6 2 6 No FLow Alarm Indicates that material does not flow through the system e Search for material block in the system 6 2 7 Exceptional Injection Time Indicates that last injection time was exceptional with respect to the average injection time e Check injection time of the injection molding machine e Check system electric wiring 6 2 8 Exceptional Plastification Time Indicates that last plastification time was exceptional with respect to the average plastification time e Check plastification time of the injection molding machine e Check system electric wiring 6 2 9 PLC Battery Low Indicates that the backup battery of the controller is weak and needs to be replaced Contact Sysmetric regarding new battery 6 2 10 Teach Failed Indicates that the teach cycle has failed e Check material supply e Check that material flows freely in the system e Activate the teach cycle again www plastore com 24 Plasticolor User Manual 6 2 11 DM DS Limit Indicates that the active DM DS reached the maximum or the minimum limit e Check the active DM DS and its limits in the Model 1 screen See Chapter Error Reference source not found e Make sure that material flows freely through the system feeder e If necessary change the DM DS limits as needed www plastore com 25 Plasticolor User Manual 7 Communication The SMART
33. n cycles 3 3 1 Main Menu F5 setting product weight and additive percentage F2 following products and material counters F3 watching the system s alarms F6 service and maintenance Note entering Service screen requires access code Default code is 1234 3 3 2 Product PRODUCT product weight Use the keypad to enter the desired value and press lt ADDITIVE additive percentage Use the keypad to enter the desired value and press lt Press Injection F4 to set injection parameters Press Back F6 to return to the Main Menu screen Note entering Injection screen is available only if the SMART is set to the plastification and injection operation mode see chapter 3 2 for changing operation mode Entering this screen requires access code Default code is 1234 www plastore com 12 Plasticolor User Manual 3 3 3 Injection ADDITIVE AT INJECTION percentage of additive to be fed during injection cycles of the injection molding machine Use the keypad to enter the desired value and press m Press Back F6 to return to the Product screen Additive fed during injection cycles 15 part of the total percentage of additive Setting percentage of additive at injection does not change the overall amount of additive that 15 fed to the injection molding machine Note Injection screen 15 available only if the SMART 15 set to the plastification and injection operation mode see chapter 3 2 for chan
34. or Operation 1 Turn the conveyer switch orange switch to 1 to activate the conveyer The orange lamp will light and the unit will load material into the conveyer hopper 2 Open the test port at the bottom of the Plasticolor and place a bucket underneath UIT ar ETE ERE lt P gt 2 3 ae Test port 3 Turn and hold the system switch green switch to TEACH for two seconds to activate the teach cycle The green lamp will start flashing alternately and the system will run the teach cycle to learn the material parameters needed for correct operation of the Plasticolor During the teach cycle material will flow out through the test port to the bucket The teach cycle lasts about 1 2 minutes and when ends the system switch lamp green lamp wlll stop flashing Note the teach cycle can last up to 5 minutes depended on material characters and screw type The teach cycle can be stopped by turning again the system switch green switch to TEACH or by turning the system switch to ON 4 Using the SMART keypad enter the required parameters for the Plasticolor operation e For injection mode product weight and additive percentage e For continuous mode set output of Kg Hour e For analog mode Kg Hour set output at 10Volt e For analog mode percentage extrusion machine output at 10Volt and additive percenta
35. ose back the conveyer hopper Note use weights of 100 500g only For larger hoppers see addendum www plastore com Plasticolor User Manual 8 3 Display Contrast The controller s display is LCD type Temperature changes effects the contrast of the display and it might need adjustment Adjusting the contrast of the display 15 done by turning using a small screwdriver the contrast trimmer Access to the contrast trimmer 1s via a small hole at the upper rear side of the controller Open the control cabinet to reach the back of the controller Contrast Trimmer gt 11 AS 3 Pia A Do Lo Communication Port Power Supply Lae SMART Controller Rear view www plastore com 34 Plasticolor User Manual 8 4 Material Level Proximity Switch The material level proximity switch capacitive switch Normally Close located in the conveyer hopper indicates the presence of material in the hopper When the proximity switch does not detect material the conveyer 15 activated to load material to the hopper Once the proximity switch detects material the conveying Is stopped Calibrating the sensitivity of the proximity switch 1s done by turning the small screw on the back of the proximity switch according to the following steps 1 Stop the system turn system switch to OFF and conveyer switch to 0 Empty material from the conveyer hopper Open the operation panel to gain access to the ba
36. ove the protecting foam lift the power supply switch MCB and close the cabinet Note the protecting foam inside the control cabinet is for protecting the controller during shipment Remove the foam before operating the cabinet Caution Electrical maintenance should be carried out by authorized personal only www plastore com 6 User Manual LOVLNOO WHY TY 0 0 DO IVNV A0 DOTVNV LAdNI 9950 LON NOLLO3NI NOILVOIJLLSV ld NO OLNY OdAre NOWIAOO 0 NOAWOD ASVHd Plasticolor ONIHDIZM OL 19 JLIHM HOLOIN OL Power supply and control wiring www plastore com Plasticolor User Manual 3 SMART Controller 3 1 General The SMART controller is a PLC Programmable Logic Controller unit with backlit display and keypad for system operation The keypad includes Functions keys F1 to F6 those keys are used to switch the different operation screens The function of each key varies and 15 displayed on the screen Digits keys those keys include the 0 to 9 digits and the decimal point and are used for entering numeral values for the system operation data After typing numeral value the Enter key must be pressed in order to set the new value The controller ignores the new value until the Enter key is pressed Enter Key this key 1s used to confirm and set numeral values This key
37. r Stock 30 S2 31 8 2 1 WelaliimnecAmplifierGCalibralion dn alta ti a 31 8 2 2 Loadcell Output and Offset Jumpers eee 32 8 2 3 Load ll uya E rc CEN 33 295 G tM 34 8 4 Material Level Proximity Switch 35 Appendix A Control Cabinet Electrical Wiring 36 ADpendix BIO VIEW w G tov VI 37 Appendix Electrical Drawinss 39 Appendix D System Specification 51 www plastore com m 8 1 Plasticolor User Manual General Description The Plasticolor Is a gravimetric dosing system designed to handle granulated material with outputs of up to 30Ke Hour The Plasticolor consist four main parts Control and operation unit SMART controller with backlit display and keypad Screw type feeding unit for driving material Weighing unit for automatic calibration of the Plasticolor s output e e e Ventury conveyer for loading material The Plasticolor supports three different modes of operation 9 a e Injection mode
38. rial from the system 3 Turn the conveyer hopper aside to gain access to the weighing bucket 4 Make sure that the weighing bucket is empty and that AMP is 0 0 5Volt If AMP is not 0 calibrate the weighing amplifier as detailed in 8 2 1 Press Zero F4 to remove tare weight Verify that WEIGHT shows 0 Enter the REF value according to the reference weight used for the calibration 7 Putthe reference weight in the weighing bucket wait 10 seconds for the WEIGHT value to stable and press Cal F5 Verify the WEIGHT shows the value of the reference weight 8 Take the reference weight off the weighing bucket and on again Verify that the WEIGHT goes down to 0 and back to the reference value accordingly If necessary repeat steps 1 4 ai www plastore com 28 Plasticolor User Manual Note valid reference weight is 100 500g 8 1 3 Model 1 Flow and Smaple Rate Parameters Flow Parameter The flow parameter DM DS reflects the weight of material that the system feeds per one step of the motor The flow parameter Is depended on many factors such as material characters granules size weight volume etc operation mode and more The parameter Is sampled and adjusted adaptively by the system according to the sample rate parameter DM order to ensure correct output of the Plasticolor The maximum and minimum values of the flow parameter can be adjusted but this should be done only at exceptional conditions Setting incompatible v
39. s extrusion with output by Kg Hour F6 for continuous extrusion with output controlled by analog voltage 0 10 Volt If injection mode was selected the SMART will switch to Injection Mode screen If continuous mode was selected the SMART will switch to System screen If analog mode was selected the SMART will switch to Analog Mode screen www plastore com 9 Plasticolor User Manual 3 2 4 Injection Mode Press the corresponding F key to select the system s injection mode F2 feeding additive only during plastification cycles of the injection molding machine This 15 the common mode and it 1s applicable with all injection molding machines F3 feeding additive during plastification cycles and during injection cycles of the injection molding machine This mode is applicable with relatively large injection molding machines where significant amount of the main material enters the extruder during the injection cycle and can spread the additive more uniformly After selecting injection mode the SMART will switch to System screen 3 2 5 Analog Mode Press the corresponding F key to select the system s analog mode F5 the Plasticolor s output 1s defined by Kg Hour F6 the Plasticolor s output 15 defined by percentage of the extrusion machine output After selecting analog mode the SMART will switch to System screen 3 2 6 System Verify the selected feeder type and system mode Press Change F5
40. t of the SMART through the network socket RJ 45 on the side of the control cabinet e Using serial communication through COM2 port RJ 11 on the side of the controller Refer to chapter 7 regarding data addresses in the SMART Note the serial communication port COM2 is not galvanic isolated Electric shock at the communication line can damage the controller It is recommended to use the network port that is galvanic isolated www plastore com 11 Plasticolor User Manual 3 3 Injection Mode For operating the Plasticolor at injection mode the user has to set the product weight and the additive percentage The SMART using those parameters will add the additive according to plastifications injections cycles of the injection molding machine The SMART controller has two sub modes of operation for injection molding machines see chapter 3 2 for changing operation mode e Feeding additive only during plastification cycles of the injection molding machine This is the common mode and it 1s applicable with all injection molding machines e Feeding additive during plastification cycles and during injection cycles of injection molding machine This mode 15 applicable with relatively large injection molding machines where significant amount of the main material enters the extruder during the injection cycle and can spread the additive more uniformly In this case the user has to set the percentage of additive to be fed during injectio
Download Pdf Manuals
Related Search